Sustainable Technologies for Small, Mid and Large-Scale Iron Ore Pellet Production and Mid-Scale DRI
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1 Sustainable Technologies for Small, Mid and Large-Scale Iron Ore Pellet Production and Mid-Scale DRI Stefan Mehl Iranian Iron & Steel Conference, September 2015, Kish International Convention Centre, Kish Island, Iran
2 Content Introduction Travelling Grate Technology for Small, Mid and Large Scale Iron Ore Pelletizing Plants Coal Based Direct Reduction Technologies Outotec Contribution to Plant Life Cycle Services Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
3 Local operations, global presence Nearly 5,000 employees Sales 1.4bn EUR in 2014 Deliveries to more than 80 countries Experts of over 60 nationalities R&D, sales and service centers in 30 countries Listed on Nasdaq Helsinki since 2006 Wide supplier network with established long-term relationships Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
4 Minerals Processing Sustainable solutions from pre-feasibility studies to complete plants and lifecycle services Our comprehensive offering makes the efficient and profitable treatment of virtually all ore types possible With more than a century of experience, we have the established R&D resources to continuously develop sustainable technologies Solutions for Concentrators Comminution Flotation Dewatering Services incl. operation & maintenance Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
5 Metals, Energy & Water Extensive range of solutions for processing virtually all types of ores and concentrates to refined metals, incl. sulfuric acid production Innovative solutions for biomass, coal, sludge, agricultural and industrial byproducts as well as sorted waste Solutions for oil winning from oil shale and phosphorus recycling from sewage sludge ashes Our solutions produce water that meets environmental discharge standards, maximize water recycling and reduce water and energy consumption Solutions for Non-ferrous metals Ferrous metals and ferroalloys Light metals Renewable & conventional energy Industrial water treatment Services incl. operation & maintenance Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
6 Pelletizing Technology Introduction Travelling Grate Technology for Small, Mid and Large Scale Iron Ore Pelletizing Plants Coal Based Direct Reduction Technologies Outotec Contribution to Plant Life Cycle Services Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
7 Outotec Pelletizing References CIS Europe 11mtpy 3 lines 20mtpy 6 lines Iran Mexico 6mtpy 4 lines Peru 1mtpy 1 lines Venezuela 7mtpy 2 lines Nige 1mtpy 1 lines Brazil 25mtpy 5 lines India 31mtpy 9 lines China 11mtpy 3 lines 63mtpy 13 lines Limonite Hematite Hematite/Magnetite Magnetite Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
8 Pelletizing Capacity and Future Iranian Opportunities % + 70% + 90% NISCO Mobarakeh Hormosghan MOFID Bahabad Markazi South Kaveh Qeshm Fasa Steel Pars Tadbir B-Misco Gohar Zamin Gol-e-Gohar Ardakan Gol-e-Gohar Khouzestan Steel Mobarakeh Incl. Current Outotec project executions Outlook Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
9 Steel consumption per capita vs. GDP in Middle East countries and ROW Finished Steel Consumption per Capita in Kg India China Iran Russia Brazil South Korea Saudi Arabia Japan UAE Kuwait Germany GDP / Capita in '000 US$ USA Australia Iranian Iron & Steel Conference, September 2015 Kish Island, Iran Qatar Steel consumption per capita in Middle East countries has further room to grow
10 Pelletizing Capacity in Iran and ME Outotec Capacity Status Pelletizing Plant mio t/a Khouzestan Steel 6,5 operation Mobarakeh 7,0 operation Gol-e-Gohar I 5,0 operation Gol-e-Gohar II 5,0 execution Gohar Zamin 5,0 execution B-Misco 5,0 execution Total 33,5 Ardakan 3.4 mtpy (GK) Mobarakeh 7.0 mtpy (TG) B-Misco 5.0 mtpy (TG) Khouzestan Steel 6.5 mtpy (TG) GIIC 12.0 mtpy (GK) Gol-e-Gohar I 5.0 mtpy (TG) Gol-e-Gohar II 5.0 mtpy (TG) Gohar Zamin 5.0 mtpy (TG) Outotec Pelletizing Plants (operating) Outotec Pelletizing Plant (execution) Others Vale Sohar 9.0 mtpy (GK) Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
11 Outotec Pellet Plants in Iran Khouzestan Steel Mobarakeh Steel Gol-e-Gohar 1 Gol-e-Gohar 2 Gohar Zamin B-Misco Start-up Original Capacity 2 x 2.5 mtpy 4.5 mtpy 5.0 mtpy 5.0 mtpy 5.0 mtpy 5.0 mtpy Current Capacity 6.5 mtpy 6.5 mtpy 6.5 mtpy Grate Area 2 x m² 708 m² 624 m² 624 m² 624 m² 720 m² Front End Dry Grinding Dry Grinding Dry Grinding Wet Beneficiation Wet Beneficiation - (Mix of purchased wet and dry concentrate) Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
12 50Years of Pelletizing Experience First Outotec reference in Iran (Khouzestan Steel) was started-up in Outotec has been doing continuous agglomeration business with Iran since the last 38 years and never left the country. The estimated global Outotec market share on pelletizing is approx. 60%, based on installed annual capacity Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
13 Pelletizing Technologies Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
14 Standard Size Plant Configuration Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
15 Layout 162m² Mini Pellet Plant Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
16 Layout 315² Midi Pellet Plant Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
17 Layout 624m² Pellet Plant Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
18 Layout 2 x 816m² Pellet Plant Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
19 Pelletizing Plant Space Requirements Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
20 Pellet Capacity vs. Process and Ore Pelletizing Capacity ever built, China not fully shown, status Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
21 Technological Advantages of the TG Feature Advantage Three recuperation principles 1. Low specific energy consumption Low operating costs 2. Low emissions (CO 2 ) Arrangement of several burners in the preheating and firing zone 3. Temperature profile easily adjustable, ensuring flexibility 4. Adaptation of different firing profiles for changing feed materials 5. Adjustment to various pellet qualities 6. Significant turn-down ratios possible Accentuated after firing zone 7. Uniform heat distribution 8. Uniform fired pellet qualities Undisturbed pellet bed 9. Minimized dust and fines generation 10. No need for minimum strength, thus reduced binder consumption 11. No compaction of pellets, maintaining high porosity Stationary refractory Grate maintenance off-line 12. Low maintenance costs, high availability, longer equipment life Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
22 Several Recuperation Systems in Outotec TG Pellet Plants 1 Direct recuperation at 900 1,000 C Wind box recuperation at C 3 Recuperation from 2 nd cooling to updraft drying at C Tosyali Pelletizing Project Meeting in Istanbul Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
23 Technological Advantages of the TG Feature Advantage Three recuperation principles 1. Low specific energy consumption Low operating costs 2. Low emissions (CO 2 ) Arrangement of several burners in the preheating and firing zone 3. Temperature profile easily adjustable, ensuring flexibility 4. Adaptation of different firing profiles for changing feed materials 5. Adjustment to various pellet qualities 6. Significant turn-down ratios possible Accentuated after firing zone 7. Uniform heat distribution 8. Uniform fired pellet qualities Undisturbed pellet bed 9. Minimized dust and fines generation 10. No need for minimum strength, thus reduced binder consumption 11. No compaction of pellets, maintaining high porosity Stationary refractory Grate maintenance off-line 12. Low maintenance costs, high availability, longer equipment life Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
24 Typical Temperature Profile UPDRAFT DRYING DOWNDRAFT DRYING PREHEATING FIRING AFTER FIRING COOLING I COOLING II Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
25 Technological Advantages of the TG Feature Advantage Three recuperation principles 1. Low specific energy consumption Low operating costs 2. Low emissions (CO 2 ) Arrangement of several burners in the preheating and firing zone 3. Temperature profile easily adjustable, ensuring flexibility 4. Adaptation of different firing profiles for changing feed materials 5. Adjustment to various pellet qualities 6. Significant turn-down ratios possible Accentuated after firing zone 7. Uniform heat distribution 8. Uniform fired pellet qualities Undisturbed pellet bed 9. Minimized dust and fines generation 10. No need for minimum strength, thus reduced binder consumption 11. No compaction of pellets, maintaining high porosity Stationary refractory Grate maintenance off-line 12. Low maintenance costs, high availability, longer equipment life Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
26 Optimum Pellet Size Preferred size 8 18mm -> mm, optimum 9.5mm Bigger sizes are possible, but mechanical (green pellet) properties deteriorate and reduction time increases Misconception: bigger pellets cause a higher pressure drop pressure drop only depends on width of size distribution, not on pellet size Reduction rate decreases with increasing diameter Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
27 Technological Advantages of the TG Feature Advantage Three recuperation principles 1. Low specific energy consumption Low operating costs 2. Low emissions (CO 2 ) Arrangement of several burners in the preheating and firing zone 3. Temperature profile easily adjustable, ensuring flexibility 4. Adaptation of different firing profiles for changing feed materials 5. Adjustment to various pellet qualities 6. Significant turn-down ratios possible Accentuated after firing zone 7. Uniform heat distribution 8. Uniform fired pellet qualities Undisturbed pellet bed 9. Minimized dust and fines generation 10. No need for minimum strength, thus reduced binder consumption 11. No compaction of pellets, maintaining high porosity Stationary refractory Grate maintenance off-line 12. Low maintenance costs, high availability, longer equipment life Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
28 Minimized Environmental Impact Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
29 DR Pellet Quality - Parameter Allocation Gas OUT Raw Material IN Transportation & Handling CCS, TI & AI Drying DR furnace C Decrepitating Index, Pre-reduction Stage DR 700 C RDI /LTB Middle of DR 950 C RI, Sticking & Swelling Product OUT Gas IN Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
30 Outotec s Recent Pelletizing References Costumer Location Order Feed Cap. [mtpy] Size [m²] Scope B-Misco Iran 2015 Mixed Ore EPS SAIL Gua Gua India 2015 Hematite LSTK Gohar Zamin Sirjan Iran 2013 Mixed Ore EPS Baotou Baotou China 2013 Mixed Ore EPS Gol-e-Gohar 2 Sirjan Iran 2012 Mixed Ore EPS Samarco 4 Ponta de Ubú Brazil 2011 Hematite LSTK Stoilensky GOK Stary Oskol Russia 2011 Magnetite EPS Ternium Porto do Acu Brazil 2010 Hematite E BPSL Jharsuguda India 2009 Hematite EPS Tata Steel Jamshedpur India 2008 Hematite LSTK Caofeidian Caofeidian China 2008 Mixed Ore EPS BRPL Jajpur Road India 2007 Hematite ES Vale Vargem Grande Nova Lima Brazil 2005 Hematite EPS Samarco 3 Ponta de Ubú Brazil 2005 Hematite LSTK VALE Tubarão VIII Vitória Brazil 2005 Hematite E Last 10 years: million tons designed capacity Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
31 Pelletizing Technology Introduction Travelling Grate Technology for Small, Mid and Large Scale Iron Ore Pelletizing Plants Coal Based Direct Reduction Technologies Outotec Contribution to Plant Life Cycle Services Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
32 Historical background of the SL/RN process Jointly developed by four companies in the 1960 s Steel Company of Canada Lurgi Republic Steel Company National Lead Corporation Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
33 Providing SL/RN technology since 50 years With over 55 own references the predominant coal-based direct reduction technology in the world Simple, robust, proven MJIS Kalimantan / Indonesia (during erection phase, 2010) Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
34 SL/RN process schematic diagram Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
35 SL/RN-Xtra DRI directly from fines. Market drivers affecting classic rotary kiln plants Shortfall of high quality lump ore Pellet premium stable to increasing even with falling ore prices SL/RN-Xtra a proven solution revisited! Direct use of concentrate Integrated pelletizing Hot charging of pellets higher efficiency lower specific consumption. Kiln waste gas heat used for pre-hardening pellets, no additional fuel for pelletizing Ore preheating step outside of kiln increases production by up to % Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
36 SL/RN-Xtra DRI directly from fines Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
37 Raw materials affecting feasibility and plant performance Main raw materials Coal Iron ore lumps or pellets (SL/RN) or concentrate (SL/RN-Xtra) Dolomite (typical) or limestone Main factors affecting performance Iron content of ore Carbon (C fix ) content of coal Ash content of coal Main factors affecting plant configuration (CAPEX, total and specific) Volatile matter content of coal Sulphur in coal and ore Location (sea level, emission limits) Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
38 Coal requirements Performance Performance Performance Performance CAPEX (Gas circuit) Feasibility Consumption wf= water free; *under reducing conditions; **depending on degradation behaviour Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
39 Direct reduction technologies in our offer SL/RN demonstration plant of Sponge Iron India Ltd. (SIIL) SL/RN grate-kiln plant of Nippon Kokan K.K. SR production at ILUKA Resources Ltd First Indian SL/RN plant at Paloncha, AP - Kiln size: 3 x 40 m - Capacity: t/a DRI Feed materials: - Local lump ore - Noncoking coal Second kiln built in 1984 In 1972 Grate length: 62 m / Kiln size: 6 x 70 m, Capacity: t/a inplant wastes Feed materials: - Metallurgical in-plant wastes - High volatile coal Plant can be regarded as predecessor of the SL/RN-Xtra process In 1984 first kiln: Kiln size: 4.6 x 68 m Capacity: t/a ilmenite In 1996 second kiln: Kiln size: 5 x 90 m for Capacity: t/a ilmenite Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
40 Pelletizing Technology Introduction Travelling Grate Technology for Small, Mid and Large Scale Iron Ore Pelletizing Plants Coal Based Direct Reduction Technologies Outotec Contribution to Plant Life Cycle Services Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
41 Outotec Plant Performance Solution Customer Challenge Plant Performance Assessment Baseline Improvement Potential Risk Analysis Improvement Planning Scenario analysis / selection Optimized CAPEX vs OPEX Improvement Program Integrated Execution Performance Support Verification, capture of benefits Return of Investment (ROI) Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
42 Outotec Plant Performance Assessment Visualization of results The Assessment enables; Understanding current operations Defining key improvement areas Speed up of continuous improvement ideology Iranian Iron & Steel Conference, September 2015 Kish Island, Iran
43 Thank you
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