Recent Developments In Agglomeration Technologies For Iron Ores Pelletizing and Sintering Colloquium 17-18 September 2008 SAIMM SAI MM - Pre Pretor toria ia
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The Steel making Routes
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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
113,4
119,8
124
98,5
101,2
134
121,6
132,7
130,4
130,1
193,3
188,3
202,3
206,8
210,3
0 2000
200 2
20 04
Japan GUS GUS
182,2 107,7
China
20 06
2 007
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 ] y r d t / $ S U [
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] So urce: www.st eelont hene t.co m
120 100 80 ] t / $ S U [
60 40 20 0 1 3 1 3 1 3 1 3 1 3 1 3 1 1 3 1 3 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q 2 2 3 3 4 4 5 5 6 6 7 7 8 0 0 1 1 0 0 0 0 0 0 0 0 0 0 2 0 0 0 2 0 0 2 0 0 2 0 0 0 2 0 0 0 2 0 0 2 0 0 0 2 0 0 0 2 0 0 2 2 0 2 2 2 2 2 2
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Development in transport charges Sea Freight Charges (Tubarao/Rotterdam) [US$ / t] source: Erzkontor, Germany
50 45 40 35 ] t 30 / $ 25 S U [
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
24h Immissionaverage 200 µg/m³
24h Immissionaverage 150 µg/m³
WHO, USEPA, WAEPA
Brazil
Emission 100 mg/m³ ntp
India
Emission 150 mg/m³ ntp
local regulations Immission 120 µg/m³ ntp
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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P ~ 6 4 e ll e t P r M e c i ll . t o j ~ 1 7 2 8 M / a u n ts 00 8 i ll . t d e r / a u e c u nd e t i r xe on e va l u a t i on
Pellet Market: New Projects 2008 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 Minas-Rio 7.0 Mill. t/a Ferrous 6.0 Mill. t/a
SNIM/Sphere 7.0 Mill. t/a
MMX Amapá 3.5 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
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
Caofeidi 4.0 Mill.
Baosteel 4.0 Mill. t/a
CVRD J 4x1.5 Mill
WISCO 5.0 Mill. t/a
Caofeidia 4.0 Mill.
JSW 3.5 Mill. t/a Brahmani River 4.0 Mill. t/a Essar Paradeep 6.0 Mill. t/a Tata Pellet 6.0 Mill. t/a
Amsteel 5.0 Mill. t/a Grange 6.0 Mill. t/a CITIC 5.0 Mill. t/
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Sinter Market: New Projects 2008
0 8 o n 0 2 s c u t i n t c j e e x e a t io o r P d e r a l u r e v t S i n l. t /a u n n d e r e i l /a u M t ~ 5 3 7 M i ll. ~ 1 9
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
Kalahari 2.5 Mill. t/a
Açominas 2.5 Mill. t/a Belgo Min. 3.0 Mill. t/a Baosteel
Usiminas 6.3 Mill. t/a Vallourec
Formosa 5.0 Mill. t/a
Tata SP4 2.3 Mill. t/a
CSA 4.8 Mill. t/a
Pecém 4.2 (5.3) Mill. t/a CSV
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
Bhushan 4.6 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
Dosing
Regrinding
Filtration
Homogenization
Wet Grinding
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Plant Sizes vs. Investment Costs 100
90
80
70
. ] % [ s t s 60 o C t n e m 50 t s e v n I c 40 i f i c e p S
Limonite/ Whethered Ores
30
Hematite 20 Magnetite 10
0 0.0
1.0
2.0
3.0
4.0
Plant C apacity [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 p t m 6 [ ) s d n a r 5 t s e l g n 4 i s ( y t i c a 3 p a c t n 2 a l P
1 0
Samarco 2 Samarco 1 Tilden Ijmuiden Hamersley Krivoi Rog Eagle Mountain Wabush Carol Lake Republic Eagle Mills Malmberget 1
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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
oncentrate
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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
standard equipment for pellet feed dewatering
Vacuum Disc Filters high investment costs (170 %),
Ceramic Filters
significant energy savings (-95%) => pay back in 3 – 5 years, larger sizes possible, few references with iron ore
Vertical Filter Presses
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
Hearth Layer
Screening
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 w ith 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
