Theme: 4M – Mining, Minerals, Metals and Materials

K Muraleedharan

Theme Director, 4M CSIR-Central Glass and Ceramics Research Institute

Kolkata 700032

First Interaction Meeting led by Theme Directorate 4 M on 13th March, 2018

India

China

World

Rest (other than Asia Pacific)

Asia Pacific

Domestic Material Consumption / Capita

Courtesy: UNEP China’s performance has been very impressive

Domestic Material Consumption: Asia Pacific

Courtesy: UNEP

In India, there has been increase Far less as compared to China

The Materials Development Cycle

DISCOVERY DEVELOPMENT

ENGINEERING MANUFACTURING

SUSTAINING We have excelled in discovery and development in the past.

However, engineering and manufacturing aspects and efforts to develop sustainable materials solutions with faster induction and reduced life-cycle cost as well as green and environment friendly solutions is the challenge today

The Challenge: Capability to develop, manufacture, and deploy advanced materials

• at least two times faster than is possible today • at a fraction of current cost

Sub Themes

• Raw Materials

• Minerals & Beneficiation

• Extraction & Refining Technologies

• Materials Processing & Equipment

• Advanced Materials

• Advanced Manufacturing

• Modeling & Simulation

• Surface Engineering

• Waste to Wealth

Area: Mining With 87 minerals (10 metallic, 47 non-metllic, 3 atomic, 4 fuel and 23

minor minerals) and nearly 2700 reported mines in India, this sector in India has a huge potential.

Some of the challenges for Indian Mining industry are: • Rising input costs • Land & its allocation • Logistics • Degrading quality of ores • Lack of proper database & of qualified manpower and • Unknown number of illegal & small mines.

The need of the hour in this sector are • A comprehensive roadmap • New geography • Life extension of exiting machinery, control of corrosion • New equipment & technology for exploration (e.g., robotics &

simulation) • Proper utilization of available resources

Area: Minerals

Mineral resources are key material basis for socio-economic development. Mineral resources are also of extreme strategic importance for the country Unlike China, India has not taken a lead in developing a comprehesive roadmap for exploitation of mineral resources The first task is to create a national roadmap where CSIR can take a lead.

Area: Metals

The Indian metal business is focused on • Steel • Aluminium • Copper • Zinc • Lead • Rare earths and • Titanium

For all metals, per capita consumption in the Indian context is substantially lower than the global average. Same is the case for R&D expenditure

Opportunities are huge due to rising demands

Lack of strategic positioning is the main challenge along with dumping by China

Iron & Steel : Current Status

India is the world’s largest producer of sponge iron with a host of coal based units, located in the mineral-rich states of the country. Indian sponge iron production contributes more than one-third of the global production.

India is world’s third larges steel producer. (~ 125 Mtpa as per data of 2017).

India is expected to reach 2nd position globally very soon (140Mtpa)

India’s per capita consumption of Steel is 57 kg/a while it is 460 kg/a in China, 507kg/a in Japan and 1157 kg/a in Korea. • The world average is 215 kg/a. Indian market is expected to

grow to 200 kg/a by 2030.

TV 2035 has defined goals for the materials for the year 2035. Metals Glass and Ceramics

Education Medical Sciences&Healthcare Food and Agriculture Water Energy Environment Habitat Transportation Infrastructure Manufacturing

Materials Information and

Communication Technology

Need of materials technologies for the strategic sector • SA to RM has compiled the requirements of materials

technologies and a approval has been sought from Government for special funds (Rs 10,000Cr)

• Similarly, an effort is ongoing for the establishment of manufacturing technologies for Defence

• ISRO have also identified the requirements and a letter from Chairman ISRO is received by DG, CSIR

• Talks are on with various units of DAE for identification of materials needs.

• Some agencies such as NTPC, BEL, BHEL etc. are also approaching CSIR for technology developments

FTT Projects Institute/Laboratory Project

CSIR-AMPRI Aluminium Composite Foams (ACFs) for Crashworthiness Applications

Fibre and particulate reinforced hybrid polymeric composite as architectural interior for building

construction material

CSIR-CGCRI

Paper-based Ceramic Separator for Li-ion Battery Application

Packaged Fiber Laser Modules for Industrial and Medical Applications

Development of Reaction Bonded Silicon Nitride Ceramic Radome

Superior Refractory for Induction Furnace to enable Refining of Steel

SiAION Insert for High Speed cutting of hard materials

Fast Recovery Trace moisture sensor and Meter for detection of trace moisture present in

transformer oil

Development of novel Ion doped Hydrxyapatite (HAp) by spray drying method and its utilization for

plasma spray coating on medical implants with/without ion doping

CSIR-IMMT

Electrophoretic Deposition (EPD) for Industrial Application

Maximize the recovery of iron values from lean grade iron ore by reduction roasting and pelletisation

of high LOI and high Blaine number iron ore fines

Process Development for production of flaky graphite, high purity graphite and graphite from natural

graphite

Recovery of Alumina from fly ash

CSIR-NML

Technology for extraction of tungsten (yellow tungsten oxide or ammonium paratungstate or

metallic W-powder) from a variety of scraps

Development of Hydrogen standard in Steel

Low Phosphorus steel through furnace route using DRI as major ferruginous raw material-an

industrial assessment

16 FTT Projects

Leads from XII Plan projects

• Needs compilation and brain storming

• Propose a group of scientists to do this

• The group may also identify New FTT projects; FTC projects from the various leads

Director of one lab/Institute – Chairman

3-4 members

Technology Compendium

• Present compilation lacks information

• Propose a group of scientists to do this afresh

• All lab Dir/s or reps to forward information to Dr Mohanty by 31 March 2018.

• The group will compile the Technology Compendum for the 4M cluster

Theme Director – Chairman

3-4 members

Sample projects • Increasing per capita consumption of all materials

• Use of Iron and steel in making • Farming equipments

• Engineering and plant machinery

• Heavy engineering

• Convert non-cocking coal to coking coal

• Recovery of Metal Values from lean and fine ores

• Technologies for use of magnetite ore in various iron making processes

• Processing of Ores, Minerals, and Mining and Industrial Waste (Plasma, pyro- and hydro- techniques)

• Indegeous refractories for metal, cement and other industries

• Reduction of impurities in ores (e.g. P in iron and silica in bauxite)

• Metal extraction technologies

Sample projects

• Metal and ceramic powder making technology for Additive manufacturing

• Waste to wealth, substitutes for wood, building materials, radiation shielding materials

• Surface Engineering; Thermal Barrier Coatings

• Bio-materials: Materials development and Product engg.

• Corrosion/erosion studies and life extension of pipe lines, mining equipments

• Modelling and simulation in mineral and metallurgical processes, materials technologies

• Increased use of steel and glass in infrastructural applications: buildings, bridges, roads

• Metal-cermet braking pads to replace current braking systems

• Advanced glass, ceramics and composites

High Purity Precursors and Raw Materials for Ceramics

99.9% purity quartz, alumina, boron nitride, silicon nitride, silicon carbide, stabilized zirconia, zirconium diboride, hafnium diboride, titania, titanium carbide, lanthanum hexaboride

Spherodized powders for net shape manufacturing

Ultra High Temperature Ceramics & Composites

Components : nose cone, leading edge of wings & tales, , parts of scramjet engine etc., combustor, shrouds, nozzles and blades

Material : UHTC (ZrB2/HfB2/TiC/SiC), C/SiC or SiC/SiC CMCs

Netshape & Additive Manufacturing / Refurbishment

Components : RBSN radomes, Ceramic Armour, Precision Optics etc.

Technology : Fused Deposition Moulding, Injection Moulding, Stereolithography, Maskless photolithography, LENS, Laser assisted refurbishment, Replicative & Incremental forming etc

Hard Ceramic Wear Parts & Cermet Break Dics

Component : Cutting tool inserts, liners, bearings, dies, break discs etc.

Material : M-AlON (e.g., SiAlON), Cermets

Ceramic Machining & Joining Technologies

Ultrasonic assisted machining, laser assisted machining, magnetorheological polishing, ductile mode machining, active brazing, high temperature adhesive bonding etc.

Advanced Ceramics & Composites : Themes

Specialty Refractory Materials

Refractory solutions for steel, cement, nonferrous and power generation sectors

Functional Materials

Smart Sensors for Manufacturing : High Curie temperature piezoceramics

Nanostructured ceramics for electronic & sensing devices

Advanced Ceramics for Energy & Environment

Energy Materials : Low temperature SOFC materials & sealing materials

Efficient & high performance ceramic membranes

NDT & SHM Technologies

• Robust techniques for NDT/SHM of ceramics and ceramic composite components

Advanced Ceramics & Composites : Themes

Activity title Participating

Labs

Additive manufacturing/ 3D printing of tailored

custom metallic and bioactive ceramic/ glass

implants for tissue engineering.

CSIR-CGCRI,

CSIR-IICB

Osteocondctive and biodegradable composites

(ceramic/polymer) for fracture and bone tissue

healing.

CSIR-CGCRI,

CSIR-IICB

Synthesis of biomaterials from biogenic sources

for bone replacement and wound healing.

CSIR-CGCRI,

CSIR-IICB

Biomimetic nanocomposite scaffolds. CSIR-NML

Biomaterials Activities under 4M Theme

Activity title Participating Labs

Materials and manufacturing technologies for hip, knee

and dental implants (including immune response of

debris).

CSIR-CGCRI, CSIR-

IICB, CSIR-NAL

The prospective treatment of type 2 diabetes by shRNA-

layered double hydroxide nanoceramic conjugate

CSIR-CGCRI

Biodegradable high-strength alloys of Mg and Fe. CSIR-NML, CSIR-

CGCRI, CSIR-NIIST

Hydrogels and their composites for tissue engineering. CSIR-IICB, CSIR-

CGCRI

Functionalized nanoparticles for diagnostics and imaging. CSIR-NML, CSIR-

CGCRI

Non-invasive cancer treatment using magnetic and

ultrasound fields.

CSIR-CGCRI, CSIR-

IICB

Biomaterials Activities under 4M Theme

Thank you