Indian Minerals

Yearbook 2011
(Part- I)
50th Edition
RESEARCH & DEVELOPMENT
(ADVANCE RELEASE)

GOVERNMENT OF INDIA
MINISTRY OF MINES
INDIAN BUREAU OF MINES
Indira Bhavan, Civil Lines,
NAGPUR 440 102
PHONE/FAX NO. +91712 - 2565471
PBX : +91712 - 2562649, 2560544, 2560648

E-MAIL : cme@ibm.gov.in
Website: www.ibm.gov.in

October 2012

RESEARCH & DEVELOPMENT

5 Research & Development

the desired level of less than 3.0% as Fe2O3 in the non-

he Science and Technology programmes (S&T)

of the Ministry of Mines, Government of India,
cover the disciplines of Geology, Exploration,
Mining, Bioleaching, Beneficiation, Rock Mechanics,
Ground Control and Non-ferrous Metallurgy and
environmental issues related to mining and
metallurgy. During 2010-11, 2 meetings were held by
Project Evaluation and Review Committee (PERC).
Based on its scrutiny report, Standing Scientific
Advisory Group (SSAG) considered and
recommended for Grant-in-Aid under S & T
programme of the Ministry of Mines. The SSAG
also approved eight projects in the 41st meeting
held on 7 June 2011.

magnetic fraction at a yield of 38%. The final process

scheme developed recommends processing of raw
bauxite lumps through roasting followed by crushing
and dry high intensity magnetic separator (85 wt%) at
particles of -1 mm + 0.15 mm. The scheme minimises
energy and water requirements while economising the
processing costs.

1.2 Beach Sand

Studies on heavies from beach and dune sands
of South-eastern coast of India with special
reference to recovery and in depth
characterisation of zircons (IMMT):

The highlights of work carried out during

2010-11 by various research organisations and
industries relating to mineral beneficiation and
mining & environment are given below:

The main objective of the study was separation of

differenet heavies by using different physical

1. BENEFICIATION
1.1 Bauxite

beneficiation techniques and characterisation of

heavies in beach sands with special reference to zircon.
Zircon (ZrSiO4) is found usually as a constituent in
heavy mineral sand assemblages which include ilmenite,
rutile, leucoxene, monazite and garnet in varying
proportions. Investigations were carried out to enrich
zircon from beach sands of Odisha coast. Recovered
zircons are used for making zircon bricks and are fired
at different temperatures in an industrial tunnel kiln.
Physical, chemical and thermo-mechanical properties
are evaluated. Mineralogical properties are correlated
with the thermo-mechanical properties. The developed
bricks were compared with the standards and found
suitable for refractory industrial applications.

Process Development to reduce iron from

bauxite for preparation of calcined bauxite
(IMMT):
The sponsor, M/s Gokul Minex Pvt. Ltd,
Ahmedabad, has plans to utilise the bauxite deposit of
Udgeri region in Kolhapur district of Maharashtra for
making calcined bauxite. The objective of the project
was to develop suitable process flow sheet for the
removal of iron from the bauxite, with Fe2O3 content of
6-8% in the ROM sample, through roasting-magnetic
separation process to prepare the quality of bauxite
suitable for preparation of calcined bauxite. Various
process schemes for removal of iron to the desired level
were tried by treating raw bauxite by both dry and wet
magnetic separation. The investigation also includes
study on the effect of roasting of bauxite followed by
magnetic separation on iron removal to meet
specifications of calcined bauxite. The results of the
study indicated that it was possible to remove iron to

Similar studies were carried out to recover zircons

from red sediment samples from Bad Lands topography
of Odisha (Basanputti village, Ganjam district) and
Andhra Pradesh (Srikakulam). Physical, chemical and
minerological properties were studied. The product
achieved from red sediment sands containing 95%
total heavy minerals (THM) through mineral

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RESEARCH & DEVELOPMENT

1.4 Gold

separator indicated 94% recovery. A product obtained

by stage spirals containing 98.9% total heavy minerals
achieved 98.6% recovery. The THM achieved from
spiral concentrator was subjected to high tension roll
separator to recover titaniferrous minerals (ilmenite and

Reovery of Gold from Bhukia (East) Block,

Banswara, Rajasthan for MECL, Nagpur (IBM):
A gold ore from Bhukia (East) Block, Banswara
district, Rajasthan sent by MECL Ltd, Nagpur
contained 2 g/t gold and 51.0 g/t silver with other major
constituents assaying 29.66% SiO2, 25.92% Fe2O3,
8.94% CaO, 11.88% S(T), 4.34% MgO, 3.13% Na2O and
6.86% LOI. The sample was sent at RODL,IBM,
Bengaluru with an objective to optimise a process for
gold recovery. By employing bottle role cyanidation,
cyanide leach concentrate with 96% Au and 40% Ag
values could be extracted by cyanide leaching followed
by Carbon In Leach (CIL) process. The
consumption of sodium cyanide would be 2.72 kg per
tonne. The results achieved appear to be encouraging.

rutile).

1.3 Copper Ore

Upgradation of composite copper ore from
Banwas, Khetri and Kolihan Mines for
HCL(IBM):
A composite copper ore sample from Khetri,
Kolihan and Banwas mines was sent at RODL, IBM,
Ajmer with an objective to achieve a concentrate of
18-20% Cu with 90-92% recovery. The as received
composite sample assayed 0.96% Cu, 59.01% SiO2,
2.52% S, 12.82% Fe and 71.65% acid insolubles.
Flotation at 62.5% minus 200 mesh grind and subjecting
the rougher float to re-grinding and cleaning in three
stages yielded a concentrate assaying 24.26% Cu,
33.91% Fe and 5.95% acid insoluble with 90.8% copper
recovery (Wt% yield 3.6). The copper concentrate
meets all the specifications stipulated by HCL.

1.5 Iron Ore

Bench Scale Beneficiation studies on Iron Ore
Fines Sample from Ghatkuri Iron Ore mines for
M/s Orissa Manganese & Minerals Limited
(IBM):
An Iron ore fine sample was received in the
Modern Mineral Processing Laboratory and Pilot Plant,
IBM, Nagpur from Ghatkuri iron ore mines, Odisha for
carrying out bench scale beneficiation studies and to
develop a process flow sheet, for producing an iron
concentrate with maximum grade and recovery.

Upgradation of a Copper Ore (Core) sample from

Chittorgarh, Rajasthan for M/s MECL (IBM):
A core sample of copper ore from Wari Copper
Project, district Chittorgarh, Rajasthan was sent by
M/s MECL, Nagpur at RODL, IBM, Ajmer to establish
the amenability of the sample to produce a copper
concentrate suitable for Indian smelters. The as
received sample assayed 1.20% Cu, 46.71% SiO2, 7.65%
Fe(T) and 74.48% acid insolubles.

The as received sample assayed 51.13% Fe(T),

12.75% SiO2, 6.53% Al2O3, 0.23% CaO, 0.01% MgO,
0.05% P, 0.41% TiO2, 0.06% Mn and 5.48% LOI.
Tabling on as received sample reduced to all -65
mesh could produce table concentrate assaying 63.90%
Fe(T), 2.87% SiO2, 2.36% Al2O3 & 2.68% LOI with weight
percent yield of 23.4 & Fe(T) recovery of 29.2%.

Flotation Test at 66.5% minus 200 mesh grind

could yield a concentrate assaying 20.94% Cu, 30.56%
Fe, 5.66% SiO2, 11.54% acid insolubles with 87.2%
copper recovery (wt% yield 4.9). The copper
concentrate meets the specifications stipulated by
M/s MECL.

Composite of table concentrate & table middling

could produce table concentrate assaying 60.85% Fe(T),
5.04% SiO2, 3.76% Al2O3 & 3.82% LOI with overall
weight per cent yield of 48.5% & overall Fe(T) recovery
57.7%.

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RESEARCH & DEVELOPMENT

Stub cyclone of the as received sample reduced to

all -100 mesh yielded a concentrate (Underflow)
assaying 58.23% Fe(T), 6.55% SiO2, 3.90% Al2O3 and
3.75% LOI with weight per cent yield of 68.5% & Fe(T)
recovery of 78.0%.

iron ore fines (-10.0 mm) to generate concentrate for

Finex process of iron making. The low grade iron ore
fines sample on an average contained 58.4% Fe, 4.3%
SiO2 and 4.7% Al2O3. The various minerals associated
in this ore are hematite, vitreous goethite, ochreous
goethite, gibbsite, kaolinite and quartz. The average
hematite content in the bulk sample is 46.30%. Various
beneficiation techniques such as scrubbing, jigging,
spiraling and magnetic separation have been used to
recover the iron values. Different alternative flowsheets have been suggested to recover the iron values
suitable for Finex process for steel making. The
investigations have indicated that iron concentrate with
64% Fe at 69% yield could be obtained by combination
of screening, jigging hydro-cyclone and magnetic
separation techniques. The settling studies of both
concentrate and tailings and the mineralogical findings
of the sample are also incorporated in the report.

Wet High Intensity Magnetic Separation (20,000

gauss) on Stub Cyclone Underflow (concentrate) could
produce a concentrate (magnetic) assaying 62.98%
Fe(T), 3.00% SiO2, 2.73% Al2O3 and 2.70% LOI with
overall weight per cent yield of 53.8% (overall Fe(T)
recovery of 66.2%).
The above concentrate produced may find utility
in iron & steel industry after pelletisation.
Beneficiation studies of BHQ ore by magnetic
separation techniques to prepare pellet grade
concentrate (IMMT):
Considering the availability of huge resources of
banded iron ores in our country, IMMT, Bhubaneswar
has explored the possibility of producing suitable iron
concentrate for pellet making from these lean ores. As
the high grade ores are dwindling sharply and to meet
the future needs of iron and steel industries, it is
essential to develop a cost effective process for the
beneficiation of lean ores like BHQ to produce quality
iron concentrate. In this connection, MSPL Limited,
Karnataka has come forward to set up a commercial
beneficiation plant to produce an iron concentrate
suitable for the iron and steel making. The lean grade
BHQ ore sample received from MSPL contains ~38.0%
Fe and 42% SiO2. The mineralogical finding of the
sample indicated that the sample contains hematite,
magnetite and quartz as major minerals and the
liberation of these minerals is around 75 microns. The
beneficiation studies consisting mainly of size
reduction followed by low and high intensity magnetic
separation have indicated that an iron concentrate with
64% Fe at 40% yield could be obtained. Alternate
process flow sheets with different combinations have
been suggested to recover the iron values suitable for
pellet making.

Beneficiation of low grade iron ore fines to produce

quality concentrate (IMMT):
The main objective of the studies was to develop a
suitable beneficiation scheme to beneficiate low grade
siliceous iron ore fines (-10.0 mm) with 50-52% Fe to
prepare quality raw material for sintering and
pelletisation and to suggest optimum flow sheet which
can generate concentrate with more than 60-63% Fe
with appreciable yields & recoveries for both the
purposes. Detailed characterisation and beneficiation
studies were carried out on low-grade siliceous iron
ore of C.N. Halli sector containing around 50% Fe and
limited studies were carried on low grade iron ore of
BBH Chitradurga with 51.0% Fe. The characterisation
studies of C.N. Halli sample indicated the presence of
hematite as major mineral with minor amount of goethite,
limonite and quartz. The low grade iron ore of BBH
showed the presence of manganese minerals. The
optimum liberation of both the samples was found to
be below 150 micron. Beneficiation studies were carried
out by conventional beneficiation techniques such as
scrubbing, hydrocyclone, spiral, magnetic separation
by WHIMS/HGMS and their combinations. Different
schemes have been suggested to get a good grade and
yield by adopting classification, jigging, magnetic

Beneficiation of iron ore fines for Finex process

of iron making (IMMT):
The objective of the studies was to develop a
suitable beneficiation scheme to upgrade the low grade
5-4

RESEARCH & DEVELOPMENT

separation. The other combination yielded higher Fe

content with low weight recoveries.

a sinter fines of +63% Fe and a pellet fines with 65% Fe

is obtainable through jigging, spiralling, hydrocyclone
and WHIMS.

Development of Commercial Flow sheet for

Beneficiation of Low Grade Ore Fines for
Pelletisation (IMMT):
Three types of low grade fine samples having below
10 mm size particles were received. Detailed size and
chemical analysis and mineralogical studies were carried
out. Two of these samples contained 55-56% Fe. After
beneficiation, the grade of concentrate could be
improved to 63-64% with yield of 65-67% using
combination of gravity and magnetic separation
processes including the desliming of the ore by
scrubbing at the beginning. Another sample contained
61.89% Fe. After beneficiation, the grade of concentrate
could be improved to 65-65.5% with yield of 81-82%.

Studies were carried out on sintering of concentrate

obtained from processing of dump fines sample from
Gua. The effect of process variables namely basicity,
bed height, vertical speed of sintering (VSS), MgO
content of sinter, on the productivity and quality
parameters of sinter was investigated. The study
shows that an acceptable RDI of 28% could be achieved
at 2.6 sinter basicity and at lower bed height. Coke
breeze at 5% of the raw mix and moisture content in
between 5.5% to 5.8% seems to be optimum for an
acceptable strength (TI) of siner and in relation to RDI
of sitner.
Beneficiation of a low grade iron ore sample
from Thakurani Iron Ore Mines, Noamundi,
District West Singhbhum, Jharkhand (IBM):

Processing of Low Grade Iron Ore Resources

(NML):
A CSIR network research programme was
undertaken at CSIR-NML, Jamshedpur with IMMT,
Bhubneswar as the nodal laboratory NEIST, Jorhat
and CEERI, Pilani as participating laboratories towards
developing technology for gainful utilisation of low
grade iron ores, through systematic studies involving
characterisation, beneficiation and agglomeration.

A low grade iron ore sample from Thakurani Iron

Ore Mines, Noamundi, District West Singhbhum,
Jharkhand was received through IBM, Kolkata office
at Modern Mineral Processing Laboratory and Pilot
Plant, IBM, Nagpur for conducting bench scale
beneficiation studies.
The as received sample assayed 37.33% Fe(T),
0.13% FeO, 45.43% SiO2, 0.40% Al2O3, 0.046% CaO,
0.004% MgO, 0.018% TiO2 and 0.30% LOI.

Low grade iron ore samples were collected from

Gua and Meghtaburu mines of SAIL and a low grade
siliceous iron ore sample from Goa. Detailed
charcterisation and beneficiation studies involving
gravity, magnetic and flotation techniques were carried
out on low grade iron ore and the flowsheet was
developed which indicated an overall yield of about

By adopting gravity concentration, the composite

table concentrate (Conc. I + Conc.II) obtained at minus
150 mesh size assayed 59.50% Fe(T) & 13.73% SiO2
with 43.2% Fe(T) recovery(Wt% yield 43.2).

75% inclusive of sinter fines with +63% Fe and pellet

fines of 65% Fe. A product with +63% Fe and 5.8%
SiO2 is obtainabale from BHQ from Meghahatuburu

The upgradation of low grade iron ore to 59.50%

Fe(T) from 37.33% Fe(T) is appreciable. This
concentrate may find application in iron industry after
blending.

through WHIMS and flotation. The flowsheet

developed for iron ore samples from Goa indicated that

5-5

RESEARCH & DEVELOPMENT

Baseline audit (Phase I) of M/s BMM Ispat Ltd

of an iron ore processing plant, Danapur,
Karnataka (IBM):

The beneficiation flow sheet comprised following

routes for obtaining desired iron concentrate:

M/s. BMM Ispat Ltd is operating an iron ore

beneficiation plant at Danapur, Hospet, Bellary District,
Karnataka using sub-grade iron ores of the region.
BMM observed that the concentrate productivity and
recovery were below design levels. Based on the inplant technical auditing studies carried out by RODL,
IBM, Bengaluru, the throughput of the plant was
increased from 120 TPH to 162 TPH i.e. 35% increase
from baseline data. Also the iron ore recovery was
increased from 75 to 82% and the tailing losses reduced
from 47.68% to 40.62% Fe. The studies helped in cost
benefit i.e. approx. 10% reduction in operating cost.
Upgradation of Iron Ore sample from BBH
Mines for M/s Voltas Limited, Bengaluru (IBM):

(a)

Tabling of the as received sample ground

to all minus 200 mesh yielded an iron
concentrate assaying 67.84% Fe(T),
2.99% SiO2 and 0.18% Al2O3 with Fe(T)
recovery of 72.2% (wt % yield 38.1).

(b)

Alternative route is that minus 200 mesh

sample when subjected to tabling
followed by ferrous wheel magnetic
separation, the combination of table and
cleaner magnetic concentrate yielded a
concentrate assaying 65.25% Fe(T),
9.47% FeO, 7.01% SiO2 and 0.18% Al2O3
with Fe(T) recovery of 83.9% (Wt% yield
46.0).

The above concentrates may find application in

pelletisation.

An iron ore sample from BBH Mines, Bheema

Samudra, Chitradurga, Karnataka was received at
RODL, IBM, Bengaluru so as to upgrade iron content
economically. Various beneficiation techniques
including washing and screening, scrubbing and sizing,
gravity separation, magnetic separation and reduction
roasting followed by magnetic separation were adopted
to upgrade iron content.

Upgradation of low grade Iron Ore fines to Pellet

grade concentrate (IBM):
A low grade iron ore fines sample from Barbil
Region, Odisha was sent by M/s Jaganathpur Steel
Limited, Ranchi, Jharkhand at RODL, IBM, Bengaluru
with an objective to evolve a flow sheet to produce a
pellet grade concentrate. The as received sample
assayed 58.15% Fe(T), 7.05% SiO2, 4.39% Al2O3, 0.07%
Mn, 0.05% CaO and 4.30% LOI. By adopting gravity
separation after grinding at 95% minus 50 mesh in rod
mill a concentrate assaying 65.83% Fe(T), 1.83% SiO2,
1.37% Al2O3, 0.05% Mn with 62.5% Fe(T) recovery with
Wt% yield of 55.5 could be obtained. The concentrate
meets the specifications of the party.

As received sample assaying 52.11% Fe(T), 7.16%

SiO2, 3.16% Al 2O3, 5.33% Mn was upgraded to a
concentrate assaying 60.30% Fe(T), 4.99% SiO2 and
4.09% Mn with 87.0% recovery( Wt% yield 75.2) by
reduction roasting at -48 mesh followed by magnetic
separation. The concentrate obtained finds industrial
application after blending.
Beneficiation of Composite iron ore sample from
Bellary district, Karnataka of M/s Allum
Prashanth, Mine Owner, Bengaluru (IBM):

1.6 Limestone

A composite iron ore sample from Bellary district,

Karnataka was sent by M/s Allum Prashanth, Mine
Owner, Bengaluru for beneficiation studies at RODL,
Bengaluru to develop the flow sheet so as to achieve
a iron concentrate assaying Fe >65% with maximum
recovery.

Beneficiation studies on a limestone sample

f r o m S a h e dp u r, d i s t r i c t M o r e n a ( M P ) f o r
M/s Abhijeet Cement Ltd, Nagpur (IBM):
The limestone sample from M/s Abhijeet Cements
Ltd, Nagpur was sent at Modern Mineral Processing
Laboratory and Pilot Plant, IBM, Nagpur to develop a
suitable process flow sheet to produce a concentrate,
which may find application in cement industry.

The as received sample assayed 36.31% Fe(T),

5.08% FeO, 42.70% SiO2, 0.40% Al2O3, 0.84% CaO, 1.44%
MgO and 0.16% LOI.

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RESEARCH & DEVELOPMENT

The concentrate produced above meets the

specification stipulated by the party for utilisation as a
sweetener in cement making.

of the project was to enhance the CaO value and reduce

the silica content of the sample through physical
beneficiation techniques. Several studies were
therefore undertaken by both dry and wet beneficiation
techniques to achieve the objective. Froth flotation
technique was found to be the most suitable method to
enhance the CaO content after grinding the material to
below 50 micron size. The results of the flotation studies
have indicated that it is possible to achieve a
concentrate of 48.4% CaO at 71.5% yield using oleic
acid as the collector, MIBC as the frother and sodium
silicate as the dispersing reagent. The silica content in
the beneficiated concentrate could be brought down
to below 7%. Although the calcium component of the
sample is very finely disseminated, it was possible to
achieve the desired concentrate after fine grinding
followed by one or two stages of cleaning. The
investigations on the commercial grade reagents were
also proved to be efficient to float the calcite values
present in the sample.

Bench scale beneficiation studies on Limestone

sample from M/s Prism Cement Limestone Mines
Ltd, Satna, M.P. (IBM):

Synthetic Flux for Basic Oxygen Steel Making

through Micro-pelletisation and Sintering of
Waste Oxides (NML):

The as received sample assayed 42.12% CaO, 1.83%

Fe2O3, 14.83% SiO2, 3.88% Al2O3, 0.63% MgO, 0.26%
TiO2, 1.43% K2O, 0.21% Na2O and 34.50% LOI .
(a)

By adopting dry screening at -40mm size a

concentrate of -40+4mm fraction assaying
44.10% CaO, 1.47% Fe2O3, 13.28% SiO2, 3.0%
Al2O3, 0.56% MgO and 35.49% LOI with
wt% yield of 88.8 and CaO recovery of 90.5%
could be obtained.

(b)

By adopting flotation route at a grind of

87.2% -200 mesh a concentrate assaying
48.11% CaO, 1.12% Fe2O3, 8.31% SiO2, 2.80%
Al2O3, 0.43% MgO and 36.59% LOI with
wt% yield 71.7 and CaO recovery of 80.9%
could be obtained.

A limestone sample assaying 35.47% CaO, 22.41%

SiO2, 2.21% Fe2O3, 3.81% Al2O3, 2.27% MgO and 31.52%
LOI was sent at Modern Mineral Processing Laboratory
and Pilot Plant, IBM, Nagpur by M/s Prism Cement
Limestone Mines Ltd, district Satna, Madhya Pradesh
with an objective to develop a flow sheet to produce a
concentrate suitable for user industry.

Ultrafine waste oxides generated in steel plant were

subjeted to micro-pelletisation followed by sintering
to develop a CaO-FeOx type pre-fused flux material
through an innovative way. The developed flux material
dissolves in hot metal bath at faster rate owing to its
low softening point and favourable chemistry forming
basic and oxidising slag. The material will find
application in BOF steel making for faster refining and
partial replacement of high melting lump lime.

By adopting flotation route a limestone

concentrate assaying 45.87% CaO, 9.83% SiO2, 1.39%
Fe2O3, 2.02% Al2O3, 1.60% MgO, 0.09% TiO2, 0.42%
K2O, 0.3% Na2O and 38.09% LOI with 80.1% CaO
recovery (wt% yield of 62.2) could be obtained.

1.7 Manganese Ore

The concentrate obtained above meets the

specifications stipulated by the party.

Beneficiation of low grade manganese ore by

wet high intensity magnetic separator (IMMT):

Beneficiation Studies of Lean grade Limestone

for Removal of Silica (IMMT):

The objective of the project for Tata Steel was

to carry out beneficiation studies of low grade
ferrugenous manganese ore of Joda region to
reduce iron content to improve Mn/Fe ratio. Four
different types of samples were subjected to
WHIMS at 14000 Gauss & 10000 Gauss to separate
iron rich minerals. The Mn/Fe ratio could be
increased to 1.5 to 3 with Mn content 35-42% by
this technique.

The limestone sample roughtly contain ~44.5 45.3% CaO and 13.5-14.3% SiO2 as the major chemical
constituents. The alumina, magnesia and iron content
in the given sample are present in very low
concentrations. The sample consists of calcite (CaCO3)
and quartz (SiO2) as major mineral phases. The objective

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RESEARCH & DEVELOPMENT

set up of this deposit. So the methods adopted

elsewhere are not be suitable for processing this ore.
For the first time an attempt will be made to recover
PGE from the low grade Indian chromite ores.

1.8 Nickel
Enrichment of Nickel in Chromite Overburden
Materials by dry beneficiation (IMMT):

1.10 Quartzite

Chromite Overburden Material from different

mining sites of Sukinda was collected for dry
beneficiation studies. As received Chromite
Overburden sample was size analysed for both wet
and dry process to find out the nickel
concentration. The material was subjected to stage
crushing using jaw crusher, roll crusher, where it
was crushed to below 2 mm size. The overburden
sample was subjected to VSK separator for
separation of coarse and fine fractions. The effect
of different operating parameters, viz, cage wheel
speed (rpm) and vibrating tube feed (rpm) were
studied at constant air rate. The feed sample of
COB containing 0.9% Ni has been enriched to
0.95% Ni in -45 microns fraction.

Recovery of float glass concentrate from

Quartzite sample, Pohara, Bhandara district,
Maharashtra (IBM):
A quartzite sample from Gadpendri (east),
district Bhandara, Maharashtra, assaying 97.99% SiO2,
0.68% Fe2O3, 0.60% Al2O3, 0.05% CaO, 0.01% MgO,
0.09% K2O, 0.07% TiO2 & 0.11% LOI was sent by M/s
Maharashtra State Mining Corporation Ltd, Nagpur at
the Modern Mineral Processing Laboratory and Pilot
Plant, IBM, Nagpur. The objective of the investigation
was to produce a quartzite concentrate suitable for use
in the float glass industry. After scrubbing followed
by wet high intensity magnetic separation, the
composite concentrate (-30 + 70 mesh and -70 + 120
mesh) non-magnetic assaying 99.16% SiO2, 0.13%

1.9 Platinum Group Elements

Waste to Wealth: Noble metal Platinum Group
Elements recovery from low grade chromite ores
of Odisha (IMMT):

Fe2O3, 0.25% Al2O3 and 0.11% LOI with 63.5% silica

recovery (wt% yield 62.7) could be obtained. The
composite concentrate meets the specifications
stipulated by the party.

Platinum group elements are very rare in nature

and their occurrence is also very limited. In India, Boula
Nausahi Igneous complex is the only proven PGE
deposit but with a very low tenor. In this set up, PGE
occurs in oxide (chromite) and sulfide (Cu-Fe-S) facies
as very tiny grains of around 20 micron. Recovery of
PGE of such fineness from the host rocks is a very
challenging task. The major focus of research will be (i)
Recovery of PGE values from the low tenor hosts by
adopting suitable beneficiation tests and (ii)
Development of process flow sheet for recovery of PGE
from Indian ores.

1.11 Rock Phosphate

Upgradation of sub-grade Rock Phosphate
sample for M/s RSMM Ltd, Rajasthan (IBM):
A sub-grade rock phosphate sample from
Jhamarkotra Mines, Rajasthan was sent by RSMM Ltd
with an objective to develop a flow sheet to obtain
phosphate concentrate which may be used in fertilizer
industry. The as received sample assayed 13.43% P2O5,

Throughout the world, PGE are recovered by a

combination of different beneficiation techniques such
as gravity and flotation depending on the nature of
association, mineralogy and size of PGE phases. The
PGE mineralisation at BNIC is totally different from most
of the PGE deposits of world in (i) PGE are very fine (ii)
PGE are present as inclusions & exsolution in the host
chromite and Cu-Fe-S (iii) and very complex geological

49.48% SiO2, 5.66% Fe2O3, 6.87% Al2O3, 20.13% CaO,

0.46% MgO and 2.68% LOI. By adopting flotation route
a phosphate concentrate assaying 32.02% P2O5, 13.33%
SiO2, 3.22% Fe2O3, 1.25% Al2O3, 14.22% acid insolubles
with P2O5 recovery of 81.9% and weight % yield of 33.8
could be obtained. This concentrate may find
application in fertilizer industry.
5-8

RESEARCH & DEVELOPMENT

1.12 Sea Nodules

Upgradation of low grade Rock Phosphate from

Hirapur for M/s Madhya Bharat Agro Products
Ltd, Madhya Pradesh (IBM):

Recovering metallic values from sea nodules

(NML):
A direct smelting process was developed on 20 kg
scale for recovering Cu, Ni & Co (as an alloy) from
polymetallic sea nodules containing 1 - 1.2% Cu & Ni
and 0.01% Co. About 90% Cu & Ni and 88% Co
recovery was achieved. The slag generated through
this process was further treated to recover Mn as
standard grade Fe-Si-Mn with overall 80% Mn
recovery. A modified reduction roast-ammonia leach
process was also developed for processing of
polymetallic sea nodules, with 94% Cu & Ni and 70%
Co recoveries. The process was tested under
continuous mode (10 kg/batch scale recycle leaching)
& the residues generated were smelted to recover Mn.

A low grade rock phosphate sample from Hirapur

mines, Madhya Pradesh sent by Madhya Bharat Agro
Products Ltd. At Modern Mineral Processing
Laboratory and Pilot Plant, IBM, Nagpur assayed
15.66% P2O5, 43.46% SiO2, 8.54% Fe2O3, 5.19% Al2O3
and 2.02% LOI.
By adopting flotation route, a phosphate
concentrate assaying 34.28% P2O5, 47.9% CaO, 7.79%
SiO2, 1.23% Al2O3 with P2O5 recovery of 58.2% (Wt%
yield 26.3) could be obtained.
The concentrate obtained meets the specifications
stipulated by the party.
Development of process flow sheet for Rock
Phosphate from Jhamarkotra for RSMML,
Udaipur (IBM):

1.13 Silica Sand

Beneficiation of silica sand for Reduction of
Fe 2O 3 content (IBM):

A rock phosphate sample from Jhamarkotra, district

Udaipur, Rajasthan sent by RSMM Ltd at RODL, IBM,
Bengaluru with an objective to
1)

2)

3)

M/s. Asahi Glass India Ltd approached Indian

Bureau of Mines with a request to explore the possibility
of utilising the silica sand available as overburden of
GMDC, Rajpardi Lignite Mine for manufacturing glass.
The original sample assayed 96.5% SiO2, 0.64% Fe2O3,
0.42% TiO2, 1.13% Al2O3 and 1.03% LOI. Ore Dressing
Division of IBM has developed a beneficiation process
for the said sand which comprises scrubbing, tabling,
magnetic separation and attrition scrubbing. The
process yielded a silica sand concentrate assaying
99.3% SiO2, 0.079% Fe2O3, 0.15% Al2O3, 0.04% TiO2 with
wt.% yield of 60. The industrial application of the above
can convert the overburden, dumped as waste, into a
useful industrial product for glass making.

Upgrade the ore to +32% P2O5 by ore

dressing techniques with maximum
possible P2O5 recovery.
Develop a process flow sheet keeping in
view the present unit operation at
RSMML.
Optimise and to reduce the reagent
consumption.

The as received sample assayed 14.20% P2O5,

36.91% CaO, 11.12% MgO, 0.54% Fe2O3, 2.98% SiO2. A
composite phosphate concentrate assaying 33.57%
P2O5, 1.42% MgO, 7.11% SiO2, was obtained with 83.5%

2. MINING

P2O5 recovery (wt% yield 35.6) by adopting flotation

National Institute of Rock Mechanics (NIRM)

route. The concentrate obtained meets the requirement

NIRM is a premier centre of research in applied
and basic Rock Mechanics. During 2010-11, NIRM
was involved in projects from construction projects in
power sector (hydel, nuclear), communication sector
(metros, rails) and mining sector. This institute
undertakes investigations at various stages of the
projects, i.e., feasibility report (FR), detailed project
report (DPR), construction and post-construction
stages. The following studies have been undertaken.

as stipulated by the party. Also, for obtaining same

grade and recovery of phosphate concentrate the
throughput can be improved by increasing the pulp
density of feed to 50% solids from the initial 34% solids
used in this investigation. By this the phosphoric acid
consumption can also be reduced.

5-9

RESEARCH & DEVELOPMENT

Geological and geotechnical investigations for

preparation of DPR for 2 x 350 MW Malshej Ghat
Storage Scheme. Maharashtra, Project No. EG0901.

Project entitled "Study on blasting dust

management system in an opencast coal mine", Coal
S &T Project (Code: EE/35), Ministry of Mines, Govt. of
India.
Preliminary Report on "Possible causes of rock fall
from sides at Hamsa Minerals & Exports Granite Mine
and Suggestions for remedial measures".

Geological investigations for underground

storage caverns at Vishakapatnam, Project No. EC0902.

Seismotectonic evaluation of KudankulamAtomic Power Plant within 30 km area, NPCL, EG0903.

Cross-hole seismic tomography at Sainj HEP,
Himachal Pradesh, Project No. GP1001.

Indian Bureau of Mines (IBM):

Mining Research Cell of TMP Division, IBM
conducted a techno-economic evaluation and prepared
a status report on availability of manganese ore.

Laboratory Rock Mechanics investigations underground rock cavern for storage of crude oil at
Padur (part B SKE&C-KCT), Project No. RF1001.

Techno-economic Evaluation of Balaghat

Holems Shaft Deepening Project at Balaghat
district of Madhya Pradesh for MOIL Ltd.

Deformation monitoring of Underground

Powerhouse Cavern of Sardar Sarovar Project, Project
No. NM0803C.

On the request of MOIL, Nagpur, study of

Techno-economic Evaluation of their Balaghat Holems
Shaft Deepening Project at Balaghat Mine, Balaghat
District, Madhya Pradesh, was carried out for
examination of techno-economic evaluation and
financial justification of proposed vertical deepening
of that shaft on the basis of financial models. In order
to maintain the leading status, development of mine to
exploit the ore reserves below the 12th level to 16.5th
level which is essential for them. The MOIL has
prepared the proposal to estimate the anticipated in &
out cash-flow of the project. The same has been
examined by IBM.

3D Numerical Modelling of Powerhouse

Complex of TapovanVishnugad HE Project and Desilting
Chamber and Power house Complex of Lohari-Nag pala
Hydroelectric Project, Project No. NM0704.

Analysis of instrumentation data of machine

hall and desilting complex of Nathpa Jhakri hydro
power station, Project No. NM0904C.
Controlled blast design for rock excavation
close structures and green concrete and ground
vibration measurement near Unit 7 & 8, Nuclear plant,
RAPP, Kota Hindustan Construction Company Limited,
Mumbai - Project No. RB 1004C.

The IBM team re-estimated the recoverable

reserves of 3.14 million tonnes for which operating
cost was considered as ` 1953/- per tonne with annual
increment factor of 5%. After examining the cash-flow
statement, IBM has stated in the report that all the
capital investment incurring in the project will be
recovered within 6-month period as cash flow in any
year before depreciation and income tax is more than
` 42 crore. Considering the calculated IRR 94% and
NPV ` 576 crore, IBM concluded that the project of
deepening of shaft between 12.5th level to 16.5th level
is viable and beneficial to MOIL.

Slope stability studies at Iron Ore Mines of

M/s Mysore Minerals Ltd, Hospet, Project No.SS 1001.

Slope stability studies at Iron ore Mines of

M/s SMIL, Goa Project No. SS0701.

Strata Monitoring during Development in

No. 3 Seam at KTK-2 Incline, Bhupalpalli Area, SCCL
Project No. GC 0903.

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RESEARCH & DEVELOPMENT

In the Amli Limestone Mine, the charge weight

per delay of 600 kg, which is presently under practice,
was kept and monitored. It was found that the ground
vibration intensity and air over pressure (sound level)
due to blasting is well within the safe limit and therefore,
no danger to any structures in the nearby area.

Status Report onAvailability of Manganese Ore

o v e r a n a r e a o f 2 6 . 9 7 h a I n Vi l l a g e :
S h a n n k e r p i p a r i y a , Ta l u k a : K h e r l a n g i ,
district:Balaghat, Madhya Pradesh, for M/s
M.V.P. Minerals (P) Ltd, Hyderabad (IBM):
On the request of M/s M.V.P. Minerals (P) Ltd,
Hyderabad (Andhra Pradesh), an assignment of
preparation of Status Report on Availability of
Manganese Ore over an area of 26.97 ha. In Village:
Shannkerpipariya, Taluka: Kherlangi, District: Balaghat,
Madhya Pradesh has been carried out. The area shows
mineralisation of manganese at two places only, i.e. in
old pits/trenches. The ore available in the area is
medium grade in manganese content with low
phosphorous. The reconnaissance survey shows that
the area appears to be manganese ore prospect with
proper prospecting/exploration.

In the Thandiberi Limestone Mine, normally the

charge weight per delay is kept below 500 kg. The peak
particle velocity for the charge weight for 500 kg for a
distance of 700 m is found to be 10.18 mm/sec which
was above the safe limit. Therefore, for Thandiberi
Mine, it was suggested that the charge weight should
be restricted to 450 kg for which calculated peak particle
velocity is 9.50 mm/sec which is well within the safe
limit as per DGMS Circular. The air over pressure (sound
level) due to blasting is also well within the limit. The
frequencies below 8 Hz are Nil and so there will not be
any danger to nearby structures of the mine.

3. ENVIRONMENT
Indian Bureau of Mines (IBM):

Study of Ground Vibration Monitoring due to

blasting in Chargao Gotadi Stone Quarry in
Bhivapur Tehsil, Near Umred, district Nagpur,
for M/s Modern Mineral Industries, Nagpur
(IBM):

During 2010-11, Mining Research Cell of T.M.P.

Division, IBM has carried out four studies, one for
Environmental Quality Monitoring, and three for
Ground Vibration due to Blasting in Mines. The salient
features of the studies and activities are as follows:

On the request of M/s Modern Mineral Industries,

Nagpur (Maharashtra), a study of Ground Vibrations
due to blasting at their Chargao Gotadi Stone Quarry,
Taluka, Bhivapur, near Umred, district Nagpur
(Maharashtra) over a lease area of 2.45 ha was carried
out to study the impact of blast induced ground
vibrations on the nearby structures, human settlement
and to suggest control measures to minimise the
adverse impact of the same. Under this study, six blasts
were carried out at Chargao Gotadi Stone Quarry site
and monitored at three different points in the area.

Study of Ground Vibrations due to Blasting in

Amil and Thandiberi Limestone Mines of
M/s Binani Cements Ltd, district: Sirohi,
Rajasthan (IBM):
On the request of M/s Binani Cements Ltd, district
Sirohi, Rajasthan, study of ground vibrations due to
blasting at their Thandiberi Limestone Mines (Lease
Area 254.125 Hect.) and Amli Limestone Mines (Lease
Area 468.68 Hect.) was carried out to study the impact
of blast induced ground vibrations on the nearby
structures, human settlements and to suggest control
measures to minimise the adverse impact of the same.
Under this study, eight blasts at the Amli Limestone
Mine area and one blast at Thandiberi Limestone Mine
were carried out and monitored at various points in the
area.

Normally, in Chargao Gotadi Stone Quarry, the

charge weight per delay is 55.60 kg (i.e. less than 60
kg). The observed peak particle velocity for this charge
weight of 55.60 kg for a distance of 100 m is
3.11 mm/sec which is well within the safe limit. The

5-11

RESEARCH & DEVELOPMENT

ground vibration intensity estimated for even maximum

National Institute of Rock Mechanics (NIRM):

charge weight per delay of 200 kg, presently not

The following projects were undertaken by

practised, is also well within the safe limit. The Mine

NIRM:

Office and labour hutments which are at a distance of

Study on ground vibration and air

overpressure due to blasting at HRT of Parbati
hydroelectric project (Stage-III) Behali, Kullu, Himachal
Pradesh, NHPC Ltd, Project No. RB 1005, August
2010.
Ground vibration and air overpressure study
at Mangampet Barytes Project using different
explosives, APMDC Ltd, Mangampet Cuddapah,
Andhra Pradesh, Project No. RB 1003C.

100 m, the calculated PPV is 46.5 mm/sec for a maximum

charge per delay of 25.0 kg which is outside the safe
limit. The frequencies below 8 Hz are considered
serious for potential structural damage. During the
study, it has been found that the frequencies below
8 Hz are Nil and hence there will not be any danger to
nearby structures. The air over pressure (sound level)
due to blasting is also well within the limit. Some safety

Technical guidance for rock blasting and

monitoring of ground vibration, air over pressure and
fly rock during excavation at underground stations of
Bangalore Metro (BMRCL).

measures have also been suggested for minimising

further blast vibrations effects in the report submitted
to the party.

5-12