Indian Rare Earths

Last updated

IREL (India) Limited
FormerlyIndian Rare Earths Limited
Company type Public Sector Undertaking
Industry Rare Earth Extraction
Founded18 August 1950 [1]
Headquarters1207, Veer Savakar Marg, Prabhadevi, near Siddhi Vinayak temple, ,
India
Key people
D. Singh
(Chairman & MD)
Products Ilmenite
Leucoxene
Rutile
Zircon
Garnet
Sillimanite
Lanthanum carbonate
Cerium(III) carbonate
Neodymium
Praseodymium
Samarium
Gadolinium
Yttrium
NdPr Oxalate
Thorium(IV) nitrate
Trisodium phosphate
Rare Earth Chloride
RevenueIncrease2.svg1,536.30 crore (US$190 million) (2021) [2]
Increase2.svg500.12 crore (US$63 million) (2021) [2]
Increase2.svg315.68 crore (US$40 million) (2021) [2]
Total assets Increase2.svg1,703.55 crore (US$210 million) (2021) [2]
Total equity Increase2.svg1,167.15 crore (US$150 million) (2021) [2]
Owner Government of India
Number of employees
1222 (March 2021) [2]
Website irel.co.in

IREL (India) Limited is an Indian Public Sector Undertaking based in Mumbai, Maharashtra. It specializes in mining and refining rare earth metals.

Contents

It has installed capacity to process about 10,000 MT of rare earth bearing mineral. As regards production, capacity and capabilities in terms of mining, processing, extraction, refining and production of high pure RE oxides is adequately available in India. [3] [4]

Production Facilities

Rare Earths Division (RED) Aluva

This plant, the first unit of IREL, was made operational way back in 1952 for processing of monazite, whose capacity was subsequently increased by about three times. Rare Earths Division (RED), Udyogamandal, Aluva is located on the banks of Periyar River in Kerala at a distance of 12 km from the port city of Kochi and 15 km from Kochi International Airport.

In the year 2012, the plant was refurbished to process mixed rare earth chlorides. It produces high pure individual rare earth compounds of lanthanum and cerium in oxide and carbonate form, and that of neodymium-praseodymium, samarium, gadolinium and yttrium in oxide and oxalate form (with more than 99% Purity). RED also produces strategic materials for the Department of Atomic Energy. [5]

Odisha Sand Complex (OSCOM) and OSCOM - Rare Earth Extraction Plant(REEP)

IREL commissioned its largest division called Odisha Sand Complex (OSCOM) [6] at Chhatrapur, Odisha. [7] [8] Today IREL operates these four units along with a corporate office in Mumbai [9] and a unit located in Manavalakurichi of Kanyakumari district. [10] It produces/sells six heavy minerals namely ilmenite, rutile, zircon, monazite, sillimanite, and garnet as well as various value added products.

From 1 May 2015 it started commercial operation of Monazite Processing Plant at Orissa to process 10000tpa monazite to produce 11220tpa of rare earth chloride, 13500 tri-sodium phosphate, 26tpa NGADU etc. Similarly High Pure Rare Earth facility also commenced operation to refine pure rare earth compounds. In 2013 Gopalpur port shipped 7,500 metric tonne of ilmenite from Orissa Sand Complex (OSCOM) to South Korea for the first time after IREL started the operation. [11] Monazite deposit in Odisha contains rare earths like, Lanthanum, Cerium, Praseodymium, Neodymium etc. It also contains Thorium which is a "prescribed substance", the list of which was revised in 2006 under the Atomic Energy Act, 1962. [12]

IREL has set up a Rare Earth Extraction plant (REEP) producing mixed Rare Earth chloride (MRCL) Tri-sodium phosphate etc, at its unit OSCOM Odisha. MRCL produced from the above plant is processed at IREL’s plant at Rare Earth Division (RED) in Aluva Kerala for producing separated High Pure Rare Earth (HPRE) Oxides/Compounds.Rare Earth processing unit having installed capacity of 11200 tpa mixed Rare Earth Chlorides was commissioned in the year 2015-16. [13]

Manavalakurichi unit (MK)

IREL opened the division in 1963 after becoming a fully public sector undertaking under the administrative control of Department of Atomic Energy(DAE), Government of India, IREL will carry out beach sand mining and extract heavy minerals at an area of 1,144.06 hectare in eight villages of Kanniyakumari district.It currently holds beach sand mining lease for an area of 178.06 hectare including 29.78 hectare in Midalam and Keezhmidalam,148.27 hectare in Manavalakurichi of Kanyakumari district.

IREL has a mineral manufacturing unit functioning in Manavalakurichi village near Colachel in Kanniyakumari for extracting ilmenite, zircon, rutile, monazite and sillimanite. [14] Annual production capacity of MK mineral separation plant is 91,200 tonnes per annum (tpa) of Ilmenite and other associated minerals such as Rutile, Zircon and Garnet. [15]

Chavara Mineral Division

Chavara mineral separation plant is located 10 km north of Kollam and 85 km from Thiruvananthapuram the Capital of Kerala. It is about 135 km from Kochi, the major port in Kerala. The nearest airport is at Thiruvananthapuram. The adjacent area of Chavara is blessed with one of the best mineral sand deposits in the country – the renowned “Q” Grade minerals.

The Chavara mines contain as high as 40% heavy minerals extending over a stretch of 23 km in the coastal belt of Neendakara and Kayamkulam, The deposits is quite rich with ilmenite, rutile, zircon, sillimanite and is unique with weathered variety having 60% TiO2 ilmenite.

The plant has a capacity to produce 2,35,900 tpa of ilmenite and associated minerals such as rutile, zircon and sillimanite. It has a facility to produce Zirflor in sizes (-300 and -200) in the zircon opacifier plant.The plant operates on an advanced modular design with state of the art equipment in mineral separation and has a well - equipped quality control laboratory for quality assurance. It is certified for ISO 9001:2008, 14001:2004 and 18001:2007.

Rare Earth Permanent Magnet Plant (REPM), Vishakapatnam

This plant was opened in 2023. IREL has set up this plant for producing Rare Earth Permanent Magnet (REPM) at Visakhapatnam based on Indigenous Technology. This plant produces samarium-cobalt permanent magnets [16] [17]

The plant has an annual capacity of 3,000 kg and overall cost is 197 crore.The Facility has been established based on indigenous technology developed by BARC and DMRL and using indigenous rare earth Samarium resources. [18]

IRERC, Kollam

The Corporate Research Centre is located at Kollam, Kerala [19] and carries out research in the field of value added products from beach sand minerals, undertakes consultancy projects on mineral separation and flow sheet development, carrying out mineral analysis and caters to the needs of internal and external customers. [20]

R & D

IREL Technology Development Council (IRELTDC) is formed with an objective of promoting industrial scale R&D that would be beneficial to the overall programme of DAE in both strategic and non-strategic fields utilizing mineral & value-added products of IREL. Council invites funds and monitors R&D project proposals from CSIR, IITs, State & Central laboratories, for large scale application & exploitation on the areas of technology of mutual interest.

list of completed R&D projects

Source: [21]

  1. Augmentation of PREE solvent extraction test facility at RED.
  2. Pilot-scale production for nanosize rare earth phosphates and development of potential industrial application areas.
  3. Design and development of environmentally secure rare earth based colorants.
  4. Inflight processing of metallised ilmenite in a DC plasma furnace for continuous production of titania-rich slag and pig iron.
  5. Development of cerium oxide based nano materials for applications as Chemical-Mechanical Planarisation/Polishing (CMP) slurry.
  6. Recovery of heavy rare earths from phosphoric acid using phosphorus-based commercial extractants and their mixtures.
  7. Synthesis and properties of electrodeposited nickel/ceria nanocomposite coatings.
  8. Catalysis by nano Crystalline Ceria Modifies with Transition Metals.
  9. Design and scale-up of Annular Centrifugal Extractor (ACE).
  10. Processing of monazite through sulphuric acid for the recovery of rare earths, thorium and uranium.
  11. Preparation of mullite and zirconia toughened mullite from sillimanite.
  12. Study of suitability of magnetic separators as replacement for air tables for recovery of monazite.
  13. Versatile nano zirconia production facility at IREL, OSCOM.
  14. High-field composite varistors based on rare earth oxides.
  15. Smart magneto rheological elastomers based on rare earth Magnets.
  16. Production of nano titania from ilmenite and set up a pilot plant to process 1 ton/batch.
  17. Production of environmentally secure rare earth oxide brown pigment for surface coating applications.
  18. Optimization of processing parameters to produce high aspect ratio synthetic wollastonite.
  19. Improving recovery of heavy minerals at IREL plants using spiral separators.
  20. Suitability of rare earth drum magnetic separator to increase plant efficiency at IREL, Chavara.

Finance

IREL records highest-ever sales turnover and PBT in FY 2021-22.According to the company, it has achieved its highest ever sales turnover and profit before tax (PBT) since its inception. The sales turnover and PBT stood at a whopping Rs 1462.05 crore, while the PBT stood at about Rs 700.00 crore, which surpassed the previous year record by 53.3 percent and 68.6 percent respectively. [22]

IREL declared and paid dividend of Rs.166.67 Crores out of the profit for the financial year 2021-22.The total income of the company was Rs. 1536.30 crore. [23]

Collaboration

IREL extracts the rare earth metal and rare earth alloy using the refining technique based on laboratory scale process developed by BARC and DMRL. [18]

IREL (India) Limited renewed its agreement with M/s. Toyotsu Rare Earths (India) Pvt. Ltd. for creating a critical minerals supply chain. [24] [25] Toyotsu Rare Earths (India) Pvt. Ltd. remarkets the rare earth oxides or carbonates like Lanthanum Oxide(LA2O3), Cerium Oxide(CEO2), Praseodymium Oxide(PR6O11), Neodymium Oxide(ND2O3), Praseodymium-Neodymium Oxide((PRND)2O3) and Cerium Carbonate (CE2(CO3)3) from IREL.

Reduction-Diffusion Technique is a process used by the Bhabha Atomic Research Centre (BARC) for the production of enriched uranium.IREL uses the same process for thorium and other radio active metals. [26] [27]

Upcoming Projects

Ambadongar Rare Earth Project

New carbonatite deposit in Gujarat. Technical feasibility and economic viability studies undertaken. [28]

IREL-IDCOL Ltd

Setting up of new mining and mineral separation plant for winning beach sand mineral deposits in Puri District of Odisha. [28]

Private Freight Terminal (PFT)- OSCOM

Conversion of IRELs Private railway siding to Private Freight Terminal [28]

Capacity expansion of OSCOM plant

Increase in capacity from 2.8 to 6.2 lakh tpa of Ilmenite and associated minerals. [28]

Related Research Articles

<span class="mw-page-title-main">Lanthanum</span> Chemical element, symbol La and atomic number 57

Lanthanum is a chemical element; it has symbol La and atomic number 57. It is a soft, ductile, silvery-white metal that tarnishes slowly when exposed to air. It is the eponym of the lanthanide series, a group of 15 similar elements between lanthanum and lutetium in the periodic table, of which lanthanum is the first and the prototype. Lanthanum is traditionally counted among the rare earth elements. Like most other rare earth elements, the usual oxidation state is +3, although some compounds are known with an oxidation state of +2. Lanthanum has no biological role in humans but is essential to some bacteria. It is not particularly toxic to humans but does show some antimicrobial activity.

The lanthanide or lanthanoid series of chemical elements comprises at least the 14 metallic chemical elements with atomic numbers 57–70, from lanthanum through ytterbium. In the periodic table, they fill the 4f orbitals. Lutetium is also sometimes considered a lanthanide, despite being a d-block element and a transition metal.

<span class="mw-page-title-main">Neodymium</span> Chemical element, symbol Nd and atomic number 60

Neodymium is a chemical element; it has symbol Nd and atomic number 60. It is the fourth member of the lanthanide series and is considered to be one of the rare-earth metals. It is a hard, slightly malleable, silvery metal that quickly tarnishes in air and moisture. When oxidized, neodymium reacts quickly producing pink, purple/blue and yellow compounds in the +2, +3 and +4 oxidation states. It is generally regarded as having one of the most complex spectra of the elements. Neodymium was discovered in 1885 by the Austrian chemist Carl Auer von Welsbach, who also discovered praseodymium. It is present in significant quantities in the minerals monazite and bastnäsite. Neodymium is not found naturally in metallic form or unmixed with other lanthanides, and it is usually refined for general use. Neodymium is fairly common—about as common as cobalt, nickel, or copper—and is widely distributed in the Earth's crust. Most of the world's commercial neodymium is mined in China, as is the case with many other rare-earth metals.

<span class="mw-page-title-main">Ilmenite</span> Titanium-iron oxide mineral

Ilmenite is a titanium-iron oxide mineral with the idealized formula FeTiO
3
. It is a weakly magnetic black or steel-gray solid. Ilmenite is the most important ore of titanium and the main source of titanium dioxide, which is used in paints, printing inks, fabrics, plastics, paper, sunscreen, food and cosmetics.

<span class="mw-page-title-main">Gadolinite</span> Nesosilicate mineral

Gadolinite, sometimes known as ytterbite, is a silicate mineral consisting principally of the silicates of cerium, lanthanum, neodymium, yttrium, beryllium, and iron with the formula (Ce,La,Nd,Y)2FeBe2Si2O10. It is called gadolinite-(Ce) or gadolinite-(Y), depending on the prominent composing element. It may contain 35.5% yttria sub-group rare earths, 2.2% ceria earths, as much as to 11.6% BeO, and traces of thorium. It is found in Sweden, Norway, and the US.

<span class="mw-page-title-main">Mischmetal</span> Pyrophoric rare-earth metal alloy

Mischmetal (from German: Mischmetall – "mixed metal") is an alloy of rare-earth elements. It is also called cerium mischmetal, or rare-earth mischmetal. A typical composition includes approximately 55% cerium, 25% lanthanum, and 15~18% neodymium, with traces of other rare earth metals; it contains 95% lanthanides and 5% iron. Its most common use is in the pyrophoric ferrocerium "flint" ignition device of many lighters and torches, although an alloy of only rare-earth elements would be too soft to give good sparks. For this purpose, it is blended with iron oxide and magnesium oxide to form a harder material known as ferrocerium. In chemical formulae it is commonly abbreviated as Mm, e.g. MmNi5.

<span class="mw-page-title-main">Monazite</span> Mineral containing rare-earth elements

Monazite is a primarily reddish-brown phosphate mineral that contains rare-earth elements. Due to variability in composition, monazite is considered a group of minerals. The most common species of the group is monazite-(Ce), that is, the cerium-dominant member of the group. It occurs usually in small isolated crystals. It has a hardness of 5.0 to 5.5 on the Mohs scale of mineral hardness and is relatively dense, about 4.6 to 5.7 g/cm3. There are five different most common species of monazite, depending on the relative amounts of the rare earth elements in the mineral:

<span class="mw-page-title-main">Bastnäsite</span> Family of minerals

The mineral bastnäsite (or bastnaesite) is one of a family of three carbonate-fluoride minerals, which includes bastnäsite-(Ce) with a formula of (Ce, La)CO3F, bastnäsite-(La) with a formula of (La, Ce)CO3F, and bastnäsite-(Y) with a formula of (Y, Ce)CO3F. Some of the bastnäsites contain OH instead of F and receive the name of hydroxylbastnasite. Most bastnäsite is bastnäsite-(Ce), and cerium is by far the most common of the rare earths in this class of minerals. Bastnäsite and the phosphate mineral monazite are the two largest sources of cerium and other rare-earth elements.

<span class="mw-page-title-main">Placer deposit</span> Accumulation of valuable minerals formed by gravity separation

In geology, a placer deposit or placer is an accumulation of valuable minerals formed by gravity separation from a specific source rock during sedimentary processes. The name is from the Spanish word placer, meaning "alluvial sand". Placer mining is an important source of gold, and was the main technique used in the early years of many gold rushes, including the California Gold Rush. Types of placer deposits include alluvium, eluvium, beach placers, aeolian placers and paleo-placers.

<span class="mw-page-title-main">Praseodymium</span> Chemical element, symbol Pr and atomic number 59

Praseodymium is a chemical element; it has symbol Pr and the atomic number 59. It is the third member of the lanthanide series and is considered one of the rare-earth metals. It is a soft, silvery, malleable and ductile metal, valued for its magnetic, electrical, chemical, and optical properties. It is too reactive to be found in native form, and pure praseodymium metal slowly develops a green oxide coating when exposed to air.

<span class="mw-page-title-main">Didymium</span> Mixture of praseodymium and neodymium

Didymium is a mixture of the elements praseodymium and neodymium. It is used in safety glasses for glassblowing and blacksmithing, especially with a gas (propane)-powered forge, where it provides a filter that selectively blocks the yellowish light at 589 nm emitted by the hot sodium in the glass without having a detrimental effect on general vision, unlike dark welder's glasses. The usefulness of didymium glass for eye protection of this sort was discovered by Sir William Crookes.

<span class="mw-page-title-main">Ferrocerium</span> Pyrophoric alloy whose primary components are cerium and iron

Ferrocerium is a synthetic pyrophoric alloy of mischmetal hardened by blending in oxides of iron and/or magnesium. When struck with a harder material, the mixture produces hot sparks that can reach temperatures of 3,315 °C (6,000 °F) when rapidly oxidized by the process of striking the rod. Striking both scrapes fragments off, exposing them to the oxygen in the air, and easily ignites them by friction heat due to cerium's remarkably low ignition temperature of between 150 and 180 °C.

<span class="mw-page-title-main">Heavy mineral sands ore deposits</span> Ore deposits of rare earth metals

Heavy mineral sands are a class of ore deposit which is an important source of zirconium, titanium, thorium, tungsten, rare-earth elements, the industrial minerals diamond, sapphire, garnet, and occasionally precious metals or gemstones.

<span class="mw-page-title-main">Kenmare Resources</span> Irish mining company

Kenmare Resources plc is a publicly traded mining company headquartered in Dublin, Republic of Ireland. Its primary listing is on the London Stock Exchange and it has a secondary listing on Euronext Dublin. Kenmare is one of the world's largest mineral sands producers and the Company owns and operates the Moma Titanium Minerals Mine. Moma is one of the world's largest titanium minerals deposits, located 160 km from the city of Nampula in Mozambique.

<span class="mw-page-title-main">Cerium</span> Chemical element, symbol Ce and atomic number 58

Cerium is a chemical element; it has symbol Ce and atomic number 58. Cerium is a soft, ductile, and silvery-white metal that tarnishes when exposed to air. Cerium is the second element in the lanthanide series, and while it often shows the oxidation state of +3 characteristic of the series, it also has a stable +4 state that does not oxidize water. It is also considered one of the rare-earth elements. Cerium has no known biological role in humans but is not particularly toxic, except with intense or continued exposure.

<span class="mw-page-title-main">Kerala Minerals and Metals</span>

Kerala Minerals and Metals Ltd is an integrated titanium dioxide manufacturing public sector undertaking in Kollam, Kerala, India. Its operations comprise mining, mineral separation, synthetic rutile and pigment-production plants. Apart from producing rutile-grade titanium dioxide pigment for various types of industries, it also produces other products like ilmenite, rutile, zircon, sillimanite, synthetic rutile etc. It is one of the best performing Public Sector Units in India. The company manufactures titanium dioxide through the chloride route. The different grades are produced by KMML under the brand name KEMOX.

<span class="mw-page-title-main">Cochin Minerals and Rutile Limited</span> Indian chemicals company

Cochin Minerals and Rutile Limited (CMRL) is a publicly listed chemicals company based in Kochi, Kerala, India. The company was founded in 1989 by Dr. S.N. Sasidharan Kartha with assistance from the Kerala State Industrial Development Corporation (KSIDC). The company is the only listed Indian entity in the synthetic rutile space.

<span class="mw-page-title-main">Economy of Kollam</span>

Kollam or Quilon is an old seaport and a city on the Laccadive Sea coast in Kerala, India, on Ashtamudi Lake. The city remains notable as the ancient commercial capital of Kerala and the southwestern Indian coast, in addition to its fame as the "Cashew Capital of the World". The Kollam Municipal Corporation has the second largest budget in Kerala in terms of revenue and expenditure.

Anzaite-(Ce) is a rare-earth element (REE) oxide mineral with the formula Ce4Fe2+Ti6O18(OH)2. An example of chemically related mineral is lucasite-(Ce), although it contains no iron. Cerium in anzaite-(Ce) is mainly substituted by neodymium, lanthanum, calcium and praseodymium. Titanium is substituted by niobium. Trace elements include thorium. The mineral is monoclinic, space group C2/m. Anzaite-(Ce) is hydrothermal mineral found in a carbonatite from the mineralogically prolific Kola Peninsula. The mineral name honors Anatoly N. Zaitsev, who is known for studies of carbonatites and REE.

<span class="mw-page-title-main">Gopalpur port</span> Port in India

Gopalpur port is a deep sea port of Gopalpur near Brahmapur city in Ganjam District, Odisha, India. The port has been developed on the banks of the Bay of Bengal. The seaport will increase the sea trade of Odisha, as well as industry and employment.

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