Agglomeration Of Iron Ores

Recent Developments In Agglomeration Technologies For Iron Ores Pelletizing and Sintering Colloquium 17-18 September 2008 SAIMM - Pretoria

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The Steel making Routes

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Steel Production World crude steel production (in million tons)

1400 269,2

1200

254,3

800 600

188,3 127,2 106,4

400 200

other

227,3

1000 203,1

422,7

489,2

280,5 112,7

116,2

120,2

119,8

124

98,5

101,2

113,4

134

121,6

132,7

130,4

130,1

193,3

188,3

202,3

206,8

210,3

0 2000

2002

2004

Japan GUS

182,2 107,7

China

2006

2007

NAFTA EU 27

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Steel Consumption in kg per Capita

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Development of raw material prices Iron Ore Price [US$ / t dry] Sources : CVRD, Wall Street Journal, US Steel and other steel producers.

140,00

fines lump ore

120,00

pellets

100,00 [US$ / t dry]

5

80,00 60,00 40,00 20,00 0,00 1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

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Development of raw material prices Coking Coal Export Price [US$ / t] Source: www.s teelonthenet.com

120 100 80 60 40 20 0 20 00 Q1 20 00 Q3 20 01 Q1 20 01 Q 20 3 02 Q 20 1 02 Q 20 3 03 Q 20 1 03 Q3 20 04 Q 20 1 04 Q 20 3 05 Q 20 1 05 Q 20 3 06 Q 20 1 06 Q 20 3 07 Q 20 1 07 Q 20 3 08 Q1

[US$ / t]

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Development in transport charges Sea Freight Charges (Tubarao/Rotterdam) [US$ / t] source: Erzkontor, Germany

50 45 40 35 [US$ / t]

7

30 25 20 15 10 5 0 2005Q1

2005Q2

2005Q3

2005Q4

2006Q1

2006Q2

2006Q3

2006Q4

2007Q1

2007Q2

2007Q3

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Environmental Regulations Emission Limits Country

Dust

SO2

NO2

Source

Germany

Emission 20 mg/m³ ntp

Emission 500 mg/m³ ntp

Emission 400 mg/m³ ntp

TA Luft

Australia

24h Immissionaverage 120 µg/m³ Emission 100 mg/m³ ntp

24h Immissionaverage 200 µg/m³

24h Immissionaverage 150 µg/m³

WHO, USEPA, WAEPA

Emission 150 mg/m³ ntp

Immission 120 µg/m³ ntp

Brazil

India

local regulations Immission 120 µg/m³ ntp

Air Act 1981

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Consumption of Reductants

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CO2 emitents in BF steel production

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~ 64 Pellet P Pellet Market: New Projects ~2008 roje Mill LKAB KK4 5.0 Mill. t/a Northland 5.0 Mill. t/a

New Millennium 2x7.5 Mill. t/a

Vöest Alpine 2.0 Mill. t/a

QCM 7.5 Mill. t/a

Essar MIS 6.0 Mill. t/a

MBR 7.0 Mill. t/a

Essar Trinidad 6.0 Mill. t/a

Tubarão VIII 7.5 Mill. t/a

CSN 2x3.0 Mill. t/a

SNIM/Sphere 7.0 Mill. t/a

MMX Amapá 3.5 Mill. t/a

Minas-Rio 7.0 Mill. t/a Ferrous 6.0 Mill. t/a Usiminas 6.0 Mill. t/a

Samarco 4 7.5 Mill. t/a Gerdau 7.0 Mill. t/a

M-GOK 5.0 Mill. t/a

Gol-e-Gohar 5.0 Mill. t/a Sangan 2.4 Mill. t/a Gohar Zamin 2x5.0 Mill. t/a

GIC 5.0 Mill. t/a CVRD Sohar 4.5 Mill. t/a Al Tuwairqi 5.0 Mill. t/a Hadeed 6.0 Mill. t/a

c . 178 Mill t/a unde ts 2008 . t/a und r execu er e valu tion atio n S-GOK 6.0 Mill. t/a

SSGPO 6.0 Mill. t/a Ferrexpo 5.0 Mill. t/a

Zhuhai YPM 1.5 Mill. t/a

Caofeidian 1 4.0 Mill. t/a

Baosteel 4.0 Mill. t/a

CVRD JV’s 4x1.5 Mill. t/a

WISCO 5.0 Mill. t/a

Caofeidian 2 4.0 Mill. t/a

JSW 3.5 Mill. t/a Brahmani River 4.0 Mill. t/a Essar Paradeep 6.0 Mill. t/a

Amsteel 5.0 Mill. t/a Grange 6.0 Mill. t/a CITIC 5.0 Mill. t/a

Tata Pellet 6.0 Mill. t/a Gua & Bolani 4.0 Mill. t/a

JSW West Bengal 6.0 Mill. t/a

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Sinter Market: New Projects 2008

008 ion 2 cts ecut on e j ro er ex luati P ter und r eva n i S l. t/a e d n l i u 3 M ill. t/a 5 ~ M 97 1 ~

Krivoi Rog 10.0 Mill. t/a

Isdemir 3.4 Mill. t/a

Nucor 2.5 Mill. t/a Kardemir 2.8 Mill. t/a

Açominas 2.5 Mill. t/a Belgo Min. 3.0 Mill. t/a Baosteel 7.0 Mill. t/a

Usiminas 6.3 Mill. t/a Vallourec 1.2 Mill. t/a

Formosa 5.0 Mill. t/a

Tata SP4 2.3 Mill. t/a

CSA 4.8 Mill. t/a Kalahari 2.5 Mill. t/a Pecém 4.2 (5.3) Mill. t/a CSV 5.0 Mill. t/a

P.R. China 33 plants 140.0 Mill. t/a Dragon Steel 2.5 Mill. t/a

Tata KPO 5.75 Mill. t/a

JSW 3 5.75 Mill. t/a Vizag Steel JSPL 3.6 Mill. t/a 7.2 Mill. t/a

JSW 2 2.3 Mill. t/a

IISCO 4.6 Mill. t/a Rourkela 3.7 Mill. t/a

Bhushan 4.6 Mill. t/a Durgapur 3.4 Mill. t/a

Bhilai 3.7 Mill. t/a

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Typical flow sheet

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Typical layout of a 7.5 million tpa plant Green Pelletizing

Induration

Central Plant Dedusting

Substation Process Gas Cleaning

Cooling System Fuel Oil System

Additive Preparation

Dosing & Mixing

Regrinding

Filtration

Homogenization

Wet Grinding

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Plant Sizes vs. Investment Costs 100

90

80

70 Specific Investment Costs [%].

16

60

50

40 Limonite/ Whethered Ores

30

Hematite 20 Magnetite 10

0 0.0

1.0

2.0

3.0

4.0

Plant Capacity [mtpy]

5.0

6.0

7.0

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Development of pellet plant size Capacity in million t/a

7.5 Million t/a

8 Samarco 3

7 Plant capacity (single strands) [mtpy]

17

6

Samarco 2

5

Samarco 1

4

Tilden Ijmuiden

3 2 1 0 1950

Hamersley Krivoi Rog Eagle Mountain Wabush Carol Lake Republic Eagle Mills Malmberget 1 1960

1970

1980

1990

2000

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Samarco 3 with 768m² and 7.5 Mtpy World’s largest Pellet Plant

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Steel belt plant – general layout Pellets

Concentrate

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Steel belt – process concept

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Simplification of Plant Design Roller Presses vs. Ball Mills

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Simplification of Plant Design Roller Presses vs. Ball Mills Slurry Storage

Bins

Bins

Grinding

Filtration

Thickening

Grinding and Filtration Section of a 4,000,000 t/a Pelletizing Plant

Roller Presses

Comminution Section of a 7,000,000 t/a Plant

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Simplification of Plant Design Conventional Vacuum Disc Filters Ceramic Filters

Vertical Filter Presses

standard equipment for pellet feed dewatering

high investment costs (170 %), significant energy savings (-95%) => pay back in 3 – 5 years, larger sizes possible, few references with iron ore simplified plant layouts due to large sizes (up to 132m² filtration area), significant energy savings, improved moisture control

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Improvement of Operating Costs Ø

Conservation or introduction of thermal energy to pellet feed/green pellets

Ø

Improved green pellet qualities with narrow size distributions

Ø

Improved screening concepts for hearth- and side layers

Ø

Increased pellet bed heights

Ø

Optimized heat balances and gas flow schemes

Ø

External cooling areas

Ø

Frequency controlled drives

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Specific Capacities

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Ore

Fluxes

Return Lime Coke Material Bins Fines

Sinter plant – typical flow sheet High Intensity Mixer

Granulator

Sinter Machine Waste Gas Fan and Gas Cleaning Sinter Cooler

Cold Crushing

Screening Hearth Layer

Product Sinter Return Fines

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Typical layout

Plant Dedusting

Sinter Machine with Ignition Furnace

Sinter Cooler

Mixing

Coke Raw Material Grinding Dosing

Screening

Waste Gas Cleaning

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Principle of EOS process

Sinter Emissions

LBS

HBS

Residual Gas Volume

-40%

-45%

Dust

-50%

-60%

NOx

-35%

-45%

SO2

-30%

CO

-45%

-50%

CO2

-25%

-30%

Dioxines

-70%

-65%

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Sinter plant with EOS hood

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EOS process principle compared to conventional sintering Conventional sintering

EOS ® Process Ambient air

Ambient air longitudinal sealing Evaporation

Evaporation

Calcining

Calcining

C combustion with O 2 of air to CO 2 Formation of CO, S ox etc.

Ambient air inleak cross and longitudinal sealing

C/CO combustion with O 2 Formation of CO, S ox etc. Recirculated gas

Residual air

Residual gas to be exhausted

Ambient air inleak cross sealing only

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LEEP waste gas recycling process

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EPOSINT waste gas recycling process

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Bag filter technology

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High intensity mixer for sinter mix

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Dust mixer/granulator

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Space requirement for drums vs. HIM

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Future developments in Sintering Ø

Use of pellet fines in the sinter mix

Ø

Fine grinding of additives and coke

Ø

Granulation process with pelletizing discs and/or drums

Ø

Mixing/granulation with HIM

Ø

Modified sinter machine feeding arrangements

Ø

Frequency controlled drives

Ø

Use of other solid fuels

Ø

Modified process gas cleaning systems

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Thank you for your attention!

Walter Gerlach Outotec GmbH [email protected]