NATIONAL METALLURGICAL LABORATORY

CSIR National Metallurgical Laboratory (NML) is a premier laboratory within the ambit of Council of Scientific and Industrial Research (CSIR), New Delhi, a statutory body under Government of India. Founded in 1950, NML has been serving local and overseas clients undertaking sponsored R&D projects and development in various fields related to Minerals, Metals and Materials pertaining to their beneficiation and value addition, extraction and processing, characterization, testing and evaluation, life cycle technology, corrosion behavior, materials development, specialized chemical analysis, modeling and simulation waste management and pollution control.


CSIR-NATIONAL METALLURGICAL LABORATORY

MADRAS CENTRE

(An ISO 9001:2008 Organisation)

CSIR National Metallurgical Laboratory (NML) is a premier laboratory within the ambit of Council of Scientific and Industrial Research (CSIR), New Delhi, a statutory body under Government of India.

Founded in 1950, NML has been serving local and overseas clients undertaking sponsored R&D projects and development in various fields related to Minerals, Metals and Materials pertaining to their beneficiation and value addition, extraction and processing, characterization, testing and evaluation, life cycle technology, corrosion behavior, materials development, specialized chemical analysis, modeling and simulation waste management and pollution control.

        Founded in 1950, NML has been serving local and overseas clients undertaking sponsored R&D projects and development in various fields related to Minerals, Metals and Materials pertaining to their beneficiation and value addition, extraction and processing, characterization, testing and evaluation, life cycle technology, corrosion behavior, materials development, specialized chemical analysis, modeling and simulation waste management and pollution control.
         To cater to the local needs of the region, NML Madras Centre (NML-MC) was established in 1973. Over the years, the Centre has undertaken several R & D projects mainly in the area of mineral beneficiation and has developed flow sheets for the beneficiation of ferrous and non-ferrous minerals.
        In recent years, the Centre has made significant contributions to the development of column flotation technology for Indian mineral industry. Recently, NML-MC has developed an innovative technology to treat
industrial effluents by electro-flotation.
        The Centre also undertakes research and development projects in the areas of micro-structural characterization and failure analysis of various industrial components including boiler tubes and automobile components, development and testing of Tiles.





CSIR NML-MC at a glance

R&D Services...

Process development in mineral beneficiation

The Centre has developed flow sheets for beneficiation of various ferrous, non-ferrous and industrial minerals such as graphite, limestone, clay, magnesite, barite, silica sand ,fluorspar etc. and transferred the technology to the user industries.  One of the major accomplishments of the Centre has been the development of Column Flotation technology for Indian Mineral Industry towards processing of various ores and minerals. 


The NML column has been field tested at major mineral industries like

M/s Gujarat Mineral Development Corporation Ltd., Ahmedabad (fluorspar)
M/s Kudremukh Iron Ore Co. Ltd., Kudremukh (iron ore)
M/s Bharat Gold Mines Ltd., KGF (gold ore)
M/s Hindustan Copper Ltd., Malanjkhand (copper ore)
M/s Hindustan Zinc Ltd., Udaipur (Pb-Zn ores)
M/s Indian Rare Earths Ltd., Chatrapur (sillimanite)
M/s Fomento, Goa (iron ore)
M/s Calpro Mineral Technologies India (Pvt.) Ltd., Salem (limestone)                
M/s JSW Ltd., Toranagallu (Iron Ore)
For the first time in the country, the Centre has developed and installed an indigenous fully microprocessor based automated laboratory column (75mm dia.) for National Mineral Development Corporation (NMDC) R&D Centre, Hyderabad.For educational and research purpose a laboratory flotation column (75 mm dia.) was supplied to Dept. of Mining Engng., Golden Valley Institution of Technology, KGF


Recently, the Centre has developed an effluent treatment system based on electro-flotation technique. The system was tested both on laboratory and pilot scale for the treatment of tannery effluents in the local tanneries of Chennai. The system totally removes the suspendedsolids and substantially reduces the COD and BOD loads
of the effluent.
The Centre has also developed a novel electrochemical system to remove Arsenic from drinking water. The field
trials of the system have been conducted for the removal of As from contaminated ground waters of West
Bengal.




Major facilities:

  • Denver sub-aerated laboratory flotation machine
  • Automated laboratory (75mm) & semi-commercial (500 mm) column flotation systemm
  • High intensity dry magnetic separator (20000 gauss)High intensity dry magnetic separator (20000 gauss)High intensity dry magnetic separator (20000 gauss)
  • Laboratory and pilot scale electro flotation effluent treatment system
  • Micronizer - Planetary mill (FRITSCH)
  • Hydrocyclone, laboratory test rig (MOZLEY)
  • Contact angle measuring system (KRUSS)
  • BET Analyser for surface area and porosity measurements of powders (MICROMETRICS)
  • Digital sieve shaker - wet & dry (RETSCH)
  • Petrological microscope (Leitz) with camera attachment
  • Particle size analyzer (0.04 to 2500 microns) - Wet, dry and photo modes (CILAS 1180)
  • Zeta meter (Zeta Corporation)
  • CHNS Analyser-gas based (Euro EA)
  • Ion selective electrodes

Design and development of flotation columns for laboratory and industrial applications

 


Testing Services

  •      Evaluation and testing of tiles

  •      Particle size analysis of powders

  •      Measurement of zeta potential, surface area and density

 

 

ONGOING PROJECTS (As on 01.10.2015)

Sl. No.

Title

Sponsor

 

1

Evaluation of Reagents for Flotation

M/s Somu Organo Chem P Ltd., Bangalore

 

2

Studies on Cement Concrete Roofing Tiles

M/s JAPEVA Engineering Pvt Ltd

 

3

Studies on cement concrete designer floor tiles

M/s Ultra Tiles Pvt Ltd., Chennai

 

4

Assistance in Design, erection and commissioning of 1000 tpd column flotation plant for barite beneficiation of

M/s Oren Hydrocarbons Pvt Ltd, Chennai

 

M/s McNally Sayaji Engineering Co. Ltd., Bangalore

5

Beneficiation of coal flotation tailings by column flotation and testing of bubble generation system developed by Tata Steel

 

M/s Tata Steel, Jamshedpur.

 

PROJECTS COMPLETED in 2014-15

Sl.No.

Title

Sponsor

 

1

Studies on brightness improvement of marble fines by reverse flotation & column flotation

M/s McNally Sayaji Engineering Co. Ltd. Bangalore

2

Beneficiation of barite by column flotation

M/s Oren Hydrocarbon Pvt Ltd., Chennai

3

Failure investigation of cooling coils in zinc plant from M/s HZL Rajasthan

M/s Hindistan Zinc Ltd., Rajasmand Dist.

4

2.5 mtr dia industrial column to M/s Andhra Barites Corpn Ltd supplied by M/s McNally Bharat Engineering Company under the scope of the agreement between NML and MBE to market the column flotation technology.

M/s McNally Sayaji Engineering Company Ltd. Bangalore

5

Characterization of cement tiles

M/s Ultra Tiles P Ltd., Chennai

7

Estimation of failure of drier in the paper mill at M/s Sevenhills Paper Mills, Samalkot, Andhra Pradesh

M/s United India Insurance Company Ltd., Kakikada.

8

Evaluation of reagents for flotation

M/s Somu Organo Chem P Ltd., Bangalore

9

Failure analysis of boiler water wall tubes

M/s Hindustan Zinc Ltd

10

Studies on Cement Concrete Roof Tiles

M/s Japeva Engineering (P) Ltd., Chennai

11

Characterization studies on rubber tiles

M/s Magna Rubber Floorings P Ltd., Chennai

PROJECTS COMPLETED in 2015-16

Sl.No.

Title

Sponsor

 

1

Evaluation of reagents for flotation

M/s Somu Organo Chem Pvt Ltd., Bangalore

 

Current research programmes

  •    Value addition of lean ores and tailings/rejects of mineral processing industries

  •    Design and development of flotation columns for laboratory & industrial applications

  •    Benificiation of minerals and coal

The Centre has developed flow sheets for beneficiation of various ferrous, non-ferrous and industrial minerals such as graphite, limestone, clay, magnesite, barite, silica sand ,fluorspar etc. and transferred the technology to the user industries.  One of the major accomplishments of the Centre has been the development of Column Flotation technology for Indian Mineral Industry towards processing of various ores and minerals. 


The NML column has been demonstrated at major mineral industries like

M/s Gujarat Mineral Development Corporation Ltd., Ahmedabad (fluorspar)
M/s Kudremukh Iron Ore Co. Ltd., Kudremukh (iron ore)
M/s Bharat Gold Mines Ltd., KGF (gold ore)
M/s Hindustan Copper Ltd., Malanjkhand (copper ore)
M/s Hindustan Zinc Ltd., Udaipur (Pb-Zn ores)
M/s Indian Rare Earths Ltd., Chatrapur (sillimanite)
M/s Fomento, Goa (iron ore)
M/s Calpro Mineral Technologies India (Pvt.) Ltd., Salem (limestone)                
M/s JSW Ltd., Toranagallu (Iron Ore)
For the first time in the country, the Centre has developed and installed an indigenous fully microprocessor based automated laboratory column (75mm dia.) for National Mineral Development Corporation (NMDC) R&D Centre, Hyderabad.For educational and research purpose a laboratory flotation column (75 mm dia.) was supplied to Dept. of Mining Engng., Golden Valley Institution of Technology, KGF


The column flotation technology developed by the Centre is transferred to Indian Rare Earths Ltd., Chatrapur for sillimanite and M/s Calpro Mineral Technologies India (Pvt.) Ltd., Salem for limestone beneficiation.

Major facilities:




  • Denver sub-aerated laboratory flotation machine
  • Automated laboratory (75mm) & semi-commercial (500 mm) column flotation systemm
  • High intensity dry magnetic separator (20000 gauss)
  • Pycnometer (Micromeritics)
  • Micronizer - Planetary mill (FRITSCH)
  • Hydrocyclone, laboratory test rig (MOZLEY)
  • Contact angle measuring system (KRUSS)
  • Surface area analyser (BET) (Micromeritics)
  • Digital sieve shaker - wet & dry (RETSCH)
  • Petrological microscope (Leitz) with camera attachment
  • Particle size analyzer (0.04 to 2500 microns) - Wet, dry and photo modes (CILAS 1180)
  • Zeta meter (Zeta Corporation)
  • Size reduction equipments (Jaw crusher, roll-crusher, ball mills and road mill)
  • Bond's work index
                                            TILE TESTING :
The tiles testing section of NML-MC has the facilities for testing and evaluation of cement tiles, ceramic tiles, concrete pavement blocks, concrete cubes, granites, marbles etc. as per Indian Standards

Testing Services
  • Abrasion resistance
  • Water absorption
  • Flexural strength
  • Compressive strength
  • Flatness
  • Bulk density
  • Apparent porosity
  • Apparent specific gravity

     

Major Facilities
  • Automatic Compression Testing Machine (2000 KN)
  • Manual compression testing machine (1000 KN)
  • Automatic Flexural Testing Machine (100 KN)
  • Manual flexural testing machine (100 KN)
  • Abrasion Testing Machine
  • Digital sieve shaker (wet and dry)
  • Tiles making machin3e
  • Portable skid resistance meter
  • Fade-O-Meter - light fastener tester
                                 

Tests:

       a.  Water absorption
  b.  Compressive strength (upto 2000 kN)
  c.  Abrasion/wear resistance (0.01 to 25 mm)
  d.  Flexural / Wet transverse strength (upto 100 kN)
  e.  Flatness
  f.  Bulk density
  g.  Apparent porosity
  h.  Apparent specific gravity

  o       Above tests are done as per IS standards

   o   No. of specimens/sample per test required:6 nos.

Minimum specimen tile/block size for flexural strength/wet transverse strength: 250 mm x 250 mm x 10 mm.

 

Quality Policy

We commit ourselves to achieve excellence in technological innovations in the field of minerals, metals and materials through emulative leadership, management and total employee involvement using state-of-the-art tools and techniques for continued measurable improvements in performance towards sustained customer satisfaction.

Quality Vision

The laboratory envisions a progressive enhancement of its resources, generation and acquisition of intellectual property assets and strives to maximize the business of R&D, meeting the customer requirement through maintenance of sustainable growth


Manpower of the Centre consists of qualified professionals in various fields of activities of metallurgy and allied disciplines

Name & Designation Qualification Professional
Membership
Area of Specialisation
Dr.S. Subba Rao
Chief Scientist
(Scientst-In-Charge)
sripadas@gmail.com
PhD (Chem. Engng)
(Uni. Of Newcastle, Australia)
Life Member IIME
Life Member IIChE
Mineral Processing, Process engineering, Quality Management Systems
T. V. Vijaya Kumar
Principal Scientist
tvvk65@yahoo.com
M.A.Sc.(Min. Proc.)
M.Sc. (Engng). (Met.)
Life Member IIME
Member IIM
Mineral Processing,
Surface Chemistry, Plant Operations
M. Ananda Rao
Senior Scientist
anandm04@gmail.com
M.Tech. (Materials and Metallurgical Engg. IIT-Kanpur)   Metallurgical Failure Analysis and mechanical activation of metals and minerals
Ms. N. Vasumathi
Senior Scientist
vasumatisamy@gmail.com
M.Tech. (Materials  Engg.)   Materials Characterization


Recent research publications of NML Madras Centre

    

o        D S Rao, T V Vijayakumar, S Subba Rao, S Prabhakar and G. Bhaskar Raju

Effectiveness of sodium silicate as gangue depressants iniron ore slimes flotation

International Journal of Minerals, Metallurgy and Materials, 18, 5, October, (2011), 515.

 

o        M.Murugananthan, S.S.Latha, G.Bhaskar Raju and S.Yoshihara

Role of electrolyte on anodic mineralization of atenolol at boron doped diamond and Pt electrodes

Sep.Purif.Technol. 79 (2011) 56-62.

 

  o        P.Sreedevi, K.Chennakesavulu, M.Kavitha, G.Bhaskar Raju and S.Prabhakar

Electrokinetic behavior of Fluorite

Journal of Dispersion Science and Technology, 32 (2011) 1306-1310

 

o        K.Chennakesavulu, P.Sreedevi, G.Bhaskar Raju, S.Prabhakar

Studies on the zeta-potential of calcite/P-sulfonato-calix[4,8] arenes

Journal of Dispersion Science and Technology, Vol 32 (2011) 1531-1536

 

o        Danda Srinivas Rao, Tadiparthi Venkata VijayaKumar, Sripada Subba Rao, Swarna Prabhakar, and G.Bhaskar Raju

Effectiveness of sodium silicate as gangue depressants in iron ore slimes flotation

International Journal of Minerals, Metallurgy & Materials, Vol 18 (5), (2011) 515-522

 

o        P.Vijayalakshmi, G.Bhaskar Raju, A.Gnanamani

Advanced oxidation and electro-oxidation as tertiary treatment techniques to improve the purity of tannery wastewater

Industrial & Engineering Chemistry Research, Vol 50 (2011) 10194-10200

 

o        B.R.V. Narasimhan, Satendra Kumar and T.S.N. Sankara Narayanan

Synthesis of manganese zinc ferrite using ferrous pickle liquor and pyrolusite ore

Environmental Chemistry Letters. 9 (2011) 243-250

 

o        B. Sivakumar, Satendra Kumar, T.S.N. Sankara Narayanan

Fretting corrosion behaviour of Ti-6Al-4V alloy in artificial saliva containing varying concentrations of fluoride ions

     Wear. 270 (2011) 317-324

 

   o        M. Jamesh, Satendra Kumar, T.S.N. Sankara Narayanan

    Corrosion behavior of commercially pure Mg and ZM21 Mg alloy in Ringer's solution - Long term evaluation by EIS

Corrosion Science. 53 (2011) 645-654

 

   o        K. Gopala Krishna, K. Siva Prasad, K. Venkateswarlu, K.C. Hari Kumar

     Microstructural evolution and aging behavior of cryorolled Al–4Zn–2Mg alloy

Mater. Sci. Eng. A535 (2012) 129-135

 

   o        K. Gopalakrishna, K. Sivaprasad, K. Venkateswarlu K. C. Hari Kumar

Microstructural evolution and aging behavior of cryorolled Al-4Zn-2Mg alloy

Materials Science and Engineering A, 535 (2012) 129-135

 

   o       K. Gopalakrishna, K. Sivaprasad, T S N Sankara Narayanan, K. C. Hari Kumar

     Localized corrosion of an ultrafine grained Al-4Zn-2Mg alloy produced by cryorolling

Corrosion Science, 60 (2012) 82-89

 

   o        K. Gopala Krishna, Nidhi Singh, K. Venkateswarlu, K.C. Hari Kumar

     Tensile behavior of ultrafine grained Al-4Zn-2Mg alloy produced by cryorolling

J. Mater. Eng. Perform. 20 (2011)1569–1574

 

   o       P. Lakshmipathi Raj, G Bhaskar Raju, Y. Sakai, Y. Takuma, A Yamasaka, S. Kato, T. Kojima

Chemical Engineering Journal, VOl.198-199, 21-218, 2012

 

   o      M Ananda Rao and TSN Sankara Narayanan

    Failure investigation of a boiler tube from a 77 & 2 MW coal based thermal power plant in the North West region of India

    Engineering Failure Analysis, 26: 12 (2012) 325-331

 


 

TECHNOLOGIES AVAILABLE FOR COMMERCIALIZATION

at

NML Madras Centre

 

Column Flotation

Process/Device

Column Flotation for the Beneficiation of Low-Grade and Finely Disseminated Ores.

Area

Mineral Processing

Uses

(i) Enrichment of ores by flotation, (ii) Flotation of ores and minerals, (iii) Quality and quantity improvement in mineral processing circuits, (iv) Flotation of base metal ores (Cu, Pb, Zn ors), iron ores (hematite, magnetite, BHQ, etc.), beach sand minerals (sillimanite) & industrial minerals (limestone, barite, etc.)

Salient Features

The merits of the flotation column includes improved metallurgical performance in terms of grade and recovery, effective cleaning action, smaller floor space, low capital investment, less operational and maintenance cost and easier control. Improved metallurgical performance is assured by column flotation as a result of (i) Less entrainment and entrapment through froth washing, (ii) Independent control of operating variables, (iii) Flotation of course and slimes particles, (iv) Can also be used as roughers and scavengers. Reduced running costs as a result of (i) No moving parts, (ii) Lower reagent consumption, (iii)Lower energy consumption. Reduced capital costs as a result of (i) Lower residence time, (ii) Higher gas holdup, (iii) Substantial reduction in floor area and (iv) One stage of column flotation is equivalent to 3 stage conventional flotation

Scale of Development

Pilot Scale

Major Raw Materials

Pilot Plant Facility

Major Plant Equipment/Machinery

Column with variable height, Indigenous sparging system, Microprocessor based level control, Auto pneumatic sampling, Digital flow measuring systems - air, water, feed, Centralized control panel

Details of specific application

For the beneficiation of Low-Grade and finely disseminated ores.

Status of Development

Completed

Ecological/Environmental Impact (if any, specify briefly)

No

Patenting details

Patent filed

Commercialisation Status

Laboratory scale 74mm diameter- 10kg/h treatment capacity (4 Nos. at NMLMC, NML-JSR, GVIT-Kolar & NEIST-Jorhat). Pilot scale 500mm diameter-1ton/h capacity (2 Nos. At NMLMC & RBSSN-Hospet, for low-grade iron ore) Commercial scale 1250mm diameter-150TPD capacity (Installed 3 Nos. at IREL-Chatrapur, Orissa, for sillimanite; Calpro-Salem, for limestone & IREL-Chavra, Kerala, for sillimanite). Installation of a 2500mm diameter column for the beneficiation of barite is in progress at Mangampet, A P.

Techno-Economics

Available on demand

Key words

Column Flotation, Beneficiation, Mineral Processing

 

Contact us
Director
NATIONAL METALLURGICAL LABORATORY
JAMESHEDPUR 831 007

Phone:
0657 2345028 | 2345000-001
          
Fax:
0657 2345213
Email: director[at]nmlindia[dot]org
Website: www.nmlindia.org
Scientist-In-Charge
CSIR NML Madras Centre, CSIR Madras Complex
Taramani, CHENNAI 600 113

Phone:
044 2254 2077 | 2254 2529 | 2254
            2523
Fax:
044 2254 1027
Email: nmlmc[at]csircmc[dot]res[dot]in