Background details:
Kerala Minerals and Metals Ltd (KMML) located at Kollam in Kerala, is one of the pioneers in the field of mineral sand industry in India.
KMML was established by a private entrepreneur in 1932 as F.X. Perira and Sons (Travancore) Pvt. Ltd. During 1956, the concern was taken over by the Kerala State Government and was placed under the control of its industries department. The unit was converted to a limited company with effect from 1.4.1972. in the name of “ The Kerala Minerals and Metals Ltd”.
KMML is now an integrated plant with Mineral Separation plant, Synthetic Rutile Plant with Acid Regeneration facility and Rutile grade Titanium dioxide (TiO2)pigment production plant in a single complex.
KMML is the India’s first and only manufacturer of Rutile Grade TiO2 by chloride route.
Since its inception, KMML has made mark in the fields of mining, mineral processing and manufacturing, with the factories at Sangaramangalam and Kovilthottam in Kerala. In 1980s, the unit went for diversification programme by way of implementing the project for TiO2 complex.
Originally, three activities were planned by KMML as part of the TiO2 complex as per the following details:
Enhanced mining and mineral separation of beach mineral sands from the 20000 tonnes per annum to produce 200000 tonnes of ilmenite per annum by deep mining with an Australian collaboration. Out of this, 100000 tonnes was to be for captive consumption and the balance for sale and exports.
The second activity was to beneficiate the 100000 tonnes of ilmenite using the Benelite process of USA using hydrochloric acid to produce about 50000 tonnes per annum of Synthetic rutile. A chlorine value recovery and recycling facility with the collaboration of Woodal Du Chem of UK based on the effluent iron chloride was also included.
The third plant was for the chlorination of Synthetic rutile to produce Titanium tetrachloride, which would be thermally oxidised to produce treated rutile, with the collaboration of Kerr McGee Chemi cal Corporation of USA.
Thus, the complex was proposed to be established with technical collaboration from four foreign companies. Collaboration agreements were finalized with three companies comprising the second and the third part of the complex and Metallurgical and Engg. Consultants Ltd. (MECON) Jamshedpur were appointed as Engineering Consultant for the project.
Of the above project schemes, the unit implemented the project concerning the manufacture of Rutile Grade TiO2 by chloride process.
There was heavy delay in the implementation of the project.
The problems of land acquisition and rehabilitation of displaced people at a thickly populated region like Kollam district in Kerala forced KMML to postpone the enhanced mining acitivity, which was basic with regard to the entire complex to a later period, KMML concentrated on the construction of plants for the third stage of chlorination and oxidation and for the second stage of beneficiation and hydrochloric acid regeneration respectively in just the reverse order.
The threats of expiry of the collaboration agreements at these stages and additional payments for their extension were also there.
Delays and difficulties in procuring the necessary import licenses and finance together with frequent labour unrest prolonged the construction, which took over seven years The entire complex which was estimated to be completed at an invstment of Rs.65 crores consumed about Rs.130 crores for the second and third stage alone. The cost consideration forced KMML to terminate the agreement with MECON halfway through.
After many problems and delays, the unit was finally commissioned in 1986. For several years, the unit suffered due to low capacity utilisation and quality problems. The unit also remained closed for a short period due to chlorine leakage and death of a few employees.
After so many problems, the unit has now stabilized its operations at the production level of around 30000 tonnes per annum of rutile grade TiO2. The unit has substantially improved its technical and financial performance.
This article further discusses the following details :
- Product range
- Expansion plans
- Export performance
- New project proposals
- Expansion of synthetic rutile facility
- Titania sponge
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