PROJECT REPORT ON CAPTIVE USE OR END USE OF MINERALS BAUXITE, PYROPHYLLITE, DIA: MINERALS BAUXITE, PYROPHYLLITE, DIASPORE & CLAY IN JARYARI, AMARPATAN, SILAPARI & PANIYARKHEDA AREA APPLICANT M/s Allied Minerals Industries Pvt. Ltd., Reg. Office : Village Jayanti Nagar, PO Pipraudh Katni, District Katni (M.P.) Correspondence Address: ‘A-24, New ACC Colony, Shanti Nagar, Distt Katni M.P. 483504PROJECT REPORT ON CAPTIVE USE OR END USE OF MINERAL. INTRODUCTION: M/s Allied Minerals Industries is a well established Company and’their main project is to use refractory mineral like Bauxite, Pyrophyllite, Diaspore, Clay etc. These minerals are being processed for sizing & calcination and then sent to the end users. M/s Allied Minerals Industries Pvt. Ltd. have been granted PL for Bauxite, Pyrophyllite, Diaspore & Clay in Jaryari, Amarpatan in Satna, Silapari in Damoh and Paniyarkhera in Tikamgarh district, the PL operation have been completed and the applicant has filed an application for ML of these areas. As per prevailing conditions, the applicant should have their own captive unit for mineral processing and end use. The applicant already have well established unit of Refractory use in Piproudh village of Katni district where minerals are being purchased and processed. Thus, offering ML to the applicant will be a key factor for upgrading the mineral value with Value Added concept. The brief details of applicant is as under: ‘TRUE-COPY For led Mineral aati) Li(S.No. | Particulars Details ‘a) | Name of the Applicant M/s Allied Minerals Indu: Pvt. Ltd., Address: ‘A-24, New A.C.C. Colony, Shanti Nagar, Katni, District Katni (M.P.) | Phone no. 07622-645901, Fax. No. 07622-268525 email: order@alliedmineralsindustries.com b) _ | Status of Applicant Ttis a registered Private Limited Company c) ‘Mineral(s) which will be | Bauxite, Pyrophyllite, Diaspore & Clay processed in Refractory unit ‘@) | Location of Refractory unit _| Jayanti Nagar, Piproudh, Jabalpur Road, Katni (M.P.) e) Capacity of unit 2007TPH unit is installed in the area ) | Feed material available |Pyrophyllite & Diaspore from Paniyarkhera ML applied area Bauxite and Clay: Jaryari in Satna District, Madhya Pradesh Pyrophyllite: Silapan in Damoh District, Madhya PradeshGENERAL INTRODUCTION: Refractory, a key input for iron and steel making, is assumed to have an ever increasing role due to high stress on production of high quality sophisticated steel, which alone accounts for the consumption of nearly 70% of the total refractories produced [1]. Refractories in general, are the non-metallic materials that are hard to melt at high temperature having enough mechanical strength and heat resistance to withstand rapid temperature change, including repeated heating & cooling and has resistance to molten slag and metals. Generally refractories are classified into two categories i.e. (i) Shaped refractories, available in the form of different brick shape, and include the oxide and non-oxide system. (ii) Unshaped refractories, which includes mortars, castables, plastics etc. [2] Three types of refractory materials exist depending upon their chemical nature as given below:- 1) Acidic refractory: - It should not be allowed to come in contact with basic products to avoid the reaction. Examples - Fireclay, Silica, Quartz, Ganister sand, Semi-silica etc. 2) Basic refractory: - It should not come in contact with acidic products. Examples - Bauxite, Lime, Magnesite, Dolomite, Alumina, Zirconia etc.3) Neutral refractory: - It can be used in conjunction with acidic or basic products, Examples - Chromite, Graphite, Carbon, Carbide, Mullite, Kyanite, etc. ALUMINA REFRACTORIES: Refractory of this group is not used so extensively because they are costly. As a general rule the refractoriness increases with increase in Alz0s content of alumina silicate refractories. Raw materials for high alumina refractory bricks which are chemical or ceramic bonded is mostly precalcined for giving lower firing shrinkage. Dry pressing is normally used for moulding the mixture of high alumina material and granular grog, although hand moulding and pneumatic ramming is also done to produce some special shapes. MARKET With the development of the consuming industries, the demand for refractories in general and monolithics in particular is mainly linked. About 75% of refractories produced in the country are being consumed by the iron and steel industries and the balance goes largely to the cement, glass, thermal power plant and other such industries. There has been a rapid change in the iron and steel industry during the past few decades. The new techniques such as basic oxygen furnaces, continuous casting etc. have called for special refractories. The technological changes and increasing demands for greater furnace output have made it imperative to turn to 4newer refractories and refractory installation techniques. Due to its inherent advantages, consumption of monolithic refractories has been continuously increasing while consumption of bricks and shapes has declined, Thus, Monolithic Refractories are having very good scope in the market. WHAT IS A REFRACTORY ? CHARACTERISTICS OF GOOD REFRACTORY Resistance against heat Resistance against corrosion Should have high fusing temperature Ability to withstand high load Should be chemically inert Should not undergo deformation Uniform expansion and contractionPRINCIPLE OPERATION The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its axis. The material to be processed is fed into the kiln from the upper end of the cylinder. As the kiln rotates, material gradually moves down towards the lower end, and undergoes a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-current), but usually in the opposite direction (counter-current). The hot gases are generated in an external furnace, or may be generated by a flame inside the kiln. Such a flame is projected from a burner-pipe (or “firing pipe") which acts like a large bunsen burner. The fuel for this may be gas, oil, pulverized petroleum coke or pulverized coal. Aluminium hydroxide is the main component of bauxite, the principal ore of aluminium. A mixture of the minerals comprise bauxite ore, including gibbsite (AI(OH)s), boehmite (y-AIO(OH)), and _ in diaspore (a- AIO(OH)) along with impurities ofiron oxides and hydroxides, quartz and clay minerals(*4l, Bauxites are found in laterites. Bauxite is purified by the Bayer process: ‘Al; + H20 + NaOH > NaAl(OH)s Al(OH); + NaOH > NaAl(OH)« Except for SiOz, the other components of bauxite do not dissolve in base. Upon filtering the basic mixture, Fe20s is removed. When the Bayer liquor is cooled, Al(OH); precipitates, leaving the silicates in solution. NaAl(OH);—> NaOH + Al(OH); The solid Al(OH); Gibbsite is then calcined (heated to over 1100°C) to give aluminium oxide:(6 2 AI(OH)s > AloO3 + 3 H20The product aluminium oxide tends to be multi-phase, ie., consisting of several phases of aluminium oxide rather than solely corundum.(29! The production process can therefore be optimized to produce a tailored product. The type of phases present affects, for example, the solubility and pore structure of the aluminium oxide product which in turn affects the cost of aluminium production and pollution control. For its application as an electrical insulator in integrated circuits, where conformal growth of thin film is a prerequisite and the preferred growth mode is atomic layer deposition, Al,0: films were prepared by the chemical exchange between trimethylaluminum Al(CHs)3 and H20:051 2 Al(CHs)3 + 3 H20 > Al2Os + 6 CHs H,0 in the above reaction was subsequently replaced by ozone (0s) as the active oxidant and the following reaction took place:1141071 2 AI(CH3)3 + Os > AlzO3 + 3 CoHe The AlzO3films prepared using 03 show 10-100 times lower leakage current density compared with those prepared by H20, known as alundum (in fused form) or aloxitel8)in the mining, ceramic, and materials Science communities, aluminium oxide finds wide use. Annual world production of aluminium oxide in 2015 was approximately 115 million tonnes, over 90% of which is used in manufacturing aluminium metal. The major use of speciality aluminium oxides is in refractories, ceramics, polishing and abrasive applications. Large tonnages of aluminium hydroxide, from which alumina is derived, are used in the manufacture ofzeolites, coating titania pigments, and as a fire retardant/ smoke suppressant.Lacelo- BAO MOMMA Co Lalare) eu ee Se ae) a) sis aF PYROPHYLLITE/ DIASPORE RAW M, \TION (SHAFT KILN) For process of Raw material calcinations, we are using Gas Plant and Shaft Kiln, Gas Plant produces Carbon Monoxide (CO) from coal. Bituminous coal is being used in gas plant size 10mm to 40mm by crushing or hand breaking to produce 26% to 28% Carbon Monoxide (CO) by coal burning in gas producer plant. It is then used in Shaft Kiln furnace for calcinations of pyrophyllite and raw material. Raw pyrophyllite and Diaspore material is carried from mines by trucks to our work place, there we are breaking the material to 5” to 6” size by crushing or hand breaking and then we are feeding it in to shaft kiln for calcination. Carbon Monoxide (CO) gas is used in Shaft Kiln as a fuel for firing pyrophyllite/ diaspore raw material. At the time of firing, the pre-heating zone temperature is maintained at 700°C to 1100°C. It is the required temperature for pyrophyllite raw material calcinations. In shaft kiln, raw pyrophyllite/ diaspore feeding is done from the top of the kiln and the fired materials comes out from the discharging door and calcined material is removed manually. After calcination, Calcined pyrophyllite/ diaspore goes to factory shed and sizing plant for making various size grains by the process of Jaw Crusher, Impact Ball Mill, vibrating screen for making of 0-1mm, 1-3mm, 3-6mm and fines powder 0-0.09mm, then it is properly packed into HDPE Bags. PROCESS OF QUALITY RAW BAUXITE CALCINATION IN ROTARY KILN Process of Raw Bauxite calcinations, we are using Producer Gas ie. burning Carbon Monoxide (Co) gas, Furnace Oil (F.0.) and Pet coke for calcination. Initially Raw Bauxite as big blocks/ boulders, before firing, is transported by trucks to our work place. These differently sized boulders/ lumps are broken manually by hammer to 6” - 8" sized boulders/ chips so that it can be used in crusher. The crusher breaks these 6” - 8" sized boulders into smaller chunks/ fragments of 10mm to 20mm size. These broken bauxite chunks are carried through Conveyor belt no. 2 to the screener where it is screened and fed via elevator into Hopper no. 2, from there the material is pushed in to the kiln as required. By maintaining the temperature of the Rotary Kiln, this material is fed as required. Process of Firing: First we charge producer gas (CO) Carbon Monoxide in to the kiln for rising preheating temperature. After the preheating temperature is achieved we charge Furnace Oil (F.0.) or Pet coke through Burner in to the Kiln. Temperature of kiln then rises up to 1600°C. Thus the materials calcination is completed, after that it is cooled in our cooling system (cooler). 10Process after calcination: This calcined material is received at the nearest platform after cooling through the cooler, and then it is dispatched to the customer as required. ‘The remaining material is sent to our sizing plant and is processed under Jaw crusher, impact, Ball mill and vibrating screen to get various sized grains of 0-1mm, 1-3mm, 3-6mm and 0-0.09mm fines powder, and then it is properly packed in HDPE bags.Refractory lining: ‘The purpose of the refractory lining is to insulate the steel shell from high temperatures inside the kiln and to protect it from the corrosive properties of the processed material. It may consist of refractory bricks or cast refractory concrete, or may be absent in zones of the kiln that are below or around 250°C. The refractory selected depends upon the temperature inside the kiln and the chemical nature of the material being processed. In some processes, such as cement, the refractory life is prolonged by maintaining a coating of the processed material on the refractory surface. The thickness of the lining generally ranges from 80mm to 300mm. A typical refractory will be capable of maintaining a temperature drop of 1000°C or more between its hot and cold faces. The shell temperature needs to be maintained below or around 350°C in order to protect the steel from damage, and continuous infrared scanners are used to give early warning of "hot-spots" indicative of refractory failure. Round Periodic Kilns: Round periodic kilns are typically used to fire silica bricks. Figure 2-8 is a diagram of a round periodic kiln. These kilns can be used to fire large refractory products that cannot be fired in a tunnel kiln and can easily accommodate changes in production (The TechnicalAssociation of Refractories, Japan, 1998). Shuttle Kilns: As illustrated in Figure 2-9, the design of a shuttle kiln resembles the firing zone of a tunnel kiln, Shuttle kilns effectively store heat and are used to fire fireclay and specialty bricks (The Technical Association of Refractories, Japan, 1998). Shuttle Kiln Refractories are generally categorized either as clay or nonclay products. To further classify the products, refractories are labelled as acidic or basic, Refractories are typically produced as shaped refractories, unshaped refractories, and fibrous materials. Shaped refractories include bricks, shapes, and crucibles. Bricks and shapes are formed by mixing raw materials with water and/or other binders and then pressing or moulding the mixture into a desired shape. Crucibles are ceramic containers used for melting metal. Unshaped refractories, also called monolithic, are unformed products that are dried to form a unified structure after application. These refractories can be used as mortars, plastics, ramming mixes, castables, and gunning mixes. Monolithic refractories are applied by pouring, pumping, trowelling or gunning.PHOTOGRAPH SHOWING STACK OF PYROPHYLLITE NEAR THE PLANT AREA 4Do Reece cn murumeeuueniasss ner al Binder & liquidsRefractory manufacturing process Reet ncu cn mucUce ties) Raw ff Rough | middl material Jf crushing | crushi oar) CreaRefractories SS i Weer Ceoics) | See ees aa bricks Cee) ee meee Alumina , Dolomite POF cso siete et ig monolithics teed Pa tae acee Peete iee tas ee ieee Ween || Melting point of pure refractory oxide aaitSTo) AlZO3 C203 CaO ZrO2 POF ced wih pao Pave MgO1. Analysis: After Calcination of Pyrophyllite in Silapari Area SiOz > 55.45% AlOs : 41.60% Fe203 : 0.90% 2. Analysis: After Calcination of Pyrophyllite in Paniyarkheda Area SiOz x 55.60% AlOs : 39.40% Fe203 t 1.65% 3. Analysis: alcinati ii Paniyarl SiOz : 28.50% Al2O3 t 68.40% Fe203 i: 1.55% 4, Analysis: alcination of ‘ite in SiOz 8 486% Al203 81.20% Fe203 2.90% 5, Analysis: After Calcination of Laterite in Jaryari Area SiO2 > 12.90% ALO; :~—- 39.84% Fe203 t 27.45% 6. Analysis: After Calcination of Fireclay in Jaryari Area SiOz $ 52.55% Al203 39.20% Fe203 t 1.80%Conclusion: Since applicant has already established Refractory unit and cash flow is already in positive, and as per received information the Internal Rate of Return is more than 40% thus by offering ML will uplift the status and industrial set up. TRUE-COPY For Allied Minerals Jndustvies (P) Lid _ B Ca Director Director Allied Minerals Industries Pvt. Ltd., ‘A-24, New ACC. Colony, Shanti Nagar, Katni, District Katni (M.P.) 2»