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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
Solutions for the Indian Iron Ore and Steel Industry
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
Solutions for the Indian Iron Ore and Steel Industry
1. Iron ore I Advanced Beneficiation processes I Specific I Magnetic
1.3 Wet High Intensity Magnetic Separation [ WHIMS]
:
-
Solutions for the Indian Iron Ore and Steel Industry
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%
alljig® | for iron ore beneficiation
Example 02
Kamaljeet Singh Ahluwalia Barbil | India
Scope of Work
Basic Engineering & Detailed Engineering
Manufacturing | Supply of proprietary equipment i.e.
2 x alljig®, 2 x scrubber®
Supervision of erection & commissioning
Complete Project Execution
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%
alljig® | for iron ore beneficiation
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
Supervision of erection & commissioning
Highlights
Plant Capacity
Fe Up gradation
Input feed size
Application
Yield
500 t|h
57.4 - 62.7%
0 - 10 mm
Pellet | Sinter
82%
alljig® | for iron ore beneficiation
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
alljig® | for iron ore beneficiation
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
allflux® | Installations for iron ore beneficiation
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
Supervision of erection & commissioning
Highlights
Plant Capacity
Feed
Product
Input feed size
Application
Yield
4 MTPA
55.6 - 57.5%
62.5 - 63.6 %
0 - 2
Pellet
70 %
allflux® | Installations for iron ore beneficiation
Example 04
Essar Steel Orissa Ltd. Dabuna | India
Scope of Work
Test Works
Manufacturing & Supply of 4 x allflux®
Supervision of erection & commissioning
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 | for iron ore processing
Example 01
ITAMINAS Mineração
Brazil
Iron ore processing
1 x gaustec®
700 t|h
start up
Feed
Product
Tailings
GX3600
1 - 0 mm
July 2010
54% Fe | 23% SiO2
66% Fe | < 3% SiO2
18% Fe | 60% SiO2
gaustec® - GX | Installations | Usiminas Mines
Sarda Mines Pvt. Ltd. | iron ore processing plant | India
Scope of Work
Basic Engineering & Detailed Engineering
Manufacturing | Supply of proprietary equipment i.e.
11 x alljig®, 4 x gaustec® WHIMS
Supervision of erection & commissioning
Complete Project Execution
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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