INTRODUCTION

Kerala has one of the richest and one of most extensive heavy mineral deposits
in the world. These deposits stretch along the seacoast between Kayamkulam
and Neendakara, a trait generally known as Chavara coast. The main
constituents in the deposits are Ilmenite, Rutile, Sillimanite, Zicron and
Monazite. The Ilmenite, Rutile are titanium bearing minerals and hence used for
the manufacture of Titanium dioxide pigment and titanium sponge metal.

In 1932, a company named M/s. F.X Pereira and Sons Travancore Pvt. Ltd was
registered. Mineral sand mining and Ilmenite separation was started by them.
In 1972 this company was taken over by Kerala Government and was renamed
as The Kerala Minerals and Metals Limited.

In 1974 permission for the manufacture of TiO2 pigment was procured and the
project work started in 1979, with the technical support of foreign companies
like M/s. Benelite Corporation of America, M/s. Woodall Duckham of U.K. and
M/s. Kerr McGee Chemical Corporation of MEA. TiO2 pigment production was
started in the Pigment Production Unit at KMML by Chloride Process. Now the
capacity of the plant has been increased to about 40,000 TPY.

KMML is the only company in the whole world where the plants for mineral
sand mining, separation, beneficiation and TiO2 production are erected under a
single roof. KMML produces mainly five grades of TiO2 pigment. The main
consumers of the product are the paint, paper, printing ink and rubber industries.

1
 COMPANY PROFILE

Bringing more to your everyday life, KMML touches you in numerous ways.
Be it the dress you wear, the cosmetics you use, the medicines you take, the
paints you decorate your home with or the utility plastic products, our products
are there. Eco-friendly & socially committed, it is the only integrated Titanium
Dioxide facility having mining, mineral separation, synthetic rutile and
pigment-production plants. Apart from producing rutile grade Titanium dioxide
pigment for various types of industries, it also produces other products like
illmenite, rutile, zirconz sillimenite, synthetic rutile etc.

Manufacturing TiO2 through the chloride route, KMML produces very pure
rutile gradeTiO2 pigment. The different grades churned out by KMML under
brand name KEMOX has a ready market which asks for more. The
commendable work in research by the R&D department has also helped KMML
to add more colours to its portfolio.

With continued growth and demand in the economy and industry, the products
of KMML are being lapped up by the eager market. This has in turn set the
wheels turning for KMML’s expansion.

KMML has always been responsive to social and environmental causes. Some
of the initiatives taken by KMML have made a significant change to the area
and its people.

KMML is now in the aerospace industry & Defence applications with the
commissioning of the Titanium Sponge Plant. The TSP is a joint venture of
KMML, Vikram Sarabhai Space Centre (VSSC) and the Defence Metallurgical
Research Laboratory (DMRL). The VSSC has fully funded the Rs.143 crore
project. With the inauguration of TSP, India becomes the & 7th country in the
world having the technology for producing titanium sponge, which is the raw
material for titanium metal.

Titanium sponge is known for its high strength but low weight, making it an
ideal material for aircraft manufacture, including fighter aircraft. The material is
also used in nuclear plants, Engine parts, Ocean platforms, Reactors, Heat
exchangers and to make dental implants and artificial bones.

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Vision & Mission
 To become the nodal agency for promoting and establishing mineral
based industries in the State to ensure value addition and effective
and controlled exploitation of the mineral reserves.
 To develop adequate supply base for the services and utility for
development of the mineral based industries.
 To create more awareness about Corporate Social Responsibilities
for chemical industries in the State.
 To become the leader in controlling Green House Gas Emissions so
as to promote the concept of Green Earth.

3
 PROCESS DESCRIPTION

The Manufacturing Plant at KMML comprises the Mineral Separation

(MS) Unit and the Titanium dioxide Pigment (TP) Unit.

The MS Unit is where the separation of Ilmenite, Rutile, Leucoxone, Monazite,

Silliminite etc from the beach sand takes place, through the various stages in the
Wet Concentration Plant, Dryer Plant, Dry Mill, Rutile & Zircon Recovery
Plants. The MS Unit employs Gravitational, Magnetic, High tension
electrostatic techniques for separation of minerals from the sand.

The TP Unit is where the raw Ilmenite obtained from the MS Unit is taken for
further processing, through the various stages in the Ilmenite Beneficiation
Plant, Acid Regeneration Plant, Pigment Production Plant, Oxygen Plant &
Utility Section. Titanium Dioxide is manufactured here using the chloride route.

4
 PRODUCT PROFILE

KMML always maintains high standards of perfection, achieving technical

excellence in every phase of production. Catering to strict guidelines, KMML
offers a wide range of products for quality conscious customers. Our products
go into the manufacture of a variety of products used in every day life. Dress
materials, facial creams, tablets, newsprints, wood paints, emulsions, enamels,
plastics, tooth paste, rubber products, cosmetics, and printing ink – All contain
titanium dioxide

Some are:

 KEMOX RC 800
 KEMOX RC 802
 KEMOX RC 808
 KEMOX RC 822
 KEMOX RC 800 PG
 KEMOX RC 813

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ILMENITE BENEFICIATION PLANT
In Ilmenite Beneficiation Plant (IBP), the raw Ilmenite containing 55 to 60%
TiO2 is processed to obtain beneficiated Ilmenite of 90 to 92% TiO2, which is
the raw material for the pigment production unit, by the following process
operations:

a) Roasting and Cooling section

b) Digestion and Filtration section
c) Calcination and cooling section

Roasting
Raw Ilmenite is fed at the rate of 6.5-9 T/hr with 10% petroleum coke
into a rotating kiln called Roaster. The ferric oxide in the raw ilmenite is first
subjected to high temperature reduction to ferrous oxide in the presence of
petroleum coke at a temperature of 900 to 9500C. The reduced Ilmenite is
discharged through a rotary cooler having cooling water tubes and collected in a
hopper.

Reaction

Fe2O3+C=2FeO+CO

Fe2O3+CO=2FeO+CO2

Leaching in Digesters
42 Tons of reduces Ilmenite is charged in a Digester and leached with 19
to 22% HCL. During leching the ferrous oxide and other impurities are
dissolved in HCL.Leaching to be carried out in two stages; First with 51M3 acid
and secondly with 38M3 acid. The spent leach liquor is blown down to the
storage tanks from where it is pumped to Acid Regeneration Plant for
regenerating the acid. The leached ilmenite after washing with 50M3
wash/process water, it is dumped into the launders. From the launder it is
pumped to the belt filter where it is filtered and the filtered leached ilmenite is
sent to calciner through belt conveyor.

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Reaction

TiO2+2HCL+FeO=TiO2+FeCl2+H2O

TiO2+6HCL+Fe2O3=TiO2+2FeCl3+3H2O

Fig 1:Digester in IBP

Tank Farm
The spent liquor and wash liquor blown down from the digesters are pumped to
the respective storage tanks, from where it is pumped to the Acid Regeneration
Plant for regenerating the acid. The recovered acid received from ARP and
make up acid from the storage tank are pumped together using ration controller
to get mixed acid of 19 to 22% concentration for use in the digesters.

Calcination
Leached ilmenite is fed into Calciner at the rate of 4 to 6T/Hr through
screw feeder, where it is calcined at 500-5500C to remove moisture and volatile
matter. The material is cooled by draft in the cooler. The cooled beneficiated
ilmenite is screened and stored in the BI godown through bucket elevator and
belt conveyor.

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Equipment Design
Roaster
Shell is provided with welded cover at feed end and a nose ring at
discharge end.
Dimension : 2430mm x 30m(length)
Speed : 0.2 to 2 rpm
Slope : 1:50
Capacity : 7.4T/Hr
Residence : 150 minutes
time
Material of : SA 285 Gr. C
construction

Digester
Spherical rotary digester
Rpm : 1(both direction)
Capacity : 99M3
Weight : 92.74 Tonne
Material of : BQ steel plate of 32mm thickness with 10mm thick
Construction butyl rubber lining

Calciner
Dimension : 2.43(ID) x 30m (length)
Slope : 1:50
Speed : 0.2 to 2rpm
Capacity : 5279 Kg/hr
Material of : SA 285 Gr. C
Construction

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9
ACID REGENRATION PLANT
The spent acid containing 17-18% total chloride from the spent liquor
storage tank (T-601A/B/C) is pumped to pre-concentrator recycle tank. The pre-
concentrator recycle pump continuously circulates the spent liquor to the pre
concentrator(C-101). This pre-concentrator spent liquor is pumped from the
recycle tank by the Roaster feed pump through a fine filter to the spray boom
assembles, at the top of the spray roaster (R-101). The spray booms are each
fitted with a number of spray nozzles which finally atomize the liquor into the
top of the roaster, the spent liquor get hydrolysed in presence of steam &
oxygen& HCL there by Fe2O3 is formed at 4000C

4FeCl2+4H2O+O2=2Fe2O3+8HCL

2FeCl3+3H2O=Fe2O3+6HCL

The heat required for this reaction is supplied by burning oil in 4 burners
which are mounted tangential, at the cylindrical bottom of the spray roaster and
cause a flow of hot gases to spiral upwards. These hot gases comes into contact
with the descending liquor droplets from the spray nozzles. The Fe 2O3 formed
collects at the bottom of spray roaster and falls down to a slurry box (C-104)
where clear water from Iron oxide pond is used to it and pumped to the pond.

The HCL gas formed in the spray roaster is drawn by a blower (B-102)
through a set of cyclones(G-101) to remove solids from the gas and then it’s
cooled in a pre-concentrator from about 375C to 960C by direct contact with
incoming spent acid. The gas then enters a set of wave cyclones (G-102) to
remove the liquid carried over from the gas. The gas from the cyclones enters at
the bottom of the Absorber (C-102) which is a packed tower filled with
interlock saddles and it absorbs the HCL content in a stream of acidic water
feed from the top. The product recovered acid having 18.8% concentration is
collected at the bottom of the absorber and overflows by gravity to storage tanks
(T-603A/B/C) which is a packed tower filled with poly propylene saddles to
remove the HCL present to 0.01%(100ppm). The gas finally let out through
exhaust stack(S-101) by the blower. Make up water is continuously added in the
scrubber and continuously bleed to the was liquor storage tank.(T-602 A/B).

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Pumps and Valves

Recycle pump

Type : Vertical centrifugal

Capacity : 60M3/Hr

Discharge Head : 20.5m

Pumping fluid : Spent acid from IBP

Slurry pump

Type : Horizontal centrifugal

Capacity : 60M3/Hr

Discharge head : 37.12m

Pumping fluid : Slurry from roaster

Roaster feed pump

Type : Horizontal centrifugal

Capacity : 10.5M3/Hr

Head : 10.5m

Pumping fluid : Spent acid from IBP

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12
UNIT-200 CHLORINATION
The solid raw materials, Beneficiated Ilmenite (BI) and Petroleum Coke
(PC) are pneumatically conveyed from respective hoppers to the Chlorinators.
Chlorine from Chlorine storage tank is also conveyed to the Chlorinators Cl 2 in
gaseous form react with BI & PC to produce TiCl4 vapour and other metallic
chlorides.

Chlorinator is a fluidised bed reactor. The bottom of the chlorinator is

boxed up with a hemispherical dish where a distributor plate with 78 nos. of
nozzles provided for the flow of gas or air required for fluidisation purposes.
The Cl2 gas is fed to the chlorinator through the bottom dished end of
chlorinators by operating control valves. The BI & PC are charged to the
Chlorinators through the side nozzles above the chlorinator bed.

During initial start up, when air (1200Nm3/hr) is fed through the bed
nozzles the material above the bed will be in a fluidised condition and the
temperature will rise gradually. When the temperature reaches 2000C Petroleum
Coke will be fed continuously to build up the level up to 40% BI is fed to the
chlorinator when the temperature reaches 6000C and the level is build up to
80%. Before feeding Cl2 gas the composition of bed to be ensured between 45
to 55%. When the chlorinator exit gas temperatures reaches 700 to 9500C
chlorine can be fed to chlorinators through the dished end. The temperature of
Cl2 from vaporiser must be a minimum of 500C. The reaction will take place
and TiCl4 vapours produced will come out through the cross over pipe and then
to the cyclone. The temperature of TiCl4 at crossover pipe is reduced to 1800C
to 2000C by spraying cooled TiCl4 inside the crossover pipe. The cooled gas
will then pass through the condensation section and the un reacted ore plus
other metallic chlorides are collected at the cyclone bottom and then pumped to
ENP.

The gas from the cyclone enters the condensing column bottom and crude
TiCl4 cooled in water cooled heat exchangers (E204/205) enters from the top
and condenses the upward flowing gas. The crude TiCl4 then flows by gravity to
quench surge tank (F204) and from that to crude TiCl4 surge tank (F 205).

The gases leaving top of condensing column is passed through water

cooled condensers (E 206 A/B) knock pot (D 207), refrigerated condensers
(E207 A/B), knock out pot (D 208) to recover all the remaining crude TiCl4.

13
The vent gas at cooled sage from refrigerated condensers passes through a series
of scrubbers with water and lime for scrubbing. A scrubber with caustic solution
is also equipped for scrubbing in case of any exigency. The vent gas from
scrubbing system connected with a blower and dilution air fan draws the gas to
atmosphere.

The crude TiCl4 from condensation section is pumped to a reactor (D

213) where it is heated and vanadium chloride is reacted with treating oil added
to form compound which is separated by distillation. The required temperature
in (D 213) reactor is maintained by circulating the contents through a steam
heated re-boiler (E 210/211). The vapour boils off and passes through the heavy
end column (D 219). The top product pure TiCl4 is cooled in the heavy ends
condenser (E 215) and collected in heavy ends accumulator (D 219). From this
accumulator a part of the product is returned to the column as reflux and the
balance is pumped to Pure TiCl4 storage tanks (D 222/223/224) for storage.

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Major Equipment

Chlorinator

It is a Fluidised Bed reactor. The bottom of the chlorinator is boxed

up with a hemispherical dish where a distributor plate with 78 nos. of nozzles
are provided for the flow of gas (or) air required for the fluidisation purposes.

Bed depth : 1.6m-2m

Exit gradient : 650-7600C

Bed temperature : 982-10370C

Gas rate : 1120-1920Nm3/Hr

Pumps and Valves

Horizontal Centrifugal Pump

The centrifugal pump used in U200 is similar to one used in IBP.

They are manufactured by Wavman Engineering.

Needle Valve

A Needle Valve is a type of valve having a small part and a

threaded need shaped plunger. It allows precise regulation of flow through it is
generally only capable of relatively low flow rate. It is usually used in flow
metering applications

15
16
UNIT-300 OXIDATION UNIT
In this unit purified TiCl4 from U-200 is mixed with AlCl3 and vapour of
this mixture is oxidiser with oxygen in presence of LPG flame to produce TiO 2
pigment. Chlorine which is obtained as a by product is filtered, cooled, dried
and compressed before sending back to U-200 for chlorination of titanium ore
there.

Pure tickle from tickle storage tank is pumped using tickle transfer
pumps(G-235 A&B) through a heater (E-323) at a temperature of 120C to 135C
to Aluminium chloride dissolving tank (D-303), pre-calculated quantity of
AlCl3 is mixed with the tickle in this tank and agitated using agitator (G-307).
This solution after settling is transferred to the surge tank (D-304) from which
the feed material for the further process is drawn. Quantity of AlCl 3 to be added
varies for different grades of raw pigment produced. Aluminium chloride is
added for enhancing nucleation reaction.

Tickle and AlCl3 solution from D-304 is taken to tickle feed vaporizer (E
301,E 302) where it is vaporized using steam in Nickel tube bundle and the
vapour is send to the tickle pre heater at a temperature of 1450C-1900C through
glass lined pipe. In the tickle pre heater this vapour is preheated to 3300C to
3700C using LPG burners.

Oxygen from Oxygen plant is preheated to 9400C-9800C in the oxygen

pre heater and sent to the oxidiser where LPG is injected and this LPG in
presence of heated oxygen forms a flame. Then the preheated tickle vapour is
admitted into the oxidizer where the TiCl4+AlCl3 vapour reacts to produce TiO2
pigment particles and chlorine. Silica sand/carbo beads are also fed into the
oxidizer to erase the pigment from downstream cooling tube side. Potassium
chloride is injected downstream of the oxidizer for de-agglomeration of the
pigment. Even though the oxidation reaction is initiated at elevated
temperatures after starting the reaction, it is exothermic and a large amount of
heat is generated. For increasing the rate of production using this heat generated
some amount of TiCl4+AlCl3 vapour from feed vaporizer outlet is directly
admitted into the reaction zone downstream of oxidizer, by passing the tickle
pre heater.

The reaction products pass through the reactor cooling tube where the
products are cooled to below 450C and enter the pigment separator. The

17
pigment particles along with the silica sand/carbo beads fall to the bottom of the
separator. These particles are dumped into the pre treatment sump and slurred
using makeup eater. The pH, viscosity and density of the slurry are controlled
by adding required quantity of NaOH, water and SHMP solution.

This slurry is pumped to primary and secondary classifier for removing

the sand/carbo beads. The slurry after removing the sand/carbo beads is pumped
to the storage tanks (F 401,402,403,404) the sand/ carbo beads separated is
washed, dried, sieved and recycled with fresh make up sand/carbo beads.

The gaseous products of the reaction (mainly chlorine) leaves the top of
the pigment separator a a temperature of 3500C-4500C and needs to filter in the
bag filter to remove the pigment particles carried along with the gas. Bt as the
bags in the bag filter to be brought down and this is done by mixing cooled,
recycled gas with the pigment separator outlet gas at the entry point to bag
filter. For this, a major portion of the gases which the recycled gas blower draws
from bag filter is cooled in the recycle gas cooler (E 324/325) and is send back
to inlet of bag filter. The product from the recycle gas blower discharge is
filtered again in the guard filter and cooled in the methanol chiller. The cooled
gases then pass through a knock out pot where the condensable components are
dried out. This cooled recycled gas is then scrubbed in the H 2SO4 scrubber for
drying and then compressed using chlorine compressor and send back to U-200
for chlorination of Titanium ore.

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19
UNIT-400 PIGMENT FINISHING UNIT
After TiO2 is obtained, next step is to impart pigmentary qualities to
TiO2. This process is termed as pigment finishing and surface treatment and is
done at U 400 & U500. Main surface treatment processes are carried out at
U400. U500 is the place where various chemicals for surface treatment are
stored. The TiO2 is pulverized in a rotating drum like structure. The process at
U 400 includes classifying TiO2 which will be in the form of pellets of
noticeable size. These pellets are then passed to the micronizer, which is a tall
structure. Here superheated steam is blasted against the TiO2 to break them in
to particles of sizes of around 0.02 microns. The output of the micronizer, which
is ready to bag, is bagged into 25 kg sacks and is stored in the go down. Various
auxiliary plants are oxygen plant, boiler plant, acid regeneration plant, brick
making plant, refrigeration plant, compressor air station etc. Then there are
plant technical services, central maintenance repair shop, vehicle maintenance
shop, compressor maintenance station and other workshop to facilitate smooth
running of the plant.

20
Sand milling and classification
Pigment slurry from storage tanks (F 401/402/403) is pumped to trash
screen (S 425) (100 mesh vibrating screen) which removes sand and trash. The
screened slurry flows to a tank (F412) by gravity flow. From this tank slurry is
pumped to sand mill (P 412 A/B) where pigment grinding with sand is done for
releasing absorbed gases like TiCl4 and O2. Sand milled slurry is stored in (D
423) tank and from there, slurry is pumped to grits classifier (S 404 A/B) and to
vibrating screen to screen out grit and sand. Screened slurry flows to (D-424)
another tank and from there slurry is pumped to product classifiers (S-415
A/B/C). Product classifier separates and microns particles as overflow for
treatment and slurry is stored in treatment feed tank (F414)

21
Treatment
In treatment, various chemicals such as sodium silicate, sodium aluminate
etc are added which when neutralized with caustic soda or sulphuric acid from
hydrous oxides. Hydrous oxide particles are very small compared to titanium
dioxide particles and tend to coat individual pigment particles.
Treatment is done in (F-415 A/B) tank on batch basis. This tank is
provided with steam sprayer and agitator having two speeds (20 rpm & 30 rpm).
Using (C-417 A&B) pumps required quantity of raw slurry is pumped to
treatment tank. Required quantity of filtrate is taken in the tank using C-420
pump. The treatment chemicals from U-500 are connected to these tanks. A
batch meter installed near the treatment tank is provided with flow totaliser,
flow indicator and start-stop switches for each of the four chemicals used for
treatment. The required quantity of chemicals can be set in the flow totaliser.
After batch treatment is completed, the whole contents are transferred to F-418
tank.

Filtration and Drying

Treated slurry is pumped to filter feed tank F-418. From this tank slurry is
fed to first stage filter (S-407 A/B). Cake is formed on the filter drum by
applying vacuum to the drum and the cake is washed by spraying hot water
through nozzles. The cake is discharged to the re-pulper where it is agitated
after diluting with water. From the re-pulper slurry goes to F-423 tank by
gravity flow. From F-423 tank, it is pumped to 2nd stage filter and after
washing and re-pulping slurry goes to F-424 tank. Pigment slurry from F-424
tank is pumped to de-watering filters (F411 A/B). De-watering filter is different

22
from washing filter since no washing is given. The cake from the de-watering
filter is falling into extruder which form pigment cake into “Macaroni” shapes
which drops into the Tunnel drier by the conveyor. As the pigment passes
through the drier it losses moisture and finally discharged to the vibrating
conveyor C-407. At this stage moisture content will be less than 1% and organic
additive is sprayed at the discharge of DD conveyor. This macaroni is stored in
F-425 tank through bucket elevator C-418 and screw conveyor.

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Micronisation and Condensate Cooling

Dried, pigment is micronized in the micronisation section. The purpose of

micronisation is to reduce the particle size to 0.28 microns. Super heated steam
of 17.6 Kg/cm2 is used as the grinding medium. “Macaroni” from feed bin (F-
425) is fed to screw feeder (C-421 A/B) which feeds macaroni to Microniser at
an adjusted rate. The pigment is injected into the microniser chamber by a high
pressure steam ejector. Superheated steam which passes through the nozzles of
microniser attains supersonic velocity. At this velocity, pigment particles collide
with each other and particle size are reduced. The steam escape in a
condenser/scrubber and micronized pigment is cooled and conveyed by low
pressure air to secondary cyclone and from there to product bin.
The steam and non-condensable gas are drawn away through a fine
scrubber and ventury scrubber by a vacuum pump to the atmospheric vent. The
slurry from (F-432 A/B) (scrubber) flows to surge tank D-412 from where it is
recycled back to (F-432 A/B) by pumping through heat exchangers (E-401 A/B)
and (E-402 A/B)

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Product bagging
The hot micronized product is cooled conveyed by low pressure air. The
finished pigment product is bagged in paper bags and stored in the pigment
storage building

25
 DIFFERENT GRADES OF TiO2 PIGMENT
At present, KMML produces 7 grades of rutile grade TiO2 pigment.

 KEMOX RC 800
KEMOX RC 800 is low oil absorption, medium durable, and alumina treated
Rutile pigment produced by chloride process. It has high gloss producing properties fo
rinterior trade sales paint and industrial coatings. It exhibits high brightness and
excellent tint strength in gloss and semi-gloss enamels. It is recommended for printing
inks, high gloss coating, industrial coatings, low abrasivity coatings, pigment for letter
press gravure, polyamide etc. and exterior applications where maximum chalk
resistance is not required.

 KEMOX RC 800 PG
KEMOX RC 800 PG is a low oil absorption, medium durable, alumina treated
and plastic grade rutile pigment produced by chloride process. It has high tint strength
and excellent dispersion property. It exhibits comparatively low abrasivity. It finds
application in plates requiring a blue white high dispersion TiO2. Other areas of
application are powder coatings, polyethylene films and vinyl sheet goods. It is used
in most other common plastic applications.

 KEMOX RC 822
KEMOX RC 822 is an excellent pigment for paints, exterior and interior applications
in residential and architectural finishing, plastics, paper and printing inks.

 KEMOX RC 804
KEMOX RC 804 is used for brilliant white color plastics or color concentrates

 KEMOX RC 802
KEMOX RC 802 is a multipurpose superior performance rutile TiO2 pigment
manufactured by chloride process. It has been surface treated with alumina and silica.
KEMOX RC 802 has good capacity and weathering property. It has good gloss and is
easily dispersible. It is intended for both exterior and interior applications. This is
recommended for architectural and industrial paints - both solvent and water based.

 KEMOX RC 813
KEMOX RC 813 is a solvent based pigment.

 KEMOX RC 808
KEMOX RC 808 is a universal grade pigment suitable for multiple uses especially for
automotive

26
 UTILITY DEPARTMENTS
Utility department have the following sections:

1. Boiler plant
2. Water treatment plant
3. Air compressor station
4. Effluent pumping station
5. Brick making plant

Boiler plant
The boiler house is equipped with two water tube boilers and one fire tube
boiler for supplying steam to production plant

Water tube boiler

Water tube boiler used in the plant is ISGEC JOHN THOMPSON. It uses
furnace oil as fuel with a rating of 33T/Hr. Its working pressure is 24Kg/cm2. It
has a total heating surface of 1727m2.

The boiler was originally designed for coal/oil fixed with spreader stoker
and feeder with an economizer. The boiler is steel cased, thin wall two-drum
integral type water tube boiler with natural circulation and balanced draft. The
exit Flue gas from boiler passes through economizer and outlet gases into
atmospheres through chimney by means of ID fans.

After de-aeration the feed water is supplied to the steam drum through
economizer using multistage feed pump. The economizer is of through integral
bare type parallel tubes for picks up the heat from the flue gas. Water in the
steam drum is circulated to the mud drum via main bank tubes, from the mud
drum it is distributed to evaporator main bank tubes and rest to the combustion
chamber wall type via feeder pipes and manifold. A steam /water mixture is
returned by natural circulation to the steam drum. This is fitted with internal
baffles and cyclone separators for separating steam water mixture then the
steam is purified by passing through scrubber box mounted on the top of the
cyclone. From the steam drum, saturated steam is conveyed to saturate
collecting header and distributed to the production plants via common
distribution header. Part of the steam from the steam drum goes to super
heater. The superheated coils are suspended in the horizontal draught between
combustion chamber and the heat recovery surfaces. There are 15 coils and

27
finally collected in super-heated collecting header and distributed to U-400 via
common distribution header

Fire tube boiler

It has a horizontal smoke tube with three pass packaged boiler. It is made
by M/s Wester Works Limited, Bombay. The evaporation rate of the boiler is
9T/Hr with a maximum working pressure of 20Kg/cm2g. The fuel used is
furnace fuel.

Water Treatment Plant

The source water is Tube wells; and there are 7 tube wells with a draw
capacity100 m3/hr. each. The plant has been designed to produce 560m3/hr.
filtered water. Process of treatment is aeration, flocculation, clarification and
filtration.

Aeration of raw water to convert iron from dissolved ferrous state to

insoluble ferric state. The aerated water after lime addition flows into a chute
and then enters into radial flow clarifier for flocculation and subsequent
clarification. The effluent from the clarifier flows to the rapid gravity filters
for filtration.

The filtered water is collected in a concrete reservoir. Filtered water is

drawn from the filtered water storage tank with the help of centrifugal pumps
and supplying to different plants, overhead tank and DM unit. Five cooling
water pumps are used supplying to circulate cooling water and 7 cooling towers
are provided for cooling the hot water. The hot water coming
from various plants sent through the vertical cross flow cooling tower cells and
cooled water iscollected in the cold sump.

There is also a demineralization plant to produce DM water; it is used in

U400, U300and boiler plant. The DM water plant consists of 3 strong acid
cation exchangers, 3 strong base anion exchangers, degasser tank, degasser
pumps, degasser blower, DM water pumps, DM water tank, and acid and alkali
storage tanks with connected pipelines.

There is a fire and drinking water supply network in the factory. The
whole plants are connected with fire and drinking water line to meet the sanitary
requirements as well as for drinking purpose and fire-fighting. The fire
and drinking water supply and emergency water to U-300& DG is provided
from the overhead tank.
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 As a part of welfare activities, KMML is supplying drinking water to
local people around KMML through 27 lines and 60 km length pipeline from
drinking waterlines. The duration of water supply to locals is 3 Hrs. per
day. This network supplying about 500m3 water to more than 10,000
beneficiaries

Air Compressor station

Operating of air compressors, driers and supply wet air and dry air to
various plants as per their requirements. There are 5 KG Khosala, two
stage twin cylinder double acting compressors each 45.44 NM3/Min capacity, 3
air receivers, 3 air driers each 75 NM3/Min Capacity at a pressure of 10Kg/cm2
and connected interplant piping

Effluent pumping station

This is for pumping of treated effluent in the polishing pond to sea.

Pumping of Effluents from various plants after neutralization is collected in
settling pond and after settling, the effluent water is collected in the polishing
pond by overflow. There is a Galigher pump with 280m3/hr. capacity and
connected pipelines for about 1.5 km. This is pumped out to sea if pH value is
in the range 5.5 to 9. All statutory rules and regulations are maintained while
doing the operation.

As the old effluent pond was almost filled, from 2008 august they had
switched over to the old system to the new effluent ETP sludge pond. There are
two vertical Galigher pump having capacity of 100M3/hr. each and the
discharge connected to the old sea pumping line. Also from December- 2009
they have commissioned supernatant water from treated effluent neutralization
system and about 50M3/hr. water is consuming from this water for their process
use in connection with the Zero discharge effluent system

Brick making plant

Iron oxide brick is the by product of KMML, using the

raw materials are iron oxide collected from iron oxide, waste sand from MS
plant, waste silica sand from U300,cement, lime and sodium silicate. They have
two brick making plant with design capacity 1200/hr. each. Contract persons
with close supervision of utility department carry out all operational functions.
After curing these bricks are supplied for construction purposes in KMML

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 POLLUTION CONTROL

KMML has an elaborate pollution control system with respect to both waste
water and pollutants.

The waste water (acidic) from ilmenite beneficiation plant is sent to the
effluent neutralization plant, a primary neutralization tank and a secondary
neutralization tank. The acidic water entering the primary neutralization tank is
treated with the spend lime solution.
From chlorination and oxidation section, lime scrubbers, the partly
neutralized slurry from primary neutralization is then sent to the secondary
neutralization tank where it is treated with fresh lime or caustic soda solution.
The totally neutralized slurry from the secondary neutralization tank is pumped
to a 50000m3 capacity settling pond provided with an impervious clay and
polythene lining at the bottom and sides, where solids are settled. The clear
solutions from the settling pond with fines are overflowed to a similarly lined
polishing pond of 25000m3 capacity where the balance solids are allowed to
settle. The clear water from the polishing pond, meeting all specifications
stipulated by the pollution control board authorities, is pumped to the Arabian
Sea.
KMML also have a sophisticated instrumentation system for the
continuous recording of the pH in the Secondary Neutralisation Tank of ETP.
The quality of the pH of the treated effluent is continuously monitored and
controlled with the aid of this system. The pH of effluent in the polishing pond
is checked daily and reported to the Pollution Control Board (PCB) every month

Construction of new secure landfill

KMML is constructing two new secured landfills for storage of the

Effluent Treaatment Plant sludge and the iron oxide. The area of these ponds is
36000m2 each and they are being constructed as per the CPCB guidelines. The
construction of these ponds are fast progressing

Air Pollution Control Measures adopted by KMML

System for Scrubbing of emission through the stack:

 KMML has efficient systems for scrubbing the waste gases before letting
out to the atmosphere.
 The waste gases from the plant are scrubbed in three stages. In the first

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 two stages, the gases are scrubbed in dilute Hydrochloric Acid (acid
scrubbing). In the third stage, gases are scrubbed with Lime Scrubber
(lime scrubbing).
 These gases are let out to the atmosphere with an additional air supply of
about 22,000 M3/hr. This supply of air helps mainly for the transportation
and discharge of the scrubbed gases to a higher elevation in the
atmosphere.
 Sampling and analysis of the stack gas is done every month through an
agency approved by the Pollution Control Board and reports are
submitted to the Board regularly.
 KMML is installing two additional scrubbers for improved scrubbing.

Online Stack Monitoring system and Ambient Air Monitoring System:

 KMML is installing an Online Monitoring System and Ambient Air

Monitoring System to help check Air Pollution.

All gaseous effluent from the chlorination, oxidation, IBP and ARP units are
scrubbed with water/lime or caustic solution to absorb the toxic gases, diluted
with enough quantity of fresh air and then let out to the atmosphere through tall
stacks.

The certain pollutant controlling devices are wet cyclone and dry cyclone
separators which produce centrifugal force and the particle will get settle
bottom.

Cyclone separator
A high speed rotating (air) flow is established within a cylindrical or
conical container called a cyclone. Air flows in a spiral pattern, beginning at the
top (wide end) of the cyclone and ending at the bottom (narrow) end before
exiting the cyclone in a straight stream through the centre of the cyclone and out
the top. Larger (denser) particles in the rotating stream have too much inertia to
follow the tight curve of the stream and strike the outside wall, falling then to
the bottom of the cyclone where they can be
removed. In a conical system, as the rotating flow moves towards the narrow
end of the cyclone the rotational radius of the stream is reduced, separating
smaller and smaller particles.

Scrubbers
Scrubbers are air pollution control devices that use liquid to remove
particulate matter or gases from an industrial exhaust or flue gas stream. This
atomized liquid (typically water) entrains particles and pollutant gases in order
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to effectively wash them out of the gas flow. In comparison to other air
pollution control devices, scrubbers are very multidisciplinary, with the ability
to remove solids, mists, and gases simultaneously while also providing cooling.
They are also capable of handling explosive and flammable gases safely.
However, scrubbers suffer from high levels of corrosion and produce slurry
waste streams which are less convenient for recycling and disposal.
Undesirable pollutants are removed by contacting the gases with an aqueous
solution or slurry containing a sorbent. The most common sorbents are lime
(Ca[OH]2)
Here Acid scrubbers as well as Lime scrubbers are used and is maintained
efficiently.

Bag filter
A baghouse, also known as a baghouse filter, bag filter, or fabric filter is
an air pollution control device and dust collector that removes particulates or
gas released from commercial processes out of the air
In reverse-air baghouses, the bags are fastened onto a cell plate at the
bottom of the baghouse and suspended from an adjustable hanger frame at the
top. Dirty gas flow normally enters the baghouse and passes through the bag
from the inside, and the dust collects on the inside of the bags.
Reverse-air baghouses are compartmentalized to allow continuous
operation. Before a cleaning cycle begins, filtration is stopped in the
compartment to be cleaned. Bags are cleaned by injecting clean air into the dust
collector in a reverse direction, which pressurizes the compartment. The
pressure makes the bags collapse partially, causing the dust cake to crack and
fall into the hopper below. At the end of the cleaning cycle, reverse airflow is
discontinued, and the compartment is returned to the main stream.
The flow of the dirty gas helps maintain the shape of the bag. However,
to prevent total collapse and fabric chafing during the cleaning cycle, rigid rings
are sewn into the bags at intervals.
Space requirements for a reverse-air baghouse are comparable to those of
a shaker baghouse; however, maintenance needs are somewhat greater.

Venturi scrubbers

Particulate Scrubbers, often called Venturi Scrubbers, are effective at

removing particulate from the exhaust with high efficiency.
Particulate Scrubbers have several advantages compared to other dust
collection equipment. They are able to handle gas streams that contain moisture
and/or are high temperature, the overall size of the equipment is typically

32
smaller, and they have the potential to remove pollutant gas at the same time as
the particulate
Dilution air fan

A flue dilution fan enables companies to disperse emissions created

during the combustion process at low levels and comply with the Clean Air Act.

ENVIRONMENTAL POLICY

To protect and safeguard the environment by:

 Strictly complying with the statutory and regulatory requirements

 Managing and continually improving processes, activities and products in
view
 To control their impact on land, air and water and thus prevent pollution
 To reduce health and safety risks
 To optimise the use of resources

KMML satisfies strict guidelines of ISO14001

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 RESEARCH AND DEVELOPMENT LAB
KMML maintains a fully equipped R & D facility in the area of Pigment and
Paint Technology with a view to establish world class products and
competitiveness. This excellent facility undertakes research, development and
product improvement. Scientists and engineers continuously pursue innovative
technologies in the area of TiO2 pigments, quality improvement and other allied
products. The technical and sales service wing extends all help to customers in
the field of applications and uses. Analytical services mainly include XRD,
XRF, AAS, carbon analyzer, particle size analyzer, Weathering Testing
Instruments and Hunter Lab Colour Instruments.

R&D is constantly working towards better management of the plant functions to

ensure that near zero pollution standards are maintained.

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 CONCLUSIONS
The Kerala Minerals and Metals Ltd is a well reputed public sector
organization. The company is a boon to India, as its main product, Titanium
dioxide forms an essential ingredient of almost all items used in our day-to-day
life. The major asset of this company is skilled staff. Moreover the efficient
management of the resources have helped them to overcome the slump in the
sales.
Through this In-Plant training it was able to fulfill the objective of study.
Detailed study on the processes and environmental considerations was made
possible by giving emphasis on the practical side of the theory. All together
it was a good experience to see the company and various processes carried out
in the plants and the various functions of the company

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