Sustainable Technologies for Small, Mid and Large-Scale Iron Ore Pellet Production and Mid-Scale DRI Stefan Mehl Iranian Iron & Steel Conference, 14 16. September 2015, Kish International Convention Centre, Kish Island, Iran
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 2 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 3 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 4 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 5 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 6 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 7 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Pelletizing Capacity and Future Iranian Opportunities 80.0 70.0 60.0 50.0 40.0 30.0 20.0 10.0 + 210% + 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 0.0 2013 Incl. Current Outotec project executions Outlook 8 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Steel consumption per capita vs. GDP in Middle East countries and ROW Finished Steel Consumption per Capita in Kg 9 1400 1200 1000 800 600 400 200 0 India 16.09.2015 China Iran Russia Brazil South Korea Saudi Arabia Japan UAE Kuwait Germany 0 10 20 30 40 50 60 70 80 90 100 GDP / Capita in '000 US$ USA Australia Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran Qatar Steel consumption per capita in Middle East countries has further room to grow
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) 10 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Outotec Pellet Plants in Iran Khouzestan Steel Mobarakeh Steel Gol-e-Gohar 1 Gol-e-Gohar 2 Gohar Zamin B-Misco Start-up 1977 1982 2005 2015 2016 2018 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 388.5 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) 11 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
50Years of Pelletizing Experience First Outotec reference in Iran (Khouzestan Steel) was started-up in 1977. 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. 12 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Pelletizing Technologies 13 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Standard Size Plant Configuration 14 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Layout 162m² Mini Pellet Plant 15 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Layout 315² Midi Pellet Plant 16 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Layout 624m² Pellet Plant 17 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Layout 2 x 816m² Pellet Plant 18 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Pelletizing Plant Space Requirements 19 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Pellet Capacity vs. Process and Ore Pelletizing Capacity ever built, China not fully shown, status 2013 20 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 21 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Several Recuperation Systems in Outotec TG Pellet Plants 1 Direct recuperation at 900 1,000 C 2 1 3 2 Wind box recuperation at 330 380 C 3 Recuperation from 2 nd cooling to updraft drying at 330 380 C 22 20.02.2015 Tosyali Pelletizing Project Meeting in Istanbul Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 23 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Typical Temperature Profile 1400 1200 1000 800 600 400 200 0 UPDRAFT DRYING DOWNDRAFT DRYING PREHEATING FIRING AFTER FIRING COOLING I COOLING II 24 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 25 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Optimum Pellet Size Preferred size 8 18mm -> 9.5 12.5mm, 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 26 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 27 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Minimized Environmental Impact 28 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
DR Pellet Quality - Parameter Allocation Gas OUT Raw Material IN Transportation & Handling CCS, TI & AI Drying DR furnace top @350 C Decrepitating Index, Pre-reduction Stage DR Shaft @ 700 C RDI /LTB Middle of DR Shaft @ 950 C RI, Sticking & Swelling Product OUT Gas IN 29 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Outotec s Recent Pelletizing References Costumer Location Order Feed Cap. [mtpy] Size [m²] Scope B-Misco Iran 2015 Mixed Ore 5.0 720 EPS SAIL Gua Gua India 2015 Hematite 4.0 504 LSTK Gohar Zamin Sirjan Iran 2013 Mixed Ore 5.0 624 EPS Baotou Baotou China 2013 Mixed Ore 5.0 624 EPS Gol-e-Gohar 2 Sirjan Iran 2012 Mixed Ore 5.0 624 EPS Samarco 4 Ponta de Ubú Brazil 2011 Hematite 9.25 816 LSTK Stoilensky GOK Stary Oskol Russia 2011 Magnetite 6.0 768 EPS Ternium Porto do Acu Brazil 2010 Hematite 7.0 768 E BPSL Jharsuguda India 2009 Hematite 3.85 504 EPS Tata Steel Jamshedpur India 2008 Hematite 6.0 768 LSTK Caofeidian Caofeidian China 2008 Mixed Ore 4.0 504 EPS BRPL Jajpur Road India 2007 Hematite 4.0 492 ES Vale Vargem Grande Nova Lima Brazil 2005 Hematite 7.0 768 EPS Samarco 3 Ponta de Ubú Brazil 2005 Hematite 7.25 768 LSTK VALE Tubarão VIII Vitória Brazil 2005 Hematite 7.0 768 E 30 16.09.2015 Last 10 years: 85.35 million tons designed capacity Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 31 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 32 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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) 33 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
SL/RN process schematic diagram 34 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 30 35 % 35 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
SL/RN-Xtra DRI directly from fines. 36 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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) 37 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Coal requirements Performance Performance Performance Performance CAPEX (Gas circuit) Feasibility Consumption wf= water free; *under reducing conditions; **depending on degradation behaviour 38 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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. 1978 - First Indian SL/RN plant at Paloncha, AP - Kiln size: 3 x 40 m - Capacity: 30 000 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: 350 000 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: 190 000 t/a ilmenite In 1996 second kiln: Kiln size: 5 x 90 m for Capacity: 250 000 t/a ilmenite 39 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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 40 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
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) 41 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Outotec Plant Performance Assessment Visualization of results The Assessment enables; Understanding current operations Defining key improvement areas Speed up of continuous improvement ideology 42 16.09.2015 Iranian Iron & Steel Conference, 14 16. September 2015 Kish Island, Iran
Thank you stefan.mehl@outotec.com