pelletisation- a way forward for sustainable steel making….. 21.07.2010

Pelletisation- A way Forward for sustainable steel Making…..

21.07.2010

Copyright © 2010 Jindal Steel & Power Ltd.2

Steel Production…………….

Current and future capacities after planned/projected expansions(million tons pa of 'Crude Steel' Capacity)

Sl Producer 2006-07 2011-12 2019-20

1 SAIL 15 20 40

2 TATA steel 6 11 25

3 JSW 4 14 30

4 Ispat Industries 3 5 7

5 Essar 4 7 15

6 RINL 3 6 10

7 JSPL 3 15 24

8 Bhushan 1 6 10

9 POSCO 0 4 12

10 Arcelor Mittal 0 3 12

11 Others 5 5 12

Total 44 96 197

Secondary & Tertiary producers not considered for yr 2006-07


Indian Steel Industry On High Growth Phase

2858

124

140

200

0

204060

80100120

140160180200

2000 2007 2012(E) 2015(E) 2020(E)

Million tons (MT)


Per Capita Steel Consumption…………….

• World- 150 Kg• Developed World- 350 Kg• INDIA – 50 Kg • CHINA – 250 Kg• The estimated India per capita consumption is expected to reach

approximately 165 kg in 2019-20.


Requirement for Iron making…

• Fe % - > 65 %• SiO2 % - ≤ 1.5 %• Al2O3 % - ≤ 1 %• LOI % ≤ 1 %• P % - < 0.005 %• S % - <0.003 %Effect:-• Slag rate in Iron making ~ 200 kg/T of Hot Metal


Chemical properties of Iron Ore (Hematite) mostly available

Cause:-Typical

• Fe % - 61 – 63 %• SiO2 % - 3.5 % - 4.5%• Al2O3 % - 2.5% - 3.5 %• LOI % - 3 - 4 %• P % - < 0.009 %• S % - <0.005 %Effect:-• Slag rate in Iron making = 350-400 kg/T of Hot Metal


Types of Indian iron Ore Deposit

» Hematite» Magnetite

Hematite is the main producing iron ore in India.

Hematite ores are found in the form of hard massive , hard

laminated, semi friable / soft laminated , powdery type.

Goethite, limonites and laterites are also found in the form of

associated with Hematite minerals.



Our Iron ore is fragile in nature and contain good amount of

goethite and kaolinite in association with hematite ore.

During beneficiation of these low grade hematite iron ore goethite

enriches along with hematite, which remain associated with the iron

ore concentrate even after beneficiation.

As the liberation of iron phase mineral is below 200 microns, the

generation of fines are more during size reduction which causes high

Blaine number

Causes high LOI and high Blaine number in iron ore concentrate after

beneficiation.



• The presence of deleterious gangue mainly Alumina and Silica are highly undesirable as they adversely increase the cost of hot metal produced.

• SiO2 - 1.5 % will reduce Slag volume - 65 kg / Tonne• Al2O3 – 1.0 %, will reduce Slag rate - 30 kg / Tonne • Coke / Flux rate reduced - 6 kg / Tonne• Productivity (Hot metal) increased – 2.75 %• Reduction of 1 Tonne of Alumina load through Washing /

Beneficiation from ore will give savings of Rs.1 Lakh in steel making process

• Note :1 % reduction of Alumina, benefit is around 100 crores per annum for 3.0 MTPA steel plant.


Iron Ore Demand-Supply MatrixFor the year 2009-10Demand* (in million tonnes) 102 MTNote: For producing 1 Tonne of crude steel/ sponge iron, 1.6 tonnes of iron ore consumption has been assumed.SupplyProduction of iron ore 226Mine-head stocks 73

(IBM Nagpur) Total = 299SurplusDemand-Supply matrix= 299-102 = 197.00Exports = 117.37

*** Surplus available (including stocks at mine- heads)= 79.63


Resource…………….

• India has 25 billion tons of iron ore reserve• India produces 222 MT with avg. recovery @27% lump ore• Huge fines/ultra fines generation • More than 60% of good quality ore is exported• By 2020

– 200 MT Steel – 480 MT Iron ore

LOW GRADE RESOURCE

Beneficiation/ Agglomeration

Low grade iron ore, iron ore fines and iron ore tailings/slimes accumulatedover the years at mine heads and generated during the existing washing processes,need to be beneficiated to provide concentrates of required quality to the Indiansteel plants.


Agglomeration

Use of Pellets - Conservation of mineral by use of fines / ultra fines to agglomerate, making it usable in the steel industry. Pellet making through …………..

Innovative Technology “Coal Gasification”

SinterSinterBriquette Pellet


Different Ore Types

Iron Ore Pellets are made from a variety of different ores.


Purpose of Pelletising……

Why Pelletising….?Why not used fines directly ???

The design and operation of Blast Furnace makes it necessary to agglomerate the fines by either Sintering or Pelletising….


Blast Furnace Operation

250oC

CO+N2

Stack

1200oC

Bosh

Tuyeres

Hearth

1700oC

1500oC

1350oC


Pellets in Blast Furnace

Gas to Solid Reactions

Permeability of Furnace Burden

Strength of Pellets

Porosity of Pellets

Gas to Solid Reactions

Permeability of Furnace Burden

Strength of Pellets

Porosity of Pellets


Steps of Pelletising

Copyright © 2010 Jindal Steel & Power Ltd.

Indurating Furnace

Seven Processing ZonesSeven Processing Zones

Drying Section Heating Section Heat Recovery Section

Pre-heating (Ramp) Firing After Firing First

CoolingSecond Cooling

Updraft Drying (UDD)

Down- draft Drying (DDD)

1 2 3 4 5 6 7

Travel


Pelletisation Process Flow with Dry Grinding

Iron Ore Bins Bentonite GrindingBall MillDryer

Mixing

Paddle Mixture Balling Discs Green Pellets Osciilating ConveyorRoller Screen

Burners Thickener & ESP Fired Pellets Pellet Discharge


Process Gas Flow


Key Equipment for Process Control


Indurating Machine

Rails

Top Strand

Bottom Strand

Burners

Direct Recup Header

Windbox

Double Dump Valve

Air Passage

Downcomer

Furnace Hood


Typical Arrangement of Pellet

Bed of green pellets on pallets


Pellet Quality PELLET QUALITY COMPARISION FOR THE YEAR 2010-11

PARAMETER JSPL ARYA JSW GIIC VALE

PHYSICAL CCS 270 249.65 243 300 230TUMBLER INDEX 95.02 93.9 93.93 92 92ABRASION INDEX 3.83 3.33 4.73 6 7POROSITY 23.64 17.85 17.17 Not Available Not Available

8-16MM 91.23 83.86 98.42 88 90 -5MM 0.41 1.16 0.85 2 4 CHEMICAL Fe 64.55 65.24 62.25 67 67.5FeO 0.58 Not Available 0.7 Not Available Not Available

SiO2 3.65 3.28 5.16 SiO2+Al2O3 =2.6

1.45Al2O3 2.28 1.96 2.62 0.75CaO 0.8 0.66 2.1 0.9MgO 0.19 0.18 0.37 0.5P 0.05 0.047 0.04 0.05 0.035S 0.005 Not Available 0.01 0.01 0.01

Degree of Metalisation Not Available Not Available 94.21 Not Available

Reductivity Not Available Not Available 96.78 Not Available Not Available


Present Pellet Manufacturing Capacity

SL NO

COMPANY CAPACITY

1 ESSAR, VIZAG 8

2 JSW, VIJAYNAGAR 4.5

3 JSPL, BARBIL 4.5

4 KIOCL, MANGALORE 4

5 ARYA, BARBIL 1.2

6 MANDVI, GOA 1.8

7 BMM, HOSPET 1.2

8 CHOWGLEY & OTHERS 4

9 TOTAL 28.6

Another 30 million ton under commissioning by 2013


Direct Cost reduction on Coke head

For a 1mtpy plant Rs.3.8 Cr can be saved per annum


Benefits of using of Pellets…………….• Good Reducibility:Because of their high porosity that is (25-30%), pellets are usually reduced considerably faster than hard burden sinter or hard natural ores/lump ores.• Good Bed Permeability:Their spherical shapes and containing open pores, gives them good bed permeability. Low angle of repose however is a drawback for pellet and creates uneven binder distribution.• Less heat consumption than sintering.Approx. 35-40% less heat required than sintering.• Uniform chemical composition & very negligible LOI:The chemical analysis is to a degree controllable in the concentration processingwithin limits dictated by economics. In reality no LOI makes them cost effective.• Easy handling and transportation.Unlike Sinter, pellets have high strength and can be transported to long distances without fine generation. It has also good resistance to disintegration.


Benefits Contd…….

The other Advantages of using iron ore pellets are:

1. The rotary kiln can produce 20% more without any changes in the design.

2. Specific consumption of coal will come down by 10%.

3. Campaign life will increase to almost 60%.

4. Metallization will be better compared to lump ore.

5. Reduce the generation of fines to 5% in the finished product against 35

to 40%, when produced with lump ore.

6. There are no losses of handling iron ore, as pellets will not break during

transport or handling because of high cold crushing strength.

7. Finally, we will have better environment to work.


29

Benefits of Using Iron ore Pellets in JSPL

• coke / coal consumption - 25 %.• Productivity of Sponge - > 20 %.• carbon content - 20 %.• Sulphur content - 5-10 %.• Phosphorous content - 5 – 10 %.• Iron content - 64.5 %. • Porosity - 18.5 - 24 %.• Direct cost saving around Rs.1800 / Tonne of pellet used in steel

making process.• Refractory repairing cost • Stable blast furnace operation.• Environmental conditions.


JSPL-Barbil Pellet Plant


JSPL’s drives towards sustainable growth… Straight Grate Technology based PelletisingJSPL operating 4.5mtpy pelletizing plant at Barbil Gas based DRIJSPL has worlds largest coal-based sponge iron manufacturing facility, which uses indigenously developed rotary kilns. JSPL leads the Indian market in this sector and has the world’s largest coal-based sponge iron plant, with a capacity of producing 1.32 MTPA DRI. Pipe line transportation for slurryJSPL is laying 178km cross country pipeline from Barbil to Angul for transport of Pellet feed concentrate. Micro Pelletised SinterJSPL- Patratu is Mapping Eirich and HPS technologies

– Technology and process– On parameters like productivity, coke usage, power consumption, lime consumption etc.


JSPL’s drives towards sustainable growth…

The DRI-BF-EAF route technology would be adopted for steel production at Angul.The DRI plant has a unique feature of using Syn Gas from the coal gasification plants as reductant. The DRI-Gasification route is being used for the first time in the world and has the advantage of using high ash coal which is predominantly available in the vicinity of the project site. JSPL has signed an agreement with Lurgi Sasol Technology Company, South Africa, for providing technology for coal gasification.

Hot DRI charging in SMS

Coal washeryJSPL has 6.0 million TPA coal washery at Tamnar, where 47-48% ash coal is washed down to 26% ash. This washery meets the requirements of coal for the sponge iron plant and in addition produces middling's for generation of captive power of about 300 MW.


JSPL’s drives towards sustainable growth…

Coal injection in BF to reduce the dependency of Coke

Organic Binder used replacing Bentonite & resulting less gangue in Pellet

High efficiency by high volume BF installation

Pelletising with Zero waste generation at Barbil

R&D & Institute ,Industry partnershipJSPL has developed Column Floatation technology for Iron recovery from Tailings with IMMT, Bhubaneswar & for recovery from BHJ, BHQ..

HESS m/c from Germany for making high quality fly ash brick at Angul

Infrastructure development JSPL is setting up a captive port in Ganjam district. It involves a capital cost of Rs 1,424 crore, while the operational cost of running the port would be Rs 152 crore per annum. The first phase is scheduled to be operational by 2017.

pelletisation- a way forward for sustainable steel making….. 21.07.2010

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