Ashok Nandi, H. Mahadevan & T.R. Ramachandran. Bauxite-Alumina Industry of India

Transcription

1 Ashok Nandi, H. Mahadevan & T.R. Ramachandran Bauxite-Alumina Industry of India October 2012

2 Presentation Plan Bauxite Alumina Industry India - Overview Present and Projected Bauxite alumina capacity New Refineries Resources and Issues Availability of non-metallurgical grade bauxite in India- quality and issues Status of bauxite beneficiation, new research directions and implementation plans October 2012

3 Bauxite Resources and Alumina Refineries of India - Alumina Refineries - Bauxite Deposits*: 1 - Gujarat Mil. Tonnes 1 NALCO Alumina Project Renukoot Muri Korba 5 Damanjodi 2,3- Central India Mil. Tonnes 4 - Western Ghats Mil. Tonnes 5 - Eastern Ghats Mil.Tonnes 6 - South India - 28 Mil. Tonnes Belgaum Mettur 6 VEDANTA Lanjigarh, ANRAK, HINDALCO Utkal & Aditya projects located in this Bauxite belt

4 Eastern Ghats Bauxite Deposits India has over 3 Billion tonnes of bauxite resources KARLAPAT Bhawanipatna LANJIGARH East coast has vast reserves of gibbisitic bauxite 1. 2,363 Mt of explored resources Koraput KISSANMALI SIJIMALI KUTRUMALI SASABAHUMALI BAPHLIMALI Doragrha KODINGAMALI PANCHPATMALI MALIPARVAT POTTANGI CHINTAMAGODNI ANDHRA PRADESH Kottavalsa Bissamcuttack Kentiguda Tikri RAYAGADA Rupkona Laxmipur KARNAPADIKONDA Parvatipuram Bobilli Srikakulam Vizianagaram Mt probable mineral inventory 3. 80% of India s proven bauxite reserves. These deposits have little overburden which makes cost of production very low. Al 2 O 3 : 42-44% ; Av. Alumina: 38-40% SiO 2 : 2-4% ; Rx. Silica: 1.8-3% Fe 2 O 3 : 22-26% & TiO 2 : 2-3% Gibbsitic bauxite with low level of impurities

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7 EXISTING ALUMINA REFINERIES Present & Projected Capacity & Production in thousand tons Refinery Capacity Production Bauxite Volume Temp. BALCO, Korba HINDALCO, Belgaum HINDALCO, Muri HINDALCO, Renukoot NALCO, Damanjodi VEDANTA, Lanjigarh High ,050 1,080 Low ,320 1,350 Double digestion ,190 2,250 High 1,950 2,800 1,550 2,325 4,650 6,975 Atmosph eric 1,000 6, ,000 2,360 18,000 Low Total 4,480 10,560 3,857 10,085 11,570 30,255

8 NEW ALUMINA REFINERIES Capacity in thousand tons Refinery Capacity Bauxite Volume Comments ANRAK 1,500 3,000 4,500 9,000 Low temp; 90% construction over, likely to be operational by 2012 end HINDALCO, Utkal HINDALCO, Aditya NALCO Alumina Refinery, Gujarat 1,500 3,000 4,500 9,000 Low temp.; Construction in progress (70% completed) 1,500 2,000 4,200 6,000 Low temp; Refinery work started 1,000 1,000 2,700 2,700 Low temp: Feasibility stage Total 5,500 9,000 15,900 26,700 Long way to go

9 ANRAK Alumina Project Designated Mines Alumina Refinery Aluminium Smelter - Jarrella ~ 240 Mt million tpa - 250,000 tpa M R P

10 Ref. : HINDALCO communications

11 Ref. : HINDALCO communications

12 Forecast Alumina & Aluminium Production in India This alumina capacity looks more realistic compared to 19 Million Tons projected earlier.

13 Indian Resources & Issues Good quality bauxite resources Qualified manpower & management Availability of technology & funds Nearness to China and other developing market Increasing production of value added bauxite-alumina by small & medium sized companies Tough local environment Delays in land acquisition & clearances Bureaucracy Conflicting interests Tribal issues

14 Indian High Grade Bauxite-Issues Small scattered bauxite deposit, mostly sandwiched between metallurgical & cement grade materials. Gujarat white bauxite is contaminated with CaO /CaCO3. High grade bauxite of western & central India has high titania and iron content, however, free from CaO. Const. I (Gujarat) II (Katni) III (Bastar) IV (Lohard) V (Netar t) Al2O min 58 min Fe2O3 3 max max 3 max TiO2 3 max max 9 max CaO 1.5 max max 1 max LOI 34 min 25 min min 28 min Large metallurgical grade bauxite deposits of Eastern Ghats has high iron content, however, they are free from any other contaminations and also has low titania content.

15 Bauxite deposits of Gujarat State 1 In Gujarat State the laterite-bauxite belt extends for about 250 kms with width varying from 100 m. to about 6 kms. These bauxite deposits are located at a close proximity of 50 to 100 km to all-weather deep water ports Porbandar, Okha, Bedi (Rozi), Mundra, Kandla. Mines and ports are well connected by roads. P P P P Bauxite Resources in Gujarat State: Total: 135 mln. tonnes P - bauxite ports 2 P 1 Kutch Area: 2 Jamnagar Area: 100 mln. tonnes

16 Bauxite deposits of Gujarat State Due to the fact that the bauxites have developed on a mixture of brecciated basalts and traps, the bauxites are represented by two varieties: high grade white bauxites suitable for calcination and metallurgical grade red bauxites. High grade white bauxites (Al 2 O %, Fe 2 O 3 5%) Metallurgical grade bauxites (Al 2 O 3 ~ 46-48%, SiO 2 ~ 3-4%, Fe 2 O 3 ~ 10-15%) Reddish brown bauxite suitable for metallurgical industry.

17 Indian Calcined Bauxite Producers Existing Units Annual Capacity (tons) Bombay Minerals Pvt. Ltd. (Ashapura Minechem) 66,000 Nataraj Ceramics Pvt. Ltd. (Captive) 33,000 Gujarat Mineral Development Corporation (GMDC) 45,000 Orient Abrasives Ltd. (Captive) 33,000 Carborandum Universal Ltd. (Captive) 50,000 Navnagar Minerals Pvt. Ltd. 33,000 Krishnamayee Minerals Industries Pvt. Ltd. 33,000 Other producers: Meena Agency (30,000), SCABAL (24,000), Kishan Minerals / Madhu Refractories (18000), Gjanan Refractories (12,000) & Sarvesh Refractories (9600) etc. 100,000 Total 393,000 Demand for calcined bauxite for the refractory and abrasive industry in India is estimated at 400,000 tpa; shortfall is presently met by imports, mostly from China.

18 Parameters Calcined Bauxite Gujarat Refractory Grade Calcined Bauxite General Grade Low Ferric BFA Grade Other Grades Proppants Grade Road Surfacing Grade Al2O3 MIN 84% 86.00% 85-88% 80-82% 83-84% Fe2O3 MAX 4.0%max 2.8% 2.5-4% 5-7% 4.5%max S1O2 Max 5.0%max 5.0% 3-6% 4-8% 6.0%max TiO2 Max 4.5%max 4.0% 2-4% 3.5-4% 4.5%max CaO MAX 2.5%max 2.0% % % %max LOI MAX 0.50%max 0.50% % B + D 3.1 GM/CC 3.15 GM/CC *Note: Particle size can be customized as per requirement. Ref :- Ashapura Communications %GM/CC

19 Non-metallurgical Bauxite Uses

20 Bauxite Beneficiation Processes for Production of High Grade Can absorb higher cost processes unlike alumina refinery The main objective is to bring down iron content in Indian bauxite. The other important impurities are TiO 2 & SiO 2. In case of Gujarat, along with above it would be necessary to bring down CaO in bauxite. It is found easier to remove iron compared to multi-elements.

21 Bauxite Beneficiation Processes for Production of High Grade (contd.) Beneficiation processes, which can be successfully applied depending on chemico-mineralogical characteristics are: High Intensity wet magnetic separation Reduction roasting followed by magnetic separation Chemical Leaching Transform bauxite impurities into high temperature phases Convert iron-titania into Ilmenite phase and separate this by simple magnetic method

22 High Intensity Wet Magnetic Separation - Eastern Ghats Bxt Crushing, grinding, screening, slurrying, removing superfines followed by high gradient wet magnetic separation SiO2 % Al2O3 % Fe2O3 % TiO2% HEAD NON-MAG

23 Bauxite reduction roasting followed by magnetic separation (China)

24 RESULTS OF EASTERN GHATS BAUXITE LEACHING TESTS BAUXITE Al 2 O % Fe 2 O % SiO % TiO % BENEFICIATED BAUXITE-I Al 2 O % Fe 2 O % SiO % TiO % Recovery - 62% BENEFICIATED BAUXITE II Al 2 O % Fe 2 O % SiO % TiO % Recovery - 76%

25 New Research Directions Transform Impurities to high temperature phases Fe 2 O 3, TiO 2 and CaO in Bauxite develop low melting phases during calcination, degrading refractory property. CSIR-CGCRI (Research Institute) has developed value added aggregates from Indian bauxite by transforming impurities to high temperature phases. High alumina refractories developed from these aggregates exhibit excellent hot properties. Details of this process will be presented in Bauxite, Alumina & Aluminium symposium to be held in India during December 3-5, 2012 (IBAAS-2012). Further R&D work is in progress to transform Fe2O3 &TiO2 into Ilmenite phase and remove this by simple magnetic separator.

26 Special Alumina Production in India Belgaum Alumina Refinery of HINDALCO in India is a leader-produces about 150,000 tons of special alumina products per annum NALCO Damanjodi Refinery has pilot plant of 600 MTPA & main plant capacity is 26,400 MTPA Several small to medium sized refractories, castables and alumina cement producers in India. Important players are Calderys India Refractories Ltd., TRL Krosaki Refractories, S P Refractories, Shanark Refractories, Sarvesh Refractories, Flaminco Refractories, Grindwell Norton and Castwell etc. Many types of Zeolites are also manufactured in India from bauxite & fly ash.

27 Alumina Ceramics Extensive R&D work is in progress in India on new applications of alumina ceramics in improving cooling efficiency, super-hydrophobic insulation, medical prosthesis etc. Leading R&D organizations working in this field are CGCRI, Ceramic Technological Institute, Bharat Heavy Electrical Limited, IFGL Bio ceramics, Carborundum Universal, TRL Krosaki Refractories etc. India has also started production of proppants (sintered bauxite) and presently a commercial pilot plant in Pune is producing bauxite based proppants. In the International Bauxite, alumina and aluminium symposium of India, two special sessions are being organised on latest developments of alumina ceramics.

28 CONCLUSIONS Eastern Ghats in the states of Orissa & Andhra Pradesh are most prolific bauxite bearing region in India and 80% country s resources are confined here. The present installed alumina capacity in the country is in the order of 5.28 Million Tons per annum, however, only 3.86 MT is produced during The projected alumina capacity in 2020 is predicted to be about 19 MT, which looks very optimistic, keeping in view the problems being faced by new refineries in mining bauxite at present India produces about 400,000 tons of calcined bauxite per annum mainly for refractory & abrasive industries. Intensive R&D work is going on to bring down iron and titania contents in Indian bauxite.

29 CONCLUSIONS (Contd.) Transforming iron and titania into high temperature phases is new direction of R&D work for developing calcined bauxite suitable for refractory industry. HINDALCO Belgaum refinery is a leader in the production of special alumina products followed by several small to medium sized enterpreneurs. Many R&D centres and companies are involved in developing alumina based ceramics in India. Extensive interaction with Special Alumina & Bauxite producers is being organised at IBAAS-2012 at Nagpur, India during 3 rd 5 th, December, Visit website

30 Contact Details: Dr. Ashok Nandi, Director Mineral Information & Development Centre s: Cell No