Realizing a state of the art All Indian Pellet plant by MECON. MECON LIMITED A House of Engineering Excellence

Transcription

1 Realizing a state of the art All Indian Pellet plant by MECON

2 Structure of the presentation Need for pelletisation Issues & Critical design aspects under Indian conditions, MECON s perspective on available design, MECON s journey in pelletisation Today MECON in Pelletisation, Advantages of All Indian Pellet plant by MECON, Salient features of our design, Recommendation on Pellet plant size. Conclusion.

3 Need for pelletisation Depletion of good quality of Indian iron ore influences us to think for utilisation of iron ore fines, accumulated at mines head Beneficiation route, emerging out as a pre-requisite to ensure supply of quality iron ore, also generates slimes /ultra fines during the process, Owing to process limitation in Sintering, Pelletisation is the best alternate route for conversion of the fines to prepared burden for feeding to iron making units.

4 Need for pelletisation. contd Pellet plants Designed & Manufactured within India - a real need of the day to ensure: Self- dependence to meet future demand Better understanding of Indian raw material, Manufacturing growth with generation of employment Minimise project cost MECON is in readiness with its state-of-art indigenous designed plant termed as All Indian Pellet plant.

5 Issues & Critical design aspects under Indian condition Issues under Indian Design aspects: condition: Sizing of Induration machine, zone Type of iron ore length LOI Adjustment in Heat cycle (drying & pre SiO2 & Al2O3 heating ) and feed rate Blaine number Minimum drop of pellets during heat hardening, Binder & moisture adjustment, Induration temperature adjustment

6 MECON s perspective on available design, Two major processes are Travelling Grate (TG) process and Grate- Kiln (GK) process, accounting for > 90% of total installed capacity in the world. TG 9% GK 33% 58% Shaft Furnace & others

7 MECON s perspective contd Item Travelling grate (TG) Grate kiln (GK) Heat cycle Pellet movement Burners Refractory lining hardening Drying, preheating, induration and cooling are done on a single grate. Pellets remain stationary throughout the process. Large number of burners along the length of induration furnace. No direct contact with pellets Drying and preheating on a grate, induration in rotary kiln and cooling in annular cooler. Pellets tumble continuously in rotary kiln. Single burner is used for the Kiln. Contact with pellets and subjected to heavy wear Others - Chunk formation inside rotary kiln Travelling grate process is preferred under Indian condition because Less fines generation, More flexibility in heating pattern for different ore quality, Lower maintenance & less refractory failure.

8 MECON s journey in Pelletisation Since inception, MECON s strive remained very strong in gaining knowledge from the latest technologies of Pelletization. A small step taken forward in the form of installation of Pellet plant at KIOCL, there has been no looking back Since then, MECON being instrumental in installation of majority of the Pellet plants in the country.

9 MECON s journey contd Projects for start-up: 3.0 MTPA for KIOCL, Mangalore, 1.6 MTPA for Delta Steel Co., Warri, Nigeria, 3.0 MTPA for Hy-grade pellet Ltd, Vizag (1 st module), 4.0 MTPA for Hy-grade pellet Ltd, Vizag (2 nd module), 3.0 MTPA to 4.2 MTPA capacity expansion for JSW, Toranagallu. 1.2 MTPA for MSPL, Hospet

10 MECON s journey contd Major role in other pellet plant installations: 4.0 MTPA PELLET PLANT, BRPL, JAJPUR 3.85 MTPA PELLET PLANT, BPSL, RENGALI 1.2 MTPA PELLET PLANT, CREST STEEL LIMITED, RAIPUR 2.0 MTPA PELLET PLANT, MONNET ISPAT & ENERGY LIMITED- RAIGARH 1.2 MTPA PELLET PLANT, SHREE JAGANNATH STEEL & POWER LIMITED, BARBIL 4.0 MTPA PELLET PLANT, RMD SAIL, GUA 2.0 MTPA PELLET PLANT, NMDC

11 Range of services Today EPC Execution From Concept to Commissioning Engineering Services BE, DE, Limited Supply DE & Consultancy in turn-key / non-turnkey mode Site Services Designer Supervision Project Management Services Project Feasibility TEFR DRR Asset Evaluation Due Diligence Study

12 Advantages of All Indian Pellet plant by MECON Complete engineering under one roof with minimum interfaces Reduced implementation time, TG process and design suiting to Indian raw material condition Indigenous design and maximise indigenous manufacturing of critical process equipment Manufacturing growth and more employment opportunity Fully developed vendor base. EPC from concept to commissioning at a very competitive price, Dependence on foreign suppliers greatly reduced

13 Salient features of our design, Compact layout, Optimise building configuration in order to have minimum volume of work, Improvement in design based feed back from operating plant, Adequate safety measures Environment friendly (dry handling ESP dust & reuse in process, PD ESP)

14 Few glimpses: 2 MT PELLET PLANT: ELEVATION OF BALLING BUILDING

15 Few glimpses: 2 MT PELLET PLANT: CROSS-SECTION OF BALLING BUILDING

16 Few glimpses: 2 MT PELLET PLANT: CROSS-SECTION OF ADDITIVE GRINDING BUIILDING

17 Few glimpses: 1 MT PELLET PLANT: TYPICAL ELEVATION & CROSS-SECTION OF INDURATING MACHINE

18 Few glimpses: 1 MT PELLET PLANT: TYPICAL ELEVATION & CROSS-SECTION OF PALLET CAR

19 Few glimpses: 1 MT PELLET PLANT: ELEVATION OF MIXING BUILDING

20 Recommendation on Pellet plant size Besides demand, the following needs to be considered for size selection : Sourcing of iron ore fines, Operating expenses, Capital investment & flexibility in operation, Recommendation: Minimum size > 1.0 Mt/yr for Travelling Grate (TG) process

21 Conclusion To meet future demand of pellets, Pellet plants Designed & manufactured within India - a real need for future Although TG process is recommended, certain issues needs to be addressed at design stage itself to have optimum plant performance MECON is readiness with state-of-art, indigenous designed & manufactured All Indian Pellet plant to meet the demand

22 THANK YOU