agglomeration of iron ores

7/30/2019 Agglomeration of Iron Ores

1/41

Recent Developments In Agglomeration Technologies

For Iron Ores

Pelletizing and Sintering Colloquium

17-18 September 2008

SAIMM - Pretoria


2/41

2/24/2009

The Steel making Routes


3/41

2/24/2009

Steel Production

193,3

134

98,5

106,4

127,2

188,3

188,3

121,6

101,2107,7

182,2

203,1

202,3

132,7

113,4

112,7

280,5

227,3

206,8

130,4

119,8

116,2

422,7

254,3

210,3

130,1

124

120,2

489,2

269,2

0

200

400

600

800

1000

1200

1400

2000 2002 2004 2006 2007

World crude steel production (in million tons)

other

China

Japan

GUS

NAFTA

EU 27


4/41

2/24/2009

Steel Consumption in kg per Capita


5/41

2/24/2009

Development of raw material prices

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

0,00

20,00

40,00

60,00

80,00

100,00

120,00

140,00

1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

[U

S$

/tdry]

fines

lump ore

pellets


6/41

2/24/2009

Development of raw material prices

Coking Coal Export Price [US$ / t]So urce: www.steelonthene t.co m

0

20

40

60

80

100

120

2

000Q1

2

000Q3

2

001Q1

2

001Q3

2

002Q1

2

002Q3

2

003Q1

2

003Q3

2

004Q1

2

004Q3

2

005Q1

2

005Q3

2

006Q1

2

006Q3

2

007Q1

2

007Q3

2

008Q1

[US$

/t]

2/24/2009


7/41

2/24/2009

Development in transport charges

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

0

5

10

15

20

25

30

35

4045

50

2005-

Q1

2005-

Q2

2005-

Q3

2005-

Q4

2006-

Q1

2006-

Q2

2006-

Q3

2006-

Q4

2007-

Q1

2007-

Q2

2007-

Q3

[US$

/t]

2/24/2009


8/41

2/24/2009

Environmental Regulations

Emission Limits

Country Dust SO2 NO2 Source

Germany Emission

20 mg/m ntp

Emission

500 mg/mntp

Emission

400 mg/mntp

TA Luft

Australia 24hImmission-

average

120 g/m

24h

Immission-

average

200 g/m

24h

Immission-

average

150 g/m

WHO,

USEPA,

WAEPA

Brazil Emission100 mg/m

ntp

local

regulations

India Emission150 mg/m

ntp

Immission

120 g/m ntp

Immission

120 g/m ntp

Air Act

1981

2/24/2009


9/41

2/24/2009

Consumption of Reductants

2/24/2009


10/41

2/24/2009

CO2emitents in BF steel production

2/24/2009


11/41

2/24/2009

Pellet Market: New Projects 2008

Tubaro VIII

7.5 Mill. t/a

Zhuhai YPM1.5 Mill. t/a

S-GOK6.0 Mill. t/a

LKAB KK4

5.0 Mill. t/a

JSW3.5 Mill. t/a

Minas-Rio7.0 Mill. t/a

GIC5.0 Mill. t/a

CSN2x3.0 Mill. t/a

Gohar Zamin2x5.0 Mill. t/a

CVRD Sohar4.5 Mill. t/a

Essar MIS6.0 Mill. t/a

New Millennium2x7.5 Mill. t/a

Northland5.0 Mill. t/a

SNIM/Sphere7.0 Mill. t/a

Sangan2.4 Mill. t/a

Brahmani River4.0 Mill. t/a

Tata Pellet6.0 Mill. t/a

Caofeidi4.0 Mill.

Essar Trinidad6.0 Mill. t/a

M-GOK5.0 Mill. t/a

Al Tuwairqi

5.0 Mill. t/aHadeed

CITIC5.0 Mill. t/

Baosteel4.0 Mill. t/a

Amsteel

5.0 Mill. t/a

Grange6.0 Mill. t/a

Essar Paradeep6.0 Mill. t/a

Gol-e-Gohar5.0 Mill. t/a

SSGPO6.0 Mill. t/a CVRD J

4x1.5 Mill

Samarco 47.5 Mill. t/a

MMX Amap3.5 Mill. t/a

Gua & Bolani JSW West Bengal

WISCO5.0 Mill. t/a

Ferrexpo5.0 Mill. t/a

Ferrous6.0 Mill. t/a

Gerdau7.0 Mill. t/a

Usiminas

MBR

7.0 Mill. t/a

PelletProjects2008

~64Mill.t/aunderexecution

~178Mill.t/aunderevaluation

QCM7.5 Mill. t/a

Vest Alpine2.0 Mill. t/a

Caofeidia4.0 Mill.

2/24/2009


12/41

2/24/2009

Sinter Market: New Projects 2008

Aominas2.5 Mill. t/a

Tata SP42.3 Mill. t/a

Usiminas6.3 Mill. t/a

JSW 35.75 Mill.

t/a

Nucor2.5 Mill. t/a

JSW 22.3 Mill. t/a

IISCO4.6 Mill. t/a

CSA4.8 Mill. t/a

Vizag Steel3.6 Mill. t/a

Bhushan4.6 Mill. t/a

Rourkela Durgapur BhilaiVallourec

1.2 Mill. t/a

Kalahari2.5 Mill. t/a

Pecm4.2 (5.3) Mill. t/a

CSV5.0 Mill. t/a

JSPL7.2 Mill. t/a

Sinter Projects2008

~53Mill.t/aunderexecution

~197Mill.t/aunderevaluation

Kardemir2.8 Mill. t/a

Tata KPO5.75 Mill. t/a

Formosa5.0 Mill. t/a Dragon Steel

2.5 Mill. t/a

Belgo Min.3.0 Mill. t/a

Baosteel7.0 Mill. t/a

Krivoi Rog

10.0 Mill. t/a

P.R. China33 plants

140.0 Mill.t/a

Isdemir3.4 Mill. t/a

2/24/2009


13/41

2/24/2009

2/24/2009


14/41

2/24/2009

Typical flow sheet

2/24/2009


15/41

2/24/2009

Typical layout of a 7.5 million tpa plant

Wet GrindingHomogenizationFiltrationRegrindingDosing& Mixing

AdditivePreparation

Green

Pelletizing Induration

Central Plant Dedusting

Process Gas Cleaning

Cooling System Fuel Oil System

Substation

2/24/2009


16/41

2/24/2009

Plant Sizes vs. Investment Costs

0

10

20

30

40

50

60

70

80

90

100

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Plant Capacity [mtpy]

SpecificInvestmentCosts[%].

Limonite/

Whethered Ores

Hematite

Magnetite

2/24/2009


17/41

2/24/2009

Development of pellet plant size

Capacity in million t/a

Samarco 3

Samarco 2

Samarco 1

Tilden

IjmuidenHamersley

Krivoi RogEagle Mountain

Wabush

Carol Lake

Republic

Malmberget 1

Eagle Mills

0

1

2

3

4

5

6

7

8

1950 1960 1970 1980 1990 2000

Plantcapacity

(singlestrands)[mtp

7.5 Million t/a

2/24/2009


18/41

2/24/2009

Samarco 3 with 768m and 7.5 Mtpy

Worlds largest Pellet Plant

2/24/2009


19/41

Steel belt plant general layout

oncentrate

Pellets

2/24/2009


20/41

Steel belt process concept

2/24/2009


21/41

Simplification of Plant Design

Roller Presses vs. Ball Mills

2/24/2009


22/41


Roller Presses vs. Ball Mills

Comminution Sectionof a 7,000,000 t/a Plant

Grinding and Filtration Sectionof a 4,000,000 t/a Pelletizing Plant

BinsBins

RollerPresses

Grinding

Thickening

Slurry Storage

Filtration

2/24/2009


23/41

standard equipment for

pellet feed dewateringConventional

Vacuum Disc

Filters

simplified plant layouts due tolarge sizes

(up to 132m filtration area),

significant energy savings,

improved moisture control

Vertical Filter

Presses

high investment costs (170 %),

significant energy savings (-95%)

=> pay back in 3 5 years,

larger sizes possible,

few references with iron ore

Ceramic Filters


2/24/2009


24/41

Improvement of Operating Costs

Conservation or introduction of thermal energyto pellet feed/green pellets

Improved green pellet qualities with narrow size

distributions

Improved screening concepts for hearth- and side layers

Increased pellet bed heights

Optimized heat balances and gas flow schemes

External cooling areas

Frequency controlled drives

2/24/2009


25/41

Specific Capacities

2/24/2009


26/41

2/24/2009


27/41

Material BinsOre Fluxes CokeReturnFines

Lime

Sinter Machine

Sinter Cooler

Screening

Waste Gas Fan andGas Cleaning

Hearth Layer

Return Fines

Product Sinter

Cold

Crushing

Granulator

High Intensity Mixer

Sinter plant typical flow sheet

2/24/2009


28/41

Raw MaterialDosing

Sinter Machine withIgnition Furnace

SinterCooler

Screening Waste GasCleaning

Typical layout

CokeGrinding

Mixing

Plant Dedusting

2/24/2009


29/41

2/24/2009


30/41

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%

2/24/2009


31/41

Sinter plant with EOS hood

2/24/2009


32/41

EOS process principle

compared to conventional sintering

Evaporation

Calcining

C combustion withO2 of air to CO2

Formation of CO, Sox etc.

Ambient air

Residual air

Ambient air inleakcross andlongitudinal sealing

Conventional sintering

Evaporation

Calcining

C/CO combustionwith O2

Formation of CO, Sox etc.

Ambient air

Residual gasto be exhausted

Ambient air inleakcross sealing only

EOS Process

Recirculated gas

longitudinal sealing

2/24/2009


33/41

LEEP waste gas recycling process

2/24/2009


34/41

EPOSINT waste gas recycling process

2/24/2009


35/41

Bag filter technology

2/24/2009


36/41

2/24/2009


37/41

High intensity mixer for sinter mix

2/24/2009


38/41

Dust mixer/granulator

2/24/2009


39/41

Space requirement for drums vs. HIM

2/24/2009


40/41

Future developments in Sintering

Use of pellet fines in the sinter mix

Fine grinding of additives and coke

Granulation process with pelletizing discs and/or drums

Mixing/granulation with HIM

Modified sinter machine feeding arrangements

Frequency controlled drives

Use of other solid fuels

Modified process gas cleaning systems

2/24/2009


41/41

Thank you for your attention!

Walter Gerlach

Outotec GmbH

[email protected]

agglomeration of iron ores

Documents