MANGANESE ORE SINTERING MISCONCEPTS AND FACTS - IIM

MANGANESE ORE SINTERINGMISCONCEPTS AND FACTSCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.Presented by - Rajendra Sane

AGENDA1.0 GESPL Company Introduction2.0 Products and services3.0 Misconcepts and Facts4.0 Recommendations5.0 Conclusions6.0 Sintering SolutionsCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

COMPANY INTRODUCTION• Established in the year 1986, GESPL is a groupof experts with collective domain experience ofmore than 35 years• Leaders in our field, GESPL is the only Indian companyto successfully commission close to 100 SAF’sin the last 24 years• SAF designs from 3.6 MVA to 33 MVA capacities• In house engineering, design, manufacturingservices (M.I.D.C area) with fully equippedinstallation and commission crew• Vast international experience with establishmentsin countries Bahrain, Democratic Republic ofCongo, Bhutan & Pakistan• Projects under execution / active discussions inIran, Oman, Vietnam, Kuwait, Kyrgyzstan, Tunisia,South Africa, Turkey, South America & BangladeshCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

PRODUCTS AND SERVICESCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

FIRST MISCONCEPTNo need for sintering. Furnace of any size can easilytolerate fines of -6mm varying from 20% to 50% withoutany problem.FACT• Irrespective of furnace size, fines should not be used.• Leads to technological abuses to smelting process,human health and equipment health.• For short time gains, log time benefits should not besacrificed.5

ExampleLUMPY ORE + FINES(WITHOUT SINTERING)SiMn – 2.2 T of 36-37% Mn ore is consumed.Suppose 50% fines are charged. Cost of Lumps & fines at 50:50 is1.1T @ Rs. 12000/T of Lumpy Ore = Rs. 13,200+ 1.1T @ Rs. 6000/T of Fines = Rs. 6,600__________= Rs.19,800 against Rs. 26,400 of100% lumps i.e. difference of Rs. 6,600/T of SiMn. This is the real culprit temptation.SINTERING OF ORECost of sintering -- Rs. 1600 /T of finesTherefore Cost of Sinter = 2.42T @ Rs. 6,600/T = Rs. 15,972+ 2.20T @ Rs.1,600/T =Rs. 3,520+ Add : interest and depreciation @ Rs. 700/T _________=Rs. 20,200/T of SiMnDifference is only Rs. 400/T which can be compensated with all the benefits of useof lumpy, porous, highly resistive sinter.6

SECOND MISCONCEPTDuring sintering, the silica content in finished sinterincreases to great extent leading to higher slag volume,higher Mn losses and higher power, so sinters areuneconomical.FACT• Oxygen loss during sintering is 9 to 10 % only(MnO2 Mn3O4).• Silica (SiO2) addition through coke is 1 to 1.2 %only.• Overall silica (SiO2) increase in Mn input is 0.6 to0.65 % only.7

THIRD MISCONCEPTSinters are very weak, friable and generate excessivefines during handling inside the plant.FACT• Mn ore sinters are almost as strong as iron ore sinters.• TI & AI can be controlled by proper coke rate, moisturecontent, sintering time & RF addition.• Mn ore sinters with 80 – 84 % TI & less than 3 % AI canbe produced.8

FOURTH MISCONCEPTSinters can not be transported by road or rail.FACT• Sinters are stable and have good physical strength.• Can be transported by road / rail, if required, withoutgenerating excessive fines.9

FIFTH MISCONCEPTFines of -1mm or -0.5mm in size can not be sintered.FACT• Fines (all -1mm with more than 50% -0.5 mm fraction)can also be sintered.• Achievable through control of balling method, moisturecontrol, coke size, permeability & suction control.10

RECOMMENDATIONS• Please get to know your ore – not only chemical analysis but itsmineralogy and mineral association also.• Every deposit is different than other. Response to sinteringprocess parameters may be different.• Conduct basic sintering study to understand amenability of yourore to sintering. A small amount invested in R&D study will bebeneficial & cost saving in the long run.• Overcome the fear and misconcept about Mn Ore sinters, withpragmatic thinking.11

CONCLUSIONSCharacteristics comparison between fines and sinters of Mn Ore forFeMn / SiMn productionSN DETAILS Mn ORE FINES Mn ORE SINTERS1Use in FeMn /SiMn Production2 Silica contentLimited to 10% (maximum) alongwith lumpy ore. Otherwise screenedore i.e. +3mm or +5mm only beVarying from 30% to 85% inused. 100% fines are nevervarious plants.tolerated in furnaces, however, fewRecent development – 100% usecases have been reported to usein SiMn production plant in12mm ore fines with furnace cap ofFrance.7.5 MVA / 9 MVA only. Tolerance inlarge furnaces (12 MVA & above) isrestricted to 5 to 8% only.Normally higher than lumps, leadingto higher slag volume which in turnincreases power.Increases by 1%(Max) over finesdue to addition of Coke finesduring sintering12

CONCLUSIONSCharacteristics comparison between fines and sinters of Mn Ore forFeMn / SiMn productionSN DETAILS Mn ORE FINES Mn ORE SINTERS3 Phos content Normally higher than lumps.4 Porosity5Thermaldissociation in thefurnaceNIL. Fines tend to decreasespermeability of charge mix and withmoisture, certainly forms crust.Tendency to hold moisture and withlow permeability leads to furnaceexplosions and eratic eruption.Eratic dissociation. Fumes lossesare high.Part of Phos reacts duringsintering and hence there isslight decrease in phos content35% to 45% porosity, whichhelps in better permeability ofcharge and much better gas solidreactions. Smelting time reduces.Sinters are stable upto 900degree C which maintainexcellent material descend in F/Cand good reaction zone isachieved. 13

CONCLUSIONSCharacteristics comparison between fines and sinters of Mn Ore forFeMn / SiMn productionSN DETAILS Mn ORE FINES Mn ORE SINTERS6 Coke consumption Same as lumps.7 ElectricaladvantageCoke consumption is slightlyreduced as sinters are partiallyprereduced. Coke breeze i.e. -5mm fines of coke are fully usedin sintering.Due to high porosity, chargeResistivity is uncertain. Segregation resistance is increased whichof different mineral particles likely to leads to improved power factortake place. Adverse effect on and in turn deeper penetration ofspecific power is noticed. High electrode. This results intopower and reduced productivity. reduced power consumption andincreased productivity.14

CONCLUSIONSCharacteristics comparison between fines and sinters of Mn Ore forFeMn / SiMn productionSN DETAILS Mn ORE FINES Mn ORE SINTERS8 Thermal stability9 Pollution ControlEruptions and slag boils become There is no moisture or fines inunavoidable. Often crust formation charge. Furnace operation isis observed leading to eratic very stable and chargebehavior, electrode slipping movement in and aroundproblems, electrode tilting and electrode is very smooth. Therebreakage leading to high power and are no eruptions or slag boil orpaste consumption.explosions with use of sinters.Lot of dust nuisance. Otherwise -2or -3 mm material needs to betotally removed leading to heavywastage of material.Since fines are separated andagglomerated there is no dustnuisance. '15

CONCLUSIONSCharacteristics comparison between fines and sinters of Mn Ore forFeMn / SiMn productionSN DETAILS Mn ORE FINES Mn ORE SINTERS10Financial Gains/LossesDue to heavy moisture andcrust formation, electricalpower is very high leading toproduction and productivityloss. On an average fines tendto increase specific powerconsumption by 200 to 400Unit/T of alloy.i) All the fines are used including finesgenerated during sintering.ii) Coke fines are gainfully utilized.iii)Entire moisture is driven off insintering and product is totally dry.iv) Fines are available at reducedprices. Even with cost of sintering it iscomparable to lumps.v) Expected saving in power upto 200KWH/T of product. (75-80% sinters infeed)Productivity increases between 4 to7%.16

GESPL SOLUTION FOR INDEGINEOUS SINTER PLANTSExclusive Licensee Agreement with MINITEC - BrasilUnique carousal design for sinter plants – cost effectiveWorld class technology from Brasil, manufacturing in IndiaSintering for iron, manganese, tin oresCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

GENERAL VIEW - CAROUSEL SIDECopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

ADVANTAGES OF MINITEC-GESPL SINTER PLANTS• Low specific investment• Waste gas leak proof system• Excellent sinter quality• Full process automation• Low cost of production• High operational flexibility• Maintenance free design• Very compact – saves spaceCopyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

Copyright 2007. Ghalsasi Engineering Systems Pvt.Ltd. All Rights Reserved.

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