A

Summer Training Report

On

Submitted By:
Ajith Kurien
B.Tech Chemical Engineering
5th Semester
A20435416012
CONTENTS
 INTRODUCTION
 INDUSTRIES IN COMPETITON
 PRODUCTS FORMED
 PROCESS FLOW DIAGRAM
 ILMENITE BENEFICIATION PLANT
 ACID REGENERATION PLANT
 CHLORINATION PLANT
 OXIDATION PLANT
 SURFACE TREATMENT PLANT
 UTILITIES
 UNIT OPERATIONS
 REFERENCES
 Source: http://kmml.com/php/gallery.php?photo_catid=20&photo_id=143&pgNo=&key=0

 The “Kerala Minerals And Metals Limited” is a public

sector undertaking in Kollam, Kerala, India.
 It produces rutile grade Titanium dioxide pigment (white)
through chloride process.
INTRODUCTION
 After the discovery of rich mineral wealth in the
beach sands of Kollam, Kerala by German scientist,
F. X. Perira and Sons established “The Travancore Pvt
Ltd. In 1932.
 Later,in 1972 it came under the Kerala state Govt. and
named as “The Kerala Minerals and Metals Ltd.”
 Today, with over 2000 employees and a range of
products, KMML has become part and parcel of local
and international life.
 It has a installed capacity of 40,000 MT per annum
with an efficiency in production up to 67% of
installed capacity.
 The plant runs for 24 hours comprising of 3 eight
hours shift. And each shift employs almost 400
employees.
 The plant has a shut down period of usually one
month for maintenance.
INDUSTRIES IN COMPETITION
NAME OF INDUSTRY LOCATION GRADE AND PROCESS CAPACITY
USED (TONS PER ANNUM)

KILBURN CHEMICALS DAHEJ, GUJARAT, INDIA ANATASE /SULPHATE 15000

PROCESS

KOLMAK CHEMICALS KOLKATA,WEST BENGAL , ANATASE /SULPHATE 22000

INDIA PROCESS

PRAKASH CHEMICALS VADODRA , GUJARAT, INDIA ANATASE /CHLORIDE 18000

PROCESS
PRODUCTS FORMED
 The industry produces TiO2 white pigment in eight
different quality depending upon the customer
demand and is sold under the brand name KEMOX.
NAME OF THE PRODUCT USES
• KEMOX RC 800 • High gloss coating, industrial coatings
• KEMOX RC 800 PG • Polyethylene films and vinyl sheet
goods
• KEMOX RC 822 • Pigment for paints, exterior and interior
applications
• KEMOX RC 804 • Brilliant white color plastics or color
concentrates
• KEMOX RC 802 • Architectural and industrial paints
• KEMOX RC 813 • Low gloss maintenances paints
• KEMOX RC 808 • Used in automobiles
PROCESS FLOW DIAGRAM
ILMENITE BENEFICIATION PLANT(IBP)

Source : http://kmml.com/php/gallery.php?photo_catid=25
 Aim : Raw ilmenite from the sand containing 55-60%
TiO2 is beneficiated to 92% TiO2.
 Process :
1) Reduction of Fe2O3 in a roaster using coke
2) Leaching in digestors
3) Calcination
 Chemical Reactions:
• 2C+O2→ 2CO
• C+CO2 →2CO
• Fe2O3+C→ 2FeO + CO
• Fe2O3+CO2→ FeO+CO2
• FeO + 2HCl → FeCl2 + H2O
• Fe2O3 + 6HCl → 2FeCl2 + 3H2O
ACID REGENERATION PLANT(ARP)

Source: http://kmml.com/php/gallery.php?photo_catid=22&photo_id=159&pgNo=&key=0
 Aim:
To regenerate the HCl from spent liquor from IBP section
only for economic purposes.

 Process :
1) spent liquor heated through a spray roaster
2) cyclones used to separate the iron oxide and HCl
3) absorption of HCl in wash liquor
4) scrubbed with H2O
CHLORINATION SECTION/ U-200

Source: http://kmml.com/php/gallery.php?photo_catid=22&photo_id=165&pgNo=&key=2

• Beneficiated ilemenite and petroleum coke is added in a fluidized bed

reactor at 1kg/cm2 and 815⁰C to produce TiCl4 (called as Tickle).

• TiO2 + 2Cl2 +2C → TiCl4 + 2CO

OXIDATION PLANT / UNIT 300

Source: http://kmml.com/php/gallery.php?photo_catid=23
 Aim:
To produce pure TiO2 (white pigment) from TiCl4 (Tickle)

 Process:
1) Tickle is added with AlCl3 and heated at 135⁰C
2) O2 is added and burnt in a furnace at 1050⁰C
3) Cl2 formed is sent to chlorination section

 Chemical Reactions:
TiCl4 + O2 → TiO2 + 2Cl2
 SURFACE TREATMENT AND
FINISHING SECTION /UNIT 400

Source: http://kmml.com/php/gallery.php?photo_catid=24
 The finished TiO2 pigment is produced in this section of
the plant.

1) Treated with sodium silicate and sodium alumina

2) Filtration and drying
3) Micronisation and product bagging
UTILITIES

 Boiler plant
 Water treatment plant
 Air compressor station
 Brick making plant
UNIT OPERATIONS

 DRYING
 SEPARATION
For drying two equipments are used:
1) Larox filter
2) Rotary drum Filter
For separation
1) Cyclone separator
LAROX FILTER

Source: http://kmml.com/php/gallery.php?photo_catid=24&photo_id=169&pgNo=&key= 1
Process Description:
1) Filtration
2) Diaphragm Pressing (pre-squeeze)
3) Cake Washing
4) Diaphragm Pressing (post-squeeze)
5) Cake Discharge and Cloth Washing
ROTARY DRUM FILTER

Process Description:
1) Vacuum suction
2) Washing
3) Drying
4) Cake cutting
CYCLONE SEPARATOR
 In the plant cyclones were used to separate gaseous HCl from
iron oxide particles in the acid regeneration plant (ARP).

 Cyclone Separator:
A cyclone is a centrifugal separator in which
particles, due to their mass, are pushed to the outer edges as a
result of centrifugal force.
The particles which are present in the air are forced to the outer
edges and leave the separator via a collection device fitted to the
bottom of the separator.
REFERENCES
 http://kmml.com/php/showContent.php?linkid=9&partid=1

 http://kmml.com/php/gallery.php

 https://www.grandviewresearch.com/industry-analysis/titanium-dioxide-industry

 http://kmml.com/php/gallery.php?photo_catid=24

 http://kmml.com/php/gallery.php?photo_catid=23

 http://kmml.com/php/gallery.php?photo_catid=25

 http://kmml.com/php/showContent.php?linkid=16&partid=1

 http://kmml.com/php/gallery.php?photo_catid=20&photo_id=143&pgNo=&key=0
CONCLUSION