Evolution and Today. KOBELCO Pelletizing System

Transcription

1 Evolution and Today KOBELCO Pelletizing System Kobe Steel, Ltd. (KSL) April, 2014 Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 1

2 Contents 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 2

3 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 3

4 KSL is composed of ; Corporate Profile Name: Kobe Steel, Ltd. Founded : September 1, 1905 Net Sales : Capital: USD billion* USD 2.48 billion* Related Companies: 206 subsidiaries 64 equity-valued affiliates Employees : 36,018* *Consolidated (KSL + subsidiaries, excluding affiliates) *Ex-rate: JP / USD Kobelco Construction Machinery Kobelco Cranes Other Businesses Construction Machinery 16% Engineering & Machinery 13% Others 7% Aluminum & Copper 16% Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. Iron & Steel, Welding 49% 4

5 Products of Kobe Steel Unique Products, Technology and Service Iron & Steel Business Unit High Strength Steel Sheet / Wire rod products for automobile IPP Unit Power Generation IPP (1,400MW) Aluminum & Copper Business Unit Aluminum forgings for automobile suspensions Welding Business Unit Various welding rods Kobelco Cranes Crawler Crane Aluminum & Copper Business Unit Copper alloy sheet for lead frame Machinery Business Unit - Various types of compressors - Rolling Mills Engineering Business Unit Iron making processes Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 5

6 Outline of Iron Making Processes Iron Ore Beneficiation Pellet Plant BF Pellet Low-Grade Iron Ore Steaming Coal Coal-Based DR Plant FASTMET/ FASTMELT ITmk3 Natural Gas Shale Gas Gas-Based DR Plant Coking Coal Scrap Molten Iron Casted Pig Iron DRI Iron Nugget Processes owned by KSL DRI Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. EAF 6

7 Business Foundation of Iron Unit Division Creation of New Iron Making Technologies MIDREX DR Process KOBELCO Pelletizing System Continuous R & D for New Iron Making Technologies in cooperation with MIDREX Technologies Inc. Knowledge & Experience Accumulated in Engineering and Project Execution Countries: 29 FTK/STK Plants: 51 FOB + SV: 25 FASTMET Process Plant Supply: Since Bangladesh Fertilizer Plant Japan Standard Engineering Quality: Thoughtfulness and Seamless Engineering Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 7

8 Contents 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 8

9 Engineering Business - Overall Past Record : FOB + SV Projects : FTK/STK Projects 1. Fertilizer (Bangladesh) 2. Bar Mill (Bangladesh) 3. Pelletizing (Japan) 4. Pelletizing (Japan) 5. Integrated Mill (Bangladesh) 6. Fertilizer (Zambia) 7. Acrylic Fiber (Korea) 8. Pelletizing (Japan) 9. Pelletizing (Japan) 10. Pelletizing (Japan) 11. Pelletizing (Japan) 12. Polypropylene (Brazil) 13. Continuous Bar Mill (Qatar) Phenol Acetone (Korea) 18. Polypropylene (Singapore) 19. Cement (Japan) 20. Bar & Wire Rod Rolling (Nigeria) 21. Cement (Japan) 22. Vinyl Acetate (Taiwan) 23. Cement (Indonesia) 24. Cement (Jordan) 25. Sulfuric Acid (Zambia) 26. Bar & Section Mill (Libya) 27. Sulfuric Acid (Iraq) 28. Cement (Japan) 29. Cement (Japan) 33. Cement (Japan) 34. Fertilizer (Indonesia) 35. Fertilizer (Malaysia) 36. Coal Liquefaction (Australia) 37. LPG Recovery (Algeria) 38. Aluminum Mill (Bahrain) 39. Wire Annealing (Nigeria) 40. Cement (Malaysia) 41. Polypropylene (Thailand) 42. Cement (Jordan) 43. Direct Reduction (Iran) 44. Direct Reduction (Egypt) 45. Steel Casting (Australia) 49. Polyethylene (Nigeria) 50. Pelletizing (Venezuela) 51. Meltblown (Netherlands) 52. Spunbond (Korea) 53. Direct Reduction (Egypt) 54. Caustic Soda (Indonesia) 55. Direct Reduction (Venezuela) 56. Iron Ore Beneficiation (Iran) 57. Cement (Vietnam) 58. Spunbond (USA) 59. Spunbond (Indonesia) 60. Pelletizing (Venezuela) 61. Direct Reduction (Egypt) 14. Direct Reduction (Qatar) 30. Cement (Japan) 46. Refinery (Ecuador) 62. FASTMET (Japan) 15. Pelletizing (Chile) 31. Cement (Jordan) 47. Cement (Egypt) 63. FASTMET (Japan) 16. Oil Gathering (Kuwait) 32. Pelletizing (Bahrain) 48. Direct Reduction (Venezuela) 64. Direct Reduction (Korea) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document Cement (Italy) 66. FASTMET (Japan) 67. Iron Ore Beneficiation (Iran) 68. Direct Reduction (Qatar) 69. Pelletizing (Iran) 70. FASTMET (Japan) 71. Pelletizing (Bahrain) 72. Direct Reduction (Oman) 73. FASTMET (Japan) 74. FASTMET (Japan) 75. Iron Nugget (USA) 76. Direct Reduction (Bahrain) 9

10 Midrex DR Plants Overall Past Record Midrex - Midrex DR Plants all over the world Since 1969, Midrex has built more than 70 Shaft Furnace Modules in 21 countries worldwide Acindar 2. ArcelorMittal Montreal 1 ArcelorMittal Montreal 2 3. ArcelorMittal Hamburg 4. ArcelorMittal Lazaro Cardenas 5. ArcelorMittal Pt. Lisas ArcelorMittal South Africa 7. Antara Steel Mills 8. Arfa Steel 9. Comsigua 10.DRIC ESISCO Essar Steel 1-6 EZDK 1-3 Ferrominera Orinoco Global Steel Holdings Hadeed A - E HOSCO 1-2 IGISCO IMPADCO JSW Ispat Steel JSW Steel Jindal Steel & Power Khorasan Steel Khouzestan Steel 1-5 LGOK 2, 3 Lion DRI LISCO 1-3 Mobarakeh Steel A - F Nu-Iron OEMK Qatar Steel Co. 1-2 Jindal Shadeed SULB Tenaris Siderca Sidor 1 Sidor 2 A - C 36. Tuwairqi Steel Mills 37. Venprecar 38. voestalpine Note: Projects written in blue were implemented by KSL (main contractor) with Midrex Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 10

11 Presence of KOBELCO Pelletizing System in Middle East Bahrain Steel (former GIIC) No.2, Bahrain Bahrain Steel (former GIIC) Ardakan Vale Oman Ardakan, Iran Flow of pellet product to consumers Kobelco Pelletizing System in Operation Pellet Plant Capacity Process Bahrain Steel (former GIIC) Chador Malu Mining & Industrial Co. (Ardakan) Vale Oman Pelletizing Company L.L.C. Total 11MTPY 5MTPY * x1 6MTPY x1 3.4MTPY 9MTPY (4.5MTPYx2) 23.4MTPY GK GK GK * Originally 4MTPY Vale / Sohar, Oman Plant Supplied by Other Suppliers <Plant in Operation> Pellet Plant Capacity Country Process Mobarakeh Steel 7MTPY Iran SG Khuzestan Steel (Ahwaz) 7MTPY Iran SG Gol-e-Gohar No.1 5 MTPY Iran SG Total 19MTPY <Plant under Construction> Pellet Plant Capacity Country Process Gol-e-Gohar No.2 5MTPY Iran SG Gol-e-Gohar No.3 (Gohar Zamin) 5MTPY Iran SG Khorasan 2.5MMTPY Iran SG Bandar Abbas 2.5MTPY Iran GK Zarand & Sirjan 2.5MTPY x 2 Iran GK Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.

12 Comprehensive Project Development Capabilities Technical Assistance Plant Diagnosis Marketing, Consultation & Finance Arrangement Spare Parts Supply Training Service Plant Design & Engineering Procurement & Inspection Service Project Management ISO9001 Shipment Haulage Commissioning & Operation Construction & Site Management Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 12

13 Summary of KSL s Service KSL fulfills Customer s requirement from multiple aspects; Project Design & Development Stage Project Study (Scoping / Conceptual / Preliminary Design) (Conceptual Layout, Preliminary Financial Analysis, Sample Test etc.) Feasibility Study & Finance Arrangement Project Execution Stage Plant Construction (Engineering, Procurement & Construction) Project Management & Supervision O & M, Training Services Provision of Aftermarket Service: Technical Assistance, O&M, Training Service and Spare Parts Supply for the smooth and timely operation of the plant. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 13

14 Performance of KOBELCO Pelletizing System Long and rich experiences in pelletizing plant construction since Delivery of the world largest grate kiln pelletizing plant for Bahrain Steel (former GIIC) No.2. Bahrain Steel No.2 (front side) (Capacity: 6.0 MTPA) Capability to support operation & maintenance aspects as a pelletization plant operator. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 14

15 Recently Built Plants - Unique Technologies Pellet Plant Vale Oman Jindal Shadeed DRI Plant - Oman Qatar Steel Company HBI/DRI Combo plant RHF based technology Fastmet - Japan Pellet Plant Bahrain Steel No2 (Former GIIC) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 15

16 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 16

17 Newly Established Collaboration KOBELCO Pelletizing System: Collaboration - Kobe Steel and FLSmidth Rich experiences & know-how in the mineral processing Worldwide network Competitive service Process owner of KOBELCO Pelletizing System (KPS) Rich experiences & know-how in project execution & plant construction Besides the process owner, KSL is an operator of KPS and a user of the pellets at its BF plant Process owner of MIDREX Process Value to Customers - Plant Construction (Beneficiation ~ Pellet Plant ~ DR plant) - After Market Service - Consultation Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 17

18 Integrated Service to Customers Integrated Service to Customers from Beneficiation to DR production Collaboration with FLSmidth Note: Midrex is a KSL s 100% subsidiary company. FLSmidth is a Licensee of KOBELCO Pelletizing System. Pellet Plant & DR Plant Engineering & Supply Operation & Maintenance of Pellet & DR Plant Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 18

19 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 19

20 Typical Process Flow DRYING GRINDING PRE-WETTING IRON ORE SLURRY BALLING LIMESTONE BENTONITE AIR HEATER KILN BURNER AIR F F F F F F F ROTARY KILN TRAVELLING GRATE ANNULAR COOLER Pellet PRODUCTS INDURATION ELECTROSTATIC PRECIPITATOR Typical Flow of KOBELCO-Pelletizing Process Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 20

21 What is Grate-Kiln Process? The Origin - Developed by Allis-Chalmers from Straight Grate Process. Grate Kiln Process - Lepol Grate-Kiln System (Cement process) is the basis. - Developed by Allis-Chalmers in 1960 to improve pelletizing process Purpose 1. Production of high quality pellet 2. Utilization of coal in the main burner Applicable to Various Kinds of Iron Ore and Variety of Fuels - Hematite, magnetite, limonite (LOI = 3.5~10%). - Gas, oil, cokes and coal. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 21

22 KOBELCO Pelletizing System (KPS) - History 1965: Kobe Steel was licensed Grate-kiln process by Allis-Chalmers. 1966: Kobe Steel installed 1 st pellet plant (1mtpy) in Kobe Works, Japan. 1970: Kobe Steel installed 2 nd pellet plant (2mtpy) in Kakogawa Works. This plant has been still in operation. 1996: Kobe Steel acquired the license of GK 1973: process. KOBELCO Pelletizing System Kobe Steel installed 3 rd pellet plant (2mtpy) in Kakogawa Works. was born Kobe Steel installed various pellet plants all over the world. Engineering & Construction know-how has accumulated as an EPC contractor. Experiences from KSL s own BF, DRI & Pellet plant operation Vast Experiences from Pellet plant construction as EPC contractor Continuous developments and improvements of the KPS from the operator s perspective Tailor made / customer oriented plant design Smooth project implementation and plant delivery for more than 40 years. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 22

23 Typical Unit Consumption Raw Material / Utility Unit Consumption Iron Ore: 1,000-1,050 kg/t-pellets (depending on LOI) (All spillages are recycled in the process.) Limestone: Depending on the chemical requirements of Pellet. Bentonite: 5-8 kg/t-pellets Anthracite (or Coke Breeze): 5-10kg/t-pellets (Hematite ore) Fuel : 190Mcal/t-pellets incl. anthracite heat (Hematite ore) Power: 23kWh/t-pellets (Induration process) Water: 0.07m3/t-pellets (In case of wet concentrate receiving) Assumption: 100% Hematite Iron Ore Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 23

24 Typical Pellet Quality Quality items Measuring Method Criteria For BF Pellet For DR pellet Size distribution (9-16mm) ISO 2194 > 93 % Size distribution (-5mm) ISO 2194 < 0.5 % Cold compression strength (Average) ISO 4700 > 300 kg Cold compression strength (-100kg) ISO 4700 < 0.5 % Tumble index (+6.3mm) ISO 3271 > 97 % Abrasion index (-0.5mm) ISO 3271 < 3.5 % Porosity JIS M 8716 > 24 % Swelling index ISO 4698 < 16 % - Reducibility ISO 7215 > 65 % - Metallization ISO > 95 % Fragmentation (+6.3mm) ISO > 99 % Fragmentation (-0.5mm) ISO < 0.5 % Note: Pellet quality is adjustable in accordance with the client s requirement. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 24

25 Capacity Lineup 1. Capacity Lineup Small Range: Medium Range Large mtpa 3.0 mtpa 4.0 mtpa 5.0 mtpa 6.0 mtpa (Largest KPS in operation in Bahrain) 2. Tailor-Made Design In accordance with the customers requirements (capacity of the plant, characteristics of raw materials, product quality, kind of fuel, etc.), KSL can deliver tailor-made plant with the following standard equipment. Traveling Grate Width: m, m Rotary Kiln Shell i.d.: 5.8 m, 6 m, 6.6 m, 6.9 m, 7.2 m Annular Cooler Nominal dia.: 17 m, 18.5 m, 20 m, 22 m, 30 m Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 25

26 Typical Layout Capacity; 4 mtpy (middle size plant) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 26

27 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System (KPS) 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 27

28 Quality Requirements from DR Plant Operators Total Fe Important elements of pellets for better operation of DR plant Importance for DR operator CCS Less Fine Generation Reducibility 1. High Fe in pellets 2. Good CCS 3. Less fine generation = Good CCS & Uniform Quality Improvement by pellet producer (Source: Independent survey by KSL) 4. Reducibility KPS can produce the most suitable pellets for DR operation. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 28

29 Reducibility: Correlation between Porosity and T. Fe Correlation between Porosity and T. Fe 100 Reducibility (%) Porosity T.Fe Reduction time (min) T.Fe=68.4%, Porosity=21.2% T.Fe=66.7%, Porosity=21.3% T.Fe=63.8%, Porosity=25.7% Reducibility correlates with T.Fe. Source: Evaluation of raw materials for gaseous direct reduction process by KSL Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 29

30 Quality Requirements from DR plant operators High Fe in Pellets means; 1. High quality of pellet feed Beneficiation 2. Less additives in pellet making Less limestone addition Binder less operation Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 30

31 High Fe in Pellets: Less Limestone Addition Limestone addition case Slag bonding Low melting temperature slag Making bridge Lower temperature Fe2O3 Fe2O3-SiO2-CaO slag Less limestone addition case Oxide bonding Diffusion of core material Higher temperature required Better induration (such as Kiln) is preferable. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 31

32 High Fe in Pellets: Less Limestone Addition 100 Correlation between Reducibility and CaO Reducibility (%) Reduction time (min) CaO=0.12% CaO=0.9% CaO=1.1% Reducibility correlates with less CaO. Source: Evaluation of raw materials for gaseous direct reduction process by KSL Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 32

33 High Fe in Pellets: Binder less Operation Reference: Binder-less operation at Kakogawa pellet plant, KSL Indirect feed Direct feed Ball mill thickener BOF Dust Intensive mixer Drum mixer Balling discs Utilizing very fine BOF dust Part of ore is ground up to higher Blaine No binder is mixed for balling Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 33

34 Uniform quality & Good CCS pellet products Comparison of Compression Strength Variation Kobelco Pelletizing System Straight-grate system (%) Uniform Quality (%) Weak pellets (cause of dust) Too strong pellets (difficult for HBI) Process Gas Burner バーナー火炎 Flame Burner Flame Radiation 輻射熱 Heat Radiation Heat Pellet Layer Overheating Proper Heating キルン回転方向 Kiln Rotation Kiln Rotation ペレット Pellet D Hearth Layer Inadequate Heating Pellets produced by KPS have more uniform quality and high CCS (= Less Fine Generation), which result in good DR plant operation. Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 34

35 Product loss by weak pellets Negative impact from Fine generation KPS Other technologies Difference Weak Pellet Ratio 0.5% 2% 1.5% Abrasion index 3.3% 5% 1.7% Economic study Assumption: Total 3.2% Pellet price: $170/t, Sinter feed price: $120/t Loss of pellet fines inside the client s DR plant site v.s Recovery of the value by selling those fines Pellet Plant capacity: 4mtpa Estimated calculation: Loss; 4.0mtpyx 3.2%x $170 = $21.8M/y Recover; 4.0mtpy x 3.2 x $ 120 = $15.4M/y Economic disadvantage from Fine generation = $ 6.4 mil/year Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 35

36 1. Corporate Profile of KSL and Iron Unit Division 2. KSL s Service Capability 3. Collaboration between KSL and FLS 4. KOBELCO Pelletizing System 5. Advantage of KOBELCO Pelletizing System (KPS) - Contribution by KPS to DR Operator 6. Project Reference (abstract) Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 36

37 Kobe Steel, Kakogawa Works Reference (abstract) Year of Completion: 1970 Capacity: 4.0 mtpy Iron ore: Mag. + Hema CMP, Chile Year of Completion: 1978 Capacity: 3.5 mtpa Iron ore: Magnetite Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 37

38 FMO, Venezuela Reference (abstract) Year of Completion: 1994 Capacity: 4.0 mtpy (Upgraded by KSL from 3.3mtpa in 2007) Iron ore: Hematite Ardakan, Iran Year of Completion: 2008 Capacity: 3.4 mtpy Iron ore: Mag. + Hema Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 38

39 Year of Completion: 1985 Capacity: 4.0 mtpa Iron ore: Hematite Reference (abstract) Bahrain Steel (former GIIC No. 1 & No.2) Year of Completion: 2010 Capacity: 6.0 mtpa Iron ore: Hematite No.2 Pellet plant No.1 Pellet plant Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 39

40 Reference (abstract) Vale / Sohar, Oman Year of Completion: 2011 Capacity: 4.5 mtpa x 2 lines Iron ore: Hematite Present status: In operation Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 40

41 Thank you very much for your kind attention Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 41

42 Quality difference on pellets (typical) Typical comparison between KPS and SG KOBELCO Pelletizing System (KPS) Straight Grate System (SG) Cold compression strength (kg) > < 100 kg inclusion (%) Approx. 0.5 Approx. 2 Tumble index (%) > Abrasion index (%) Porosity (%) > Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 42