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A REPORT ON THE TOUR TO PCSIR

(Pakistan Council of Scientific and Industrial Research)

By

MUHAMMAD ZUBAIR IDREES Institute of Geology, University of the Punjab,

Lahore

ABSTRACT: The Pakistan Council of Scientific and Industrial Research (PCSIR) was established in 1953. The

prime objective of setting up research establishments in various parts of the country for undertaking

scientific research for the utilization of the indigenous raw materials and also on problems faced by

the country's nascent industries. The present complexion of the PCSIR is that it has been reorganized

as an Autonomous Body under Act No. XXX of 1973 with greater emphasis on industrial research

oriented to the solution of important national problems.

INTRODUCTION:

We arrange a one day tour to Pakistan Council of Scientific and Industrial Research (PCSIR). We

reached PCSIR on 10:00 a.m., 13 Jan. 2011. We visted two main sections of PCSIR under the

supervision of our teacher Sir. Syed Mehmood Ali Shah. The first department we visited is Mineral

Processing Research Centre (MPRC) and the Second is Pakistan Institute of Technology for

Minerals and Advanced Engineering Materials (PITMAEM).

The PCSIR autonomy is functional within the framework of two constitutional bodies created under

the Act of 1973.

Council, the policy making body, is headed by the Chairman of PCSIR and the remaining

membership thereto includes three members of PCSIR (Science, Technology, Finance), four

representatives of Federal Ministers (S & T, Industries, Production), four Directors of Industries (one

from each province), three commerce Directors of PCSIR establishments, and six representatives of

industries.

Governing Body, the executive arm, is headed by the Chairman of PCSIR and includes two

Members (Science, Technology), one Member Finance (representative of Ministry of Finance), and

Secretary of PCSIR (ex-officio).

PCSIR has laboratory establishments in the federal and all the four provincial capitals

These are organized into four multifunctional research laboratories in Karachi, Peshawar, Quetta,

and Lahore by far the larger and therefore set-up in the structures of laboratories complexes.

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A wide range of S & T disciplines are organized into quasi-independent Centres / Divisions such as

applied chemistry, minerals & metallurgy, glass & ceramics, biotechnology & food, environmental

protection, medicinal botanics, fine chemicals & pharmaceuticals, rural technologies, instrumentation

& electronics, research industrialization, polymers & plastics, and marine & applied biology.

The monofunctional units include National Physical & Standards Laboratories at Islamabad. Fuel

Research Centre at Karachi, Leather Research Centre at Karachi, Solar Energy Research Centre at

Hyderabad, and Food Processing- cum - Demonstration Unit at Skardu. There also is a Scientific

Information Centre at Karachi which in addition to miscellaneous information related matters puts out,

now in its 49th-5 volume of publication, the Pakistan Journal of Scientific & Industrial research

publishing articles from national and international contributors after peer review.

Trained manpower needs of the industrial sector are met through two Centres in Karachi and Quetta,

namely, Pak-Swiss Technical Centre for middle-level technicians, and the national Institute of

Industrial Electronics & Engineering producing high quality graduates.

Objectives of PCSIR:

Optimum utilization of indigenous raw material resources for the development of industrial

processes.

Development of technologies around local resources from bench to pilot plant stages, and leasing

them out for industrial exploitation leading to import substitution and export enhancement.

To conduct R&D work on problems faced by the industrial sector and maintain linkages through

seminars, workshops, publications, and provision of assistance to academic institutions.

To undertake cooperative research with local and foreign R&D organizations and commerce-

industrial outfits on projects of national interest.

Human resource development through organized training courses and diffusive on – job grooming of

manpower for industry and research centers to broaden the science & technology base in the country.

Activities of PCSIR: The broad-based activities of the PCSIR encompass almost the entire industrial sector in the country;

for the industrial units in operation have their ground-work in science and technology in which the

PCSIR is both prominent and all too visible an organization on the national plan. The PCSIR being the

foremost industrial R & D organization is the largest producer of indigenous technologies in an

organized fashion. The R & D projects of the PCSIR fall into two major categories:

Those that are sponsored or are user liked.

Those for which a user is likely to be available but has to be found out.

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Evaluation of Locally Available Raw Materials:

Pakistan is replete with respect to natural resources and their exploitation should have been the top

priority in the process of industrialization of the country but instead of using local materials, a

consumer industry based on imported raw materials was largely established.

PCSIR's main thrust in the starting years was to investigate the physico-chemical composition of the

locally available raw materials and to find out their possible utilization. Out of the large number of

research publications (over 4000) that PCSIR produced during the period, 70 percent relates to the

evaluation of local materials. The data thus generated is the single most important contribution of the

PCSIR, which no other organization in the country can claim. It is available in the form of research

papers, technical bulletins, brochures and reports, etc. It covers the areas from minerals, ores, clays,

forest produced herbs, plants to marine and animal wastes. PCSIR can undertake survey and

evaluation studies of raw materials and products on behalf of the industry.

Process and Product Development:

The Scientists and Technologists of PCSIR developed 684 industrial processes and products and 350

numbers of patents, mostly based on the locally available raw materials. Out of these nearly 400

processes have commercially been exploited on industrial scale. It has also executed around 50 Annual

Development Programme (ADP) projects, which were mainly pilot plant studies, based on the data

generated on the laboratory level.

Investigative Analysis and Import substitution:

A large number of formulated products are being imported at exorbitant rates resulting in the

expenditure of costly foreign exchange by the textile, leather, pharmaceutical, cosmetics, household

chemicals, food additives and consumer products industries in the form of emulsions, surfactants,

resins, adhesives, plastic parts, perfumes, flavors and other chemical and non-chemical products. Most

of these items are imported under brand names. The expertise and technical manpower available in the

PCSIR have been able to decode and analyses over 2000 of these products and helped the local SME's

in the development of import-substituted materials.

Analytical and Testing Services:

PCSIR is capable of undertaking large number of tests of raw materials and industrial products and

can provide physical, chemical, chromatographic and spectroscopic analytical services in the

diversified fields. It has the requisite highly qualified, trained and experienced resource manpower not

available which is in any other organisation of the country. It has the necessary infrastructure in terms

of quality control, equipment and analytical instruments and laboratories. It has the capability to

investigate, improve and introduce latest methodology of testing and quality control in the production

and application. PCSIR at present is serving over 4000 SME's / clients all over the country annually in

quality control, analytical and testing area.

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Quality Control Services to the Exporters:

The major exports of Pakistan are textile, leather, food, sports and surgical goods and products, which

are based on locally available raw materials. The exports are essentially made to western European

countries, America and Japan. These countries are becoming more quality conscious and introducing

various parameters and checks to monitor the quality of the imported products. ISO 9000, 14000 and

17025 etc standards are being brought in to monitor the desired quality. Pakistan has faced much

Competition in the region for exports and in order to remain competitive there is a need to educate,

support and provide technical and quality control services to the producers and exporters of goods.

PCSIR is doing its best to extend these services to the exporters. Textile and leather exportable items

are examined for forbidden dyes, PCP, formaldehyde, heavy metals, pesticides and fungicides and

most of other undesirable chemicals on the request of the exporters and issuing analytical reports /

certificates which are being accepted in Europe and elsewhere. PCSIR has developed credibility for

these test reports. Similarly food items being exported by Nestle and others are being tested for their

microbial contamination and shelf life. Exporters of surgical goods, and sports goods are also getting

technical and analytical help from PCSIR. Under the supervision of EPB and technical guidance of

Mineral and Metallurgy Research Centre of PCSIR, a Material Testing Laboratory has been

established at Sialkot to Cater to the needs of the exporters of that area and PCSIR is imparting

training to the technical staff posted in M T Labs Sialkot.

Services to Government Departments and NGOs:

Various Government departments such as Customs, Excise, Police, Administration, Health and NGO's

avail the analytical testing and advisory services of PCSIR in resolving disputes, fake and genuine

products categorization investigative matters, narcotics, screening of medicines for steroids, etc.

Help in Crisis Situations:

Due to the availability of diverse expertise and extensive laboratory infrastructure, PCSIR enjoy the

status of focal point in the crisis situations and its scientific and technical staff are always ready to

extend to the local Administration the technical help to solve the problems and ameliorate the

situation. The major areas where PCSIR has significant contributions are:

Trouble shooting problems of the industry

Fire accidents

Poisonous gases leakage

Explosions

Environment and Pollution Control:

The expertise available in PCSIR in the field of Environment and Pollution Control is not only training

of its own S&T staff in the assessment, monitoring and control systems of air, water and soil pollution

but is also helping the local industry for self-monitoring and impact assessments. It is also helping the

Ministry of Environment, Local Government and Rural Development, Planning Division, Ministry of

Industries in framing and implementing National Environment Quality Standards (NEQS) of air,

water, industrial liquid and solid effluents and gasses emissions. PCSIR is also assisting the local

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industry in acquisition, modification of existing plants, handling of hazardous wastes, treatment of

effluents, control of emissions, etc. for environmentally clean and safe productions. PCSIR

laboratories have already been recommended by the EPA as environmental laboratories to carry out

testing of environment samples. PCSIR scientists/technologists are helping Ministry of Environment

to prepare, organize and execute training programmes in the field of environment monitoring and

assessment.

ISO - 9000/14000 Certifications:

On the introduction of the ISO-9000 series of the standards, the specified quality of the products has

become a vital issue for all the companies of the country to conduct their business according to the

requirements of applicable standards.

In Pakistan PCSIR is the only organization, which is capable of doing quality management work

successfully as it has all desired facilities available within its premises in each of the province of the

country. PCSIR has over one hundred different types of latest equipments and highly trained

manpower to test and evaluate a factory's raw materials, in process inventories, finished products and

the packed products which are to be marketed. The manpower of PCSIR is also capable of doing the

Environmental Impact Assessment studies in and around the vicinity, a plant is operating.

The scientists of PCSIR are well aware of the ISO-9000, ISO-14000 and WTO requirements which

have introduced new world order for improving the quality of products, services and management

systems of the organizations. In this context, PCSIR plan to get ISO-9000 certification and

accreditation against ISO-17025. In the very recently under a joint project of MOST & M/O

Commerce. Some 500 industries have been examined by PCSIR scientists for the certification and

about 250 industries have adopted/received certification for ISO 9000 under the programme. An

Incentive grants of Rs. 200,000/- has also been provided to each successful client upon recommend

actions of PCSIR.

Pre-Feasibility, Feasibility & Techno-Economic Studies:

PCSIR has experienced and trained scientific and technical manpower to undertake these studies on

behalf of the industry. A number of technical reports and pre-feasibility studies has been executed by

PCSIR on the request of the local industry, Government agencies such as PUNJMIN, RDC, NDFC,

SDA, BDA for survey, evaluation, upgrading of raw materials required and projects based on the

locally available raw materials.

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PCSIR Lab Complex Lahore is composed of the following centers/divisions:

1- Applied Chemistry Research Centre (ACRC)

2- Mineral and Material Research Centre (MMRC)

3- Biotechnology and Food Research Centre (BFRC)

4- Glass and Ceramics Research Centre (G&CRC)

5- Leather Research Centre (LRC)

6- Applied Physics, Computer and Instrumentation Centre (APC&I)

7- Centre for Development of Laboratory Equipment (CDLE)

8- General Services Division (GSD)

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MINERALS & METALLURGY RESEARCH CENTRE

Technology Available In Minerals and Metallurgy Deptmartment:

1. Mineralogy and geochemistry

2. Mineral processing / ore beneficiation.

3. Pyrometallurgy

4. Hydrometallurgy

5. Electrometallurgy

6. Physical metallurgy

7. Foundry technology

8. Corrosion and protection

9. Development of brighteners and electroplating chemicals

10. Heat treatment salt compositions

11. Evaluation of foundry sands moldings, silicates, bentonites and bonded sands

12. Graphite crucibles

13. Minerals based chemicals

Brief Description:

The Centre is engaged in R&D activities in areas related to mineralogy and geochemistry,

mineral processing pyro-metallurgy, electro-metallurgy, physical metallurgy, cast metals

technology, chemical evaluation, corrosion protection, product development, technological

promotion and industrial relations, Modern research facilities are available in the fields

mentioned above. The Centre is divided into five sections to carry out research and

development work in the specialized research areas. The details of Sections research and

development work in specialized research areas are as follows.

Mineral Processing Section:

It undertakes studies on the beneficiation of mineral raw materials to produce value added

products in the form of concentrates, which provide the feedstock for metallurgical

operations. The section has facilities to carry out-processing of mineral raw materials both

on laboratory and pilot plant scales. The data so generated provide the basis for

commercial exploitation of mineral resources. Chemical beneficiation and hydro-

metallurgical treatment of ores and mineral concentrates are also undertaken. The Section

is also engaged in the development of process flow sheets and preparation of pre-

investment feasibility on the processing of various ores and minerals. The section

possesses capabilities to undertaken beneficiation of any mineral raw material comparable

in quality to all international standards and competitive in processing cost.

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Physical Metallurgy Section:

Physical metallurgy section has the following laboratory facilities: Metallurgical

Laboratory: metallurgical technique is employed to control quality of metals during

production processes such as casting of metals and alloys, rolling forging, forming and heat

treatment etc. The technique is also used to assess the metal damage due to mechanical

conditions such as fatigue, creep, impact loading and environmental conditions or

corrosion.

Cast Metal Technology:

The Cast Metal Technology (CMT) section is equipped with facilities for melting and

casting steel alloy steels, iron, non ferrous metals such as brasses, bronzes and aluminum

alloys. The facilities are being used for research purposes and customized production of

castings, Elaborate molding and testing facilities are also available.

Mechanical Testing Laboratory:

The mechanical test laboratory is equipped with machines such as universal testing

machine, impact (Charpy testing machine, fatigue testing machine and hardness testing

machine etc.

X-Ray Laboratory:

The X-Ray Laboratory is equipped with XRF and XRD which are being used for materials

identification and qualitative and quantitative analyses of metals, alloys, ores and minerals.

Electro Chemistry & Evaluation Section:

This section is engaged in electro-metallurgy, non-ferrous metallurgy, electroplating,

anodizing and surface treatment process. In these fields achievements have been made for

the extraction of antimony from stibnite, production of magnesium and calcium metal and

number of surface finish processes. Besides this, evaluation and testing of raw materials,

metallic and finished products, treatment of water and water is also one of the activities of

the section. An average of 50 requests is being handled monthly, for testing and evaluation

of raw materials and the finished products. The section has published a number of papers

regarding new analytical methods.

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Geochemistry & Applied Mineralogy Section:

This section is equipped with instruments for industrial mineralogy, material sciences,

chemical and instrumental analysis. Number of pre-feasibility studies were completed as

in-house, R&D and sponsored projects of clients e.g.SDA PIDC PAKSTEEL PMDC

NESPAK AL, ODC FATA PECO WAPDA BDA ICI HMC etc. New projects of economic

importance from private entrepreneurs are undertaken at reasonable fee in the following

fields: Minerals based chemicals, Industrial minerals, Geological evaluation, Process

mineralogy, Composite materials, Hi-Tech products, Construction materials, Surface

Coatings (paints, Corrosion).

Research and Quality Control Facilities:

Microscopy (TL/IL,POL & REF), Geo-chemical analysis, X-Ray crystallography, XRD,

Atomic Absorpotion, Thermal analysis (DTA, TGA), Electron micro probe(EPMA) Data

analysis/computation, Inductively Coupled Plasma (ICP

Product Development & Technological Promotion Section:

This section is engaged mainly in research and development of industrial chemicals from

indigenous metallic and non-metallic minerals. The achievements of the section include:

industrial chemicals from gypsum namely, sodium sulphide, sodium sulphate and calcium

carbonate; production of phosphoric acid and its salts from indigenous phosphate rock, and

zinc chemicals from lead-zinc ore, sodium dichromate and chromosol on pilot scale from

chromite ore. Indelible ink, detoxification processes, phosphatizing salts and sodium acid

pyrophosphate have been produced on commercial scale. Thje section has potential to

provide technical know-how for then production of industrial chemicals on commercial

scale.

Industrial Trouble Shooting, Quality Control:

The industries that acquire the advisory and quality control services are ICI, packages,

pioneer Cement, Maple leaf Cement, Bata, kohinoor, noon, ATS, khawaja Wajid, Shaheen

Grinders, Hala, WAPDA,Glaxi, Ghulam Rasool & Co. Shaukat Khanum memorial Trust,

KSB Pumps, TEPA, SIMCO Engg. Master Tiles, Honda Atlas, Services Industries, Auroj

Fabrics, Ordnance Factories Wah, etc.

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Pakistan Institute Of Technology For Minerals And

Advanced Engineering Materials

(PITMAEM)

Objectives of PITMAEM:

Provide help to the local industries for updating the existing technological setup

absorbing new technologies

Reduce the import bill and enhance the export by creating facilities to introduce

technologies in the fields of bio orthopaedic implants, surface technologies, nano

technology, new and smart low cost composite materials and foundry technology.

To provide help to the local industries for updating the existing technological setup

absorbing new technologies for value added product exports and imports substitution of

engineering components.

To undertake human resource development and to create research and trainging facilities

for M.Sc., M.Phil, Ph.D. on the lines of AIT and MIT.

To meet the requirements of WTO, develop ISO-certification for testing and R&D work

Provide opportunities to the engineers/scientists to undertake international and local

collaborative research for the solution of technological problems to meet the future

requirements.

Mission of PITMAEM:

To conduct fundamental and applied research in the field of materials science and

engineering.

To develop the new materials.

To improve the performance of traditional engineering materials.

To promote high quality scientific and engineering research, identifying the nation's need

and help in its progress.

To enhance interdisciplinary research and international collaboration.

Consultancy Services:

A committment to investment in the latest technology ensures that the lab can provide cost

effective and flexible service. Over the year we had developed the capabilities to offer

complete know-how in the country and are committed to provide our customers with the

best possible vices.

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Consultancy services are also available for all the materials related failure analysis, trouble

shooting, product developments, investigations, registrations and auditing of materials &

processing standards.

Major Facilities:

1. Centre of Excellence in Industrial Coatings

2. Foundry Technology Centre

3. Nano Coatings and Powders

4. Industrial/ Advanced Composites Manufacturing Facilities

5. Heat Treatment and Rolling Facilities

6. Labs facilities of Powder Metallurgy

7. Labs facilities of Non Destructive Testing

8. Labs facilities for Assaying and Hallmarking of Jewellery and Gem Testing

LABS VISITED IN PITMEAM

1. Emission Spectroscopy Lab:

Here they perform chemical analysis of samples.

Apparatus Available in this lab:

Emission Spectrometer:

Emission spectroscopy is a spectroscopic technique which examines the wavelengths ofphotons emitted by atoms or molecules during their transition from an excited state to a lower energy state. Each element emits a characteristic set of discrete wavelengths according to its electronic structure, by observing these wavelengths the elemental composition of the sample can be determined. Emission spectroscopy developed in the late 19th century and efforts in theoretical explanation of atomic emission spectra eventually led to quantum mechanics.

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2. Sample Preparation Lab:

Here they prepare the sample for future investigations.

The preparation of sample is performed in three steps:

I. Grinding

II. Polishing

III. Etching

This lab also provides the facility of micro structure analysis and it also deals with

microstructures defect analysis like porosity defects, fracture defects, etc. To detect the

defected area they use the White Light Microscope then use Measuring microscope to give

the dimensions of the defects.

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3. Non-destructive Testing Lab:

Here they perform the following tests for surface and subsurface defects:

Dye Penetrant Tesing (DPT):

This method employs a penetrating liquid, which is applied over the surface of the component and

enters the discontinuity or crack. Subsequently, after the excess penetrant has been cleared from the

surface, the penetrant exudes or is drawn back out of the crack is observed. Liquid penetrant testing

can be applied to any non-porous clean material, metallic or non-metallic, but is unsuitable for dirty or

very rough surfaces. Penetrants can contain a dye to make the indication visible under white light, or a

fluorescent material that fluoresces under suitable ultra-violet light. Fluorescent penetrants are usually

used when the maximum flaw sensitivity is required. Cracks as narrow as 150 nanometers can be

detected.

Magnetic Particle Testing (MPT):

The Magnetic Particle Inspection method of Non-Destructive testing is a method for locating surface

and sub-surface discontinuities in ferromagnetic material. It depends for its operation on the face that

when the material or part under test is magnetized, discontinuities that lie in a direction generally

transverse to the direction of the magnetic field, will cause a leakage field, and therefore, the presence

of the discontinuity, is detected by use of finely divided ferromagnetic particles applied over the

surface, some of these particles being gathered and held by the leakage field, this magnetically held

collection of particles forms an outline of the discontinuity and indicates its location, size, shape and

extent.

Dry magnetic particle examinations and wet fluorescent magnetic particle examinations are performed

on ferromagnetic materials to detect surface and slight subsurface discontinuities. Specialized wet

fluorescent magnetic particle techniques are available for black light internal examinations of

equipment through borescopes.

Ultrasonic Inspection (UFD):

Ultrasonic methods of NDT use beams of sound waves (vibrations) of short wavelength and high

frequency, transmitted from a probe and detected by the same or other probes. Usually, pulsed beams

of ultrasound are used and in the simplest instruments a single probe, hand held, is placed on the

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specimen surface. An oscilloscope display with a time base shows the time it takes for an ultrasonic

pulse to travel to a reflector (a flaw, the back surface or other free surface) in terms of distance

traveled across the oscilloscope screen. The height of the reflected pulse is related to the flaw size as

seen from the transmitter probe. The relationship of flaw size, distance and reflectivity are complex,

and a considerable skill is required to interpret the display. Complex mutiprobe systems are also used

with mechanical probe movement and digitization of signals, followed by computer interpretation are

developing rapidly.

Ultrasonic examinations are performed for the detection and sizing of internal defects, flaws or

discontinuities in piping, castings, forgings, weldments or other components. Exact sizing techniques

have been developed to detect and monitor progressive cracking in a variety of equipment.

Portable Hardness:

Per ASTM E110, this testing is normally used for on-site applications or on very large samples. The

TCR portable hardness unit performs the hardness testing by applying a 5 kg. Vickers load indenter

and electronically converts the values in the preferred scale.

4. Coating Centre Lab (PVD lab):

To give more life to metals and metallic instruments like drilling bits, there should be given wear

resistance (Coating). There are two types of coating;

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1. Titanium nitrite Coating:

Titanium nitride was the first general purpose coating. It's been around for a long time for one simple

reason, ... it works. Whether it's cutting tools, punching or forming, or injection molding, users know

they are going to get anywhere from two to ten times the tool life by using this coating. The

strippability of TiN makes it ideally suited for applications that use expensive tooling such as injection

molding and forming.

Also, since the body tolerates this coating well, TiN is used in numerous medical (implants, surgical

instruments, etc) and food processing applications.

2. DLC Coating (Diamond-Like Carbon Coating):

DLC coatings are formed when ionized and decomposed carbon or hydrocarbon species land on the

surface of a substrate with energy typically 10-300eV. DLC films may possess exceptional mechanical

(high hardness), optical (high optical band gap), electrical (high electrical resistivity), chemical (inert)

and tribological (low friction and wear coefficient) properties and can be deposited at low substrate

temperature(<200°C).

DLC films are generally amorphous (i.e have no dominant crystalline lattice structure) and consist of a

mixture of sp2 (graphite) & sp

3 (diamond) phases.

5. Bio Material Centre:

Here we see the Carbon Sulphur Determinator which is used to determine the carbon and sulphur

contents in metals. This works by burning the sample in a stream of oxygen and analysing the gases

produced by infra-red absorption. Typical samples include steel, cement, fly ash, rocks and minerals.

Artifical Bones (Hydroxy Apatite) are also prepared here successfully.

6. Analytical Lab:

This lab is focus on thermal research and the following appratus are used here;

Differential Scanning Calorimeter:

Differential scanning calorimetry or DSC is a thermoanalytical technique in which the difference in

the amount of heat required to increase the temperature of a sample and reference is measured as a

function of temperature. Both the sample and reference are maintained at nearly the same temperature

throughout the experiment. Generally, the temperature program for a DSC analysis is designed such

that the sample holder temperature increases linearly as a function of time. The reference sample

should have a well-defined heat capacity over the range of temperatures to be scanned.

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Differential heat flux scanning calorimeter

Thermalgravimeter Analysis:

Thermogravimetric analysis or thermal gravimetric analysis (TGA) is a type of testing performed on

samples that determines changes in weight in relation to change in temperature. Such analysis relies on

a high degree of precision in three measurements: weight, temperature, and temperature change. As

many weight loss curves look similar, the weight loss curve may require transformation before results

may be interpreted. A derivative weight loss curve can identify the point where weight loss is most

apparent. Again, interpretation is limited without further modifications and deconvolution of the

overlapping peaks may be required.

Dilatometer:

A dilatometer is a scientific instrument that measures volume changes caused by a physical or

chemical process. A familiar application of a dilatometer is the mercury-in-glass thermometer, in

which the change in volume of the liquid column is read from a graduated scale. Because mercury has

a fairly constant rate of expansion over normal temperature ranges, the volume changes are directly

related to temperature.

Laser Particle Size Analyzer:

The Coulter Principle, also known as ESZ (Electrical Sensing Zone Method), the Multisizer IIe and 3

Coulter Counter provides number, volume, mass and surface area size distributions in one

measurement, with an overall sizing range of 0.4 to 1,200 microns (practical limits for most industrial

powders are from 0.06 to 200 microns). Its response is unaffected by particle color, shape,

composition or refractive index.

Particles suspended in a weak electrolyte solution are drawn through a small aperture, separating two

electrodes between which an electric current flows. The voltage applied across the aperture creates a

"sensing zone". As particles pass through the aperture (or "sensing zone"), they displace their own

volume of electrolyte, momentarily increasing the impedance of the aperture.

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7. Jewelry Hallmarking Lab:

Apparatus Available in the lab:

XRF (X-ray fluorescence spectrometer):

An X-ray fluorescence (XRF) spectrometer is an x-ray instrument used for routine, relatively non-

destructive chemical analyses of rocks, minerals, sediments and fluids. It works on wavelength-

dispersive spectroscopic principles that are similar to an electron microprobe (EPMA). However, an

XRF cannot generally make analyses at the small spot sizes typical of EPMA work (2-5 microns), so it

is typically used for bulk analyses of larger fractions of geological materials. The relative ease and low

cost of sample preparation, and the stability and ease of use of x-ray spectrometers make this one of

the most widely used methods for analysis of major and trace elements in rocks, minerals, and

sediment.

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The analysis of major and trace elements in geological materials by x-ray fluorescence is made

possible by the behavior of atoms when they interact with radiation. When materials are excited with

high-energy, short wavelength radiation (e.g., X-rays), they can become ionized. If the energy of the

radiation is sufficient to dislodge a tightly-held inner electron, the atom becomes unstable and an outer

electron replaces the missing inner electron. When this happens, energy is released due to the

decreased binding energy of the inner electron orbital compared with an outer one. The emitted

radiation is of lower energy than the primary incident X-rays and is termed fluorescent radiation.

Because the energy of the emitted photon is characteristic of a transition between specific electron

orbitals in a particular element, the resulting fluorescent X-rays can be used to detect the abundances

of elements that are present in the sample.

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9. Common Instrumentation Lab:

SEM attached with EDX:

SEM-EDX is the name of the energy-dispersive X-ray spectroscopy analysis conducted by means

of SEM. It allows to determine the chemical composition of a specimen, for instance soot particles

formed in the combustion of Diesel engines or biomass, as well as its morphology and structure. The

information on particle composition and morphology is extremely useful for understanding the

expected life of components like a gas turbinefed though gasification of biomass or a diesel particulate

filter and quality of air.

A scanning electron microscope (SEM) is a type of electron microscope that images a sample by

scanning it with a high-energy beam of electrons in a raster scan pattern. The electrons interact with

the atoms that make up the sample producing signals that contain information about the sample's

surface topography, composition, and other properties such as electrical conductivity. The types of

signals produced by an SEM include secondary electrons, back-scattered electrons

(BSE), characteristic X-rays, light (cathodoluminescence), specimen current and transmitted electrons.

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Tribology – Surface profilometer:

Profilometer is a measuring instrument used to measure a surface's profile, in order to

quantify its roughness. Vertical resolution is usually in the nanometer level, though lateral resolution is

usually poorer. While the historical notion of a profilometer was a device similar to a phonograph that

measures a surface as the surface is moved relative to the contact profilometer's stylus, this notion is

changing along with the emergence of numerous non-contact profilometery techniques.

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Mineral Processing Research Centre (MPRC)

Multipurpose Ore Beneficiation Plant:

The Centre has a well oriented multipurpose ore beneficiation pilot plant, which is a centralized

facility capable of beneficiation studies on various types of metallic and non-metallic minerals.

Elaborate research facilities are available in the fields mentioned above. The R&D activities of the

Centre broadly are related to:

Identification and evaluation of the mineral resources.

Evaluation and heat treatment of metals and alloys.

Testing and evaluation of metals and other industrial products.

Feasibility reports on different mineral based industries.

Advisory services and training facilities to the mineral-based industries, and universities.

ACHIEVEMENTS: The Centre has undertaken projects in a number of subject areas related with

minerals and metallurgy. It has completed R&D projects on bench and pilot plant scale for the

corporate clients in private and public sectors. Some of the more significant projets include: Saindak

copper project in Baluchistan, graphite processing plant in Mardan, nephyline syenite and chromite

processing plant near Peshawar, and aggregate material evaluation for Kala Bagh Dam.

Mineral Processing:

In the field of extractive metallurgy, mineral processing, also known as mineral dressing or ore

dressing, is the process of separating commercially valuable minerals from their ores.

Unit Operation:

Mineral processing can involve four general types of unit operation:

1. Comminution – particle size reduction;

2. Sizing – separation of particle sizes by screening or classification;

3. Concentration by taking advantage of physical and surface chemical properties

4. Dewatering – solid/liquid separation.

In all of these processes, the most important considerations are the economics of the processes and this

is dictated by the grade and recovery of the final product. To do this, the mineralogy of the ore

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needs to be considered as this dictates the amount of liberation required and the processes that can

occur. The smaller the particles processes, the greater the theortical grade and recovery of the final

product, but this however is diffucult to do with fine particles as they prevent certain concentration

processes from occurring.

1. Comminution:

Comminution is particle size reduction of materials. Comminution may be carried out on either dry

materials or slurries. Crushing and grindingare the two primary comminution processes. Crushing is

normally carried out on "run-of-mine"[2]

ore, while grinding (normally carried out after crushing) may

be conducted on dry or slurried material.

Jaw Crusher (Primary Crusher):

A jaw or toggle crusher consists of a set of vertical jaws, one jaw being fixed and the other being

moved back and forth relative to it by a cam or pitman mechanism. The jaws are farther apart at the

top than at the bottom, forming a tapered chute so that the material is crushed progressively smaller

and smaller as it travels downward until it is small enough to escape from the bottom opening. The

movement of the jaw can be quite small, since complete crushing is not performed in one stroke. The

inertia required to crush the material is provided by a weighted flywheel that moves a shaft creating an

eccentric motion that causes the closing of the gap.

Single and double toggle jaw crushers are constructed of heavy duty fabricated plate frames with

reinforcing ribs throughout. The crushers components are of high strength design to accept high power

draw. Manganese steel is used for both fixed and movable jaw faces. Heavy flywheels allow crushing

peaks on tough materials. Double Toggle jaw crushers may feature hydraulic toggle adjusting

mechanisms.

Operation of a jaw crusher

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Roll Crusher (Secondary Crusher):

Roll crushers are also frequently used as secondary crushers. The name roll crusher is indicative of the

way in which a roll crusher works. The rock is run between two large steel wheels, which presses

down on it, crushing it into a smaller size. Roll crushers are a compression or compression/shear type

crusher mostly used in primary and secondary operations for limestone, coal, sedimentary, friable

rock, non abrasive ores or wet sticky materials. Smooth roll crushers consist of a pair of horizontal

cylindrical rolls, rotating in opposite directions. One roll is fixed and the other is floating but fixed

with a preset amount of force to allow uncrushable bodies to pass. Material is pulled into the rotating

rolls and the material is fractured and reduced by compressive forces down to the size of the gap

between the rolls. These roll crushers should be starvation fed to prevent them from choking as well as

being fed at an even rate across the width of the rolls. Smooth roll crushers are most often used for

friable non abrasive ores. Other types of roll crushers include a single toothed roll facing a breaker

plate or two toothed rolls. These crushers use a combination of compression and shear to reduce

material size and are most often used for coal, coke, limestone or gypsum.

2. Sizing:

Sizing is the general term for separation of particles according to their size.

The simplest sizing process is screening, or passing the particles to be sized through a screen or

number of screens. Screening equipment can include grizzlies, bar screens,wedge wire screens,banna

screens, multi deck screens, vibratory screed, fine screens, flip flop screens and wire mesh screens.

Screens can be static (typically the case for very coarse material), or they can incorporate mechanisms

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to shake or vibrate the screen. Some considerations in this process includes the screen material, the

aperature size, shape and oreintation, the amount of near sized particles, the addition of water, the

amplitude and frequency of the virbations, the angle of inclination, the presence of harmful materials,

like steel and wood, and the size distribtuion of the particles.

Classification refers to sizing operations that exploit the differences in settling velocities exhibited by

particles of different size. Classification equipment may include ore sorters, gas

cyclones, hydrocyclones, rotating trommels, rake classifiers or fluidized classifiers.

An important factor in both comminution and sizing operations is the determination of the particle size

distribution of the materials being processed, commonly referred to as particle size analysis. Many

techniques for analyzing particle size are used, and the techniques include both off-line analyses which

require that a sample of the material be taken for analysis and on-line techniques that allow for

analysis of the material as it flows through the process.

3. Concentration:

There are a number of ways to increase the concentration of the wanted minerals: in any particular

case the method chosen will depend on the relative physical and surface chemical properties of the

mineral and the gangue.

Gravity concentration

Historically the earliest method used, particles can be classified based on their specific gravity.Air is

the main fluid medium used for the process. Gravity concentration processes include:

Heavy media or dense media separation (these include, baths, drums, larcodems, dyana whirlpool

separators, and dense medium cyclones)

Shaking tables, such as the Wilfley table

Spiral separators

Batac jigs

Centrifugal bowl concentrators

Jig concentrators are continuous processing gravity concentration devices using a pulsating fluidized

bed.

Multi gravity separators (Falcon, Knelson, Mozley and the Kelsey Jig)

Inline pressure Jigs

Reichert Cones

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These processes can be classified as either dense medium separation or gravity separation. The

difference between the two that gravity separation does not use a dense medium to operate, only water

or air. Dense medium separation can be performed with a variety of mediums. These include, organic

liquids, aqueous solutions, suspensions in water and suspensions in air. Of these, most industrial

processes use suspensions in water. THe organic liquids are not used due to their toxicity and

difficulties in handling. The aqueous solution as a dense medium is used in coal processing in the form

of a belknap wash and the suspension in air is used in water-deficient areas, like china, where sand is

used to separate coal from the gangue minerals. The dense medium separation is also classified as

absolute gravity separation as the sinks and the floats travel in different directions. The gravity

separation is also called relative gravity separation as they separate particles due to their differences in

the magnitude of the particle response to a driving force.

These processes can also be classified into multi-G and single G processes. The difference is the

magnitude of the driving force for the separation. Multi-G processes allow the separation of fine

particles to occur and these particles can be in the range of 10 to 50 micron. The single G process are

only capable of processing particles that are greater than 80 micron.

Of the gravity separation processes, the spiral concentrators are one of the most economical due to

their simplicity and use of space. They operate by flowing film separation and can either use

washwater or be washwater-less. The washwater spirals separate particles more easily but can have

issues with entrainment of gangue with the concentrate produced.

Froth flotation:

Froth flotation is an important concentration process. This process can be used to separate any two

different particles and operated by the surface chemistry of the particles. In flotation, bubbles are

introduced into a pulp and the bubbles rise through the pulp. In the process, hydrophobic particles

become bound to the surface of the bubbles. The driving force for this attachment is the change in the

surface free energy when the attachment occurs. These bubbles rise through the slurry and are

collected from the surface. To enable these particles to attach, careful consideration of the chemistry of

the pulp needs to be made. These considerations include the pH, Eh and the presence of flotation

reagents. The pH is important as it changes the charge of the particles surface and the Eh effects the

chemisorption of collectors on the surface of the particles.

The addition of flotation reagents also effects the operation of these processes. The most important

chemical that is added is the collector, This chemical binds to the surface of the particles as it is a

surfactant. The main considerations in this chemical is the nature of the head group and the size of the

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hydrocarbon chain. The hydrocarbon tail needs to be short to maximize the selectivity of the desired

mineral and the headgroup dictates which minerals it attaches to.

The frothers are another important chemical addition to the pulp at it enables stable bubbles to be

formed. This is important as if the bubble coalesce, minerals fall off their surface. The bubbles

however should not be too stable as this prevents easy transportation and dewatering of the concentrate

formed. The mechanism of these frothers is not completely known and further research into their

mechanisms is being performed.

Depressants and activators are used to selectively separate one mineral from another. Depressants

inhibit the flotation of one mineral or minerals while activators enable the flotation of others.

Examples of these include CN-, used to depress all sulfides but galena and this depressant is believed

to operate by changing the solubility of chemisorbed and physisorbed collectors on sulfides. This

theory originates from Russia. An example of an activator is Cu2+

ions, used for the flotation of

sphalerite.

There are a number of cells able to be used for the flotation of minerals. these include flotation

columns and mechanical flotation cells. The flotation columns are used for finer minerals and they

typically have a higher grade and lower recovery of minerals than mechanical flotation cells. The cells

in use at the moment can exceed 300 m3. This is done as they are cheaper per unit volume than smaller

cells, but they are not able to be controlled as easily as smaller cells.

This process was invented in the 19th century in Australia. It was used to recover

a sphalerite concentrate from tailings, produced using gravity concentration. Further improvements

have come from Australia in the form of the Jameson cell. This operated by the use of a plunging jet

that generates fine bubbles. These fine bubbles have a higher kinetic energy and as such they can be

used for the flotation of fine grained minerals, such as those produces by the isamill.

Electrostatic separation:

There are two main types of electrostatic separators. These work in similar ways, but the forces

applied to the particles are different and these forces are gravity and electrostatic attraction. The two

types are electrodynamic separators (or high tension rollers) or electrostatic separators. In high tension

rollers, particles are charged by a corona discharge. This charges the particles that subsequently travel

on a drum. The conducting particles lose their charge to the drum and are removed from the drum with

centripetal acceleration. Electrostatic plate separators work by passing a stream of particles past a

charged anode. The conductors loose electrons to the plate and are pulled away from the other

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particles due to the induced attraction to the anode. These separators are used for particles between 75

and 250 micron and for efficient separation to occur, the particles need to be dry, have a close size

distribution and uniform in shape. Of these considerations, one of the most important is the water

content of the particles. This is important as a layer of moisture on the particles will render the non-

conductors as conductors as the layer of the water is conductive.

Electrostatic plate separators are usually used for streams that have small conductors and coarse non-

conductors. The high tension rollers are usually used for streams that have coarse conductors and fine

non-conductors.

These separators are commonly used for separating mineral sands, an example of one of these mineral

processing plants is the CRL processing plant at Pinkenba in Brisbane Queensland. In this

plant, zircon, rutile and ilmenite are separated from the silica gangue. In this plant, the separation is

performed in a number of stages with roughers, cleaners, scavengers and recleaners.

Magnetic separation:

Minerals such as ilmenite and magnetite are naturally magnetic, and so can be separated from non-

magnetic particles using strong magnets. There are a number of different processes that can be used.

These include HGMS, HIMS and LIMS. The HIMS and HGMS are differentiated as the HGMS

separators are a batch process while the HIMS are a continuous process. These two processes are

typically used forparamagnetic particles while the LIMS are used for ferromagnetic particles. The

main considerations that need to be taken account when processing an ore is the size distribution, the

presence of tramp metal and the liberation of the particles being separated.

This process operates by moving particles in a magnetic field. The force experienced in the magnetic

field is given by the equation f=m/k.H.dh/dx. with k=magnetic susceptibility, H-magnetic field

strength, and dh/dx being the magnetic feild gradient. As seen in this equation, the separation can be

driven in two ways, either through a gradient in a magnetic field or the strength of a magnetic field.

The different driving forces are used in the different concentrators. These can be either with water or

without. Like the spirals, washwater aids in the separation of the particles while increases the

entrainment of the gangue in the concentrate.

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4. Dewatering:

Dewatering is an important process in mineral processing. The purpose of dewatering is to remove

water contained in particles. This is done for a number of reasons, specifically, to enable ore handling

and concentrates to be transported easily, allow further processing to occur and to dispose of the

gangue. The water removed from dewatering can be recycled through a mineral processing plant. The

main processes that are used in dewatering include dewatering screens, sedimentation, filtering, and

thermal drying. These processes increase in difficulty and cost as the particle size decreases.

Dewatering screens operate by passing particles over a screen. The particles pass over the screen while

the water passes through the apertures in the screen. This process is only viable for coarse ores that

have a close size distribution as the apertures can allow small particles to pass though and are not able

to be produced for small particles.

Sedimentation operates by passing water into a large thickener or clarifier. In these devices, the

particles settle out of the slurry under the effects of gravity or centripetal forces. These are limited by

the surface chemistry of the particles and the size of the particles. To aid in the sedimentation process,

floculants and coagulants are added to reduce the repulsive forces between the particles. This repulsive

force is due to the double layer formed on the surface of the particles. The floculants work by binding

multiple particles together while the coagulants work by reducing the thickness of the charged layer on

the outside of the particle.

Thermal drying is usually used for fine particles and to remove low water content in the particles.

Some common processes include rotary dryers, fluidised beds, spray driers, hearth dryers and rotary

tray dryers. This process is usually expensive to operate due to the heating requirements of the dryers.

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REFERANCES:

www.pcsir.gov.pk

www pitmaem.edu.pk

www.wikipedia.org

www.geo.mtu.edu

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