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Advanced Beneficiation Techniques for DRI,

Sinter and Pellet Feed

Dr.-Ing. Heribert Breuer

:

- Indian crude steel capacity is projected to reach 200 mtpy in 2020

- Such capacity would require > 300 mtpy of high grade iron ore

- Actually approx. 200 mtpy are produced of which 60 mtpy are exported, i.e. 140 mt are

available for the local steel industry

- Based on the above figures anual production has to be increased by > 150 mt

- Not only quantity but also quality has to be improved as steel producers are demanding

low contamination mainly low SiO2 and Al2O3

- Ressources of DSO of such qualities are very limited, i.e. low grade ores have to be

upgraded.

Scenario of the Indian Iron Ore Industry

:

- all depends on the ore characteristics, but produce High Grade Concentrates as coarse

as possible

- The finer the feed the higher Capex and Opex, i.e. if feasable producing coarse

concentrates is the most economical way

- If High Grade lumps can be produced, at least for this portion no sintering resp.

pelletizing is required

- Grinding of coarse material from which High Grade products can be processed to

complete liberation size in a first step generates more ultrafines and lowers the possible

yields

- As long as liberation is sufficient to produce High Grade concentrates, do it, no matter if

it´s at a size of 30, 10 or 1 mm and then

- Crush resp. grind the rejects of these steps to the next liberation size and consequently

optimize your yields and costs

Solutions for the Indian Iron Ore and Steel Industry

1. Iron ore I Advanced Beneficiation processes I General

:

- because it´s relatively simple and cheap compared to Heavy Media Processes and

- any high density cut can be selected, typically > 4,0 g/ cm³

1.2 Upstream classifier for < 1 mm

- High capacity units of up to 400 tph, i.e. again low Capex and Opex

- Automatically controlled, i.e. variations in feed composition do not affect product quality

- No manual adjustments required as with spirals for example

- Typically up to 40 % can be product, which reduces the load for the following separation

processes substantially

- generates two more intermediate products which can be processed separately for

optimized settings and performance of + and - 0,1 mm


1. Iron ore I Advanced Beneficiation processes I Specific I Density

1.1 Jigging of > 1 mm

:

- Again, high capacity units for up to 800 tph for optimized economics with the

advantages of :

- Low specific costs per ton of feed

- Much less ancillary equipment like pumps, screen etc.

- Small footprint, i.e. less building costs

- Easier operation


1. Iron ore I Advanced Beneficiation processes I Specific I Magnetic

1.3 Wet High Intensity Magnetic Separation [ WHIMS]

:

-


1. Iron ore I Advanced Beneficiation processes I

1. 4 Practical examples, from small to huge

for:

- coal

- iron ore

- sand | gravel

- rubble

- contaminated soils

- metal-slag

- non ferrous minerals

- diamonds

- salt and others

alljig® | up gradation of low grade iron ore | 1 - 40 mm

alljig® - applications | more than 450 units worldwide

alljig® | for iron ore beneficiation

Example 01

Janki Corp. Ltd. Bellary | India

Scope of Work

Basic Engineering & Detailed Engineering

Manufacturing | Supply of proprietary equipment i.e.

1 x alljig®, 1 x scrubber®

Supervision of erection & commissioning

Complete Project Execution

Highlights

Plant Capacity

Fe Upgradation

Input feed size

Application

Yield

0.8 MTPA

64%

4 - 18 mm

DRI

up to 80%


Example 02

Kamaljeet Singh Ahluwalia Barbil | India

Scope of Work



2 x alljig®, 2 x scrubber®



Highlights

Plant Capacity

Fe Upgradation

Input feed size

Application

Yield

1.6 MTPA

63%

5 - 18 mm I 18 - 40 mm

DRI

up to 70%


Example 08

Sree Metalliks Ltd. Keonjhar | India

Scope of Work

Test Works | Flow sheet Development

Basic &Detailed Design & Engineering

Manufacturing & Supply of proprietary

equipment i.e., alljig®, allflux® & gaustec® WHIMS


Highlights

Plant Capacity

Fe Up gradation

Input feed size

Application

Yield

500 t|h

57.4 - 62.7%

0 - 10 mm

Pellet | Sinter

82%


Example 05

Sarda Mines Pvt. Ltd

India

Iron ore processing

6 x alljig®

5 x alljig®

1500 t|h

start up

G - 2200 x 3000

F - 2500 x 3000

5 - 30 mm

1 - 5 mm

December 2010


Example 01

24 of more than 450 alljigs®

– worldwide

Sishen Mine | South Africa

iron ore separation

24 x alljig®

4.000 t|h

start up

8 GUB 4000 x 3000

8 MUB 3500 x 3000

8 FUB 2200 x 3000

0 - 30 mm

mid 2007

allflux® | Technology

more than 120 installations worldwide

allflux® | up gradation of iron ore fines | 0 - 1 mm

The allflux® separator is a

round, center feed process

vessel that is sized

according to the hydraulic

load. The process uses a

unique combination of

rising current and fluidized

bed techniques and can be

divided into three stages.

The principle of an allflux®

separator is schematically

shown in the following

illustration.

allflux®

allflux® | Installations for iron ore beneficiation

Fortescue Metal Group (FMG)

Cloud Break | CSI Christmas Creek I

Australia

Iron ore separation

6 x allflux®

1.100 t|h

start up

4 x allflux®

1.100 t|h

start up

750

0 - 1 mm

2008

750

0 - 1 mm

2011


Example 03

Brahmani River Pellets Barbil | India

Scope of Work

Test Works | Flow sheet Development

Manufacturing & Supply of proprietary

2 x allflux® | 3 x gaustec® WHIMS


Highlights

Plant Capacity

Feed

Product

Input feed size

Application

Yield

4 MTPA

55.6 - 57.5%

62.5 - 63.6 %

0 - 2

Pellet

70 %


Example 04

Essar Steel Orissa Ltd. Dabuna | India

Scope of Work

Test Works

Manufacturing & Supply of 4 x allflux®


Highlights

Plant Capacity

Feed

Product

Input feed size

Application

Yield

8 MTPA

53.7 - 54.0 %

60.6 - 62.5 %

0-2

Pellet

53 - 67 %

Sree Metalliks Ltd. | allflux® installations | India

Wet High Intensity

Magnetic Separator

More than 80 installations

in less than 8 years

gaustec® | Technology

gaustec® | up gradation of iron ore fines | < 0.1 mm

Larger distance between poles

makes maintenance a simple job

Adjustment of effective magnetic

area of the pole

to achieve energy economy

& higher magnetic inductions

Specific Power Consumption

is minimum

gaustec® | Unique Advantages

gaustec® | Installations | Sarda Mines Pvt. Ltd.

gaustec® - GX | Installations | Usiminas Mines

Sarda Mines Pvt. Ltd. | iron ore processing plant | India

Scope of Work



11 x alljig®, 4 x gaustec® WHIMS



Highlights

Plant Capacity

Fe Up gradation

Alumina reduction

Input feed size

Beneficiation sizes

Application

Yield

11 MTPA

61.7 - 64.1%

3.4 - 1.9 %

0 - 30 mm

0 - 1 | 1 - 5 | 5 - 30

Pellet | Sinter I DRI

85%

Integrated Flowsheet | SMPL

1.999 JSPL Barbil

m % Al2O3 %

100,0 3,4

40,0 5,2 20,0 2,6 40,0 2,0

35,2 2,5 20,8 1,7 30,0 1,4

86,0 1,9 14,0 12,4

Products Rejects

64,1 47,3

Pelletfeed Sinterfeed Blastfurnace/ DRI

Jigging Jiggingallflux/ WHIMS

63,9 64,1 64,5

5-30 mm

62,8 63,259,9

< 1 mm

Mass- balance

Fe %

Feed

61,8

Screening

1 - 5 mm

Sarda Mines Pvt. Ltd. | iron ore processing plant | India

allmineral | worldwide I Iron Ore Equipment

allmineral – wherever you are, worldwide!

On every continent you will find competent assistance from the experts at allmineral, who will provide you

with advice and support for your questions. Please let us know if you need brochures, would like to

arrange a visit, or if you have questions or comments. Or simply give us a call. We'll find a solution.

34 alljigs®

16 allflux®

21 gaustec®

25 alljigs®

7 allflux®

38 alljigs®

29 allflux®

1 gaustec®

14 alljigs®

56 gaustec®

2 alljigs®

2 gaustec®

2. Coal - a scarce raw material

-- how can DRI survive !!!!

At present, India is able to produce 450 MTPA of raw coal as against national demand

of 550 MTPA

India is compelled to import 100 MTPA of coal to meet its domestic demand

Captive power plants are mostly depending on imported coal from Indonesia

Steep increase in prices of this imported coal is forcing the domestic consumer to

depend on E-auction, which in turn causing further price rise of domestic coal.

Viability/sustainability of DRI and Captive Plant is becoming a question in this scenario

It is very important to consider use of DRI waste

ie., Dolochar after beneficiation

Generation,Composition of Dolochar

A 100 TPD DRI Kiln produces approximately 40 TPD of dolochar.

A typical composition of dolochar is presented in the following table

Serial No. Constituents Composition (Mass %)*

1 Carbon 14-16

2 Ash 82-85

3 Volatile Matter <1.0

4 Sulphur -

5 Hydrogen 0.53

6 Nitrogen 0.6

7 Moisture 4.2

8 Oxygen 2.42

9 Gross Calorific Value (kcal/kg) 1400-1550

Way to utilize ..... !

It has notified by MoEF that under no circumstances the industry shall store any dust, coal

char, coal fines etc. in open space. Either use char for their in- house consumption in

boilers as fuel OR provide the char to other industries in the region who have

commissioned AFBC/CFBC boilers using dolochar as fuel.

ABFC boiler using dolochar as fuel are designed for a gross calorific value (GCV) of

2100-2200 kCal/kg. It is difficult to use raw char directly in AFBC boiler because of the

presence of mineral matters like silica, iron particle which enhance clinker formation in

bed resulting in reduced boiler efficiency.

For using Dolochar and upgrading GCV up to 2100-2200 Kcal/Kg, allmineral introduced an

unique Dry washing technology called Allair®.

The allair has a remarkable achievement in char beneficiation for removing iron bearing

material and other mineral matters.

The CAPEX & OPEX can be optimized for DRI/Power industries to beneficiate the char

and make it usable in AFBC Boiler. By blending the char and washery rejects the raw

material cost to AFBC boiler can be reduced substantially, resulting overall cost

reduction.

allair® | for dry coal / char beneficiation

air exhaust

pulsed airflow

constant airflow

light particles

heavy particles

feed

allair® jig results of Char

SL. NO. TYPS OF SAMPLE % ASH % VM % FC % ASH REDUCTION % FC UPGRADATION

1

FEED TO JIG 85 0.8 14.2

10.12 7.1 CLEAN CHAR 74.88 3.82 21.3

REJECT CHAR 92.2 0.3 7.5

2

FEED TO JIG 82.65 1.49 15.86

12.58 9.14 CLEAN CHAR 70.07 5.82 25

REJECT CHAR 91.55 0.2 8.25

3

FEED TO JIG 80.82 1.81 17.37

11.79 7.88 CLEAN CHAR 69.03 5.72 25.25

REJECT CHAR 95.2 0.93 3.87

allair® jig results of Char

SL. NO. TYPS OF SAMPLE % ASH % VM % FC % ASH REDUCTION % FC UPGRADATION

1

FEED TO JIG 80.6 2.71 16.69

10.81 7.49 CLEAN COAL 69.79 6.03 24.18

REJECT COAL 91.63 0.12 8.25

2

FEED TO JIG 80.64 1.76 17.6

15.24 10.76 CLEAN COAL 65.4 6.24 28.36

REJECT COAL 92.35 0.4 7.25

3

FEED TO JIG 82.69 0.88 16.43

11.19 7.82 CLEAN COAL 71.5 4.25 24.25

REJECT COAL 95.28 0.23 4.56

allair® | for coal / char beneficiation I more than 30 installations in India

Example 01

SCAN STEELS LTD.

India

1 x allair®

50 t|h

start up

4‘ x 8‘

0 - 30 mm

2008

allair® | for coal / char beneficiation

Example 02

JANKI CORP LTD.

India

1 x allair®

50 t|h

start up

4‘ x 8‘

5 - 20 mm

2008

Dry coal/ char beneficiation is an unique technology for Indian power plants

Utilization of Dolochar in AFBC/CFBC Boiler, to reduce fuel cost and make-up for the

coal shortages.

Reduced environmental hazard.

Techno economic feasibility for the dry char beneficiation plant.

Optimized OPEX with Dolochar and coal mix in boiler.

Less generating cost of electricity in captive power plant using dolochar as a

fuel.

Ground water conservation achieved by Dry Process.

2. Coal I Summary :

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