03 Recent Developments In Agglomeration Technologies … Recent Developmen… · Steel Production...
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Recent Developments In Agglomeration Technologies For Iron Ores Pelletizing and Sintering Colloquium 17-18 September 2008 SAIMM - Pretoria
Transcript of 03 Recent Developments In Agglomeration Technologies … Recent Developmen… · Steel Production...
Recent Developments In Agglomeration Technologies For Iron Ores
Pelletizing and Sintering Colloquium17-18 September 2008
SAIMM - Pretoria
2/24/20092
The Steel making Routes
2/24/20093
Steel Production
193,3
134
98,5
106,4
127,2
188,3
188,3
121,6
101,2
107,7
182,2
203,1
202,3
132,7
113,4
112,7
280,5
227,3
206,8
130,4
119,8
116,2
422,7
254,3
210,3
130,1
124
120,2
489,2
269,2
0
200
400
600
800
1000
1200
1400
2000 2002 2004 2006 2007
World crude steel production (in million tons)
other
China
Japan
GUS
NAFTA
EU 27
2/24/20094
Steel Consumption in kg per Capita
2/24/20095
Development of raw material prices
Iron Ore Price [US$ / t dry]Sources : CVRD, Wall Street Journal, US Steel and other steel producers.
0,00
20,00
40,00
60,00
80,00
100,00
120,00
140,00
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
[US
$ / t
dry
]
fines
lump ore
pellets
2/24/20096
Development of raw material prices
Coking Coal Export Price [US$ / t]Source: www.s teelonthenet.com
0
20
40
60
80
100
120
2000
Q1
2000
Q3
2001
Q1
2001
Q3
2002
Q1
2002
Q3
2003
Q1
2003
Q3
2004
Q1
2004
Q3
2005
Q1
2005
Q3
2006
Q1
2006
Q3
2007
Q1
2007
Q3
2008
Q1
[US
$ / t
]
2/24/20097
Development in transport charges
Sea Freight Charges (Tubarao/Rotterdam) [US$ / t]source: Erzkontor, Germany
0
5
10
15
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30
35
40
45
50
2005-Q1
2005-Q2
2005-Q3
2005-Q4
2006-Q1
2006-Q2
2006-Q3
2006-Q4
2007-Q1
2007-Q2
2007-Q3
[U
S$
/ t]
2/24/20098
Environmental RegulationsEmission Limits
Country Dust SO2 NO2 Source
Germany Emission20 mg/m³ ntp
Emission500 mg/m³
ntp
Emission400 mg/m³
ntp
TA Luft
Australia 24hImmission-
average120 µg/m³
24hImmission-
average200 µg/m³
24hImmission-
average150 µg/m³
WHO, USEPA, WAEPA
Brazil Emission100 mg/m³
ntp
local regulations
India Emission 150 mg/m³
ntp
Immission120 µg/m³ ntp
Immission120 µg/m³ ntp
Air Act 1981
2/24/20099
Consumption of Reductants
2/24/200910
CO2 emitents in BF steel production
2/24/200911
Pellet Market: New Projects 2008
Tubarão VIII7.5 Mill. t/a
Zhuhai YPM1.5 Mill. t/a
S-GOK6.0 Mill. t/a
LKAB KK4 5.0 Mill. t/a
JSW3.5 Mill. t/a
Minas-Rio7.0 Mill. t/a
GIC 5.0 Mill. t/a
CSN2x3.0 Mill. t/a
Gohar Zamin2x5.0 Mill. t/a
CVRD Sohar4.5 Mill. t/a
Essar MIS6.0 Mill. t/a
New Millennium 2x7.5 Mill. t/a
Northland 5.0 Mill. t/a
SNIM/Sphere7.0 Mill. t/a
Sangan 2.4 Mill. t/a
Brahmani River 4.0 Mill. t/a
Tata Pellet6.0 Mill. t/a
Caofeidian 14.0 Mill. t/a
Essar Trinidad 6.0 Mill. t/a
M-GOK5.0 Mill. t/a
Al Tuwairqi5.0 Mill. t/a
Hadeed6.0 Mill. t/a
CITIC5.0 Mill. t/a
Baosteel4.0 Mill. t/a
Amsteel5.0 Mill. t/a
Grange6.0 Mill. t/a
Essar Paradeep6.0 Mill. t/a
Gol-e-Gohar5.0 Mill. t/a
SSGPO6.0 Mill. t/a CVRD JV’s
4x1.5 Mill. t/a
Samarco 47.5 Mill. t/a
MMX Amapá3.5 Mill. t/a
Gua & Bolani4.0 Mill. t/a
JSW West Bengal 6.0 Mill. t/a
WISCO5.0 Mill. t/a
Ferrexpo5.0 Mill. t/a
Ferrous6.0 Mill. t/a
Gerdau7.0 Mill. t/a
Usiminas6.0 Mill. t/a
MBR7.0 Mill. t/a
Pellet Projects 2008
~ 64 Mill. t/a under execution
~ 178 Mill. t/a under evaluation
QCM 7.5 Mill. t/a
Vöest Alpine 2.0 Mill. t/a
Caofeidian 24.0 Mill. t/a
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Sinter Market: New Projects 2008
Açominas2.5 Mill. t/a
Tata SP42.3 Mill. t/a
Usiminas6.3 Mill. t/a
JSW 35.75 Mill.
t/a
Nucor2.5 Mill. t/a
JSW 2 2.3 Mill. t/a
IISCO4.6 Mill. t/a
CSA4.8 Mill. t/a
Vizag Steel3.6 Mill. t/a
Bhushan4.6 Mill. t/a
Rourkela3.7 Mill. t/a
Durgapur3.4 Mill. t/a
Bhilai3.7 Mill. t/a
Vallourec1.2 Mill. t/a
Kalahari2.5 Mill. t/a
Pecém4.2 (5.3) Mill. t/a
CSV5.0 Mill. t/a
JSPL 7.2 Mill. t/a
Sinter Projects 2008
~ 53 Mill. t/a under execution
~ 197 Mill. t/a under evaluation
Kardemir2.8 Mill. t/a
Tata KPO5.75 Mill. t/a
Formosa 5.0 Mill. t/a Dragon Steel
2.5 Mill. t/a
Belgo Min.3.0 Mill. t/a
Baosteel7.0 Mill. t/a
Krivoi Rog10.0 Mill. t/a
P.R. China 33 plants140.0 Mill.
t/aIsdemir
3.4 Mill. t/a
2/24/200913
2/24/200914
Typical flow sheet
2/24/200915
Typical layout of a 7.5 million tpa plant
Wet GrindingHomogenizationFiltrationRegrindingDosing & Mixing
AdditivePreparation
GreenPelletizing Induration
Central Plant Dedusting
Process Gas Cleaning
Cooling System Fuel Oil System
Substation
2/24/200916
Plant Sizes vs. Investment Costs
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0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Plant Capacity [mtpy]
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cific
Inve
stm
ent C
osts
[%].
Limonite/Whethered Ores
Hematite
Magnetite
2/24/200917
Development of pellet plant size
Capacity in million t/a
Samarco 3
Samarco 2
Samarco 1
Tilden
Ijmuiden
Hamersley
Krivoi RogEagle Mountain
WabushCarol Lake
Republic
Malmberget 1Eagle Mills
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Pla
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apac
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sing
le s
trand
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tpy]
7.5 Million t/a
2/24/200918
Samarco 3 with 768m² and 7.5 MtpyWorld’s largest Pellet Plant
2/24/200919
Steel belt plant – general layout
Concentrate
Pellets
2/24/200920
Steel belt – process concept
2/24/200921
Simplification of Plant DesignRoller Presses vs. Ball Mills
2/24/200922
Simplification of Plant DesignRoller Presses vs. Ball Mills
Comminution Section of a 7,000,000 t/a Plant
Grinding and Filtration Section of a 4,000,000 t/a Pelletizing Plant
BinsBins
RollerPresses
Grinding
Thickening
Slurry Storage
Filtration
2/24/200923
standard equipment for pellet feed dewateringConventional
Vacuum Disc Filters
simplified plant layouts due to large sizes (up to 132m² filtration area),significant energy savings,improved moisture control
Vertical Filter Presses
high investment costs (170 %),significant energy savings (-95%)=> pay back in 3 – 5 years, larger sizes possible,few references with iron ore
Ceramic Filters
Simplification of Plant Design
2/24/200924
Improvement of Operating Costs
Ø Conservation or introduction of thermal energy to pellet feed/green pellets
Ø Improved green pellet qualities with narrow size distributions
Ø Improved screening concepts for hearth- and side layers
Ø Increased pellet bed heights
Ø Optimized heat balances and gas flow schemes
Ø External cooling areas
Ø Frequency controlled drives
2/24/200925
Specific Capacities
2/24/200926
2/24/200927
Material BinsOre Fluxes Coke Return Fines
Lime
Sinter Machine
Sinter Cooler
Screening
Waste Gas Fan andGas Cleaning
Hearth Layer
Return FinesProduct Sinter
ColdCrushing
Granulator
High Intensity Mixer
Sinter plant – typical flow sheet
2/24/200928
Raw Material Dosing
Sinter Machine withIgnition Furnace
SinterCooler
Screening Waste GasCleaning
Typical layout
CokeGrinding
Mixing
Plant Dedusting
2/24/200929
2/24/200930
Principle of EOS process
Sinter Emissions LBS HBS
Residual Gas Volume
-40% -45%
Dust -50% -60%
NOx -35% -45%
SO2 -30%
CO -45% -50%
CO2 -25% -30%
Dioxines -70% -65%
2/24/200931
Sinter plant with EOS hood
2/24/200932
EOS process principle compared to conventional sintering
Evaporation
Calcining
C combustion withO2 of air to CO2
Formation of CO, Sox etc.
Ambient air
Residual air
Ambient air inleakcross andlongitudinal sealing
Conventional sintering
Evaporation
Calcining
C/CO combustionwith O2
Formation of CO, Sox etc.
Ambient air
Residual gasto be exhausted
Ambient air inleakcross sealing only
EOS® Process
Recirculated gas
longitudinal sealing
2/24/200933
LEEP waste gas recycling process
2/24/200934
EPOSINT waste gas recycling process
2/24/200935
Bag filter technology
2/24/200936
2/24/200937
High intensity mixer for sinter mix
2/24/200938
Dust mixer/granulator
2/24/200939
Space requirement for drums vs. HIM
2/24/200940
Future developments in Sintering
Ø Use of pellet fines in the sinter mix
Ø Fine grinding of additives and coke
Ø Granulation process with pelletizing discs and/or drums
Ø Mixing/granulation with HIM
Ø Modified sinter machine feeding arrangements
Ø Frequency controlled drives
Ø Use of other solid fuels
Ø Modified process gas cleaning systems
