Post on 02-Jul-2018
Protection notice / Copyright notice Protection notice / Copyright notice Delhi, 10th of September 2012
We didn’t invent
Pelletizing…
We just made it better.
Circular Pelletizing Technology
General Presentation
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Circular Pelletizing Technology (CPT)
Introduction
1 Trends in Iron Ore Mining
2 Circular Pelletizing Technology – A Smart Combination
3 Circular Pelletizing Technology – Layout, Plant Options
4 CPT in Figures
5 Advantages of Siemens VAI Circular Pelletizing Plant
6 Cooperation Agreement
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Trends in
Iron Ore Mining
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Why Pelletizing?
Global Decrease of Lump and Sinter Feed Ores
This tendency makes the utilitsation of fine and ultra
fine ores more and more important in next decades, for
which pelletizing is the only industrial scale proven
process.
Good Bed Permeability and Reducilbility
Due to the spherical shapes and the high porosity of
the pellets a high bed permeability and a high
reducibility of pellets is achieved, which is leading to
less energy consumption in the downstream processes.
Uniform chemical analysis
By beneficiating of ultrafines a very constant quality is
achieved leading to constant operation conditions.
Easy handling and transportation
By induration an excellent strength of pellets for further
handling and processing is achieved.
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Fines
From Ore to Iron
Process Routes in Ironmaking
Ore with high iron content Ore with low iron content
Beneficiation
Concentrate
Screening
Lump ore
Pelletizing Sintering
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Circular Pelletizing
Technology
A Smart Combination
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The Challenge of making iron ore pellets
Typical Flow Sheet of a Pelletizing Plant
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Straight Grate Pelletizing Technology
Induration Process
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Siemens VAI Sintering Technology
Mechanical design of a circular dip rail cooler
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Circular Pelletizing Technology
A SMART combination
+
Circular Pelletizing Technology
Straight grate induration process
= Mechanical system of SVAI circular dip rail cooler
Siemens VAI combines the well-
proven travelling grate process with
the simple and robust mechanical
design of a circular dip rail cooler.
The result is the revolutionary
Circular Pelletizing Technology.
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CPT combines proven process with reliable mechanical system
Design Criteria
Circular Grate technology is based on proven design of straight grate
Simple and robust design of equipment and gas flow
Circular design and small footprint of induration furnace with efficient
and optimized equipment utilization
Location of Circular Pelletizing Plant not necessarily at mine site, but also
at steel works or direct reduction plants
Induration furnaces for capacities between 0.8 and 3.0 mt/a considered
Production of high quality Blast Furnace and Direct Reduction grade
pellets as well as Manganese pellets
Circular Pelletizing Technology
Characteristics and Design Criteria
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Circular Pelletizing Technology
The Induration Process in Circular Arrangement
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By careful design of the pallet cars and the drive system combined with a
detailed stress analysis of the complete system a reliable and easy
maintainable indurating machine could be realized.
Development of Indurating Machine
Circular Pelletizing Technology
Technical Challenges during Engineering
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By simulating the process gas flows inside the indurating hood the
optimum arrangement and specific power of the burners could be defined.
Circular Pelletizing Technology
Technical Challenges during Engineering
Development of Process Gas Flow
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Circular Pelletizing
Technology –
Layout, Plant Options
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
1
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
1
2
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
1
3
2
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
4- Induration Furnace
1
3
2
4
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
4- Induration Furnace
5- Product Classification
1
3
2
4
5
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
4- Induration Furnace
5- Product Classification
6- Product Pile 1
3
2
4
5
6
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
4- Induration Furnace
5- Product Classification
6- Product Pile
7- Process Air Cleaning 1
3
2
4
5
6
7
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Circular Pelletizing Technology
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:
1- Dosing & Green Balling
2- Additive Storage & Grinding
3- Mixing Station
4- Induration Furnace
5- Product Classification
6- Product Pile
7- Process Air Cleaning
8- Coal Gasification Plant 8
1
3
2
4
5
6
7
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Circular Pelletizing Technology
Dual Fuel Burner Principle Scheme
Indigenous
Coal
Air
Ash
Flare
HFO
Primary
Air
Fuels can be mixed in
every ratio.
Coal
Gasif.
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Circular Pelletizing Technology
Coal Gas Operational Data
Minimum Properties of Coal
Coal composition
C 30-35%
H 4,64%
N 1,85%
S 0,95%
Lower heat-value at 10%
wet
3,300
kcal/kg
Coal-grain size: 25 - 50 mm
Ash content of coal 40% +/-2%
Lowest Ash melting
point 1,080°C
Data of Coal Gas per Gasifier
(typical)
Coal input 1,76 t/h
Coal gas output 1250 Nm³/h
HV of coal gas 1250 kcal/Nm³
Coal gas temp. 350°C
Coal gas
C0 25%
H2 9%
CxHy 2,5%
CO2 6,5%
N2 57%
Dust content 300 mg/Nm³
Tar content 25-30 g/Nm³
Ash amount 0,69 t/h
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*The comparison has been prepared for India based on Indian unit rates.
The OPEX comparison considers 50% utilization of Coal Gas
Circular Pelletizing Technology
Coal Gas OPEX Benefit
HFO Coal
Pellet production in tons per hour 153 t/h 153 t/h
Consumption in tons per hour 3,5 t/h 14,1 t/h
Cost for 1 ton of fuel* 608 € 54 €
Cost for fuel per hour 2129 € 758 €
Cost per ton of pellets 14 € 5 €
Cost per year (7920 hours) for 100% of one fuel ~16,86 M€ ~6,1 M€
Cost per year for fuel considering an availability of
50% of the Coal gasification plant ~8,43 M€ ~3,00 M€
OPEX savings per year when substituting 50% of fuel
requirement with coal gas ~5,43 M€
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
1
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
1 2
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
1
3
2
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
4- Additive Storage & Grinding
1
3
2
4
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Sept‘12 Circular Pelletizing Technology Page 31
Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
4- Additive Storage & Grinding
5- Induration Furnace
1
3
2
4
5
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
4- Additive Storage & Grinding
5- Induration Furnace
6- Product Classification
1
3
2
4
5
6
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Sept‘12 Circular Pelletizing Technology Page 33
Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
4- Additive Storage & Grinding
5- Induration Furnace
6- Product Classification
7- Product Intermediate Bin
1
3
2
4
5
6 7
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Circular Pelletizing Technology
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:
1- Iron Ore Grinding
2- Dosing & Mixing Building
3- Green Balling
4- Additive Storage & Grinding
5- Induration Furnace
6- Product Classification
7- Product Intermediate Bin
8- Process Air Cleaning
8
1
3
2
4
5
6 7
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Circular Pelletizing Technology
Plant Layout 2.5 Mtpa CPT + Midrex 1.7 Mtpa DRI Plant
CPT Plant Combinations:
By the production of DR-grade pellets the
next generation module size of CPT plants is
the ideal basis for a MIDREX® 1.7 Mtpa DRI
plant.
The new module can also be combined with
a 1.5 Mtpa COREX® plant for the production
of hot metal.
The complete combined plant solutions can
be offered by Siemens VAI.
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CPT in Figures
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Circular Pelletizing Technology
Production Figures
Productivity 0.8 – 3.0 Mtpa
Product Size < 5 mm < 5%
Product Size > 16 mm < 3%
CCS (Cold Crushing Strength) Av. 2500 N/Pe
TI (Tumble Index) > 6.3 mm > 92%
Reducibility (ISO 7215) > 70%
Swelling Index < 15%
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Circular Pelletizing Technology
Consumption Figures
Electr. energy requirement < 40 kWh / tpe
Heat energy requirement < 250 Mcal / tpe
Water requirement < 0.2 m³ / tpe
Compressed air < 25 m³ / tpe
Bentonite < 7 kg / tpe
Coke < 11 kg / tpe
Limestone < 11 kg / tpe
Refractories < 0.1 kg / tpe
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Circular Pelletizing Technology
Environmental Figures
Dust in waste gas (mgdry / Nm³) < 50
Work zone dust content (mgdry / Nm³) < 5
Noise level (dB(A)) < 85 (at 1 m from source)
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Advantages of CPT
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Compact plant layout, low building profile, short process air
ducts, completely standardized equipment
Efficient use of indurating machine because only 25% of pallets
cars not inside the furnace
Lowest weight of equipment and structural steel compared to
straight grate and rotary kiln pelletizing plants of similar capacity
Low overall CAPEX, specific investment costs comparable with
large pellet plants
Modular CPT concept for larger pellet capacities allows the
flexibility of producing different pellet qualities and quantities
specificlly to the market and Customer requirements
Benefits of CPT
Circular Pelletizing Technology
Advantages
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Excellent pellet quality as produced in straight grate induration
machines (BF vs DR grade pellets)
Low OPEX due to the compact layout (e.g. short process ducts)
and also due to use of various energy source for firing process
(e.g. indigenous coal via direct gasification)
Flexibility to define plant location: at mine or in steel plant site
due to low space requirement
Maintenance friendly: short shut-down time for pallet grate
exchange
Fully automated process control and plant operation
Benefits of CPT
Circular Pelletizing Technology
Advantages
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Cooperation
Agreement
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A cooperation agreement between JIPL and Siemens VAI has been established
in September 2011 for joint marketing and project execution of the CPT
Technology in combination with allminerals beneficiation Technology in India.
CPT Project Setup for India
Cooperation JIPL + Siemens VAI
+ Siemens VAI GmbH, Austria
Siemens VAI India Pvt. Ltd.
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CPT Project Setup for India - JIPL & Siemens VAI
A reliable and best performing project team
+ SVAI Austria Scope of Work
• Process Technology
• Basic Engineering
• Supply of key equipment
• Advisory Services
Key Responsibilities
• Design of Pelletizing Process
• Plant Performance
• Specification of Plant Equipment
SVAI India Scope of Work
• Detail Engineering
• Supply of plant equipment
• Electrics and Automation
• Advisory Services
Key Responsibilities
• Timely project execution
• Reliable E&A equipment based
on Siemens components
• After sales service and support
JIPL India Scope of Work
• Detail Engineering
• Supply of plant equipment
• Project Execution
• Advisory Services
Key Responsibilities
• High quality and economical
manufacturing of equipment
• Local expertise in engineering
and equipment procurement
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Contact:
Andre Fulgencio
Global Marketing Manager IR
+43 664 615 0236
Siemens VAI
Metals Technologies GmbH
Turmstr. 44, P.O. Box 4,
A 4031 Linz - Austria
Tel: +43 (0) 70 6592-74495
Fax: +43(0) 70 6980-5772
E-mail: andre.fulgencio@siemens.com
www.siemens-vai.com
Thank you for your attention!