KMML Manufacturing

I wanted to know about the KMML Manufacturing facilities? please provide me the details about that?

[Shaleen]

The Manufacturing facility of KMML is equipped by following plants:

Mineral sepration unit
Limenite beneficial plant
Acid regeneration plant
Pigment production plant
Oxygen plant
Utility section


MINERAL SEPARATION UNIT

The mineral-rich sands harvested from the captive beaches are first taken to the Mineral Separation Unit (MS Unit) where the separation of Ilmenite, Rutile, Leucoxone, Monazite, Silliminite etc from the beach sand takes place..

The Process at MS Unit goes through the several plants given below:
Wet Concentration Plant
Dryer Plant
Dry Mill
Rutile Recovery Plant
Zircon Plant

ILMENITE BENEFICIATION PLANT
The Ilmenite Beneficiation Plant is designed and installed based on the BCA Cyclic Process Technology supplied by M/s. Benilite Corporation of America. The Plant is in a single stream and is subdivided into six major sections, based on operation:

Raw Material and Reductant handling
Roasting and Cooling
Digestion and Filtration
Calcination and Cooling
Acidic Liquor Treatment
Tank Farm

ACID REGENERATION PLANT

Acid regeneration system
The spent leach liquor from the pre-concentrator is processed in the spray roaster in which the liquid spray entering the furnace is heated by burning oil. The spent liquor then decomposes to metallic oxides and Hydrochloric acid. The Hydrochloric acid vapour is first cooled in the pre-concentrator and then absorbed in the wash liquor generated in the IBP.

4FeCl2 + 4H2O + O2 = 2Fe2O3 + 8HCl
2FeCl3 + 3H2O = Fe2O3 + 6HCl


PIGMENT PRODUCTION PLANT

The Pigment Production Plant at KMML consists of 3 units.

Chlorination Plant (U 200):
Oxidation Plant (U 300):
Pigment Surface Treatment and Finishing (U 400)


OXYGEN PLANT
This Plant supplies oxygen at 99.98% pure oxygen.
The Oxygen Plant takes in air where it is purified, liquefied and separated into oxygen and nitrogen for use mainly in Unit-300.
In addition to this Plant have a PSA Plant which produces 300 NM3/hr of oxygen at a purity of 95 % to 96%.

UTILITY SECTION

The Utility Section of KMML Manufacturing Facility comprises:
Boiler Plant (24 Ts saturated steam and 9 Ts superheated steam per hour it have two main Boilers and one Packaged Boiler.
Air Compressor Station (5 nos.)
Water Treatment & DM Plant