Anda di halaman 1dari 41

Essar Projects

Making Mega Projects Possible.

RESURGENT INDIA- VISION 2020 IN METALS AND MINERALS SECTOR

Utilization of Iron Ore Fines /


Pellets in Iron Making

28-09-12, Delhi

Contents

India Steel Production and Iron ore scenario

Why - Utilization of Iron ore fines

Essars contribution in utilization of iron ore fines & slimes

Benefciiation
Agglomeration
Slurry pipeline transport
Essars BF operation with pellets in burden

Brief details of Essars iron ore Beneficiation plants, Slurry pipelines and
Pellet plants

Initiatives required from Industry in usage of iron ore fines

Essar Projects India Ltd Brief EPC capabilities in Minerals & Metals

India Steel Production & Iron Ore Scenario

Annual production of steel In India is expected to reach close to 200 million


tonnes mark by the year 2020 making India worlds second largest steel
producer

Current Scenario of Iron ore reserves

India has about 28.5 billion tonnes of Iron ore reserves

Around 60% of Indian ore mined is in the form of fines with relatively lower
grade of iron

India is amongst the highest consumers of CLO for its steel production. About
25% - 30% of Indias steel production is through sponge iron route which is
excessively dependent on CLO as feed

With the projected steel production, requirement of iron ore is expected to be


around 350 to 400 million tonnes per year. At this rate of consumption, the
available good quality reserves would probably not last more than a few
decades

Why - Utilization Of Iron Ore Fines

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

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

It is estimated that more than 600 million tonnes of Iron ore fines dumps are
available across 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 these
fines & slimes, not only to earn additional revenue to iron ore industries but also
from the view point of conservation of mineral wealth

Utilization Of Iron Ore Fines

Beneficiation process is generally customized as per the ore mineralogy and


has to be established through laboratory and/or pilot scale tests

Locating Beneficiation plant


 Close to the mine head or at a place with good connectivity from mines,
sustainable source of water & power, safe and easy disposal of tailings
 Nearby pellet plant / slurry transportation by pipe line to port based pellet
plant

Beneficiated concentrate would need to be further processed for facilitating


its use in Iron making process

Agglomeration processes of Sintering and Pelletizing enable the usage of


fines / concentrate in Iron making

ESSARS CONTRIBUTION TOWARDS IRON ORE


BENEFICIATION & PELLETISATION UTILISING
LOW GRADE FINES & SLIMES

Essars Strategy

By installation of Iron ore beneficiation plants at mine head, Essar is able to


utilize low grade fines & Slimes(< 58% Fe Hematite ore) and impart value
addition

Adoption of slurry pipe line for concentrate transportation eases logistics


and environmental issues

Conversion of iron ore concentrate / pellet feed to pellets at port based


plants facilitates easy shipment to its ISP

Essar group has gained good experience in Beneficiation and Pelletization,


reducing dependence on foreign technology providers and equipment
suppliers

Essar is already operating its Blast Furnace with ~55 % Pellet in burden

Essar is in discussions with R&D institutes for building up a 100 kg/h pilot
scale Beneficiation & Pelletization plant using BHQ ores, high blaine index
and higher LOI concentrates for Pelletization

Essars Pioneering Value Addition To Iron Ore


Fines/ Slimes
Facility

Feed quantity

2X4 MTPA Beneficiation Plant in Kirandul,


10-11 MTPA of fines & slimes
Chattisgarh with Pellet Plant in Vizag
3X4 MTPA Beneficiation Plant in Dabuna,
Odisha with 2 X6 MTPA Pellet Plant in
Paradip

17 MTPA of fines & dumps

1X7 MTPA Integrated Pellet Plant in


Minnesota, USA

About 23 MTPA of ROM

to support Intergraded Steel Plants at

10 MTPA ISP at Hazira, Gujarat

4 MTPA ISP at Algoma, Canada

Integrated Steel Plant @ Hazira - Process Flow


r1

Slide 9
r1

Can be deleted
ryellepeddi, 26-Sep-12

Advantages Of Beneficiation

Utilization of available dumps

Reduction in smelting cost due to reduction in quantity of feed processed

Unwanted material is discarded at the site of ore processing reducing


logistics related costs and concerns

Consistency in quality and uniformity in size of product obtained after


processing improving the efficiency of smelters

Advantages Of Slurry Transportation By


Pipelines

Slurry transportation ensures zero wastage as there is no in-transit material


loss

Pipelines have high availability and low maintenance requirement

Pipelines are techno- economically more viable when compared to other


transportation modes. It gives considerable savings on transportation,
specific to locations

Eliminates dependency on logistics providers like Railways, Road, etc.

Slurry pipelines are environment friendly, as they do not cause noise, dust
pollution or negative visual impacts

Minimum land is required for laying the under ground pipeline and land can
be restored to its original condition

Sintering
Sinter feed
 Ideal feed size range is 90% of material between10mm to 1mm
 Feed size below 1 mm is generally restricted to 10%
Micro pelletization
 Imparts flexibility in the usage of ultra fines in the sinter feed mix
 Augments usage of ultra fines by additional 10 - 15%
100% utilization of ultra fines/Pellet feed as sinter feed through
micro Pelletization is not possible as it adversely impacts the
operation, productivity and quality of sinter
Test works are being carried out to use pellet feed in sintering and
assess the impact on quality/ production parameters

Pelletization

The limitation in the utilization of beneficiated ultrafine concentrates in


Sintering could be overcome through the process of Pelletization

In fact, it is desirable to have concentrates in the size range of 45 micron for


effective Pelletization

Pellets have high resistance to abrasion and facilitate transportation over


long distances. This makes Pelletization an attractive option of
agglomeration either for captive consumption or as a merchandised product

Lesser heat consumption than sintering

The industry is gaining operational and economic advantages by the usage


of pellets in the Iron making process as compared to lump ore

Sponge Iron Kilns have reported an increase in production by 25% due to


the utilization of pellets instead of CLO. Reduction in fines generation and
reduction in coal consumption by 10% is also experienced

Advantages Of Pellets In Iron making

Spherical shape of pellets gives better & uniform permeability resulting in


smoother furnace operation

Pellets have very high cold crushing strength resulting in negligible


generation of fines in stock house

High porosity (i.e. ~ 20%) leads to faster reduction

High strength of pellet (180 - 250 kg/cm2) provides good resistance to


disintegration during the descent of burden

Uniform chemical composition compared to lump ore

Benchmarked Blast Furnaces have 50% pellets in their BF burden.

14

BF Operation At Essar, Hazira


Description

Unit

Design

With 30% pellet

With 50% pellet

t/d

5000

4800

5200

thm/cum/day

2.27

2.18

2.36

Sinter

55.0

42.0

40.0

Pellet

30.0

30.0

54.0

Iron ore

15.0

28.0

6.0

Slag rate

kg/thm

380

328

324

Fuel rate

kg/thm

530

564

540

Coal rate

kg/thm

150

133

121

Si in hot metal

0.8

0.6

0.66

Hot blast temperature

0C

1150

1165

1130

Oxygen enrichment

3.0

3.2 3.4

2.8 3.0

bar(g)

1.76

1.52

1.45

Hot metal prod. (Avg.)


Productivity (U.V.)

Top pressure

Essars Long Term Plans In India


Essar is proposing to install ISPs at the following locations as a part
of its long term plans, with maximum utilization of pellets in Blast
furnace burden, thereby further usage of low grade fines in these
areas.
 6 MTPA ISP at Paradip
 3 MTPA ISP in Chattisgarh
 6 MTPA ISP in Jharkhand

BRIEF DETAILS OF ESSARS


IRON ORE BENEFICIATION PLANTS,
SLURRY PIPELINES AND PELLET PLANTS

12 MTPA Beneficiation Plant At Dabuna

3x4 MTPA Beneficiation Plant At Dabuna

Conceptualized the process flow


based on the lab & plant scale
tests

Plant based on modular design


concept

Equipment selected based on


latest technologies and
operational expertise

Equipment sized based on


availability & operational
flexibility to process wide range of
quality of ores

Usage Of Slimes At Kirandul


Beneficiation Plant

7 MTPA Beneficiation Plant At Minnesota

Crusher
 Primary crusher
 Scalping grizzly
 Secondary crusher

Concentrator
 AG mills
 Ball mills
 Magnetic separators
 Floatation cells
 Thickeners
 Slurry pipe line

Essars Beneficiation Plants-Summary


Particulars

Kirandul

Capacity

8 MTPA (2x 4 MTPA )

Source

Bailadila range iron ore


fines & slimes of NMDC

Iron ore & nature

Dabuna (under
implementation)
12 MTPA (3 x 4 MTPA)

7 MTPA (3 x 2.17 MTPA )

Butler Taconite mine


Pvt. Mines around Barbilnear Nashwauk,
Joda sector
Minnesota
Hematite fines and slimes, Hematite, 58-60%(BF)
Total Fe, % 30.36
58%Fe
Magnetic Fe, % 20.46
Hematite, 62-64%(DR)
Concentrate,63.8%(BF)

Plant output

Concentrate, 66.5% (DR)

Yield

80% to 84%

~70% /75%

Key processes

Gravity separation,
Magnetic separation

Scrubbing, Gravity
separation, Magnetic
separation

Benchmark operability

Minnesota (under
implementation)

NMDC slimes feed along


with fines
Recovery of Fe units from
plant tailings

Concentrate,66.2%(DR)

All flux hindered


separator & small
capacity SLONs, future
plans to process BHQ

68.5 to 69.5 % (DR)


66.0 66.3 % (BF)
29.75% (DR)
30.8% (BF)
Magnetic separation,
Hydro-cyclones &
flotation
Dry cobber & flotation
circuits

Kirandul Vizag Slurry Pipe Line

Kirandul to Vizag Slurry Pipe Line

Essar Slurry Transportation Facilities-Summary


Particulars

Kirandul - Vizag

Dabuna Paradip

Minnesota

Distance

267 km

253 km

3.5 km

Benchmark
operability

Indias longest slurry


pipeline

2nd longest iron ore


slurry pipeline in India

--

Control

Supervisory control and data acquisition systems (SCADA)

Pumps

Diaphragm type
Diaphragm type
Differential Head
positive displacement positive displacement
pumps
pumps of GEHO make pumps of GEHO make

Coverage area

Pipeline passes
through 3 states in
India (Chattisgarh,
Odisha, Andhra
Pradesh)

Across Odisha

Coverage within
plant premises only

2X6 MTPA Pellet Plant At Paradip

Flow Sheet Of Pelletization Plant At Paradip

Consistent Value Addition In Pelletisation-Summary


Particulars
Capacity

Vizag
8 MTPA (1 x 420 m2 &
1 x 444

m2)

Paradip

Minnesota

12 MTPA (2 x 744m2) 7 MTPA (1 x 744 m2)

Technology

Lurgis Straight grate


process

Aker Solutions
Aker Solutions
straight grate process straight grate process

Process
improvement

Capacity enhancement
through zone
rearrangement and
introduction of after
cooler

Customized process
based on previous
learning, multi-staged
screening of green
pellets

Processing taconite
ore, Improved
environmental
performance SOx,
NOx and Mercury
emission control

Grade of pellet

BF & DR grade

BF & DR grade

BF & DR grade

64 % (BF)

63.8% (BF)

60.5- 61% (BF)

66.5% (DR)

66.2% (DR)

66.5- 67 %(DR)

Fe Content

Essars Unique Initiative

Essars unique initiative Environmental regulations at Minnesota


NOx mitigation at source
 Collaborated with FNAC, USA
Treatment of gaseous emissions
 Collaborated with FLSmidth to implement solutions for
treatment of Hg and SOx emissions in the process exhaust

INITIATIVES REQUIRED USAGE OF IRON ORE FINES/DUMPS/SLIMES

Technology Look Ahead

Develop indigenous & viable technology to improve yield and effective


utilization of low grade iron ore including BHJ/BHQ/BMQ, fines & slimes to
produce quality concentrate by deep beneficiation.

Use of tailings as building/construction material, ceramics, etc.

New blast furnaces should have design provision to maximize pellet


utilization in their feed burden

Upgrade the existing blast furnaces to accept higher pellet in burden

Commercialization of alternate iron making technologies that directly use


low grade fines or concentrates as feed

Initiatives To Encourage Fines Utilization

Significant steps have to be taken by the Ministry of Steel to encourage the


establishment of beneficiation and pellet plants
 Ascertain proven reserves of fines/dumps and allot the resources to
pellet or pellet feed producers Mine owners/integrated steel producers
 Ensure long term securitization of ore linkage of a specific range of
quality to entrepreneurs so that periodical capital infusion is avoided
 Improving the infrastructure and logistics support at mine head
 Encourage rotary kiln based DRI producers to use pellets instead of
CLO

Initiatives To Encourage Fines Utilization


 Providing tax incentives
 Facilitate easy sanction of right of way for slurry pipelines
 Establishing dedicated pipeline corridors for trouble free and safe
operation of slurry pipelines
 Developing pellet hubs close to consumer points / seaports
 The technologists, R&D institutions and the steel industry as a whole,
need to support the development of cost effective and environmentally
friendly solutions and processes

EPC Capabilities

EPC Capabilities

Essar has a mixture of Design & Engineering, Operating, Maintenance and


Construction/Project knowledge. As a result the plants designed will be
operator friendly taking in to account all practical aspects

For Iron & Steel plants Essar has the exposure to alternate routes of various
processes and ready access to operating plants

With in-house operating plants, Essar has ready made access to all
operating data useful for improving successive designs.

Having the practical knowledge of the plant, Essar is in better position to


select technology and equipment (giving better OPEX & CAPEX).

Expertise In Iron & Steel Making

Beneficiation And Pellet Plant Projects


Pellet plants executed by EPIL on EPC basis





Vizag Essar Steel Limited, 8.0 MTPA


Paradip ESOL, 12.0 MTPA
Minnesota, USA 7.0 MTPA
Vale, Oman 8.0 MTPA (Engineering and procurement assistance)

Other Beneficiation and Pellet plant activities


 Front end loading studies for 6.0 MTPA pellet plant project of Vale,
Malaysia
 Process audit of Sarda Mines Pvt. Limited Beneficiation plant

EPC capability in Beneficiation & Pellet


Plants
Sl.
No.

Description

Beneficiation Plant

Slurry
Pipeline

Technical knowhow & lab testing

Flow sheet development


by laboratories

Tech
supplier

Basic
Engineering

Detail
Engineering

EPIL

Pellet Plant
Only Induration area by a
Tech Supplier

EPIL

EPIL
(excl Induration area)

EPIL

EPIL

EPIL

Supply of
equipment

EPIL

EPIL

EPIL

Construction &
commissioning

EPIL

EPIL

EPIL

EPIL Advantage. Creating Enduring Value

Group with experience of executing projects from concept to commissioning

Pan India presence with offices at all key locations

Hands on experience of setting up & operating Iron & Steel, Power, Refinery
and Ports in India & overseas locations

State of the Art Engineering Centre & Reference Engineering Data available
from operating plants

Construction infrastructure with modern tools & a large fleet of construction


machinery

Global Procurement team conversant in dealing with steel plant equipment


ongoing sub-vendor relations & logistics support

Steel available for EPIL on priority from the Essars plant

Strategically located fabrication / manufacturing facility along the waterfront


@ Hazira for efficient & hassle free shipment

A Positive Attitude Powered by Positive Action

LETS BEGIN ..
THANKS