jasbir khosa, xstract mining: examining developments in iron ore sintering to handle more...
DESCRIPTION
Jasbir Khosa, Principal Consultant, Processing, Xstract Mining delivered this presentation at the 2013 FE Tech Conference. The event focussed on the economics of processing and the beneficiation of iron ore. In light of the slowdown in demand for iron ore and pricing decreases, the need to process more efficiently and cost effectively is a challenge. The conference examined on how we can achieve greater value from the iron ore supply chain, with topics addressing optimisation and streamlining processes, applying improved technologies, understanding the ore body and how to properly characterise it, knowing the steel makers needs. For more information please visit the conference website: http://www.informa.com.au/fe-techTRANSCRIPT
XstractGroup.com Xstract - Excellence from the Outset
GEOLOGY GEOTECH MINING PROCESSING VALUATION/RISK TECHNOLOGIES ENVIRONMENT TRAINING
Sintering challenging ores
Jasbir Khosa
Calibre Global Companies:
3 integrated companies working
with parent company Calibre Global
and independently to provide
comprehensive services to the
resources and infrastructure sectors.
Calibre Minerva
Bulk materials handling and process engineering
specialists providing innovative engineering and
design solutions to the mining and infrastructure
sectors.
Safety & Rescue Australia (SRA)
An Australian Registered Training Organisation
offering safety training and assessment services,
leadership and supervisory consulting.
.
Xstract Mining Services
A mining and resources consultancy providing
independent, professional services to exploration
and mining companies, engineering firms,
financial institutions and investors.
.
Calibre Global Companies Comprehensive capability across the value chain
Enduring Value 2
Xstract disclaimer
© 2013 Xstract Mining Consultants Pty Ltd. All rights reserved.
This presentation has been prepared by Xstract Mining Consultants Pty Ltd (“Xstract”) (ABN 62 129 791 279). It is being made available for information purposes only. The information in this presentation is of a general nature only, and represents Xstract’s preliminary views. Xstract makes no representation or warranty as to the accuracy, reasonableness or completeness of any statement or projection in this presentation. The information contained in this presentation is confidential and must not be disclosed to any other person without the prior consent of Xstract.
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4
Presentation overview
• Sintering process and granulation • Challenging iron ores • Granule design • Sinter bed • Bed charging • Strand support • MEBIOS/RF-MEBIOS • Modern sinter plant
5
Sinter Plant
Granulation
0 1
2mm
0 50 100µm
0 5
10µm
0 100
200µm
source: Khosa et al,ISIJ int, vol47 (2007) No.7 pp965-972
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Challenging Iron Ores • High LOI and porosity, rapid melt, high fuel rate • Fine size distribution, poor bed permeability
source: LOO et al,ISIJ Int, Vol. 47 (2007), No. 3, pp. 349–358, Khosa et al, Iron Ore 2005, Perth
-0.4
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
0.4
0.01 0.1 1 10
average size range (mm)
ch
an
ge
in
O
pt %
H2O
w
ith
%
in
cre
ase
in
p
artic
les
HAP
LAP
MM
H/MM
FMH
CMH
DH
binding
particles
intermediate particles
nucleus
particles
8
Granule structure
• Nucleus: fines, rapid melting, weak structure • Nucleus: Fe particle, stable open bed, flooded pores • Nucleus: fuel, calcined, unreacted, hot spot
Source: Khosa et al, Iron Ore 2005, Perth
Granule design
Source: Umadevi, JSW, steel research int. 81 (2010) No. 9, JFE Steel tech report, www.jfe-steel.co.jp/en/ report
10
Deep bed sintering/ bed densification
Increase bed depth • Improve sinter strength • Improve yield • Lower fuel consumption
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
40 42 44 46 48 50 52 54 56 58 60
fuel rate (kg/t)
pro
du
ctivity (
t/m
2d
)
330 mm
500 mm
860 mm
860 mm, 2%HL
330 mm
500 mm
860 mm
2% HL
RFB, TI
1.42, 62.9
1.40, 62.9
1.08, 76.8
1.08, 68.4
0.99, 77.6
1.03, 77.4
1.25, 71.9
0.98, 76.3
1.12, 69.6
0.93, 77.7
19% RF
0.98, 72.6
bed depth
1.13, 72.7
1
2
3
4
source: Khosa et al, Iron Ore 2007, Perth, Nakano, NSC, ISIJ Int. 2013
0
5
10
15
20
25
30
35
40 45 50 55 60 65 70 75 80 85 90
Fuel (kg/t)
Sin
ter
fra
ctio
n +
25
mm
(%
)
Ore A
Ore B
Ore C
Blend
hematite
marra mamba
pisolite
860 mm
500 mm
330 mm
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Bed charging
• large particles lower in the bed for stability • Chute build-up vs. segregation
Source: Nakano, ISIJ Int. 2013
Stand support sintering • NSC Kimitsu works
Source: Higuchi et al, ISIJ Int. 2013
MEBIOS • Mosaic Embedding Iron Ore sintering
• Modify the supporting structure within the sinter bed
• NSC Wakayama No5 sinter plant
Source: Kamijo et al, ISIJ Int. 2013
RF-MEBIOS • Return fines separation based on Mosaic Embedding Iron Ore sintering
• Coarse RF (1-5mm) addition after granulation
• Improved granulation and bed permeability from friction with dry RF
• Sumitomo Kashima, Wakayama and Kokura works
Source: Matsumura et al, ISIJ Int. 2013
Largest Sinter Plant in China
15 Source: BSIET, Shougang Jing Tang Steel, Google maps, www.midrex.com
• 5.5 Mtpa of sinter (17,000 tpd) • 550 m2 sinter strand • Shougang Jingtang United, Hebei Deep bed sintering (860mm) • Coke size distribution • Feed blend control • Intensive mixing and balling • Preheating green feed, drive of moisture • Bed feeding, shuttle and roll distributor • BTP control • Further improvement MEBIOS (50-60 => 60-70 MM/CID)
Thank you