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Advanced Beneficiation Techniques for DRI,<br />
Sinter and Pellet Feed<br />
Dr.-Ing. Heribert Breuer
Scenario of the Indian Iron Ore Industry<br />
:<br />
- Indian crude steel capacity is projected to reach 200 mtpy in 2020<br />
- Such capacity would require > 300 mtpy of high grade iron ore<br />
- Actually approx. 200 mtpy are produced of which 60 mtpy are exported, i.e. 140 mt are<br />
available for the local steel industry<br />
- Based on the above figures anual production has to be increased by > 150 mt<br />
- Not only quantity but also quality has to be improved as steel producers are demanding<br />
low contamination mainly low SiO 2 and Al 2 O 3<br />
- Ressources of DSO of such qualities are very limited, i.e. low grade ores have to be<br />
upgraded.
Solutions for the Indian Iron Ore and Steel Industry<br />
:<br />
1. Iron ore I Advanced Beneficiation processes I General<br />
- all depends on the ore characteristics, but produce High Grade Concentrates as coarse<br />
as possible<br />
- The finer the feed the higher Capex and Opex, i.e. if feasable producing coarse<br />
concentrates is the most economical way<br />
- If High Grade lumps can be produced, at least for this portion no sintering resp.<br />
pelletizing is required<br />
- Grinding of coarse material from which High Grade products can be processed to<br />
complete liberation size in a first step generates more ultrafines and lowers the possible<br />
yields<br />
- As long as liberation is sufficient to produce High Grade concentrates, do it, no matter if<br />
it´s at a size of 30, 10 or 1 mm and then<br />
- Crush resp. grind the rejects of these steps to the next liberation size and consequently<br />
optimize your yields and costs
Solutions for the Indian Iron Ore and Steel Industry<br />
1. Iron ore I Advanced Beneficiation processes I Specific I Density<br />
:<br />
1.1 Jigging of > 1 mm<br />
- because it´s relatively simple and cheap compared to Heavy Media Processes and<br />
- any high density cut can be selected, typically > 4,0 g/ cm³<br />
1.2 Upstream classifier for < 1 mm<br />
- High capacity units of up to 400 tph, i.e. again low Capex and Opex<br />
- Automatically controlled, i.e. variations in feed composition do not affect product quality<br />
- No manual adjustments required as with spirals for example<br />
- Typically up to 40 % can be product, which reduces the load for the following separation<br />
processes substantially<br />
- generates two more intermediate products which can be processed separately for<br />
optimized settings and performance of + and - 0,1 mm
Solutions for the Indian Iron Ore and Steel Industry<br />
1. Iron ore I Advanced Beneficiation processes I Specific I Magnetic<br />
1.3 Wet High Intensity Magnetic Separation [ WHIMS]<br />
:<br />
- Again, high capacity units for up to 800 tph for optimized economics with the<br />
advantages of :<br />
- Low specific costs per ton of feed<br />
- Much less ancillary equipment like pumps, screen etc.<br />
- Small footprint, i.e. less building costs<br />
- Easier operation
Solutions for the Indian Iron Ore and Steel Industry<br />
1. Iron ore I Advanced Beneficiation processes I<br />
:<br />
1. 4 Practical examples, from small to huge<br />
-
alljig ® - applications | more than 450 units worldwide<br />
for:<br />
- coal<br />
- iron ore<br />
- sand | gravel<br />
- rubble<br />
- contaminated soils<br />
- metal-slag<br />
- non ferrous minerals<br />
- diamonds<br />
- salt and others<br />
alljig ® | up gradation of low grade iron ore | 1 - 40 mm
alljig ® | for iron ore beneficiation<br />
Example 01<br />
Janki Corp. Ltd. Bellary | India<br />
Scope of Work<br />
Basic Engineering & Detailed Engineering<br />
Manufacturing | Supply of proprietary equipment i.e.<br />
1 x alljig ® , 1 x scrubber ®<br />
Supervision of erection & commissioning<br />
Complete Project Execution<br />
Highlights<br />
Plant Capacity<br />
Fe Upgradation<br />
Input feed size<br />
Application<br />
Yield<br />
0.8 MTPA<br />
64%<br />
4 - 18 mm<br />
DRI<br />
up to 80%
alljig ® | for iron ore beneficiation<br />
Example 02<br />
Kamaljeet Singh Ahluwalia Barbil | India<br />
Scope of Work<br />
Basic Engineering & Detailed Engineering<br />
Manufacturing | Supply of proprietary equipment i.e.<br />
2 x alljig ® , 2 x scrubber ®<br />
Supervision of erection & commissioning<br />
Complete Project Execution<br />
Highlights<br />
Plant Capacity<br />
Fe Upgradation<br />
Input feed size<br />
Application<br />
Yield<br />
1.6 MTPA<br />
63%<br />
5 - 18 mm I 18 - 40 mm<br />
DRI<br />
up to 70%
alljig ® | for iron ore beneficiation<br />
Example 08<br />
Sree Metalliks Ltd. Keonjhar | India<br />
Scope of Work<br />
Test Works | Flow sheet Development<br />
Basic &Detailed Design & Engineering<br />
Manufacturing & Supply of proprietary<br />
equipment i.e., alljig ® , allflux ® & gaustec ® WHIMS<br />
Supervision of erection & commissioning<br />
Highlights<br />
Plant Capacity<br />
Fe Up gradation<br />
Input feed size<br />
Application<br />
Yield<br />
500 t|h<br />
57.4 - 62.7%<br />
0 - 10 mm<br />
Pellet | Sinter<br />
82%
alljig ® | for iron ore beneficiation<br />
Example 05<br />
Sarda Mines Pvt. Ltd<br />
India<br />
Iron ore processing<br />
6 x alljig ®<br />
5 x alljig ®<br />
G - 2200 x 3000<br />
F - 2500 x 3000<br />
1500 t|h<br />
5 - 30 mm<br />
1 - 5 mm<br />
start up<br />
December 2010
alljig ® | for iron ore beneficiation<br />
Example 01<br />
24 of more than 450 alljigs ®<br />
– worldwide<br />
Sishen Mine | South Africa<br />
iron ore separation<br />
24 x alljig ®<br />
4.000 t|h<br />
start up<br />
8 GUB 4000 x 3000<br />
8 MUB 3500 x 3000<br />
8 FUB 2200 x 3000<br />
0 - 30 mm<br />
mid 2007
allflux ® | Technology<br />
more than 120 installations worldwide<br />
The allflux® separator is a<br />
round, center feed process<br />
vessel that is sized<br />
according to the hydraulic<br />
load. The process uses a<br />
unique combination of<br />
rising current and fluidized<br />
bed techniques and can be<br />
divided into three stages.<br />
The principle of an allflux®<br />
separator is schematically<br />
shown in the following<br />
illustration.<br />
allflux ® | up gradation of iron ore fines | 0 - 1 mm
allflux ®
allflux ® | Installations for iron ore beneficiation<br />
Fortescue Metal Group (FMG)<br />
Cloud Break | CSI Christmas Creek I<br />
Australia<br />
Iron ore separation<br />
6 x allflux ®<br />
1.100 t|h<br />
start up<br />
750<br />
0 - 1 mm<br />
2008<br />
4 x allflux ®<br />
1.100 t|h<br />
start up<br />
750<br />
0 - 1 mm<br />
2011
allflux ® | Installations for iron ore beneficiation<br />
Example 03<br />
Brahmani River Pellets Barbil | India<br />
Scope of Work<br />
Test Works | Flow sheet Development<br />
Manufacturing & Supply of proprietary<br />
2 x allflux ® | 3 x gaustec ® WHIMS<br />
Supervision of erection & commissioning<br />
Highlights<br />
Plant Capacity<br />
Feed<br />
Product<br />
Input feed size<br />
Application<br />
Yield<br />
4 MTPA<br />
55.6 - 57.5%<br />
62.5 - 63.6 %<br />
0 - 2<br />
Pellet<br />
70 %
allflux ® | Installations for iron ore beneficiation<br />
Example 04<br />
Essar Steel Orissa Ltd. Dabuna | India<br />
Scope of Work<br />
Test Works<br />
Manufacturing & Supply of 4 x allflux ®<br />
Supervision of erection & commissioning<br />
Highlights<br />
Plant Capacity<br />
Feed<br />
Product<br />
Input feed size<br />
Application<br />
Yield<br />
8 MTPA<br />
53.7 - 54.0 %<br />
60.6 - 62.5 %<br />
0-2<br />
Pellet<br />
53 - 67 %
Sree Metalliks Ltd. | allflux ® installations | India
gaustec ® | Technology<br />
Wet High Intensity<br />
Magnetic Separator<br />
More than 80 installations<br />
in less than 8 years<br />
gaustec ® | up gradation of iron ore fines | < 0.1 mm
gaustec ® | Unique Advantages<br />
Larger distance between poles<br />
makes maintenance a simple job<br />
Adjustment of effective magnetic<br />
area of the pole<br />
to achieve energy economy<br />
& higher magnetic inductions<br />
Specific Power Consumption<br />
is minimum
gaustec ® | Installations | Sarda Mines Pvt. Ltd.
gaustec ® - GX | for iron ore processing<br />
Example 01<br />
ITAMINAS Mineração<br />
Brazil<br />
Iron ore processing<br />
1 x gaustec ®<br />
700 t|h<br />
start up<br />
GX3600<br />
1 - 0 mm<br />
July 2010<br />
Feed<br />
Product<br />
Tailings<br />
54% Fe | 23% SiO 2<br />
66% Fe | < 3% SiO 2<br />
18% Fe | 60% SiO 2
gaustec ® - GX | Installations | Usiminas Mines
Sarda Mines Pvt. Ltd. | iron ore processing plant | India<br />
Scope of Work<br />
Basic Engineering & Detailed Engineering<br />
Manufacturing | Supply of proprietary equipment i.e.<br />
11 x alljig ® , 4 x gaustec ® WHIMS<br />
Supervision of erection & commissioning<br />
Complete Project Execution<br />
Highlights<br />
Plant Capacity<br />
Fe Up gradation<br />
Alumina reduction<br />
Input feed size<br />
Beneficiation sizes<br />
Application<br />
Yield<br />
11 MTPA<br />
61.7 - 64.1%<br />
3.4 - 1.9 %<br />
0 - 30 mm<br />
0 - 1 | 1 - 5 | 5 - 30<br />
Pellet | Sinter I DRI<br />
85%
Integrated Flowsheet | SMPL<br />
1.999 JSPL Barbil<br />
Mass- balance<br />
m % Fe % Al 2 O 3 %<br />
Feed<br />
100,0 61,8 3,4<br />
Screening<br />
< 1 mm<br />
1 - 5 mm<br />
5-30 mm<br />
40,0 59,9 5,2 20,0 62,8 2,6 40,0 63,2 2,0<br />
allflux/ WHIMS<br />
Jigging<br />
Jigging<br />
35,2 63,9 2,5 20,8 64,1 1,7 30,0 64,5 1,4<br />
Pelletfeed Sinterfeed Blastfurnace/ DRI<br />
Products<br />
Rejects<br />
86,0 64,1 1,9 14,0 47,3 12,4
Sarda Mines Pvt. Ltd. | iron ore processing plant | India
allmineral | worldwide I Iron Ore Equipment<br />
2 alljigs®<br />
2 gaustec®<br />
34 alljigs®<br />
16 allflux®<br />
21 gaustec®<br />
14 alljigs®<br />
56 gaustec®<br />
25 alljigs®<br />
7 allflux®<br />
38 alljigs®<br />
29 allflux®<br />
1 gaustec®<br />
allmineral – wherever you are, worldwide!<br />
On every continent you will find competent assistance from the experts at allmineral, who will provide you<br />
with advice and support for your questions. Please let us know if you need brochures, would like to<br />
arrange a visit, or if you have questions or comments. Or simply give us a call. We'll find a solution.
2. Coal - a scarce raw material<br />
-- how can DRI survive !!!!<br />
‣ At present, India is able to produce 450 MTPA of raw coal as against national demand<br />
of 550 MTPA<br />
‣ India is compelled to import 100 MTPA of coal to meet its domestic demand<br />
‣ Captive power plants are mostly depending on imported coal from Indonesia<br />
‣ Steep increase in prices of this imported coal is forcing the domestic consumer to<br />
depend on E-auction, which in turn causing further price rise of domestic coal.<br />
‣ Viability/sustainability of DRI and Captive Plant is becoming a question in this scenario<br />
It is very important to consider use of DRI waste<br />
ie., Dolochar after beneficiation
Generation,Composition of Dolochar<br />
A 100 TPD DRI Kiln produces approximately 40 TPD of dolochar.<br />
A typical composition of dolochar is presented in the following table<br />
Serial No. Constituents Composition (Mass %)*<br />
1 Carbon 14-16<br />
2 Ash 82-85<br />
3 Volatile Matter
Way to utilize ..... !<br />
‣ It has notified by MoEF that under no circumstances the industry shall store any dust, coal<br />
char, coal fines etc. in open space. Either use char for their in- house consumption in<br />
boilers as fuel OR provide the char to other industries in the region who have<br />
commissioned AFBC/CFBC boilers using dolochar as fuel.<br />
‣ ABFC boiler using dolochar as fuel are designed for a gross calorific value (GCV) of<br />
2100-2200 kCal/kg. It is difficult to use raw char directly in AFBC boiler because of the<br />
presence of mineral matters like silica, iron particle which enhance clinker formation in<br />
bed resulting in reduced boiler efficiency.<br />
‣ For using Dolochar and upgrading GCV up to 2100-2200 Kcal/Kg, allmineral introduced an<br />
unique Dry washing technology called Allair ®.<br />
‣ The allair has a remarkable achievement in char beneficiation for removing iron bearing<br />
material and other mineral matters.<br />
‣ The CAPEX & OPEX can be optimized for DRI/Power industries to beneficiate the char<br />
and make it usable in AFBC Boiler. By blending the char and washery rejects the raw<br />
material cost to AFBC boiler can be reduced substantially, resulting overall cost<br />
reduction.
allair ® | for dry coal / char beneficiation<br />
feed<br />
air exhaust<br />
pulsed airflow<br />
constant airflow<br />
heavy particles<br />
light particles
allair ® jig results of Char<br />
SL. NO. TYPS OF SAMPLE % ASH % VM % FC % ASH REDUCTION % FC UPGRADATION<br />
FEED TO JIG 85 0.8 14.2<br />
1<br />
CLEAN CHAR 74.88 3.82 21.3<br />
10.12 7.1<br />
REJECT CHAR 92.2 0.3 7.5<br />
FEED TO JIG 82.65 1.49 15.86<br />
2<br />
CLEAN CHAR 70.07 5.82 25<br />
12.58 9.14<br />
REJECT CHAR 91.55 0.2 8.25<br />
FEED TO JIG 80.82 1.81 17.37<br />
3<br />
CLEAN CHAR 69.03 5.72 25.25<br />
11.79 7.88<br />
REJECT CHAR 95.2 0.93 3.87
allair ® jig results of Char<br />
SL. NO. TYPS OF SAMPLE % ASH % VM % FC % ASH REDUCTION % FC UPGRADATION<br />
FEED TO JIG 80.6 2.71 16.69<br />
1<br />
CLEAN COAL 69.79 6.03 24.18<br />
10.81 7.49<br />
REJECT COAL 91.63 0.12 8.25<br />
FEED TO JIG 80.64 1.76 17.6<br />
2<br />
CLEAN COAL 65.4 6.24 28.36<br />
15.24 10.76<br />
REJECT COAL 92.35 0.4 7.25<br />
FEED TO JIG 82.69 0.88 16.43<br />
3<br />
CLEAN COAL 71.5 4.25 24.25<br />
11.19 7.82<br />
REJECT COAL 95.28 0.23 4.56
allair ® | for coal / char beneficiation I more than 30 installations in India<br />
Example 01<br />
SCAN STEELS LTD.<br />
India<br />
1 x allair ®<br />
50 t|h<br />
4‘ x 8‘<br />
0 - 30 mm<br />
start up<br />
2008
allair ® | for coal / char beneficiation<br />
Example 02<br />
JANKI CORP LTD.<br />
India<br />
1 x allair ®<br />
50 t|h<br />
4‘ x 8‘<br />
5 - 20 mm<br />
start up<br />
2008
2. Coal I Summary :<br />
‣ Dry coal/ char beneficiation is an unique technology for Indian power plants<br />
‣ Utilization of Dolochar in AFBC/CFBC Boiler, to reduce fuel cost and make-up for the<br />
coal shortages.<br />
‣ Reduced environmental hazard.<br />
‣Techno economic feasibility for the dry char beneficiation plant.<br />
‣ Optimized OPEX with Dolochar and coal mix in boiler.<br />
‣ Less generating cost of electricity in captive power plant using dolochar as a<br />
fuel.<br />
‣ Ground water conservation achieved by Dry Process.
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