RESEARCH & DEVELOPMENT
5 Research & Development
T he Science and Technology programmes
(S &T) of the Ministry of Mines, Government of
India, initiated in 1978, cover the disciplines of Geology,
Exploration, Mining & Environment, Bioleaching,
Beneficiation, Rock Mechanics, Ground Control and
Non-ferrous Metallurgy. During the current year, eight
new projects have been approved along with one
modified project.
The highlights of work carried out during
2008-09 by various research organisations and
industries relating to mineral beneficiation and
mining & environment are given below:
BENEFICIATION
Bauxite
Bench-scale Beneficiation Studies on Bauxite Sample
from Mevasa Mines, Jamnagar, Gujarat (IBM)
A bauxite sample from Mevasa Mines, Jamnagar
area, Gujarat, sent by GMDC Science and Research
Centre, Ahmedabad, was received at Modern Mineral
Processing Laboratory and Pilot Plant, Nagpur for
conducting bench-scale studies. The as-received
sample assayed 49.6% Al2O3, 1.66% SiO2, 16.80% Fe2O3
and 2.49% TiO2. The as-received sample was ground to
-100 mesh and after subjecting it to Wet High Intensity
Magnetic Separation (WHIMS), a non-magnetic product
assaying 52.75% Al2O3, 1.55% SiO2 and 11.54% Fe2O3
with a recovery of 82.8% (wt% yield 77.8) was obtained.
The Fe2O3 content even after grinding to -100 mesh
could not be reduced to 9.98% in a non-magnetic
fraction mainly due to coating of gibbsite grains with
iron oxide. Also higher losses of Al2O3 values in the
magnetic fraction were reported as a result of thick
coating of iron oxides on gibbsite grains. The non-
magnetic bauxite concentrate produced find utilisation
in abrasive/metallurgical industries.
Beach Sand
Studies on Heavies from Beach and Dune Sands
(IMMT)
Preliminary studies on sand deposits from Konark-
Ramchandi beach and dunes revealed the presence of
7.7% total heavy minerals. The particle size distribution
of beach sand was marginally higher than the dune sand
samples. Thirty beach and dune samples collected from
Rushikulya coastal area were also subjected to
mineralogical and beneficiation studies. Dune samples
indicated 9.5% total heavy mineral content with 3.4%
5-1
very heavy minerals. Heavy minerals like ilmenite, rutile,
zircon, garnet and sillimanite were detected.
Cobalt
Polymetallic Sea-nodules and Cobalt Crust of
Indian Ocean: A mineralogical and Geochemical
Investigation (NML)
This project had been undertaken in the “CSIR-
Young Scientist Awardee Scheme” effective 01.09.2006.
The main objective of the project was to establish the
mineralogy of the sea-nodules and cobalt crust from
Central Indian Ocean Basin (CIOB); microstructural
relations between ore mineral and gangue phases; major,
trace and rare earth element (REE) composition of the
nodules; inter-elemental and mineral relationships in the
nodule & crust samples; and to prepare a genetic model
& metallogenesis of manganese in the CIOB.
Polished sections of sea-nodules have been
studied under optical microscope and SEM. The
manganese nodules are characterised by a nucleus
comprising of hard rock debris, organic fragments, clay-
rich material, or volcanic tuffs. Various minerals have
been identified in the nucleus. The outer shell comprises
Fe-Mn minerals in concentric layers forming colloformic
laminations with alternate layers of Mn-rich light and
Mn-poor dark-colored bands. The mineral phases are
too fine-grained (few microns only) and occur in forms
of higher oxides and hydroxides of manganese and
iron. Some Fe-Mn phases are amorphous. Some
accessory minerals have been recorded in the Fe-Mn
concentric layers. These are rutile, barytes and pure
iron oxides. Most of these are detritus in nature. A few
iron oxides contain titanium as well. A rare occurrence
of authigenic badelleyite (ZrO2) has been recorded for
the first time.
Copper Ore
Upgradation of Drill Core Copper Sample from
Sangneer, Rajasthan (IBM)
A drill core copper sample from Sangneer
block of Bhilwara area, Rajasthan, as part of MoM
Project sent by MECL, Nagpur, was taken up for
investigation at IBM's RODL, Ajmer, to evolve a
suitable process flow sheet for recovery of copper
concentrate. The sample as-received assayed
0.20% Cu, 0.11% Zn, 11.0% Fe(T), 53.48% SiO 2,
11.18% Al 2O 3, 4.89% CaO, 6.94% MgO & 0.48%
S(T) with traces of Au.
 RESEARCH & DEVELOPMENT
A copper concentrate assaying 23.76% Cu
with 91.1% Cu recovery and wt% yield of 0.75 was
obtained at 83% (-) 200 mesh. However, after
grinding at 45.2% passing 200 mesh followed by
regrinding, a yield of copper concentrate assaying
24.91% Cu with 93.4% Cu recovery (wt% yield 0.8)
was obtained. Both the concentrates met the
specification indicated for copper smelter
requirement. However, the second route affirmed
reduction in total energy consumption.
Recovery of C opper Concentrate from S lag
Sample of Birla Copper (Dahej, Gujarat) for
M/s Hindalco Industries Limited (IBM)
A discarded slag sample of Birla Copper, Dahej,
Gujarat, was received from M/s Hindalco Industries
Limited at the Modern Mineral Processing
Laboratory and Pilot Plant, IBM, Nagpur, for
developing a process flow sheet to produce copper
concentrate of around 25% Cu with maximum
recovery of copper. The as-received sample assayed
1.31% Cu, 0.67% Pb and 0.82% Zn.
By adopting flotation, a copper concentrate
assaying Cu 28.41% with a copper recovery of
52.3% (wt % yield 2.4) was obtained. The major
recovered valuable was Cu (52%). Loss of
valuables in tailings is mainly due to inclusion of
valuable mineral within iron silicate matrix
(Fayalite) or copper mineral superficially coated /
rimmed with iron silicate coating. Even the finer
grind of 100% all passing 325 mesh size failed to
liberate these locked up valuables. The sample is
amenable to beneficiation but with a moderate
recovery of around 52% Cu.
Beneficiation of Low-grade Copper Ore from
MECL (IBM)
A low-grade exploratory copper ore sample from
Dhobani Copper Project, Singhbhum district,
Jharkhand, sent by M/s MECL, Nagpur, was taken
up for investigation at IBM's Modern Mineral
Processing Laboratory and Pilot Plant, Nagpur, with
an objective to develop a flow sheet so as to yield a
copper concentrate of high-grade and recovery.
The as-received sample assayed 0.51% Cu,
12.87% Fe(T), 1.57% S(T),52.69% SiO2 and 0.002 ppm
Ag. By adopting flotation route, a copper
concentrate assaying 22.45% Cu with a recovery of
89.4% (wt% yield 2.0) was obtained. The copper
concentrate produced met the specification required
for smelters. MECL is expected to send this
exploratory sample for pilot-scale investigation so
as to develop suitable data for plant design that
would enable industrial exploitation of the ore.
5-2
Copper-Gold Ore
Recovery of Copper Concentrate from Gold
Bearing Copper-Gold Ore (IBM)
A gold bearing copper ore sample sent by
M/s MECL, Nagpur, was taken for investigation
at RODL, Ajmer, so as to recover a copper
concentrate assaying minimum 20% copper and
also to study the possibility of recovery of a gold
pre-concentrate. The as-received sample assayed
1.15% Cu, 8.07% Fe 2O3, 3.81% S, 79.05% SiO2, 1.03
ppm Ag and 1.31 ppm Au. By adopting flotation
route, a copper concentrate assaying 21.52% Cu
with 92.1% copper recovery with (wt% yield 4.8)
was obtained. This concentrate also contained
10.45 ppm Au. The possibility of recovery of a
separate gold pre-concentrates however, remained
remote despite having the rougher tails subjected
to gravity operation. Copper concentrate thus
evolved did meet the specifications for smelting.
Graphite Ore
Beneficiation of Low-grade Graphite Ores to
Produce Concentrates (IMMT)
Low-grade graphite ore samples of M/s Orissa
Manganese & Minerals Pvt. Ltd, Kolkata, with
9–12% fixed carbon were beneficiated to enrich
the fixed carbon content to above 80% while
keeping the particle size as coarse as possible.
Flotation studies indicated that it is possible to
upgrade the fixed carbon content up to 85% with
a recovery of about 85%. A combination of
mechanical flotation cells and flotation columns
that would give better grade and recovery of the
valuable material has been suggested. A process
flow sheet has been recommended to the client.
Iron Ore
Upgradation of Iron Ore from Donimalai,
Karnataka (IBM)
An iron ore sample assaying 63.50% Fe(T),
3.30% SiO 2 and 2.75% Al 2O 3 from Donimalai Iron
Ore mines, Karnataka, sent by M/s Nadeem Mines,
Bangalore, to RODL, IBM, Bangalore, with an
objective to reduce the SiO 2 and Al2 O 3 content
and obtain an iron concentrate assaying more than
65% Fe. Screening and subjecting the different
products to magnetic separation yielded a
composite iron concentrate assaying 65.99%
Fe(T), 1.59% SiO 2, 1.30% Al 2 O 3 with 76% Fe(T)
recovery and weight % yield of 73.3. The sample
was upgraded to the desired level as specified by
the party with a good recovery of 76%.
 RESEARCH & DEVELOPMENT
Pilot-scale Studies on an Iron Ore Sample from
Hiremagi Ramthal, Karnataka (IBM)
Pilot-scale beneficiation studies were conducted
on a low-grade iron ore sample sent by M/s Doddanwar,
H.R. Mines, Bagalkot, Karnataka, to confirm the
results obtained on a laboratory-scale investigation
(R.I. No. 1820) carried out at Modern Mineral Processing
Laboratory and Pilot Plant, Nagpur, and also to obtain
other data required for Plant design.
The as-received sample assayed 54.64% Fe(T),
11.77% SiO2, 4.96% Al2O3, and 4.09% LOI. The final iron
ore concentrate obtained (composite of +10 mm
scrubbed fraction, jig concentrate and magnetic stub
cyclone underflow) assayed 61.20% Fe(T), 5.42% SiO2,
3.08% Al2O3 and 2.78% LOI with overall weight
percentage yield of 69.3 (overall Fe(T) recovery 77.9%).
Further reduction in the silica values in final
concentrate is precluded due to interlocking of quartz
with iron oxide at final size. However, blending this
concentrate with low silica concentrate yielded a
product that could find industrial application. The work
is considered appreciable for reasons that such low-
grade material, too, could be upgraded to obtain a
product that could find useful application.
Upgradation of Iron Ore Sample from Barbil,
Keonjhar District, Orissa (IBM)
An iron ore sample from Barbil, Keonjhar district
Orissa, was received at IBM's RODL, Bangalore, with
an objective to produce a flow sheet to yield a iron ore
concentrate suitable for making pellets.
The as-received sample assayed 56.97% Fe(T),
7.60% SiO2, 4.86% Al2O3 and 4.02% LOI. The sample
after being subjected to various processes yielded a
composite concentrate that assayed 65.45% Fe(T),
1.69% SiO2, 1.05% Al2O3 with an iron recovery 48.4%
Fe(T) (wt% yield 41.6). The concentrate obtained did
meet the specification of the party, although, the
recovery was low.
Beneficiation of a Low-grade Iron Ore Sample from
Ambargatti – Tigolli, Karnatka (IBM)
A low-grade bonded iron ore sample from
Ambargatti–Tigolli, Bailahongala Taluk, Belgaum
district, Karnataka, sent by M/s Shri Keshev Cements
& Infra. Ltd, Belgaum, was taken up for bench-scale
beneficiation studies, at RODL, Bangalore so as to
evolve a process flow sheet that would yield a blast
furnace pellet grade concentrate.
The as-received sample that assayed 34.97% Fe(T),
48.08% SiO2, 0.49% Al2O3 and 1.03% LOI, after being
subjected to crushing, grinding & magnetic separation
yielded a concentrate that assayed 65.42% Fe(T), 4.58%
SiO2, 0.31% Al2O3 & 0.5% LOI with 63.2% Fe recovery.
5-3
The concentrate obtained met the specification as
desired by the party.
Upgradation of Low-grade Iron Ore for Industrial
Application (IBM)
A low-grade iron ore sample collected from Uliburu
Mines of M/s B.K. Mohanty at the behest of IBM,
Bhubaneswar, Orissa, was taken up for bench-scale
beneficiation studies so as to upgrade the iron content
and establish its suitability for industrial application.
The as-received sample that assayed 48.56% Fe(T),
22.12% SiO2, 4.64% Al2O3 & 2.69% LOI after being
subjected to gravity separation yielded a iron
concentrate that assayed 63.12% Fe(T), 6.81% SiO2,
1.30% Al2O3 with Fe(T) recovery of 33.4% (wt% yield
25.8). The concentrate obtained could find industrial
application in iron & steel Industry.
Beneficiation of Lean Grade Iron Ore (NMDC)
A process has been developed for beneficiation of
Banded Hematite Jasper at NMDC's R&D centre.
Considering the presence of huge reserve of BHJ type
lean grade iron ore in Donimalai range, this project was
commissioned. The iron, silica and alumina content in
the as-received material were 41%, 39% & 0.9%,
respectively, which were upgraded to 65%, 4.5% & 0.5%,
respectively, with 28–30% recovery.
Slime Beneficiation & Pelletisation Studies (NMDC)
During iron ore processing at Bailadila and
Donimalai sectors, huge quantities of slime get
generated which are dumped near the mine site. The
iron, silica and alumina content in the as-received slime
from Bailadila which were 61.0%, 7.33% & 1.8%,
respectively, after beneficiation were upgraded to 66.0%,
1.90% & 1.00%, respectively, with 70-75% recovery.
Similarly, the iron, silica and alumina content in the as-
received slime sample from Donimalai which were 60.0%,
5.00% & 3.50% respectively, after beneficiation were
upgraded to 66.0%, 1.50% & 1.00%, respectively, with
70-75% recovery.
Additionally, slime concentrates from both Bailadila
& Donimalai slimes were found suitable for pellet
making. BF grade & DR grade pellets were produced in
pot grate furnace from this slimes.
Encouraged by the above studies NMDC Ltd is
setting up 2.0 & 1.2 million tonnes capacity beneficiation
and pelletisation plant at Bailadila and Donimalai,
respectively. Slime will be the raw material for the
proposed plants.
Pilot Plant for Beneficiation of Iron Ore Tailings at
Essar-Kirandul (IMMT)
Essar Steel Ltd erected a 0.6 m diameter flotation
column of 8 m height in the premises of its iron ore
 RESEARCH & DEVELOPMENT
beneficiation plant at Kirandul on the basis of design
furnished by IMMT. The fabrication and erection job
was also supervised by the scientists of IMMT. Test
run of the plant was carried out by using the tailings
generated from the existing beneficiation plant. The
tailing slurry containing 30–40% solids was conditioned
with required dosages of reagents in the primary
conditioner and then transferred to a secondary
conditioner by gravity process. The slurry was diluted
with additional waste to achieve a pulp density to 1.2.
The unit, with a solid feed rate of about 2 tph, was
satisfactorily run for about six hours. Continuous
operation has also been streamlined.
Beneficiation of Iron Ore Fines to Produce
Concentrate for Iron Making (IMMT)
Detailed investigations were carried out on low-
grade iron ore fines of M/s Jagannathpur Steel
Limited, Ranchi, with 57.5% Fe, 7% SiO2 and 5.3%
Al2O3. The size and chemical analyses of each size
fraction indicated that iron values are uniformly
distributed but particle size (-0.045 mm) contained
less iron. Particles of hematite, the major iron-bearing
mineral present in the sample, sometimes are seen
locked with vitreous and ochreous goethite. Martite,
an oxidation product of magnetite was also
occasionally seen in the sample. Most of silica
particles were coarse-grained. Liberation studies
carried out by sink and float methods at different
size fractions of feed to jig indicated that iron
concentrate of more than 67% Fe can be achieved
by adopting gravity concentration techniques.
Detailed investigations were carried out by adopting
various beneficiation unit operations. A combination
of scrubbing, hydrocyclone and magnetic separation
was found promising to produce iron concentrate
with 63.3% Fe at 80% weight recovery. The grade
can be further improved by introducing jigging in
addition to the above to a concentrate with 65.7% Fe
at 70% yield which is suitable for pellet preparation.
Beneficiation of Low-Grade Iron Ores and Fines
for Pelletisation (IMMT)
Borehole samples for M/s Usha Martin
Limited, Kolkata, containing hematite, goethite,
kaolinite, gibbsite and quartz were characterised.
The degree of liberation of hematite was around
74% and 93% at -150, +75 and -75, +38 micron sizes,
r e s p e c t i v e l y. T h e t o t a l h e m a t i t e i n t h e
investigated sample was 35.54%. Goethite
contained 58.64% Fe, 3.8% SiO 2, 4.9% Al 2O 3 and
6.7% LOI. Silica content in the sample was slightly
lower than the alumina content. The loss on
ignition of this sample was quite high indicating
the presence of goethite or limonitic mateial in it.
5-4
Sink and float studies indicated that it is possible
to achieve more than 65% of iron in the finer size sink
fractions indicating the liberation of iron particles at the
finer sizes. These studies have given sufficient
indication that gravity separation can be adopted to
enrich iron content. Jigging studies indicated that a
good grade concentrate can be produced by jigging at
finer sizes. Detailed beneficiation studies carried out
involving scrubbing, screening, jigging, grinding and
magnetic separation indicated that a good grade
concentrate with 63.8% Fe can be produced at 72.0%
yield by recovering most of the iron values. The rejects
contained 46.2% Fe which can be discarded. A flow
sheet with materials balance was suggested to the client.
A project was taken up for M/s Shyam Steel
Limited, Kolkata, to develop a suitable process flow sheet
to utilise low-grade iron ore fines for making pellets so
that all variety of low-grades available at mine pit can
be utilised. Mineralogical, physical, sequential heating
and chemical characterisation were carried out for 15
high, low, very low and blue dust samples from Barbil
area. The percentage of goethite and kaolinite which
were the main cause of LOI percentage of fines, were
determined by sequential heating. Even after
beneficiation, some of the products required
blending with high-grade samples or blue dust to
maintain iron, alumina and silica content along with
required LOI for pelletisation. Based on the
characterisation studies, two low-grade samples were
selected for detailed beneficiation studies using bulk
samples of 10 tonnes each.
Beneficiation for Recovery of Iron Values from
Siliceous Iron Formation (IMMT)
BHQ sample of M/s Matrix Metallics Private
Limited, Mumbai, with 39% Fe, 42.5% SiO2 and 1.0%
Al2O3 was studied. Silica was the major impurity in the
sample while other impurities were in traces. The size
and chemical analysis of each size fraction indicated
that both iron and silica are distributed uniformly.
Liberation studies carried out by sink and float at
different size fractions of ground material indicated that
the iron minerals and gangue minerals were not fully
liberated even below 75 microns size. As dry
beneficiation studies carried out by magnetic separation
techniques at coarser sizes did not give any encouraging
results, all the beneficiation studies were carried out
after grinding the entire sample to below 100 microns
and 75 microns by wet method. Magnetic separation
studies using WHIMS and HGMS have indicated that
it is possible to achieve a concentrate of >63% Fe with
42.3% yield. Flotation studies carried out by using
conventional cell and column have indicated that 63%
Fe with 26 to 34% weight recovery could only be
achieved. It has also been observed that the pH of the
 RESEARCH & DEVELOPMENT
slurry, collector concentration, frother and dispersant
play an important role in the performance of the flotation.
Recovery of Iron Values from Tailings of Washing
Plant (IMMT)
Development of a suitable process flow sheet to
recover quality iron ore super-fines with preferably less
than 1.5% alumina from the slimes present in the existing
tailing ponds at Joda was attempted under a Tata Steel
sponsored project with the aim to produce suitable
concentrate for production of pellet for utilisation in
DRI plant. Mineralogical, physical and chemical
analyses of fifteen samples containing different range
of alumina (low, medium and high) were carried out to
study the amenability for upgradation. The Fe values
of the samples carried in the range 56–60% and a good
amount of goethite was available. Some of the hematite
particles in these samples had cavity, which led to
formation of voids in the particles ranging from 5–50%.
The samples also contained appreciable quantities of
clay minerals, which required proper dispersing using a
reagent before processing. As high and medium alumina
samples contained more than 90% of 45-micron particles,
both magnetic and flotation techniques were used. Since
the low alumina samples contained good amount of
coarse particles, the gravity separation technique was
also used to beneficiate the coarse size particles. A
common flow sheet was developed for all the three
types of samples using spiral, magnetic separator and
column flotation. The alumina content was reduced to
below 2% with 66–67% Fe in the product at 50–60%
yield. The process was demonstrated to the client. A
proposal to undertake a continuous study under pilot-
scale, using a 0.5 dia column flotation unit, at the plant
site has been initiated.
Beneficiation of Iron Ore Fines for Finex process of
Iron Making (IMMT)
Low-grade iron ore fines of M/s Mideast Integrated
Steel Limited, New Delhi, was beneficiated to prepare
quality products for Finex process of iron making. The
fines contained 58.4% Fe, 4.6% silica and 4.7% alumina
on an average. Various techniques applied to enhance
the iron values in order to make them suitable for Finex
process indicated that a combination of screening,
jigging, hydrocyclone and magnetic separation may be
an ideal route to produce a product with 64.7% Fe at the
yield of 69.1%. A comparison of typical size distribution
of Finex process and products size distribution obtained
by different schemes indicated that coarse product
obtained from this sample deviates slightly from the
lower limit of Finex size distribution while finer products
fall within the same size range. Thus, blending of the
coarse and fine products in appropriate proportion is
required to balance the required size distribution pattern
for Finex process as these products were generated
separately in the flow sheet.
5-5
Development of Advanced Eco-friendly Energy
Efficient Processes for Utilisation of Iron Ore (NML)
As per the National Steel Policy 2005, the total
production of iron ore in the country is targeted at 300
million tonnes by 2019-20 along with achievement of
capabilities to meet all export commitments . With the
present pace of expansion it would be difficult to meet
the expected levels. To meet the growing demand and
while simultaneously exacting measures for
conservation of iron ore resources, there is a compelling
need to develop technology for gainful utilisation of
low-grade iron ores, dumped fines and slimes. The
proposed research programme aims to address these
challenges through systematic studies involving
characterisation, beneficiation and agglomeration. The
participating laboratories in this CSIR network project
are: National Metallurgical Laboratory (NML),
Jamshedpur; Institute of Minerals and Materials
Technology (IMMT), Bhubaneswar; North-East Institute
of Science & Technology (NEIST) and Central Electronic
Engineering Research Institute (CEERI), Pilani while
IMMT is the nodal laboratory. The objective of the
project is to increase the resources base. The four-
pronged strategy of the project is as follows:
• Utilisation of low-grade ores to reduce cut-
off grade to 52% from the present level of
58%.
• Development of processing techniques for
lean grade ores, such as, BHQ/BHJ.
• Utilisation of slimes and tailings from
existing processing plants.
• Utilisation of beneficiated waste for value
addition.
In association with SAIL, low-grade iron ores,
dumped fines and slimes samples were identified for the
proposed studies. Field visits were made to their mines
at Meghatuburu & Gua and samples were collected after
detailed field investigation. Detailed characterisation,
beneficiation involving gravity, magnetic & flotation and
agglomeration studies are to be undertaken on low-
grade iron ores/fines/slimes samples. Considering the
poor liberation of iron bearing minerals from the
associated gangues and the high percentage of fine
grained iron bearing minerals associated with fines and
slimes sample, emphasis is laid on developing improved
technology for processing of fine particles. Studies
carried out on recovering iron values from particles
passing below 150 micron by flotation and magnetic
separation techniques have shown encouraging results.
Enhanced gravity separation technique also produced
promising results for the sample from Gua mines of SAIL.
Further studies are in progress.
 RESEARCH & DEVELOPMENT
Lead–Zinc
Upgradation of Lead-Zinc Sample from Orissa for
M/s New Metal Refinery, Vashi, Mumbai (IBM)
In an investigation sponsored by M/s New Metal
Refinery, Vashi, Mumbai, a lead-zinc ore sample from
Orissa was taken up at the Modern Mineral Processing
Laboratory and Pilot Plant, Nagpur with an objective to
develop a suitable process flow sheet so as to obtain a
lead concentrate assaying +60% Pb and Zn concentrate
assaying +50% Zn with optimum lead and zinc recovery.
The as-received sample that assayed 13.65% Pb,
10.46% Zn, 0.13% Cu, 8.05%Fe(T), 13.10% S(T) and
44.60% SiO2 after adoption of differential flotation
yielded a lead concentrate assaying 65.80% Pb and
7.15% Zn with 83% lead recovery (wt % yield 16.80) and
a zinc concentrate assaying 52.83% Zn and 2.40% Pb
with zinc recovery of 69.4% (wt% yield 14.0). The
concentrates obtained met the specifications as
specified by the party and could find industrial
application.
Limestone
Upgradation of a Composite Grey Chocklate
Argillaceous Limestone Samples of Bargarh Cement
Works, Orissa, forM/s ACC Ltd (IBM)
Bench-scale beneficiation studies were carried out
earlier on grey Chocklate Argillaceous limestone sample
(BCW II) and Chocklate Argillaceous limestone sample
(BCW III) from Dungri Mines sent by Bargarh Cement
Works, Orissa, for M/s ACC Ltd. Encouraged by the
results the party desired to carry out the test work on
the blended sample in ratio 1:1, so as to confirm the
results obtained on individual samples to generate the
data for plant design.
The sample as-received assayed 64.45% Total
Carbonate (TC), 34.85% CaO, 26.74% SiO2, 2.05% Fe2O3,
4.05% Al2O3, 1.20% MgO and 28.63% LOI. After
conducting extensive test work, a concentrate assaying
76.93% TC, 41.77% CaO, 16.24% SiO2, 3.04% Al2O3, 1.61%
Fe2O3, 0.95% MgO, 34.20% LOI with 75.9% TC recovery
with wt% yield of 63.6 was obtained. Fine inclusions of
mica and quartz within calcite in the size range of 0–40
microns inhibited the attainment of higher grade. The
other data for plant design, i.e., thickener area, filter cake
moisture, filter productivity, bond’s work index was also
determined. The results obtained met the requirement
as specified by the party.
Upgradation of a Limestone Sample from Lakheri
Mines, Rajasthan, for M/s ACC Ltd (IBM)
In middle series wobbled and screened limestone
sample from Lakheri Mines Rajasthan for M/s ACC Ltd
was sent to Modern Mineral Processing Laboratory and
Pilot Plant, IBM, Nagpur, with the purpose to obtain
5-6
concentrate assaying more than 80% Total Carbonates
(TC) preferably by dry methods failing which by flotation
at high pulp densities, with maximum TC/CaO recovery,
that could be suitable for Cement Industry. The as-
received sample assayed 70.25% TC, 38.20% CaO, 3.12%
Al2O3, 1.68% Fe2O3, 22.81% SiO2, 0.93% MgO and 0.13%
TiO2 & 31.32% LOI.
By flotation process, the sample yielded
concentrate assaying 80.86% TC, 44.65% CaO, 13.70%
SiO2, 2.08% Al2O3, 1.29% Fe2O3, 0.70% MgO and 35.93%
LOI with a TC recovery of 86.0% (wt yield 74.8%). The
concentrate so produced was as per the requirements
of M/s ACC Ltd.
Upgradation of Limestone Sample from Sheopura
Kesarpura Mines on Promotional Basis (IBM)
A low-grade limestone (calcareous schist) sample
designated as Sample No.3 from Sheopura Kesarpura
Mine of M/s Shree Cement Limited, Beawar, Rajasthan,
was subjected to beneficiation studies on promotional
basis. The as-received sample assayed 32.68% CaO,
2.60% MgO, 3.74% Fe2O3, 6.24% Al2O3 , 25.09% SiO2
and 26.86% LOI.
Both dry and wet beneficiation processes were
applied to upgrade the sample so as to obtain a
concentrate of industrial utility. However, finer
association of calcite with quartzite and iron oxides made
it difficult to separate them by dry process. By adopting
flotation route at a finer grind of 85.8% passing minus
200 mesh yielded a limestone concentrate assaying
43.40% CaO, 13.81% SiO2, 3.71% Fe2O3 & 35.65% LOI
with 93.8% recovery (wt% yield of 71.8).
Upgradation of Limestone Reject Fines for Industrial
Utilisation(IBM)
A low-grade limestone fines sample lying as mine
reject at Nimbathi Mines, Pali, Beawar district, Rajasthan,
of M/s Shree Cement Limited, Beawar, Rajasthan, was
collected for beneficiation studies on promotional basis.
The as-received sample that assayed 35.04% CaO, 2.06%
MgO, 4.74% Fe2O3, 5.72% Al2O3, 24.59% SiO2 and 27.22%
LOI after being subjected to flotation technique yielded
a concentrate assaying 47.86% CaO, 8.10% SiO2, 2.11%
Fe2O3 and 38.19% LOI with a CaO recovery of 88.7%.
(wt% yield 64.5).
The limestone fines which hitherto were lying as
rejects in huge amount at mine site could now be
economically exploited and utilised as a sweetner grade
in Cement Industry.
Beneficiation of Low-grade Limestone (IMMT)
Two projects on beneficiation of low-grade
limestone for cement making purpose have been
initiated for M/s Ambuja Cements Limited, Maharashtra
and M/s Jindal Steel & Power Ltd, Barbil. The main
 RESEARCH & DEVELOPMENT
objective of these projects is to upgrade the calcium
content by reducing the silica content in the low-grade
limestone varieties which were considered unsuitable
for cement making purpose due to the presence of high
silica content. Preliminary studies indicated that both
the samples are amenable for beneficiation and that it is
possible to reduce silica below 10% SiO2 and increase
the lime content to more than 42% CaO. The
beneficiation process of the ores to reduce the silica
content to below 8–10% and development of suitable
process flow sheet are contemplated.
Manganese Dust
A Flue Gas Bag Filter Dust from Ferro Alloy Plant
for M/s Sarda Energy & Minerals Ltd (IBM)
A Flue Gas bag filter dust from Ferro Alloy Plant
for M/s Sarda Energy & Minerals Ltd, Raipur (C.G.) that
assayed 22.96% Mn was upgraded to 32% Mn by simple
washing system with Mn recovery of 90%. The sample
80% (-) 10 microns in size was hygroscopic and corrosive
in nature and highly soluble in water. The leached liquor
so obtained assayed high in alkalis, i.e., 14.68% K2O,
2% Na2O and 0.13% lithium and may offer great potential
for recovery of potassium in particular. The process
developed enables recovery of not only Mn from the
dust of ferro-manganese industries but also offers
additional scope for recovery of alkalis. This most
importantly serves ways & means for addressing the
auxiliary environmental parameters of handling &
storing dust generate at such Ferro Alloy plants.
Phosphate Ore
Commercial Processes for Beneficiation of Low-grade
Phosphate Ore (IMMT)
Samples of M/s Coromandal Fertilizers Limited,
Secunderabad, with about 12–13% P2O5 were studied
with the purpose to enrich their phosphate content to
above 30%. Flotation studies indicated that it is possible
to upgrade the phosphate content up to 30% with
recovery values of about 50%. Laboratory optimisation
studies were carried out to achieve maximum grade and
recovery of phosphate material and a process flow sheet
has been proposed for beneficiation of low-grade
phosphate ores.
Silica Sand
Upgradation of Low-grade Silica Sand from Kalya
Sota for Glass Making (IBM)
A ROM silica sand sample from Kalya Sota area of
M/s Hindustan National Glass and Industries, Kolkata,
was received for bench-scale beneficiation studies at
the Modern Mineral Processing Lab. and Pilot Plant ,
IBM, Nagpur. The objective of the study was to explore
possibility of obtaining a glass-grade sand concentrate
5-7
at the size range of -30+120 mesh assaying Fe2O3 0.05%
(max.) & Al2O3 1% (max.)
The as-received sample assayed 88.58% SiO2, 6.20%
Al2O3, 0.20% Fe2O3, 0.10% TiO2, 0.10% CaO, 0.06% MgO,
2.5% K2O, 30 ppm Cr2O3 and 1.44% LOI.
The composite of the +30 mesh product ground to
(-) 30 mesh and screened and -30+120 mesh subjected
to attrition scrubbing and desliming yielded a
concentrate assaying 97.91 SiO2, 0.824% Al2O3, 0.046%
Fe2O3 & 0.608% K2O with wt% yield of 75.2. This
concentrate met the specifications for glass-grade silica.
Also a value-added product of potash felspar
concentrate as by-product which finds application in
industry was obtained. It assayed 66.53% SiO2, 16.17%
Al2O3, 0.20% Fe2O3 & 13.10% K2O with overall weight
recovery of 4.6%.
Production of Glass-grade Silica Sand Concentrate
for M/s ACE Glass Containers Ltd, Puducherry (IBM)
M/s ACE Glass Containers Ltd, for its Silica Sand
Beneficiation Plant in Puducherry, had sought technical
expertise of Ore Dressing Division, IBM, to study the
flow sheet and suggest modifications, if necessary, with
a view to make the process of upgradation more
economical by particularly emphasising on deployment
of wet magnetic separation in lieu of the existing costly
dry magnetic separation process. Consequently after
the visit of IBM officials, the company sponsored an
investigation assignment to be taken up by IBM on a
sample for developing an economical beneficiation route.
The sample as-received assayed 98.30% SiO2, 0.49%
Al2O3, 0.22% Fe2O3, 0.081% K2O, 58 ppm Cr2O3, 0.091%
TiO2 and 0.44% LOI.
After conducting mineralogical studies, the
following process was adopted for upgradation of the
samples: (a) Wet screening followed by tabling and
WHIMS produced a silica sand concentrate assaying
99.18% SiO2, 0.036%Fe2O3, 0.012% TiO2, 0.16% Al2O3
and 8 ppm Cr2O3 (Wt % yield 67.2). (b) Tabling and
WHIMS produced a silica sand concentrate assaying
98.8% SiO2, 0.036% Fe2O3, 0.01% TiO2, 0.13% Al2O3 &
13 ppm Cr2O3 (wt % yield 13.8). The composite silica
sand concentrate assayed 99.19% SiO2 and 0.036%
Fe2O3 (wt % yield 81.0).
The concentrate produced did meet the
specification of silica sand stipulated by the party.
The simple process flow sheet developed in IBM's
Ore Dresing Laboratory (ODL), Nagpur, did establish
that the complicated process flow sheet presently
adopted in the plant could be replaced and the several
unit operations particularly dry high intensity
magnetic separation could be dispensed with. The
new beneficiation route suggested could be more
economical and viable and could be made effective
with little modification.
 RESEARCH & DEVELOPMENT
Tin
Production of Tin Concentrate from Cassiterite Sample
from Democratic Republic of Congo (IBM)
A ROM high-grade Cassiterite sample from
Democratic Republic of Congo was sent by M/s Met
Trade India Limited, Delhi, with an objective to reduce
iron, silica and alumina at -3mm particle size. The as-
received sample that assayed 57.62% Sn, 5.64% Fe(T),
9.38% SiO2, 3.91% Al2O3, 0.39% TiO2 and 1.34% LOI
after gravity operation yielded a tin concentrate that
assayed 65.26% Sn, 3.53% Fe(T), 4.45% SiO2, 1.89%
Al2O3 with 93% Sn recovery (wt% yield 82.6). The iron,
alumina and silica content were considerably reduced
as specifed by the party.
MINING
National Institute of Rock Mechanics (NIRM)
The Institute has been extending its R&D
support to the industry in the following areas:
1. Hard Rock Mines/Metalliferous mines.
2. Coal Mines
3. Hydroelectric & Tunnelling Projects
4. Other Civil Construction Projects
The Institute had completed one S&T project and
three were in progress. By the end of 2007-08,
investigations in respect of 22 projects were completed
and the work in other 25-odd projects was in different
stages of progress.
Non-coal Mines
The key areas of research were geotechnical
studies, numerical modelling, geophysical exploration
and ground control investigations for hard rock mines
and design of controlled blasting and laboratory testing
of samples. The major areas of research included:
* optimum design of mining operations and
excavation systems;
* design of support system for improving safety,
conservation and productivity;
* prediction of unknown subsurface features;
and
* monitoring stability of excavations.
Support is also extended in areas of environmental
studies, exploitation of dimensional stones and
seismological studies.
Coal Mines
One of the major thrust areas of the Institute is to
improve safety and productivity of the underground
coal mines in the country. NIRM is involved in assessing
the feasibility of new mining methods and safe roof
supports in coal mines.
The strata control investigations in this sector
include:
5-8
* Rock mass characterisation, and RMR studies;
* Design of rock reinforcement systems;
* Coal mine pillar design;
* Development of new mining methods for
increased safety and productivity;
* Study of parting behaviour in multiple seam
extraction; and
* Mapping of barriers around old workings from
underground.
Hydroelectric Projects
The Institute has been conducting rock mechanics
studies required for excavations in several
hydroelectric projects in India. Main areas of rock
engineering investigations carried out by NIRM in this
field include:
* Investigations for determination of the in situ
stress and deformability properties;
* Geophysical investigations for bed rock
delineation and stratigraphic mapping;
* Instrumentation and monitoring;
* Numerical modelling for stress analysis and
design of support systems; and
* Design of controlled blasting parameters.
During 2008-09, in situ investigations were
determined for four major hydel projects.
Civil Construction Projects
NIRM has been involved in a big way in various
investigations assignments under the prestigious
Katra-Qazigund rail link project which were undertaken
and completed in the mountainous terrains in Jammu &
Kashmir. Geophysical investigations were carried out at
various tunnel portals and bridge abutments were
proposed along the 140 km long railway line. Rock samples
from these sites were tested at NIRM to determine their
physico-mechanical properties. NIRM's ongoing
investigations relating to geotechnical mapping and blast
design for the first underground LPG storage cavern of
the country that is being constructed in Visakhapatnam
are presently under progress. The institute has also
secured the project for surface investigations at an oil
storage Cavern site in Karnataka. Seismic survey was
also done for mapping bed rock profile at Teesta Stage -
II and Stage-VI projects in Sikkim.
Testing Services
In addition to these field investigations, NIRM has
done extensive testing of rock samples as per
international standards. The studies carried out on
various rock samples include:
* Measurement of strain at high temperature
under uniaxial and triaxial compressive stress
conditions;
* Thermomechanical behaviour of rocks;
 RESEARCH & DEVELOPMENT
Fundamental research in the area of
engineering and mechanical properties of rock
joints under shear, and studies on Kaiser effect,
were some of the unique research areas of the
Institute in the field of Fracture Mechanics.
Further, wire rope testing and non-destructive
testing (NDT) of mining equipment/components
are carried out on regular basis.
The following were the S & T projects undertaken
at NIRM
* Underground coal mining, Singareni Coalfields;
* Establishment of broad band seismic station,
Kolar;
* Study on blasting dust management system in an
opencast coal mine;
* Industry Sponsored Projects;
* Tapovan-Vishnugad Hydro-Electric Project,
Uttarakhand;
* Determination of in situ stress by Hydrofracturing
Method at the proposed underground LPG cavern
at Mangalore, Karnataka, RITES;
* Seismic refraction survey for Sleemanabad Carrier
Canal Project near Katni in Madhya Pradesh;
* GPR and Resistivity Survey for assessing the
stability of HMRB Oil Pipeline of IOCL Raniganj
Coalfield, West Bengal;
* Instrumentation, monitoring and data analysis at
power house complex, Tala Hydroelectric
Underground Project, Bhutan;
* Support design for tunnel at Nettempadu Lift
Irrigation Scheme, Stage-II, Andhra Pradesh;
* Measurement of ground vibration and air
overpressure produced from quarry blasting
b e y o n d 5 0 0 m f r o m Ye l e r u R e s e r v o i r,
Yeleswaram, East Godavari, Andhra Pradesh,
Department of Mines and Geology, Govt. of
Andhra Pradesh, Hyderabad;
* Ground vibration and air overpressure study
conducted during test blasts at an alternate site
for Bangalore Metro Rail Corporation Ltd
(BMRCL);
* Geological survey using GPR for investigating
buried objects near an archaeologically important
monument adjacent to the proposed metro
alignment for Bangalore Metro Rail Corporation
Ltd; and
* Assessment and expert opinion on Rock
Strata Classification at Pattuvam and
adjoining villages for Contract Package-3
o f J B I C a s s i s t e d K e r a l a Wa t e r S u p p l y
Project, Kerala;
5-9
ENVIRONMENT
Indian Bureau of Mines (IBM)
During the year 2008-09, Mining Research Cell
of TMP Division carried out eight studies—three
geo-technical investigations, two ground vibration
studies due to blasting in mines, two environmental
quality monitoring and one study on attenuation of
hexavalent chromium by bio-remediation technology
in Sukinda Chromite belt, Orissa (which was a S&T
Project). The salient features of these studies and
activities are as follows:
A. Geo-technical Investigation Activities
(for Slope Stability and Pit Slope Design)
Slope Stability at Jambunath Iron Ore & Red Oxide
Mine
Geo-technical investigation for slope stability was
carried out at Jambunath Iron Ore & Red Oxide Mine of
M/s Gogga Gurusanthiah & Bros., Hospet, Distt. Bellary,
Karnataka.
Geo-technical investigations were carried out for
assessment of footwall stability. Field work and
laboratory tests of samples for footwall, ore zone and
hanging wall were carried out for physio-mechanical
properties. Limiting Equilibrium Method of analysis was
carried out using GALENA software. Based on the
studies, a pit slope angle of 38o to 25o was recommended
for the ultimate pit limit at 650 mRL with a Factor of
Safety 1.779 to 3.544. The analysis was aimed at helping
the mine management stabilise the pit slopes.
Slope Stability Studies at Karadikolla Iron Ore Mine,
Karnataka
Geo-technical investigation for slope stability was
carried out at Karadikolla (Suresh) Iron Ore Mine of
M/s Balasubba Setty & Sons, Hospet, Distt. Bellary,
Karnataka.
Geo-technical investigations were carried out for
assessment of footwall stability. Field work and
laboratory tests of samples from footwall, ore zone and
hanging wall were carried out for physio-mechanical
properties. Limiting Equilibrium Method of analysis was
carried out using GALENA software. Based on the
studies, a pit slope angle of 47o to 45o was recommended
for the ultimate pit limit at 685 mRL with a Factor of
Safety more than unity. The analysis was aimed at
helping the mine management stabilise the pit slopes.
Studies for Slope Steepening at Jaquela Pale Iron Ore
Mine
Geo-technical investigations for slope steepening
was carried out at Jaquela Pale Iron Ore Mine of M/s
R.N.S. Bandekar Bros., Goa.
 RESEARCH & DEVELOPMENT
Geo-technical investigations were carried out to
conduct slope stability investigations up to -28 mRL at
Pit No.3 (South). Representative rock/soil samples were
collected for conducting the tests for physico-
mechanical properties of different lithounits, which
formed different benches. Slope stability analysis was
performed by using Bishop’s Circular Method.
Sensitivity analysis of numerical modelling revealed
that for slope angle of 28o and 38o to a depth of -28
mRL, the factor of safety works out to be above unity.
The factor of safety could further be enhanced by
adopting protective measures as suggested in the report.
B. Ground Vibration Studies Due to
Blasting in Mines
Ground Vibration Studies at Maratha Limestone Mines
A study of ground vibrations caused due to
blasting was taken up at Maratha Limestone Mines
near Upparwahi, District Chandrapur (M.S.) for
M/s Ambuja Cements Ltd.
The study monitored eight blasts at four
different locations using Blasting Seismograph.
From the study, it was observed that peak particle
velocity for the charge weight of 60 kg for a distance
of 360 m was 9.67 mm/s which fell well within the safe
limit. It was further suggested that blasting carried
out near Ammonium Nitrate storage room which is at
a distance of 360 m should have charge weight per
delay not more than 120 kg. The air over pressure
was also found to be within the safe limit.
Monitoning of Ground Vibrations at Adityana
Limestone Mine, Gujarat
A study monitoring ground vibration due to
blasting was carried out at Adityana Limestone
Mine in Porbandar District of Gujarat for
M/s Saurashtra Chemicals Ltd, Gujarat.
The study was carried out mainly to assess the
impact of blast induced ground vibrations on
Jambuvanti cave – a site of archaeological importance –
which is 1.5 km away from the lease boundary. The
study was carried out during February 2008 by IBM's
TMP Division. For this study, a total of nine blasts
were studied at various points and the impact of ground
vibrations on the Jambuvanti caves was monitored. The
study revealed that the peak particle velocity was below
the permissible limit and hence there can be no adverse
impact on the Jambuvanti caves.
5-10
C. S&T Project – Attenuation of Hexavalent
Chromium in Sukinda Chromite Belt, Orissa,
by Bio-remediation Technology
S&T Project on “Attenuation of Hexavalent
Chromium in Sukinda Chromite Belt, Orissa, by
Bio-remediation Technology” was taken up in
association with Department of Botany, Utkal
University, Bhubaneswar (Orissa). The objective of
the S&T project was basically to address the problem
of hexavalent chromium present in the mine
discharge water, which could cause environmental
pollution of water bodies and adversly impact the
soil, flora & fauna of the surrounding areas. Sukinda
valley of Orissa attributes to 94% of total chromium
deposit of the country and reportedly produces
about 3.6 million tonnes per year. The opencast
mining of chromite practiced in the area is known to
considerably release hexavalent chromium which is
carcinogenic into the surroundings thereby
contaminating the soil and water quality in the
adjacent area. The adverse effects on the plant
growth and microbial activity in the soil resulting in
their degeneration were too alarming in proportions.
The standard permissible limit of hexavalent
chromium in discharge water is 0.1 mg per litre,
whereas, in drinking water, it is 0.05 mg per litre.
However, observations reveded that C +6 in the
ground water of Kaliapani area ranged from 0.12 to
4.5 mg per litre. Presently, the treatment of mine
discharges include addition of ferrous-sulphate
solution to decrease the pH followed by addition of
time to neutralise the water. The study further
observed that Cr +6 is stable in alkaline condition of
soil and water.
Under the project, experimental test plots that
cultivated different crops were selected near
South Kaliapani Chromite Mine and the mine
discharge water was allowed to pass through the
plots in a controlled condition. Two seasonal
crops of paddy were cultivated periodically along
with different types of para-grasses and water
hyacinth in the experimental plots. The study
reveals in the affirmative the positive impact of
environment friendly bio-remediation technique in
reduction of hexavalent chromium in water & soil
and further suggests its use in regular fields. The
final study report was submitted to the Ministry
for affirmation.