First and the foremost, I shall thank God Almighty who gave me the inner strengt
h, resource and ability to complete the work successfully, without which all my
efforts would have been in vain.
I express my sincere gratitude to our principal, Dr. C. J. Joseph for providing
me good guidance to do it in the required way. I am thankful to Prof.Binoy Baby
of Department of Mechanical Engineering, for his valuable advice and motivation.
I wholeheartedly thank my group tutors Mr.Peter Jose (Asst. Professor, Dept. of
Mechanical Engineering) and Mr. Bonny John(Asst. Professor, Dept. of Mechanical
Engineering) for their valuable advice and support.
I also extend my sincere thanks to Kerala Minerals And Metals Ltd. For the permi
ssion granted for conducting industrial visit in the companies. Finally I take t
his opportunity to acknowledge the coordinators of our industrial visit program,
who arranged it successfully
CONTENTS
Chapter
Title
Page No:
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Introduction
3
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Raw Materials
Manufacturing Facility
11
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15
Products
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18
Process
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20
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21
Conclusion
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22
Reference
1. INTRODUCTION
Bringing more to your everyday life, KMML touches you in numerous ways. Be it th
e 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 f
2. HISTORY
The history of thebeaches of Sankarmangalam and nearby areas is inextricably int
ertwined with the history of the precious beaches and KMML. Precious, as was dis
covered in 1909 by the German scientist Dr. Schomberg who found traces of monazi
te in the sand flakes on the imported coir from Sankaramangalam. The beaches wit
h a wealth of rare earth minerals became the center of scientific attraction.
By 1932, a visionary private entrepreneur established the F. X. Perira and Sons
(Travancore) Pvt. Ltd, the forerunner to KMML. During the course of time, KMML c
hanged hands three times over. In 1956 it was taken over by the state government
and was placed under the control of the industries department. The unit was sub
sequently converted as a limited company in 1972 by the name of The Kerala Minera
ls and Metals Ltd. with the following broad objectives.
1. Optimum utilization of mineral wealth found along the sea coast of Kollam-Ala
ppuzha Districts.
2. Large scale generation of employment in the state in general.
3. Overall growth and development of the local area in particular and the state
in general.
1974
Letter of Indent for the production of 48,000 tonnes of Titanium Dioxide
Pigment through Chloride process technology. Collaboration agreement with:
Benelite Corporation of America, USA Synthetic Rutile Plant. Woodall Duckham, U.
K Acid Regeneration Plant Kerr McGee Chemical Corporation, USA
Titanium Dioxide
Pigment (Chloride process)
1979
Construction of plants started at Sankaramangalam, Chavara, Kollam
1983
R&D recognition for KMML laboratory by DSIR.
1984
Commissioned the first fully integrated Titanium Dioxide Pigment Plant i
n the world. Launched for the first time in India, Rutile grade Titanium Dioxide
Pigment under Trade Name: KEMOX RC-822.
1992
Launched another grade of Titanium Dioxide Pigment KEMOX RC-800.
1992
Launched Plastic Grade Pigment KEMOX RC-800 PG. 1992
1992
Won the First National Award for in-house R&D efforts in Industry for Te
chnology Absorption under TAAS programmed by DSIR
1997
A new grade of pigment for the new water based paint application was int
roduced
KEMOX RC-813.
1998
Launched another improved grade pigment
KEMOX RC-822SG (Renamed as KEMOX
RC-802)
1998
Commercial production of Iron Oxide Bricks from the waste Iron Oxide an
innovative development by in-house R&D.
1998
Supported Combustion Process was successfully commissioned in one of thest
reams in the Oxidation Plant. This In-house developed process is a significant b
reak through which enables KMML to improve productivity of the plant and for fur
ther capacity enhancement.
1999
Bypass system in both streams and support combustion in other streams wa
s also
commissioned.
1999
Erected and commissioned one more Chlorinator in Chlorination section.
2003
New modern Lime Preparation Plant (LPP) for effluent neutralization was
commissioned.
2004
Commissioned new DM Plant and added two more digesters in IBP.
2004
Commissioned a new product packaging machine, modern energy efficient fi
lter and drier system, DCS system in Unit-400.
2005
World class quality management systems like ISO 14001 and OSHAS-1800 imp
lemented
2006
Capacity enhancement to 40,000MT
2006
Foundation stone laid for Titanium sponge plant
2007
Commissioned Recovery cyclone
2008
Commissioned new ETP sludge and Oxide pond
2009
Development of Nano Titanium Dioxide particles in laboratory scale.
2010
Commissioned the Enhahced Zircon Recovery plant at MS Unit.
2011
India s first commercial titanium oxy chloride pilot plant commissioned on
16/6/2011
2011
India s first commercial plant for synthesis of nano titanium dioxide comm
issioned on 19/7/2011
2011
Commissioned the Siliminite Recovery Sysytem at MS Unit
2011
Started the sale of Siliminite. --on 18th August 2011
2011
Birth of First Batch of Titanium Sponge on 06.09.2011
3. RAW MATERIALS
Material
Approximate Annual Req.
Silica Sand 1,200 MT
Sodium Silicate
3,280 MT
Beneficiated Ilmenite 4,644 MT
Hydrated Lime 12,800 MT
Aluminium Chloride
950 MT
Sulphuric Acid
1,800 MT
Potassium Chloride
114 MT
Petroleum Coke
Npf Grade
6228 MT
Hydrochloric Acid
24,537 MT
Liquid Chlorine In Containers 8,043 MT
Caustic Soda Lye
3,400 MT
Raw Ilmenite 12,000 MT
Floculant
11,330 MT
Cabosil
1.900 MT
Trimethylol Ethane (trimet) 240 MT
Zirconium Orthosulphate
300MT
Tri Iso Proponol Amine
27 MT
Succinic Acid 6 MT
Furnace Oil 28,029 KL
Liquified Petrolium Gas
4,000 MT
Aluminium Hydrate
1,280 MT
Calcined Petroleum Coke
18,500 MT
4. MANUFACTURING FACILITY
The sands are washed onto the beach by the waves every day. They are called beach
washing . These sands are the raw materials naturally harvested by KMML for the m
anufacture of the finest grades of Titanium Dioxide pigment and other products.
KMML is India's only RUTILE GRADE TITANIUM DIOXIDE MANUFACTURING FACILITY (throu
gh Chloride Route). The Manufacturing Plant at KMML comprises the Mineral Separa
tion Unit and the TP Unit (Ilmenite Beneficiation Plant, Acid Regeneration Plant
, Pigment Production Plant, Oxygen Plant & Utility Section).
The facility follows stringent Safety, Health and Environmental Policies and Pra
ctices at every step of the manufacturing process.
4.1 Titanium Sponge Plant (TSP):
Fig 4.2: Titanium Sponge Plan
t
Titanium Sponge Plant is first plant in India to produce Titanium Sponge, which
is the intermediate product to Titanium Metal. Titanium Sponge Plant has its thr
ee sections as below.
4.2 Tickle Purification Plant (TPP):
Fig 4.3: Tickle Purificatio
n Plant
Titanium Tetra Chloride (TiCl4) is the main raw material for the production of T
itanium Sponge, which is available as pigment grade TiCl4in the Titanium Pigment U
nit of KMML. This pigment garde TiCl4is further purified in to metal grade TiCl4th
ough double stage fractional distillation in Tickle Purification Plant.
4.3 Metal Production Plant (MPP):
Formation of Titanium Sponge took place at the Metal Production Plant of TSP thr
ough Kroll Process.The raw materials used are metal grade TiCl4and the high purity
Magnesium (Mg) metal. The processes involves reduction of TiCl4with Mg and pyro-v
acuum distillation to tap out the MgCl2produced as by product during the process.
Fig 4.4: Metal Production Plan
t
6. PROCESS
The Kerala Minerals and Metals Ltd (KMML) is the world s first fully integrated Ti
tanium Dioxide Plant. KMML is also India s first and only manufacturer of Rutile G
rade Titanium dioxide by chloride process.
6.1 The Process in Brief:
8. CONCLUSION
Titanium Dioxide is used in paints and all paints are formed by adding colours t
o this component. As in the report the process of titanium dioxide is discussed
by making an efficiency of almost 85% by reusing the components and producing th
e several components in easy ways.
Such a firm could be more profitable if careful handling of machines is done. Si
nce Schomberg has discovered the minerals in Sankaramangalam we are able get a f
irm like this going and who knows there aren t more such treasures in our earth ev
en the sand we stand upon.
9. REFERRENCE
www.kmml.com
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Wikipedia
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Information collected from the personals of the firm