agglomeration of iron ores
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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
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
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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.
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
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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]
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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]
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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
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Consumption of Reductants
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CO2emitents in BF steel production
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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.
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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
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Typical flow sheet
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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
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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
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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
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Samarco 3 with 768m and 7.5 Mtpy
Worlds largest Pellet Plant
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Steel belt plant general layout
oncentrate
Pellets
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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
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
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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
Simplification of Plant Design
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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
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Specific Capacities
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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
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Raw MaterialDosing
Sinter Machine withIgnition Furnace
SinterCooler
Screening Waste GasCleaning
Typical layout
CokeGrinding
Mixing
Plant Dedusting
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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
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
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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
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
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Thank you for your attention!
Walter Gerlach
Outotec GmbH