Ujjal Chakraborty5th Sep 2014

Pelletisation Scenario Pelletisation Scenario Pelletisation Scenario Pelletisation Scenario

in India and Tata in India and Tata in India and Tata in India and Tata

Steel's Initiatives...Steel's Initiatives...Steel's Initiatives...Steel's Initiatives...

1. Organization Profile

2. Iron ore value proposition – Pellet case

3. Pellet Plant specification and the journey so far

4. Some of the learning experiences

Outline of presentation

2

Tata Steel Group: A Global Steel Company

USA

� Distribution centres

EU (Excluding UK & Netherlands)

� 13 Distribution centresMajor Production facilities

Thailand

� 3 Production facility� 3 distribution centresIndia

Singapore

� 1 Production facility� 4 distribution centres

Netherlands

� 1 Production facility� 3 distribution centres

UK & Ireland

� 4 Production facilities� 33 distribution centers

� Capacity: ~9.7 mtpa� 22 distribution centers

Tata Steel Group

Tata Steel India

Nat SteelTata Steel Thailand

Tata Steel Europe

India (30%)

Asia excluding

India (13%)UK (52%)

EU Excluding UK (5%)

Revenue in FY13(Rs. 1,48,614 Crore)

Geographically widespreadin 5 Continents with

Manufacturing Units in 26 Countries

Product Segments

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Tata Steel India: Brownfield Growth

1.82.0

2.32.8

3.4

4.7

6.66.9

8.1

9.2

LD1 Steelmaking

FY80

Sinter Plant, Bar & Rod Mill

G Blast Furnace, LD2, Slab caster, HSM

Capacity up-gradation in HSM, CRM

Larger Blast Furnaces (H&I)

Pellet Plant & TSCR

FY90 FY00 FY10 FY11 FY13 FY14

Crude Steel Capacity grew

by ~100% in last 10 years

Crude Steel Production (mtpa) 4

1. Organization Profile

2. Iron ore value proposition – Pellet case

3. Pellet Plant specification and the journey so far

4. Some of the learning experiences

Outline of presentation

5

Utilization Of Iron Ore Fines

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• Improving the resource base and exploitation of Mineral resources remains one of themost important geological and economical tasks in India and is the need ofthe hour

• The conventional iron ore processing generates slimes to the tune of 10 to 15% ofrun-off-mine (ROM)

• It is estimated that more than 600 million tonnes of Iron ore fines dumps are availableacross India and this needs to be clearly assessed.

• Fines/ Slimes occupy huge space and cause environmental and ecological problems

• It is essential to beneficiate and recover the additional iron values from thesefines & slimes, not only to earn additional revenue to iron ore industries but alsofrom the view point of conservation of mineral wealth

Long term strategy for higher productivity in BFs

•Resource efficiency-Beneficiation development – reducing gangue load-Value perspective – to enmesh bought out and local materials

• Process and energy efficiency- Agglomerates and coke – productivity and cost- BF improvements - efficiency

•Managing environmental impact- dust emission and process condition connection - environment- energy recovery potential / solution – carbon foot print / CO2

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The need of higher agglomerates in BFs ?

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If the working was only with Sinter, from 62% to 85%

The disadvantage of rising slag rates in BF is well known

� Comfort zone with regard to technology, experience of 5 decades:• SP#1: 1959• SP#2: 1989 Established on• SP#3: 2005• SP#4: 2007

� But disadvantage of high slag rates

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Looming problem of deteriorating ore quality….

The rising ore quality disadvantage

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Value proposition of Pellets vs lumps

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Rs/T

on

1. Organization Profile

2. Iron ore value proposition – Pellet case

3. Pellet Plant specification and the journey so far

4. Some of the learning experiences

Outline of presentation

12

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Pellet plant process flow diagram

Pellet plant specifications

Capacity (t) 6,000,000

Availability (dpy) 330

Grate size (m2) 768

Grate factor (t/d m2) 23.68

Green

pelletizer

(Nos) 10 (Disc)

Dimensions(Ø) (m) 7.5

Screening (--) Roller screen

Drying & Grinding

Dryers (Nos) 2

Fuel for drying (--) BF gas

Ball mill capacity (tph) 433 * 2 Nos

Ball mill size (Ø*L) 6.0m*12.2m

Induration Machine (Travelling grate)

Total reaction area (m2) 192*4 = 768

Bed height (mm) 400

Burners (Nos) 16 Coke oven gas24 Coal tar

Updraft drying zone (m2) 60

Downdraft drying zone (m2) 84

Pre-heating zone (m2) 168

Firing zone (m2) 216

Cooling zone (m2) 240

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� Coal tar is a extremely high viscose Coke plant by-product. It is a complex and variable mixtures of phenols, polycyclic aromatic hydrocarbons (PAHs), and heterocyclic compounds.

� Not new to Tata Steel. Operational experience of Coal tar injection in Blast furnace for more than a decade. Patent with Tata Steel 1986/Cal/96 dt 15.11.1996

� Pre Pelletizing usage Blast furnace (30%), Tar Dolo Plant (10%), Sales (60%)

�Post Pelletizing usage Pellet plant(45%), Blast furnace(25%), Sales(30%)

Unique case, using Coal Tar as fuel in induration

Coal Tar properties

Carbon (%) 90-92

Hydrogen (%) 5

Sulphur (%) 0.3

Sp Gravity (gm/cc) 1.13-1.15

Viscosity (Rw-Sec) 50o : 400 70o : 15090o : 75

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Unique case, using dual flux as additives in Pellet Making

Tailor-made bonding phase was established using dual flux through thermodynamic simulation

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Conventional flux (Lime stone)

Dual flux(Limestone+Olivine/ Pyroxenite)

Chemistry Carbonate Carbonate + Silicate

Heat requirement for reaction High Medium

Bonding phase Calcium silicate Calcium-magnesium silicate

Melting behavior of bonding phase Melts at low temp Melts at high temp

Quartz addition in Blast furnace Required for silica adjustment

Not required

Other Unique feature of TATA Pellet plant

• World first integrated steel plant to have 6MTPA pellet plant

• World largest running plant with grate area 768m2 along with Samarco #3 of 7.2mtpa

• India’s Longest furnace 192m, next is Essar Steel Limited (Paradeep): 188m

• 1st 6mtpa straight grate plant to have dry grinding process

• Dry lintels used for refractory heat dissipation

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1. Organization Profile

2. Iron ore value proposition – Pellet case

3. Pellet Plant specification and the journey so far

4. Some of the learning experiences

Outline of presentation

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Learning experiences….

1. Coal Tar Burner chocking.

2. Excessive dust generation.

3. Sagging of Pallet Car of Indurating Machine due to overheating and slide track failure

4. Nuisance tripping due to DCS communication failure

5. Drying & Grinding availability improved by:

5.1 Interconnecting Silos of ground concentrate

5.2 Eliminating HAG light up problem

5.3 Dense phase conveying problem solved

5. Improvement and stabilization of Ball Mill product Blaine No. from 3000 Cm2/gm to <2400 Cm2/gm

Perennial Problem Faced

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Challenge faced in burner system and solution for mitigation

Modified Coal tar pumping system

4

1

3

2

2

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1Failure of Tar Oil PumpsSolution: Use of Plunger type pump in place of screw pump

2

Frequent Jamming of Coal Tar FiltersSolution

a. Reducing filter mesh size.b. Additional Filter at source

c. Use of Automatic Cleaning

Filters

3Frequent Jamming of Burner NozzlesSolution: Optimize flushing & tar

temperature

Limited storage capacity No settling time Solution: Additional Tank for

enough settling time

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A.I 4%

CCS 257

A.I 40%

CCS137

A.I 40%

CCS137

Use of Statistical analysis for High dust generation through Dissection studies of pellet bed

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A.I 4%

CCS 257

A.I 40%

CCS137

A.I 40%

CCS137

Use of Statistical analysis for High dust generation through Dissection studies of pellet bed

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A.I 4%

CCS 257

A.I 40%

CCS137

A.I 40%

CCS137

Use of Statistical analysis for High dust generation through Dissection studies of pellet bed

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A.I 4%

CCS 257

A.I 40%

CCS137

A.I 40%

CCS137

Use of Statistical analysis for High dust generation through Dissection studies of pellet bed

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Conclusion

• Introduction of Pellets enhance value derived from captive Iron ore

• Introduction of Pellets enhances mine life by using lower grade ore.

• Pellet with a combination of sinter enhances Blast furnace productivity with >85%agglomerates.

• Stabilization of Coal Tar as a fuel for pellet induration—Significant step!!!!!

• Superior Pellet Quality using dual flux at Pellet plant.

•Critical learning during process stabilization using statistical process control.

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