Recent Developments In Agglomeration Technologies For Iron Ores. Pelletizing and Sintering Colloquium September 2008 SAIMM - Pretoria

Transcription

1 Recent Developments In Agglomeration Technologies For Iron Ores Pelletizing and Sintering Colloquium September 2008 SAIMM - Pretoria

2 The Steel making Routes

3 Steel Production World crude steel production (in million tons) ,3 269, ,3 127,2 106,4 98, ,3 203,1 182,2 107,7 101,2 121,6 188,3 227,3 280,5 112,7 113,4 132,7 202,3 422,7 116,2 119,8 130,4 206,8 489,2 120, ,1 210,3 other China Japan GUS NAFTA EU

4 Steel Consumption in kg per Capita

5 Development of raw material prices Iron Ore Price [US$ / t dry] Sources : CVRD, Wall Street Journal, US Steel and other steel producers. 140,00 120,00 fines lump ore pellets 100,00 [US$ / t dry] 80,00 60,00 40,00 20,00 0,

6 Development of raw material prices Coking Coal Export Price [US$ / t] Source: [US$ / t] Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q1

7 Development in transport charges Sea Freight Charges (Tubarao/Rotterdam) [US$ / t] source: Erzkontor, Germany [US$ / t] Q Q Q Q Q Q Q Q Q Q Q3

8 Environmental Regulations Emission Limits Country Dust SO 2 NO 2 Source Germany Emission 20 mg/m³ ntp Emission 500 mg/m³ ntp Emission 400 mg/m³ ntp TA Luft Australia 24h Immissionaverage 120 µg/m³ 24h Immissionaverage 200 µg/m³ 24h Immissionaverage 150 µg/m³ WHO, USEPA, WAEPA Brazil Emission 100 mg/m³ ntp local regulations India Emission 150 mg/m³ ntp Immission 120 µg/m³ ntp Immission 120 µg/m³ ntp Air Act 1981

9 Consumption of Reductants

10 CO 2 emitents in BF steel production

11 Pellet Market: New Projects 2008 LKAB KK4 5.0 Mill. t/a Pellet Projects 2008 ~ 64 Mill. t/a under execution ~ 178 Mill. t/a under evaluation New Millennium 2x7.5 Mill. t/a QCM 7.5 Mill. t/a MBR 7.0 Mill. t/a Essar MIS 6.0 Mill. t/a CSN 2x3.0 Mill. t/a Minas-Rio 7.0 Mill. t/a Ferrous 6.0 Mill. t/a Usiminas Tubarão VIII 7.5 Mill. t/a Essar Trinidad 6.0 Mill. t/a MMX Amapá 3.5 Mill. t/a Samarco Mill. t/a Gerdau 7.0 Mill. t/a SNIM/Sphere 7.0 Mill. t/a Northland 5.0 Mill. t/a Vöest Alpine 2.0 Mill. t/a Gohar Zamin 2x5.0 Mill. t/a GIC 5.0 Mill. t/a CVRD Sohar 4.5 Mill. t/a Gol-e-Gohar 5.0 Mill. t/a Sangan 2.4 Mill. t/a Al Tuwairqi 5.0 Mill. t/a Hadeed M-GOK 5.0 Mill. t/a JSW 3.5 Mill. t/a S-GOK 6.0 Mill. t/a Brahmani River 4.0 Mill. t/a Essar Paradeep 6.0 Mill. t/a Tata Pellet 6.0 Mill. t/a Gua & Bolani Zhuhai YPM 1.5 Mill. t/a WISCO 5.0 Mill. t/a Caofeidia 4.0 Mill. SSGPO 6.0 Mill. t/a Ferrexpo Baosteel 4.0 Mill. t/a CVRD JV 4x1.5 Mill. 5.0 Mill. t/a Caofeidian 4.0 Mill. t Amsteel 5.0 Mill. t/a Grange 6.0 Mill. t/a CITIC 5.0 Mill. t/a JSW West Bengal

12 Sinter Market: New Projects 2008 Nucor 2.5 Mill. t/a Krivoi Rog 10.0 Mill. t/a Kardemir 2.8 Mill. t/a Sinter Projects 2008 ~ 53 Mill. t/a under execution ~ 197 Mill. t/a under evaluation Isdemir 3.4 Mill. t/a P.R. China 33 plants Mill. t/a Formosa 5.0 Mill. t/a Dragon Steel 2.5 Mill. t/a Belgo Min. 3.0 Mill. t/a Baosteel 7.0 Mill. t/a CSA 4.8 Mill. t/a Açominas 2.5 Mill. t/a Usiminas 6.3 Mill. t/a Vallourec 1.2 Mill. t/a Pecém 4.2 (5.3) Mill. t/a CSV 5.0 Mill. t/a Kalahari 2.5 Mill. t/a Tata SP4 2.3 Mill. t/a JSW Mill. t/a Vizag Steel 3.6 Mill. t/a IISCO 4.6 Mill. t/a Tata KPO 5.75 Mill. t/a JSW Mill. t/a JSPL 7.2 Mill. t/a Bhushan 4.6 Mill. t/a Rourkela Durgapur Bhilai

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14 Typical flow sheet

15 Typical layout of a 7.5 million tpa plant Green Pelletizing Induration Central Plant Dedusting Substation Process Gas Cleaning Cooling System Fuel Oil System Additive Preparation Dosing & Mixing Regrinding Filtration Homogenization Wet Grinding

16 Plant Sizes vs. Investment Costs Specific Investment Costs [%] Limonite/ Whethered Ores Hematite Magnetite Plant Capacity [mtpy]

17 Development of pellet plant size Capacity in million t/a Million t/a Samarco 3 Plant capacity (single strands) [mtpy Ijmuiden Hamersley Krivoi Rog Eagle Mountain Wabush Carol Lake Republic Eagle Mills Malmberget 1 Tilden Samarco 1 Samarco

18 Samarco 3 with 768m² and 7.5 Mtpy World s largest Pellet Plant

19 Steel belt plant general layout Pellets oncentrate

20 Steel belt process concept

21 Simplification of Plant Design Roller Presses vs. Ball Mills

22 Simplification of Plant Design Roller Presses vs. Ball Mills Slurry Storage Grinding Bins Bins Filtration Thickening Roller Presses Grinding and Filtration Section of a 4,000,000 t/a Pelletizing Plant Comminution Section of a 7,000,000 t/a Plant

23 Simplification of Plant Design Conventional Vacuum Disc Filters Ceramic Filters Vertical Filter Presses standard equipment for pellet feed dewatering high investment costs (170 %), significant energy savings (-95%) => pay back in 3 5 years, larger sizes possible, few references with iron ore simplified plant layouts due to large sizes (up to 132m² filtration area), significant energy savings, improved moisture control

24 Improvement of Operating Costs Conservation or introduction of thermal energy to pellet feed/green pellets Improved green pellet qualities with narrow size distributions Improved screening concepts for hearth- and side layers Increased pellet bed heights Optimized heat balances and gas flow schemes External cooling areas Frequency controlled drives

25 Specific Capacities

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27 Ore Fluxes Coke Material Return Lime Fines Bins Sinter plant typical flow sheet High Intensity Mixer Granulator Waste Gas Fan and Gas Cleaning Sinter Machine Sinter Cooler Cold Crushing Hearth Layer Screening Return Fines Product Sinter

28 Typical layout Plant Dedusting Sinter Machine with Ignition Furnace Sinter Cooler Mixing Coke Grinding Raw Material Dosing Screening Waste Gas Cleaning

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30 Principle of EOS process Sinter Emissions LBS HBS Residual Gas Volume -40% -45% Dust -50% -60% NO x -35% -45% SO 2-30% CO -45% -50% CO 2-25% -30% Dioxines -70% -65%

31 Sinter plant with EOS hood

32 EOS process principle compared to conventional sintering Conventional sintering Ambient air EOS Process Ambient air longitudinal sealing Evaporation Evaporation Calcining Calcining C combustion with O 2 of air to CO 2 Formation of CO, S ox etc. Ambient air inleak cross and longitudinal sealing C/CO combustion with O 2 Formation of CO, S ox etc. Ambient air inleak cross sealing only Recirculated gas Residual air Residual gas to be exhausted

33 LEEP waste gas recycling process

34 EPOSINT waste gas recycling process

35 Bag filter technology

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37 High intensity mixer for sinter mix

38 Dust mixer/granulator

39 Space requirement for drums vs. HIM

40 Future developments in Sintering Use of pellet fines in the sinter mix Fine grinding of additives and coke Granulation process with pelletizing discs and/or drums Mixing/granulation with HIM Modified sinter machine feeding arrangements Frequency controlled drives Use of other solid fuels Modified process gas cleaning systems

41 Thank you for your attention! Walter Gerlach Outotec GmbH