Presentation on Low Grade Iron ore beneficiation!

Transcription

1 Presentation on Low Grade Iron ore beneficiation!

2 Quality!Policy!!! We! shall! con+nuously! strive! and! exceed! customer! requirements! by! maintaining! high! standards! in! produc+on,! safety,! +mely! delivery! of! products! and! services! through! con+nuous! improvement.

3 Iron ore- Chemistry Requirement for Iron making (assay)! Fe!%!!!7!>!64!%! SiO2!%!!7!!1.5!%! Al2O3!%!!7!!1!%! LOI!%!!!!1!%! P!%!!!7!<!0.008!%! S!%!!!7!<0.004!%! Effect:F! Slag!rate!in!Iron!making!~!200_210!kg/T!of!Hot!Metal! 05/02/16! 9!

4 ! Australian!standard!Iron!Ore! "!Major!HemaLte!Iron!ore!and!others!!is!fragile!and!contain!good!amount!of! goethite!and!kaolinite!in!associalon!with!hemalte!ore.! "!During!beneficiaLon!of!these!low!grade!hemaLte!iron!ore!goethite!enriches! along!with!hemalte,!which!remain!associated!with!the!iron!ore!concentrate! even!awer!beneficialon.! "!As!the!liberaLon!of!iron!phase!mineral!is!below!200!microns,!the!generaLon! of!fines!are!more!during!size!reduclon!which!causes!high!blaine!number! " Causes!high!LOI!and!high!Blaine!number!in!iron!ore!concentrate!aWer! beneficialon.!! 05/02/16! 10!

5 Iron Ore The presence of deleterious gangue mainly Alumina and Silica are highly undesirable as they adversely increase the cost of hot metal produced. SiO % will reduce Slag volume - 65 kg / Tonne Al2O3 1.0 %, will reduce Slag rate - 30 kg / Tonne Coke / Flux rate reduced - 6 kg / Tonne Productivity (Hot metal) increased 2.75 % Reduction of 1 Tonne of Alumina load through Washing / Beneficiation from ore will give savings of Rs.1 Lakh in steel making process 1 % reduction of Alumina, benefit is around 100 crores per annum for 3.0 MTPA steel plant. The design and operation of Blast Furnace makes it necessary to agglomerate the fines by either Sintering or Pelletising. In DRI operation, Pellets are the main feed. 05/02/16! 11!

6 Low!Grade!Iron!ore!! India!has!!25!billion!tons!of!iron!ore!reserve! More!than!60%!of!good!quality!ore!is!exported! By!2020! 200!MT!Steel!!! 480!MT!Iron!ore! Low!grade!iron!ore,!iron!ore!fines!and!iron!ore!tailings/slimes!accumulated!! over!the!years!at!mine!heads!and!generated!during!the!exislng!washing!processes,!! need!to!be!beneficiated!to!provide!concentrates!of!required!quality!to!the!indian!! steel!plants.!! Low grade Lumpy ore Low grade Fines/ Slimes BHJ/BHQ/BMQ 05/02/16! 12!

7 Different!Ore!types!7! 05/02/16! 13!

8 Effects!of!Iron!ore! SINTERING BLAST FURNACE IRON ORE MIX SINTER REDUCIBILITY SINTER RDI PRODUCTIVITY SLAG RATE SLAG FLUIDITY SiO2 Al2O3 < 0,15 mm 05/02/16! 14!

9 Brazilian,!Australian!and!Canadian!Ore! SUPPLIERS MINERALOGY IN FINES (%) Hematite Fe2O3 Goethite FeOOH Magnetite Fe3O4 Australia r Brazil Canada t 37 t /02/16! 15!

10 Mineral!CharacterizaLon! HEMATITE GOETHITE 1.5% LOI 9.0% LOI INCREASING Fine 10 µm HAMERSLEY HYDRATION YANDI CARAJAS Mt. NEWMAN ROBE RIVER ITABIRA 100 µm Coarse CAROL LAKE INCREASING CRYSTAL SIZE 05/02/16! 16!

11 !!!!!!!!Advance!CharacterizaLon! Basis: Average Crystal Size, µm Ultra Fine size crystals Medium size crystals Coarse size crystals ORE TYPE A Carajas and Australian ores ACS!<!40! ORE TYPE B Itabira ores!!!!!!40!<!acs!<!120! ORE TYPE C Canadian ores ACS!>!120! REDUCIBILITY PRODUCTIVITY MECHANICAL STRENGTH RDI 05/02/16! 17!

12 Advance!CharacterisaLon! Basis: Hydration Degree (LOI) %!!!!!Ore!type!A1!!!!!!!!!Carajas!!!!!!LOI!<!1.5! PRODUCTIVITY!!!Ore!types!A2!and!A3! Brockman!and!M.Mamba! 2.0!<!LOI!<!6.0!!!!Ore!types!A4!and!A5!!!!!!Yandi!and!R.!River! LOI!>!9.0! COKE BREEZE REDUCIBILITY 05/02/16! 18!

13 Typical!Orissa!Low!Grade!iron!ore!beneficia+onF case!study! Two!Iron!ore!samples!of!Fe!58.29%!and!Fe! 61.26%!with!Alumina!contains!of!5.60%!and! 4.56%!with!Silica!contains!of!6.73%!and!4.63%! is!taken.! Ore!is!contaminated!with!Alumina!and!Silica! and!beneficialon!such!as!to!scrubbing,! washing,!desliming,!gravity!and!magnelc! separalon!is!carried!out.! 05/02/16! 19!

14 Orissa!Local!Ore! Microphotograph! Optical photomicrograph of massive type ore showing acicular crystals of specular hematite. The small cavity towards the centre is partially filled with clay. 05/02/16! 20!

15 Orissa!Local!Ore! Microphotograph! Patches of goethite developed within hematite matrix. The dark-brown smaller patches are clays.! 05/02/16! 21!

16 Technological Process Flow chart 05/02/16! 22!

17 Conclusion7Pellet!feed! The beneficiation process is schematically shown in earlier slide. It may be noted that two stages of hydrocycloning have been adopted to improve iron recovery. The process basically involves two stages of crushing to mm, closed circuit grinding to 0.15 mm, classification using hydrocyclone (100 mm diameter), spiralling of cyclone underflow, further desliming of cyclone overflow from 100 mm diameter cyclone using 25.4 mm diameter cyclone, wet high intensity magnetic separation of middlings and tailings from spiralling operation alonwith underflow from 25.4 mm cyclone followed by dewatering of the products. The final iron concentrate analysed per cent Fe, 1.98 per cent Al 2 O 3 and 2.23 per cent SiO 2 with iron recovery of 65 per cent. The samples were found to contain hematite as the major mineral with clay as the dominating gangue. The ore was found to be fine grained with about 84 per cent liberation below 150 micron. Beneficiation of the samples based on gravity and magnetic separation techniques resulted in products with varying iron recovery and grade of the concentrate. 05/02/16! 23!

18 ! Good!Iron!ore!means!effec+ve!pellet!in!BF! Controls!!Gas!to!Solid!ReacLons! Controls!!Permeability!of!Furnace!Burden!!Strength!of!Pellets!is!important!!Porosity!of!Pellets!is!important! 05/02/16! 24!

19 Pellet!Quality! PELLET!QUALITY!COMPARISION!FOR!THE!YEAR!2010F11! PARAMETER! JSPL! ARYA! JSW! GIIC! VALE! PHYSICAL!!!!!! CCS! 270! ! 243! 300! 230! TUMBLER!INDEX! 95.02! 93.9! 93.93! 92! 92! ABRASION!INDEX! 3.83! 3.33! 4.73! 6! 7! POROSITY! 23.64! 17.85! 17.17! Not!Available! Not!Available! 8716MM! 91.23! 83.86! 98.42! 88! 90!!75MM! 0.41! 1.16! 0.85! 2! 4! CHEMICAL!!!!!! Fe! 64.55! 65.24! 62.25! 67! 67.5! FeO! 0.58! Not!Available! 0.7! Not!Available! Not!Available! SiO2! 3.65! 3.28! 5.16! SiO2+Al2O3!=2.6! 1.45! Al2O3! 2.28! 1.96! 2.62!! 0.75! CaO! 0.8! 0.66! 2.1!! 0.9! MgO! 0.19! 0.18! 0.37!! 0.5! P! 0.05! 0.047! 0.04! 0.05! 0.035! S! 0.005! Not!Available! 0.01! 0.01! 0.01! Degree of Metalisation Not!Available! Not!Available! Not!Available!! Reductivity Not!Available! Not!Available! Not!Available! Not!Available! 25!

20 Indian!PelleLsaLon!capacity!!!! Company! Capacity!(m!ton)! 1!!! Essar!Vizac! 8.0! 2!! JSW!Vijaynagar! 4.5! 3! JSPL!Barvil! 4.5! 4! KIOCL!Mangalore! 4! 5! ARYA!Barvil! 1.2! 6! Mandvi!Goa! 1.8! 7! BMM!Hospet! 1.2! 8! CHOWGLEY!and!others! 4.0! 9! Tata!Steel! 6.0! A!total!of!34.6!milion!capacity!is!already!in!place.! 05/02/16! 26!

21 Steps!in!PelleLsaLon! 05/02/16! 27!

22 Way!Forward! We!can!assist!handhold!and!do!the!Pre! Feasibility!and!Feasibility!study!to!finalise!the! Process!circuits!and!Project!Planning.! The!Low!Alumina!Pellet!Feed,!produced!from! Orissa!Low!grade!Iron!ore,!is!very!much! suitable!even!for!produclon!of!!pellets.!!the!enlre!pellelsing!and!mineral! BeneficiaLon!plant!engineering,!project!and! operalon!management!can!be!done!by!us.!! 05/02/16! 28!

23 References!! Published!documents!and!litratures.!!JSPL7!Barbil!PresentaLon.! 05/02/16! 29!

24 Thank!You!! 05/02/16! 30!