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C.V. key skills: Metallurgical Investigations / Projects & Services: Base Minerals & Metals Processing- Copper in particular
________________________________________________________________________
EXPERIENCE SUMMARY:
Presently working with NFTDC (Non Ferrous Materials Technology Development Center), Hyderabad, India, as Senior Scientist- Metallurgical Projects. I have 30 plus years of experience in the mineral & metal industry in various metallurgical disciplines. My primary field of expertise has been in mineral & metal processing at ZCCM (Zambia Consolidated Copper Mines) and Hindustan Copper Limited. & related R & D involvement at NFTDC.

EDUCATION:

 Good first class degree (≈ GPA:90%)of Bachelor Of Engineering-Metallurgical Eng. ( B.E.) from Indian Institute of Technology (IIT),Roorkee ( Formerly University of Roorkee - India )Graduated: 1971
 PGDBA: Post Graduate Diploma in Business Administration:1994, Annamalai University, India.

WORK EXPERIENCE:
Major overall - Responsibilities:
* To provide technical & process expertise & leadership to resolve issues related to process & plant / equipment maintenance related to metallurgical plants on a global scale.
* To direct & undertake investigations into technical problems affecting plant & process efficiencies & initiate remedial action, including innovative ideas, related to processing of copper ores, copper & its alloys together with molybdenite processing.
* Process route alterations / modifications to enhance recovery & product quality.
* Suggest ways & means to improve on a long & sustained basis (continuous improvement-kaizen)vis-à-vis technology up-gradation from time to time.
* To undertake technical audits / in-depth technical investigation into plant problems with a view to save costs & improve operations.
* Research & development of innovative processes & technologies.
* Direct & undertake trouble shooting into plant problems to diagnose/resolve issues to operations.
* Managed and led teams of senior metallurgists at ZCCM and HCL and plant personnel.

* Career Achievements:
* Acquired rich experience and exposure to complex metallurgical (including mineralogical) problem identification & diagnostics skills. Besides, possess strong trouble shooting /problem solving skills.
* Enhancement of flotation recovery from 92.5% to 94% at Mufulira concentrator (capacity:30,000mt/day), Roan consolidated copper mines /ZCCM, Zambia, by incorporating various circuit modifications / suggestions including up gradation and improvement of regrind mills circuit.
* Revival of Konkola concentrator (formerly Bancroft), Chililabombwe, Nchanga division, ZCCM (Zambia consolidated copper mines) by successfully floating oxides from mixed sulphides & slimes (incorporating differential flotation)& commissioning of the new plant which helped improve flotation recovery from 69% to 88-89%.&
* Commissioned & streamlined Khetri ore concentrator & slag treatment plant (STP) operations at Hindustan Copper Limited, India.
* Was instrumental in implementing reduced mill feed size to enhance mill throughput & reduce power costs as crushing costs are considerably lower than milling costs & modified crushing & screening circuits accordingly to cater increased recirculating loads.
* Improved final concentrate grade at Khetri Concentrator (HCL) by circuit route modifications & effectively suppressing pyrites & gangue material without loss in recovery.
* Supervision & monitoring of mill rubber lining installations (Skega - Sweden) in regrind mills at Mufulira concentrator & in primary ball mill as well as 200mt/hour primary ball mill at Chambishi concentrator, Roan consolidated copper mine on close monitoring life of shell liners was increased by 30%(from 20,000hrs to 30,000hrs) whilst that of feed & discharge end liners were doubled resulting in massive cost savings.
* Successfully undertook the project entitled" molybdenum extraction & production of molybdenum metal powder from molybdenite." at nonferrous materials technology development center, Hyderabad, India.
* Resolved complex metallurgical accounting problems at Mufulira Concentrator, Roan consolidated copper mines, ZCCM
Zambia which had been experiencing huge unaccounted losses / gains from time to time.
* Associated with processing of OFEC( Oxygen free electronic copper) & development of OFE Copper based specialty & high tech alloys & their down stream processing into products.
* Recovery of gold values from Concentrator tailings.

Summary of positions held at a glance for ready reference:

Position held From To Company / organization / Remarks
Senior Scientist ( Metallurgical Projects) June 2003 To date NFTDC, Hyderabad, India.
Chief Manager ( Metallurgy) Oct 1999 Jan 2003 Hindustan Copper limited, Khetri Copper complex / Taloja Copper Project, India.
Manager ( Metallurgy) June 1995 Sept 1999 Hindustan Copper limited, KCC, India.
Dy. Manager( Metallurgy) June 1990 May 1995 Hindustan Copper limited, India. Took break for house building activity.
Plant Metallurgist / Acting Concentrator Superintendent June 1986 March 1989 Zambia Consolidated Copper Mines, Nchanga Division
Plant Metallurgist / Acting Concentrator Superintendent July 1983 May 1986 Zambia Consolidated Copper Mines, Mufulira Division, Zambia.

Senior Assistant Metallurgical Engineer / Acting Plant Metallurgist. May 1979 June 1983 Roan Consolidated Copper Mines, Mufulira Division, Zambia.
Deputy Plant Engineer. Oct 1976 May 1979 Hindustan Copper limited, KCC, India
Astt. Metallurgical Engineer Jan 1974 Sept 1976 Hindustan Copper limited, KCC, India
Graduate Engineer Jan 1972 Dec 1974 Hindustan Copper limited,KCC, India

 NFTDC (Non Ferrous Materials Technology Development Center),, Hyderabad India ( June 2003 –To Date), post being held: Senior Scientist ( projects)
Responsibilities:
* Research & development of innovative processes.
* To meet production targets vis-à-vis meet stringent quality requirements on processed materials.
 To provide technical & process expertise & leadership to resolve issues related to process& plant equipment maintenance.
 To undertake process and efficiency improvements & initiate remedial action as necessary.
 Process route modifications to enhance recovery & product quality.
 Suggest ways & means to improve on a long & sustained basis (continuous improvement-kaizen)vis-à-vis technology up gradation from time to time.
 To undertake technical audits /in-depth technical investigation into plant problems with a view to save costs & improve operations develop new materials & technologies for the center
Achievements:
 successfully undertook the project entitled" molybdenum extraction & production of molybdenum metal powder from molybdenite." at nonferrous materials technology development center, Hyderabad, India.
 Had the privilege of commissioning of OFEC VIM plant (oxygen free electronic copper - vacuum induction melting furnace)& subsequently its processing into various products.
 Associated with development of OFE Copper based specialty & high tech alloys & their down stream processing into products.
 Recovery of gold values from Concentrator tailings.


 HCL (Hindustan Copper Limited, India, June 1990 to January 2003. Post held Dy. Manager / Manager/ Chief Manager (Metallurgy).

Achievements:
* Improved concentrate grades by suppressing pyrites in the cleaner circuit without affecting flotation recovery at Khetri ore concentrator together with some circuit routes modifications.
* Suggested finer mill feed size to enhance mill throughput & reduce power costs as crushing costs are considerably lower than milling costs.
* Converted slag autogenous primary grinding mill to semi -autogenous grinding (SAG) mill to enhance throughput & reduce operating costs.
* Brought in improvement in cc rod quality by preventing micro porosity in the cast bar prior to hot rolling mill operation.
* Also involved with expansion program of Khetri concentrator, smelter & refinery plants.
*

 ZCCM ( Zambia Consolidated Copper Mines), Zambia, (May 83 1983 to March 1989 ) as Plant Metallurgist /
Acting Concentrator Superintendent.

Achievements:
 Revival of Konkola concentrator/mine(formerly Bancroft), Chililabombwe, Nchanga division, Zambia Consolidated Copper mines, ZCCM, Zambia by successfully floating oxides from mixed sulphides & slimes (incorporating differential flotation)& commissioning of the new plant which helped improve flotation recovery from 69% to 88/89%.
 Provision of swing cells between rougher & scavenger cells to cater to highly fluctuating feed grades.
 Senior member of the task force during erection & commissioning of new flotation plant at Konkola concentrator.

 RCM (Roan Consolidated Copper Mines) Zambia, (May 1979 to April 1983) Position held: Senior Metallurgical Engineer / Plant Metallurgist.

Achievements:
 Enhancement of flotation recovery from 92.5% to 94% at Mufulira concentrator (capacity:30,000mt/day), RCM-Roan Consolidated Copper Mines, Zambia, by incorporating various modifications / suggestions including up gradation and improvement of regrind mills circuit.
 Supervision of mill rubber lining installations (Skega, Sweden) in regrind mills at Mufulira concentrator & in primary ball mill as well as 200mt/hour primary ball mill at Chambishi concentrator, roan consolidated copper mine.
 On close monitoring life of shell liners was increased by 30 % (from 20,000hrs to 30,000hrs) whilst that of feed & discharge end liners were doubled resulting in massive cost savings.
 Resolved complex metallurgical accounting problems at Mufulira Concentrator, RCM-Roan Consolidated Copper Mines, Zambia.

 HCL ( Hindustan Copper Limited ) Khetri -India ( Jan 1972 to April 1979) Position held: Dy Plant Engineer /Asst Metallurgical Engineer / Graduate Engineer.

PUBLICATIONS AND PRESENTATIONS

The following publications and presentations have been to my credit encompassing mineral processing, hydrometallurgical, powder and pyrometallurgical disciplines:

1. Paper titled "Strides towards competitiveness through hydro route in copper processing- viable propositions" was presented in the national seminar on challenges and opportunities before non-ferrous mineral industries on the 20th annual day Jan 2000 IIM (Indian Institute of Metals) Chapter Khetrinagar, India.

2. Presented a paper entitled "Molybdenum extraction and production of molybdenum metal powder from molybednite" on the natural metallurgist day 14th November 1999, IIM Khetrinagar chapter, Khetrinagar, India.

3. "Various aspects and treatment of mixed slime/sulphide and oxide are bodies" technical talk was presented at international seminar on copper and copper alloys (ISCCA-97), 17th & 18th January 1997, non-ferrous division of IIM chapter Khetrinagar.

4. Technical paper entitled "Recovery of copper values from the current arisings of final tails at Malanjhkhand Concentrator, Hindustan copper limited" was presented during a seminar on " The process optimization on concentration processes, hydrometallurgical & bio-hydrometallurgical operations sep 20-22, 1990 at Kanha safari lodge.

5. "Flotation scale-up criteria" was co-authorized and published in the leading technical magazine, Mines and Metals review (1976), the same was later presented at an IIME (Indian Institute of Mineral Engineers) meet at Hyderabad.

MAJOR WORK EXPERIENCE / HIGHLIGHTS RELATED TO MINERAL PROCESSING DISCIPLINE:
Have the privilege of being engaged in the following activities/project work:
1) Enhancement of flotation recovery from 92.5 % to 94% AT MUFULIRA CONCENTRATOR, ZCCM by incorporating various modifications / suggestions including up gradation / improvement of regrind circuit.
2 ) Revival of Konkola Concentrator, (formerly Bancroft), Chililabombwe, Nchanga Division, ZCCM, Zambia by successfully floating oxides (incorporating differential flotation) from sulphide- oxide ore bodies & commissioning of the new plant which helped improve flotation recovery from 69% to 88/89%.
3) Supervision of Mill Rubber lining installations ( Skega- Sweden) in regrind mills at Mufulira Concentrator, & as well as in primary ball mill in 200MT/hour ball mill at Chambishi Concentrator, Roan Consolidated Copper Mines. With close monitoring life of shell liners was increased by 30% (from 20,000 hrs to 30,000 hrs) whilst that of feed &
discharge end liners were doubled, resulting in massive cost savings.
4) Optimization of Davcra (Column flotation type) cells operation in an effort to maximize cleaner circuit recovery with considerable reduction in re-circulating loads.
5) Incorporated reduced mill feed size to enhance mill throughput & reduce power costs as crushing costs are considerably lower than milling costs & modified crushing & screening circuits accordingly to cater increased recirculating loads.
6) Determined Grind / Concentrate grade / Recovery relationships for various types of ores ( keeping head grade constant).
7) Implementation of float – performance – optimization mechanism through monitoring via a Minexan on stream analyzer (Outo Kumpu Oy make) by having to float pre-set rougher concentrate grade targets on both east & west flotation circuits ( Mufulira Concentrator) when variation on feed grade was widely fluctuating on day to day basis.
8) Establishing a regular tie-up with mine draw control section for obtaining feed back on mineralogy on a daily basis & in turn enabled timely necessary changes to reagent suite & grind coupled with relevant plant operating parameters for steady metallurgical operations.
9) Grinding media plant trials employing white cast iron Vs steel balls & cast steel balls.
10) Plant trial of slugs as grinding media & implementation of recommendations thereof
11) Plant trials of several frothers & collectors at roughing & scavenging operations.
12) Employing of different frothers & collectors at roughing & scavenging stages[ viz: use of more selective collector-SEX ( sodium ethyl xanthate), in roughing whilst stronger one-PAX Potassium amyl xanthate) in scavenging] replacing common collector SIPX with promising results.
13) Commissioning & operational experience of STP (Slag Treatment Plant- Outo Kumpu Oy design) at Khetri, Hindustan Copper Limited,, India & fully conversant with problems associated with its treatment ( slow cooled slag).
14) Possess requisite skills & expertise of treating mixed slimes, sulphides & oxide ore bodies & sand flotation.
15) Have privilege of working in four Concentrators ( Khetri, Khetri Slag Treatment Plant, Mufulira (RCM/ZCCM)), Konkola ( formerly Bancroft, NCCM/ZCCM) besides having active interaction with several other Concentrators during regular interaction as part of company's policy such as Luanshya, Chambishi, Rokana & Chingola etc on Zambian Copper belt.
16) Introduction of swing cells between roughing & scavenging streams to cater to periods of highly fluctuating feed grades to prevent abnormal tail losses & optimize flotation recovery during adverse times whilst shift grades fluctuated on shift to shift basis.
17) Reduction in grinding media consumption in mill primary circuits by optimizing mill operating parameters.
18) Comparison of mill performance operating in closed circuit with cyclones & classifiers & suitable recommendations thereof.
19) Devised high grade spillage treatment for better recovery & uninterrupted float operations.
20) Capably skilled for trouble shooting & resolving complex float control problems related to mineralogical aspects amongst other parameters viz: when carbonaceous quartzite was found to be associated with chalcocite in the mill feed, both being very similar in nature in appearance under the microscope.
21) Associated with study of two stage classification of mill discharge.
22) Involved with the replacement of flotation cells with large flotation Wemco Fagergan cells.
23) Determination of processing mode for recovery of metal values contained in fines (present in final concentrates thickener overflows & scrubber returns) through unconventional routes other than recycling back to float. This had a distinct advantage on the float performance.
24) To improve existing flow sheets & develop new ones as called for.
25) Optimization of Concentrator grade & insoluble relationship / Concentrator recovery Vs smelter recovery in the overall interest of the company.
26) Provided strong metallurgical inputs & trouble shooting skills /support to problem solving campaigns throughout.

References: One reference from present employer ( metallurgical consultant) is attached, more references & support documents can be sent when desired.

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