Recent Developments In Agglomeration Technologies For Iron Ores
Pelletizing and Sintering Colloquium 17-18 September 2008 SAIMM - Pretoria
2/24/2009
The Steel making Routes
2/24/2009
Steel Production
World crude steel production (in million tons)
1400 1200 1000 800 600 400 200 0 2000 2002 2004 2006 2007 188,3 127,2 106,4 98,5 134 193,3 203,1 280,5 182,2 107,7 101,2 121,6 188,3 112,7 113,4 132,7 202,3 116,2 119,8 130,4 206,8 120,2 124 130,1 210,3 227,3 422,7 489,2 269,2 254,3 other China Japan GUS NAFTA EU 27
2/24/2009
Steel Consumption in kg per Capita
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.
140,00 120,00 100,00 [US$ / t dry] 80,00 60,00 40,00 20,00 0,00 1999
fines lump ore pellets
2000
2001
2002
2003
2004
2005
2006
2007
2008
2/24/2009
[US$ / t] 100 120 20 40 60 80 0
Development of raw material prices
Coking Coal Export Price [US$ / t]
Source: www.s teelonthenet.com
20 00 Q1 20 00 Q3 20 01 Q1 20 01 Q 20 3 02 Q 20 1 02 Q 20 3 03 Q 20 1 03 Q3 20 04 Q 20 1 04 Q 20 3 05 Q 20 1 05 Q 20 3 06 Q 20 1 06 Q 20 3 07 Q 20 1 07 Q 20 3 08 Q1
2/24/2009
Development in transport charges
Sea Freight Charges (Tubarao/Rotterdam) [US$ / t]
source: Erzkontor, Germany
50 45 40 35 [US$ / t] 30 25 20 15 10 5 0 2005Q1 2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 2007Q2 2007Q3
2/24/2009
Environmental Regulations
Emission Limits
Country Germany Dust Emission 20 mg/m ntp 24h Immissionaverage 120 g/m Emission 100 mg/m ntp Emission 150 mg/m ntp SO2 Emission 500 mg/m ntp 24h Immissionaverage 200 g/m NO2 Emission 400 mg/m ntp 24h Immissionaverage 150 g/m Source TA Luft
Australia
WHO, USEPA, WAEPA local regulations
Brazil
India
Immission 120 g/m ntp
Immission 120 g/m ntp
Air Act 1981
2/24/2009
Consumption of Reductants
2/24/2009
CO2 emitents in BF steel production
2/24/2009
Pellet Market: New Projects 2008
LKAB KK4 5.0 Mill. t/a New Millennium 2x7.5 Mill. t/a QCM 7.5 Mill. t/a Northland 5.0 Mill. t/a Vest Alpine 2.0 Mill. t/a
M-GOK 5.0 Mill. t/a
~ 64 Pellet P ~ 17 Mill. t/ roje cts a 8M ill. t under 2008 /a u nde execut i r ev alua on tion
S-GOK 6.0 Mill. t/a Zhuhai YPM 1.5 Mill. t/a Baosteel 4.0 Mill. t/a WISCO 5.0 Mill. t/a
Essar MIS 6.0 Mill. t/a
Essar Trinidad 6.0 Mill. t/a
Gol-e-Gohar 5.0 Mill. t/a Sangan 2.4 Mill. t/a Gohar Zamin 2x5.0 Mill. t/a
SSGPO 6.0 Mill. t/a Ferrexpo 5.0 Mill. t/a
Caofeidia 4.0 Mill.
CVRD JV 4x1.5 Mill.
Caofeidian 4.0 Mill. t
MBR 7.0 Mill. t/a CSN 2x3.0 Mill. t/a
Tubaro VIII 7.5 Mill. t/a MMX Amap 3.5 Mill. t/a Samarco 4 7.5 Mill. t/a
SNIM/Sphere 7.0 Mill. t/a
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 Gua & Bolani
Amsteel 5.0 Mill. t/a Grange 6.0 Mill. t/a
GIC 5.0 Mill. t/a CVRD Sohar 4.5 Mill. t/a Al Tuwairqi 5.0 Mill. t/a Hadeed
Minas-Rio 7.0 Mill. t/a Ferrous 6.0 Mill. t/a Usiminas
CITIC 5.0 Mill. t/a
Gerdau 7.0 Mill. t/a
JSW West Bengal
2/24/2009
Sinter Market: New Projects 2008
8 200 tion ts je c execu ation ro r P nder valu te Sin l. t/a u der e Mil . t/a un 3 ~ 5 Mill 197 ~
P.R. China 33 plants 140.0 Mill. t/a Dragon Steel 2.5 Mill. t/a
Krivoi Rog 10.0 Mill. t/a Nucor 2.5 Mill. t/a Kardemir 2.8 Mill. t/a
Isdemir 3.4 Mill. t/a Formosa 5.0 Mill. t/a Tata KPO 5.75 Mill. t/a
CSA 4.8 Mill. t/a Aominas 2.5 Mill. t/a Belgo Min. 3.0 Mill. t/a Baosteel 7.0 Mill. t/a Usiminas 6.3 Mill. t/a Vallourec 1.2 Mill. t/a Kalahari 2.5 Mill. t/a Pecm 4.2 (5.3) Mill. t/a CSV 5.0 Mill. t/a
Tata SP4 2.3 Mill. t/a JSW 2 2.3 Mill. t/a
JSW 3 5.75 Mill. t/a Vizag Steel JSPL 3.6 Mill. t/a 7.2 Mill. t/a IISCO 4.6 Mill. t/a Rourkela Bhushan 4.6 Mill. t/a Durgapur Bhilai
2/24/2009
2/24/2009
Typical flow sheet
2/24/2009
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 Preparation
Dosing & Mixing
Regrinding
Filtration
Homogenization
Wet Grinding
2/24/2009
Plant Sizes vs. Investment Costs
100
90
80
70 Specific Investment Costs [%].
60
50
40 Limonite/ Whethered Ores Hematite 20 Magnetite 10
30
0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Plant Capacity [mtpy]
2/24/2009
Development of pellet plant size
Capacity in million t/a
8 7
Plant capacity (single strands) [mtpy] Samarco 3
7.5 Million t/a
6 5 4 3 2 1 0
1950 Samarco 1 Tilden Ijmuiden Hamersley Krivoi Rog Eagle Mountain Wabush Carol Lake Republic Eagle Mills Malmberget 1 1960 1970 1980 1990
Samarco 2
2000
2/24/2009
Samarco 3 with 768m and 7.5 Mtpy Worlds largest Pellet Plant
2/24/2009
Steel belt plant general layout
Pellets
Concentrate
2/24/2009
Steel belt process concept
2/24/2009
Simplification of Plant Design Roller Presses vs. Ball Mills
2/24/2009
Simplification of Plant Design Roller Presses vs. Ball Mills
Slurry Storage Grinding Roller Presses Bins Bins
Filtration
Thickening
Grinding and Filtration Section of a 4,000,000 t/a Pelletizing Plant
Comminution Section of a 7,000,000 t/a Plant
2/24/2009
Simplification of Plant Design
Conventional Vacuum Disc Filters Ceramic Filters
standard equipment for pellet feed dewatering
high investment costs (170 %), significant energy savings (-95%) => pay back in 3 5 years, larger sizes possible, few references with iron ore simplified plant layouts due to large sizes (up to 132m filtration area), significant energy savings, improved moisture control
Vertical Filter Presses
2/24/2009
Improvement of Operating Costs
Conservation or introduction of thermal energy to 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
Specific Capacities
2/24/2009
2/24/2009
Ore
Fluxes
Coke Return Lime Material Bins Fines
Sinter plant typical flow sheet
High Intensity Mixer
Granulator
Sinter Machine Waste Gas Fan and Gas Cleaning Sinter Cooler
Cold Crushing
Screening Hearth Layer
Product Sinter Return Fines
2/24/2009
Typical layout
Plant Dedusting
Sinter Machine with Ignition Furnace
Sinter Cooler
Mixing
Coke Raw Material Grinding Dosing
Screening
Waste Gas Cleaning
2/24/2009
2/24/2009
Principle of EOS process
Sinter Emissions Residual Gas Volume Dust NOx SO2 CO CO2 Dioxines
LBS -40% -50% -35%
HBS -45% -60% -45% -30%
-45% -25% -70%
-50% -30% -65%
2/24/2009
Sinter plant with EOS hood
2/24/2009
EOS process principle compared to conventional sintering
Conventional sintering
Ambient air longitudinal sealing Evaporation Calcining C combustion with O 2 of air to CO 2 Formation of CO, S ox etc. Ambient air inleak cross and longitudinal sealing Evaporation Calcining C/CO combustion with O 2 Formation of CO, S ox etc. Recirculated gas Residual air Residual gas to be exhausted Ambient air inleak cross sealing only
EOS Process
Ambient air
2/24/2009
LEEP waste gas recycling process
2/24/2009
EPOSINT waste gas recycling process
2/24/2009
Bag filter technology
2/24/2009
2/24/2009
High intensity mixer for sinter mix
2/24/2009
Dust mixer/granulator
2/24/2009
Space requirement for drums vs. HIM
2/24/2009
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
Thank you for your attention!
Walter Gerlach Outotec GmbH walter.gerlach@outotec.com
