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Circular Pelletizing Technology<br />
General Presentation<br />
We didn’t invent<br />
Pelletizing…<br />
We just made it better.<br />
Delhi, 10 th of September 2012<br />
Protection notice / Copyright notice
Circular Pelletizing Technology (CPT)<br />
Introduction<br />
1 Trends in Iron Ore Mining<br />
2 Circular Pelletizing Technology – A Smart Combination<br />
3 Circular Pelletizing Technology – Layout, Plant Options<br />
4 CPT in Figures<br />
5 Advantages of <strong>Siemens</strong> <strong>VAI</strong> Circular Pelletizing Plant<br />
6 Cooperation Agreement<br />
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Trends in<br />
Iron Ore Mining<br />
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Why Pelletizing?<br />
Global Decrease of Lump and Sinter Feed Ores<br />
This tendency makes the utilitsation of fine and ultra<br />
fine ores more and more important in next decades, for<br />
which pelletizing is the only industrial scale proven<br />
process.<br />
Good Bed Permeability and Reducilbility<br />
Due to the spherical shapes and the high porosity of<br />
the pellets a high bed permeability and a high<br />
reducibility of pellets is achieved, which is leading to<br />
less energy consumption in the downstream processes.<br />
Uniform chemical analysis<br />
By beneficiating of ultrafines a very constant quality is<br />
achieved leading to constant operation conditions.<br />
Easy handling and transportation<br />
By induration an excellent strength of pellets for further<br />
handling and processing is achieved.<br />
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From Ore to Iron<br />
Process Routes in Ironmaking<br />
Ore with high iron content<br />
Ore with low iron content<br />
Screening<br />
Beneficiation<br />
Lump ore<br />
Fines<br />
Concentrate<br />
Sintering<br />
Pelletizing<br />
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Circular Pelletizing<br />
Technology<br />
A Smart Combination<br />
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The Challenge of making iron ore pellets<br />
Typical Flow Sheet of a Pelletizing Plant<br />
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Straight Grate Pelletizing Technology<br />
Induration Process<br />
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<strong>Siemens</strong> <strong>VAI</strong> Sintering Technology<br />
Mechanical design of a circular dip rail cooler<br />
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Circular Pelletizing Technology<br />
A SMART combination<br />
Straight grate induration process<br />
+<br />
<strong>Siemens</strong> <strong>VAI</strong> combines the well-<br />
proven travelling grate process with<br />
the simple and robust mechanical<br />
design of a circular dip rail cooler.<br />
The result is the revolutionary<br />
Circular Pelletizing Technology.<br />
=<br />
Mechanical system of S<strong>VAI</strong> circular dip rail cooler<br />
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Circular Pelletizing Technology<br />
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Circular Pelletizing Technology<br />
Characteristics and Design Criteria<br />
Circular Grate technology is based on proven design of straight grate<br />
Design Criteria<br />
• Simple and robust design of equipment and gas flow<br />
• Circular design and small footprint of induration furnace with efficient<br />
and optimized equipment utilization<br />
• Location of Circular Pelletizing Plant not necessarily at mine site, but also<br />
at steel works or direct reduction plants<br />
• Induration furnaces for capacities between 0.8 and 3.0 mt/a considered<br />
• Production of high quality Blast Furnace and Direct Reduction grade<br />
pellets as well as Manganese pellets<br />
CPT combines proven process with reliable mechanical system<br />
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Circular Pelletizing Technology<br />
The Induration Process in Circular Arrangement<br />
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Circular Pelletizing Technology<br />
Technical Challenges during Engineering<br />
Development of Indurating Machine<br />
By careful design of the pallet cars and the drive system combined with a<br />
detailed stress analysis of the complete system a reliable and easy<br />
maintainable indurating machine could be realized.<br />
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Circular Pelletizing Technology<br />
Technical Challenges during Engineering<br />
Development of Process Gas Flow<br />
By simulating the process gas flows inside the indurating hood the<br />
optimum arrangement and specific power of the burners could be defined.<br />
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Circular Pelletizing<br />
Technology –<br />
Layout, Plant Options<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
1<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
1<br />
2<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
1<br />
3<br />
2<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
4- Induration Furnace<br />
1<br />
4<br />
3<br />
2<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
4- Induration Furnace<br />
5- Product Classification<br />
1<br />
4<br />
3<br />
5<br />
2<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
4- Induration Furnace<br />
5- Product Classification<br />
6- Product Pile 1<br />
4<br />
3<br />
5<br />
2<br />
6<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
4- Induration Furnace<br />
5- Product Classification<br />
6- Product Pile<br />
7- Process Air Cleaning<br />
1<br />
7<br />
4<br />
3<br />
5<br />
2<br />
6<br />
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Circular Pelletizing Technology<br />
Standard Plant Layout CPT 1.2M<br />
CPT Standard Plant Layout:<br />
1- Dosing & Green Balling<br />
2- Additive Storage & Grinding<br />
3- Mixing Station<br />
4- Induration Furnace<br />
5- Product Classification<br />
6- Product Pile<br />
7- Process Air Cleaning<br />
8- Coal Gasification Plant<br />
1<br />
4<br />
7<br />
8<br />
3<br />
5<br />
2<br />
6<br />
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Circular Pelletizing Technology<br />
Dual Fuel Burner Principle Scheme<br />
Indigenous<br />
Coal<br />
Flare<br />
Primary<br />
Air<br />
Air<br />
Coal<br />
Gasif.<br />
Ash<br />
Fuels can be mixed in<br />
every ratio.<br />
HFO<br />
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Circular Pelletizing Technology<br />
Coal Gas Operational Data<br />
Minimum Properties of Coal<br />
Coal composition<br />
Lower heat-value at 10%<br />
wet<br />
Coal-grain size:<br />
C 30-35%<br />
H 4,64%<br />
N 1,85%<br />
S 0,95%<br />
3,300<br />
kcal/kg<br />
25 - 50 mm<br />
Ash content of coal 40% +/-2%<br />
Lowest Ash melting<br />
point<br />
1,080°C<br />
Data of Coal Gas per Gasifier<br />
(typical)<br />
Coal input<br />
Coal gas output<br />
HV of coal gas<br />
1,76 t/h<br />
1250 Nm³/h<br />
1250 kcal/Nm³<br />
Coal gas temp. 350°C<br />
Coal gas<br />
Dust content<br />
Tar content<br />
C0 25%<br />
H2 9%<br />
CxHy 2,5%<br />
CO2 6,5%<br />
N2 57%<br />
300 mg/Nm³<br />
25-30 g/Nm³<br />
Ash amount<br />
0,69 t/h<br />
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Circular Pelletizing Technology<br />
Coal Gas OPEX Benefit<br />
The OPEX comparison considers 50% utilization of Coal Gas<br />
HFO<br />
Coal<br />
Pellet production in tons per hour 153 t/h 153 t/h<br />
Consumption in tons per hour 3,5 t/h 14,1 t/h<br />
Cost for 1 ton of fuel* 608 € 54 €<br />
Cost for fuel per hour 2129 € 758 €<br />
Cost per ton of pellets 14 € 5 €<br />
Cost per year (7920 hours) for 100% of one fuel ~16,86 M€ ~6,1 M€<br />
Cost per year for fuel considering an availability of<br />
50% of the Coal gasification plant<br />
OPEX savings per year when substituting 50% of fuel<br />
requirement with coal gas<br />
~8,43 M€ ~3,00 M€<br />
~5,43 M€<br />
*The comparison has been prepared for India based on Indian unit rates.<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
3<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
Page 29<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
4<br />
3<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
4- Additive Storage & Grinding<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
4<br />
3<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
4- Additive Storage & Grinding<br />
5- Induration Furnace<br />
5<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
4<br />
3<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
4- Additive Storage & Grinding<br />
5- Induration Furnace<br />
6- Product Classification<br />
6<br />
5<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
4<br />
3<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
4- Additive Storage & Grinding<br />
5- Induration Furnace<br />
6- Product Classification<br />
7- Product Intermediate Bin<br />
7<br />
6<br />
5<br />
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Circular Pelletizing Technology<br />
Top View of a CPT 1.2M in a Steelworks<br />
1<br />
2<br />
3<br />
4<br />
8<br />
CPT Plant Layout:<br />
1- Iron Ore Grinding<br />
2- Dosing & Mixing Building<br />
3- Green Balling<br />
4- Additive Storage & Grinding<br />
5- Induration Furnace<br />
6- Product Classification<br />
7- Product Intermediate Bin<br />
8- Process Air Cleaning<br />
7<br />
6<br />
5<br />
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Circular Pelletizing Technology<br />
Plant Layout 2.5 Mtpa CPT + Midrex 1.7 Mtpa DRI Plant<br />
CPT Plant Combinations:<br />
By the production of DR-grade pellets the<br />
next generation module size of CPT plants is<br />
the ideal basis for a MIDREX ® 1.7 Mtpa DRI<br />
plant.<br />
The new module can also be combined with<br />
a 1.5 Mtpa COREX ® plant for the production<br />
of hot metal.<br />
The complete combined plant solutions can<br />
be offered by <strong>Siemens</strong> <strong>VAI</strong>.<br />
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CPT in Figures<br />
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Circular Pelletizing Technology<br />
Production Figures<br />
Productivity<br />
0.8 – 3.0 Mtpa<br />
Product Size < 5 mm < 5%<br />
Product Size > 16 mm < 3%<br />
CCS (Cold Crushing Strength)<br />
Av. 2500 N/Pe<br />
TI (Tumble Index) > 6.3 mm > 92%<br />
Reducibility (ISO 7215) > 70%<br />
Swelling Index < 15%<br />
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Circular Pelletizing Technology<br />
Consumption Figures<br />
Electr. energy requirement<br />
Heat energy requirement<br />
Water requirement<br />
Compressed air<br />
Bentonite<br />
Coke<br />
Limestone<br />
Refractories<br />
< 40 kWh / t pe<br />
< 250 Mcal / t pe<br />
< 0.2 m³ / t pe<br />
< 25 m³ / t pe<br />
< 7 kg / t pe<br />
< 11 kg / t pe<br />
< 11 kg / t pe<br />
< 0.1 kg / t pe<br />
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Circular Pelletizing Technology<br />
Environmental Figures<br />
Dust in waste gas (mg dry / Nm³) < 50<br />
Work zone dust content (mg dry / Nm³) < 5<br />
Noise level (dB(A))<br />
< 85 (at 1 m from source)<br />
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Advantages of CPT<br />
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Circular Pelletizing Technology<br />
Advantages<br />
Benefits of CPT<br />
• Compact plant layout, low building profile, short process air<br />
ducts, completely standardized equipment<br />
• Efficient use of indurating machine because only 25% of pallets<br />
cars not inside the furnace<br />
• Lowest weight of equipment and structural steel compared to<br />
straight grate and rotary kiln pelletizing plants of similar capacity<br />
• Low overall CAPEX, specific investment costs comparable with<br />
large pellet plants<br />
• Modular CPT concept for larger pellet capacities allows the<br />
flexibility of producing different pellet qualities and quantities<br />
specificlly to the market and Customer requirements<br />
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Circular Pelletizing Technology<br />
Advantages<br />
Benefits of CPT<br />
• Excellent pellet quality as produced in straight grate induration<br />
machines (BF vs DR grade pellets)<br />
• Low OPEX due to the compact layout (e.g. short process ducts)<br />
and also due to use of various energy source for firing process<br />
(e.g. indigenous coal via direct gasification)<br />
• Flexibility to define plant location: at mine or in steel plant site<br />
due to low space requirement<br />
• Maintenance friendly: short shut-down time for pallet grate<br />
exchange<br />
• Fully automated process control and plant operation<br />
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Cooperation<br />
Agreement<br />
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CPT Project Setup for India<br />
Cooperation JIPL + <strong>Siemens</strong> <strong>VAI</strong><br />
+<br />
<strong>Siemens</strong> <strong>VAI</strong> GmbH, Austria<br />
<strong>Siemens</strong> <strong>VAI</strong> India Pvt. Ltd.<br />
A cooperation agreement between JIPL and <strong>Siemens</strong> <strong>VAI</strong> has been established<br />
in September 2011 for joint marketing and project execution of the CPT<br />
Technology in combination with allminerals beneficiation Technology in India.<br />
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CPT Project Setup for India - JIPL & <strong>Siemens</strong> <strong>VAI</strong><br />
A reliable and best performing project team<br />
S<strong>VAI</strong> Austria<br />
Scope of Work<br />
• Process Technology<br />
• Basic Engineering<br />
• Supply of key equipment<br />
• Advisory Services<br />
Key Responsibilities<br />
• Design of Pelletizing Process<br />
• Plant Performance<br />
• Specification of Plant Equipment<br />
+<br />
S<strong>VAI</strong> India<br />
Scope of Work<br />
• Detail Engineering<br />
• Supply of plant equipment<br />
• Electrics and Automation<br />
• Advisory Services<br />
Key Responsibilities<br />
• Timely project execution<br />
• Reliable E&A equipment based<br />
on <strong>Siemens</strong> components<br />
• After sales service and support<br />
JIPL India<br />
Scope of Work<br />
• Detail Engineering<br />
• Supply of plant equipment<br />
• Project Execution<br />
• Advisory Services<br />
Key Responsibilities<br />
• High quality and economical<br />
manufacturing of equipment<br />
• Local expertise in engineering<br />
and equipment procurement<br />
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Thank you for your attention!<br />
Contact:<br />
Andre Fulgencio<br />
Global Marketing Manager IR<br />
+43 664 615 0236<br />
<strong>Siemens</strong> <strong>VAI</strong><br />
Metals Technologies GmbH<br />
Turmstr. 44, P.O. Box 4,<br />
A 4031 Linz - Austria<br />
Tel: +43 (0) 70 6592-74495<br />
Fax: +43(0) 70 6980-5772<br />
E-mail: andre.fulgencio@siemens.com<br />
www.siemens-vai.com<br />
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