THE USE AND OPTIMISATION OF FERROUS FEED AT THE WHYALLA BLAST FURNACE AUSIMM Iron Ore 2015 Conference, Perth Australia 13 15 July 2015 Presented by John Tsalapatis
Whyalla Location Whyalla Adelaide 2
Steelworks Layout PELLET PLANT BLAST FURNACE 3
Mining at Iron Knob - 1900 4
No.1 Blast Furnace - 1941 5
Middleback Ranges Iron Ore N IRON KNOB Katunga Hills QUARTZ QUARRY Coffin Bay Iron Knob Iron Baron Iron Duke Port Augusta WHYALLA Ardrossan ADELAIDE Cooyerdoo Kangaroo Island South Australia NORTH MIDDLEBACK RANGE Camel Hills IRON BARON WHYALLA IRON KNIGHT IRON DUCHESS SOUTH MIDDLEBACK RANGE IRON DUKE Spencer Gulf 6
Blast Furnace Raw Materials Iron ore pellets Lump ore Limetsone Dolomite Quartz Coke 7
Pellet Supply Major Changes Changed from acid to fluxed pellets in late 1970s. Changes throughout 1980s and early 1990s aimed to improve pellet properties and reduce variability. Observed greatly improved blast furnace production and efficiency. Pellet supply quality has slowly declined since mid 1990s, mostly due to cost pressures and ore reserves. In 2007 changed from hematite ore to magnetite concentrate for pellet production. 8
Whyalla Pellet Chemistry Whyalla pellet specification 1988 : Item Aim Range % Fe 59.5 58.5 60.5 % SiO 2 4.0 3.7 4.3 % Al 2 O 3 1.9 1.65 2.15 % MgO 1.95 1.8 2.1 % Mn 0.60 0.04 0.8 CaO/SiO 2 1.35 1.25 1.45 9
Whyalla Pellet Chemistry 2.5 2.25 2 1.75 1.5 1.25 1 0.4 Std Dev MgO 0.3 0.2 0.1 0 1 0.8 0.6 0.4 0.2 0 0.3 10 %MgO Std Dev SiO2 5 4.5 4 3.5 3 2.5 2 0.2 0.1 0 %SiO2 1.5 1.4 1.3 1.2 1.1 1 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 CaO/SiO2 Nov 13 Std Dev CaO/SiO2 2004 Reline Magnetite transition Average Std Dev
Pellet High Temperature Properties Reduction Under Load test approximates the performance of pellets in the Blast Furnace. % Reduction 100 90 80 70 60 50 40 30 20 10 0 Whyalla Pellet RUL Reduction Curve 0 200 400 600 800 1000 1200 1400 Temperature o C 11
Descending Probe Descending probe measures temperature across the furnace radius. Can be correlated with RUL test results. 12
Project Magnet Converted pellet plant to use magnetite concentrate to enable sale of hematite reserves. Magnetite ore chemistry is very different to hematite ore in terms of gangue elements. OneSteel test work simulated effects of magnetite based pellets on blast furnace operation. Confirmed by companies including Kobe, CSIRO, COREM and Corus. E.g. Pot grate tests for induration extent during pre-heating. 13
Magnetite Concentrate Test Pellets Hematite Microstructure of low basicity pellet after preheating showing full oxidation to hematite. (Firth et al, 2004) 14
Magnetite Concentrate Test Pellets Hematite Magnetite High basicity pellet after preheating showing distinct core of unoxidised magnetite. (Firth et al, 2004) 15
Lump Ore Major Changes Significant effort in 1980s to improve quality and consistency of the lump ore. During mid 1990s cost pressures and dwindling ore reserves saw a winding back of the improvements, with deleterious effects at the blast furnace. Ore Beneficiation Plant (OBP) installed in 2005. 16
Ore Beneficiation Plant Ore Beneficiation Plant (OBP) uses jigs, vibrating screens and spirals. Installed to produce lump for the blast furnace from high grade ore dumps. Any magnetite reports to the product. Magnetite ore is bad news in a blast furnace. OBP process greatly affected by geology and physical condition of the ore. 17
Std Dev Fe Lump Ore Fe and SiO 2 68 67 66 65 64 63 62 61 60 2 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 18 %Fe 5 4 3 2 1 0 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 %SiO2 Nov 13 Std Dev SiO2 2004 Reline OBP Lump %SiO2 StDev SiO2
Lump Ore MgO and CaO 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0.5 0.4 0.3 0.2 0.1 0 19 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 %MgO Nov 13 Std Dev MgO 1.3 1.1 0.8 0.6 0.3 0.1 0.2 Wt% Std Dev 0.6 Std Dev CaO 2004 Reline OBP Lump 0.4 0.2 0 %CaO
OBP Lump Ore Analysis Typical blast furnace lump ore analysis from the Iron Duke OBP : Fe SiO 2 Al 2 O 3 CaO MgO Mn FeO Average 62.47 3.93 0.97 1.09 1.22 0.33 0.735 Std. Dev. 1.825 1.455 0.366 0.649 0.520 0.236 0.382 12 month average of all production samples for BF feed (Nov 2012 to Mar 2014) 20
Blast Furnace Operations Third campaign (Jan 1981 Jun 2004) produced world class results. Raw material quality and consistency was a major factor. Used highly fluxed pellets. High alumina loading. Continuous improvement in fuel rate. Fourth campaign brought challenges with raw material supply and resulting operational issues. 21
Whyalla blast furnace dimensions and equipment 3 rd Campaign 4 th Campaign 2-Jan-1981 18-Aug-04 13-Jul-2011 4-Jun-2004 08-May-11 Inner Volume 1543 1884 1858* Working Volume 1358 1686 1660* Hearth Diameter 8.6 9.0 Tuyeres 18 18 Tapholes 2 2 Top Charging IHI Two-Bell High Pressure Top with GHH Movable Armour Paul Wurth Central Feed Bell-less Top Burden High % Fluxed Pellet / Lump Ore (Typically 80% Fluxed Pellets / 20% Lump Ore) Stack Cooling High alumina refractory & 7 rows cast iron staves/ 7 rows cast iron staves/ copper cooling plates 3 rows copper staves 2 rows copper staves/ Graphite & high density copper cooling plates Bosh Cooling High alumina refractory & high density copper cooling plates 2 rows copper staves / 2 rows copper cooling plates & SiC brick Graphite & high density copper cooling plates Hearth Cooling Salt water shower cooling Treated demineralised water shower cooling Underhearth Cooling Treated demineralised water pipe cooling *Following bosh cooling system repair in 2011. 22
Blast Furnace Operations 3750 3500 3250 3000 2750 2500 2250 2000 23 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Tonnes/day Aug 05 May 08 Feb 11 Nov 13 Production 2004 Reline Quarterly average Production
Blast Furnace Operations 54 52 50 48 % 46 44 42 40 24 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 Gas Efficiency Quarterly average EtaCO 2004 Reline
Blast Furnace Operations 600 575 550 525 500 475 450 25 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 kg/tonne hot metal Aug 05 May 08 Feb 11 Nov 13 Fuel Rate 2004 Reline Quarterly average Fuel Rate
Blast Furnace Operations 375 350 325 300 275 250 225 200 175 26 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 kg/tonne hot metal Aug 05 May 08 Feb 11 Nov 13 Slag Volume 2004 Reline Quarterly Average of Slag Volume
Blast Furnace Operations 19 18 17 16 15 14 13 12 11 10 9 8 7 27 Jan 81 Sep 83 Jun 86 Mar 89 Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 % Aug 05 May 08 Feb 11 Nov 13 Slag %Al 2 O 3 2004 Reline Quarterly Average of Al2O3
Iron and slag analysis Whyalla blast furnace iron and slag data for third campaign : 1980s 1990s 2000s pre reline Mean Std. Dev. Mean Std. Dev. Mean Std. Dev. Iron Si % 0.86 0.146 0.49 0.128 0.50 0.11 Iron S % 0.019 0.005 0.021 0.006 0.016 0.005 Iron P % 0.114 0.011 0.083 0.006 0.096 0.006 Iron Mn % 0.814 0.150 0.275 0.054 0.384 0.109 Iron Temp C 1510 17.4 1501 12.9 1502 9.0 Slag Volume (kg/t) 348.6 15.53 253.9 8.56 265.0 11.41 Slag Basicity 1.35 0.051 1.44 0.04 1.41 0.04 Slag Al 2 O 3 % 16.39 0.304 17.50 0.48 16.74 0.44 Table date periods 1980s = Jan-1984 Dec-1984 1990s = Apr-1997 Mar-1998 2000s pre reline = Jun-2003 May-2004 28
Iron and slag analysis Whyalla blast furnace iron and slag data for fourth campaign : 2000s 100% pellets post reline Mean Std. Dev. Mean Std. Dev. Iron Si % 0.58 0.08 0.58 0.106 Iron S % 0.025 0.007 0.018 0.004 Iron P % 0.088 0.012 0.075 0.011 Iron Mn % 0.366 0.088 0.149 0.051 Iron Temp C 1506 9.5 1500 10.2 Slag Volume (kg/t) 240.7 15.87 230.5 2.88 Slag Basicity 1.39 0.04 1.38 0.027 Slag Al 2 O 3 % 15.70 0.32 7.75 0.348 Table date periods 2000s post reline = Sep-2006 Aug-2007 100% pellets = Apr-2014 Aug-2014 29
Future Developments : Alternate Potential Uses for By-Product Stream Materials Currently in the process of exploring novel recycling uses and realising better value from our large number of available by-product stream materials. Listed below are some materials under consideration : Chemical % Analyses of By-product Stream Under Consideration Fe SiO2 Al2O3 CaO P Mn MgO Zn S C Coke Fines 0 0 0 0 0 0 0 0 0 86.06 Quencher Basin Dust 0 0 0 0 0 0 0 0 0 82.31 BF Dust 21.64 6.24 2.6 3.03 0.05 0.14 0.97 0.07 0.04 56.7 Millscale & Metallic Fines 73.51 0.525 0.001 0.065 0.014 1.115 0.06 0.0085 0.02 0 BOS Precipitate 59 2.2 0.2 6.7 0.07 0.7 1.8 1.1 0.06 0 Dolomite Fines 0.56 1.22 0.3 30.29 0.01 0 20.47 0.003 0.012 0 BF Slag 0.34 37.66 9.58 40.12-0.21 10.36-0.75-30
Future Developments : By-Product Material Use Recycling of by-product materials. Composite pellet using carbon and ferrous dusts. Have commenced pellet reduction tests for composite pellets. 31
Whyalla By-Product Dust Composite Pellet Test work Time Types of carbon 0 sec 30 sec 90 sec 150 sec 270 sec Reference C - material C - Option 1 C - Option 2 C - Option 3 32
Whyalla By-Product Dust Composite Pellet Test work Percent reduction 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Percent reduction vs time 0 50 100 150 200 250 300 Time (seconds) C Option 1 HV coal Reference C Graphite C Option 3 Skip Pit C Option 2 QBB Stage 1 Stage 2 I Stage 2 II Stage 3 Stage 4 Reaction rate 33
Conclusion Since 1941, ferrous materials for Ironmaking in Whyalla have been sourced exclusively from the nearby Middleback Ranges. Key objective is to maintain high blast furnace process availability, efficiency and stability at lowest cost, by exercising innovative process design and control methodologies. There is the ever present challenge of diminishing absolute quality and increased variability in raw material inputs for the blast furnace. Rigorous benchmarking is practiced. The fundamental raw material attribute sought is consistency. 34
Acknowledgements Authors: John Tsalapatis Stefan Kerec Bob Keil Matthew Middleton Graeme Caddy 35
Element Loadings 950 945 940 935 930 925 37 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 Fe Loading Quarterly Fe Loading
Element Loadings 180 160 140 120 100 80 60 40 20 0 38 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 SiO 2 Loading Quarterly SiO2 Loading
Element Loadings 70 60 50 40 30 20 10 0 39 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 Al 2 O 3 Loading Quarterly Al2O3 Loading
Element Loadings 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 40 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 P Loading Quarterly P Loading
Element Loadings 150 140 130 120 110 100 90 80 70 60 41 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 CaO Loading Quarterly CaO Loading
Element Loadings 35 30 25 20 15 10 5 0 42 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 MgO Loading Quarterly MgO Loading
Element Loadings 18 16 14 12 10 8 6 4 2 0 43 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 Mn Loading Quarterly Mn Loading
Element Loadings 3 2.75 2.5 2.25 2 1.75 1.5 1.25 1 44 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 S Loading Quarterly S Loading
Element Loadings 6 5 4 3 2 1 0 45 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 TiO 2 Loading Quarterly TiO2 Loading
Element Loadings 0.3 0.25 0.2 0.15 0.1 0.05 0 46 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 Zn Loading Quarterly Zn Loading
Element Loadings 3 2.5 2 1.5 1 0.5 0 47 Jan 81 Sep 83 Jun 86 Mar 89 kg/thm Dec 91 Sep 94 Jun 97 Mar 00 Nov 02 Aug 05 May 08 Feb 11 Nov 13 K 2 O Loading Quarterly K2O Loading
Hot Metal Element Trends 1.4 1.2 1 0.8 0.6 0.4 0.2 0 48 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %Si %Si quarterly average
Hot Metal Element Trends 0.05 0.04 0.03 0.02 0.01 0 49 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %S %S quarterly average
Hot Metal Element Trends 0.16 0.14 0.12 0.1 0.08 0.06 0.04 0.02 0 50 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %P %P quarterly average
Hot Metal Element Trends 1.2 1 0.8 0.6 0.4 0.2 0 51 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %Mn %Mn quarterly average
Hot Metal Element Trends 0.16 0.14 0.12 0.1 0.08 0.06 0.04 0.02 0 52 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %Ti %Ti quarterly average
Hot Metal Element Trends 0.012 0.01 0.008 0.006 0.004 0.002 0 53 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 %Zn %Zn quarterly average
Hot Metal Element Trends 1540 1520 1500 1480 1460 1440 1420 1400 54 Jan 80 Sep 82 Jun 85 Mar 88 Dec 90 Sep 93 Jun 96 Mar 99 Nov 01 Aug 04 May 07 Feb 10 Nov 12 Aug 15 May 18 Hot Metal Temperature HM Temp quarterly average
Slag Analysis Trends 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 55 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %FeO Quarterly average of FeO
Slag Analysis Trends 1.6 1.5 1.4 1.3 1.2 1.1 1 56 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 Basicity Quarterly average of Basicity
Slag Analysis Trends 1.2 1 0.8 0.6 0.4 0.2 57 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %TiO 2 Quarterly average of TiO2
Slag Analysis Trends 39 37 35 33 31 29 58 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %SiO 2 Quarterly average of %SiO2
Slag Analysis Trends 0.8 0.7 0.6 0.5 0.4 0.3 0.2 59 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %K 2 O Quarterly average of K2O
Slag Analysis Trends 12 11 10 9 8 7 6 5 4 60 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %MgO Quarterly average of %MgO
Slag Analysis Trends 1 0.9 0.8 0.7 0.6 0.5 0.4 61 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %S Quarterly average of S
Slag Analysis Trends 1.4 1.2 1 0.8 0.6 0.4 0.2 0 62 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %MnO Quarterly average of MnO
Slag Analysis Trends 43 42 41 40 39 38 37 36 35 63 Nov 81 Jul 84 Apr 87 Jan 90 Oct 92 Jul 95 Apr 98 Dec 00 Sep 03 Jun 06 Mar 09 Dec 11 Sep 14 %CaO Quarterly average of % CaO