Recent Developments In Agglomeration Technologies For Iron Ores

Pelletizing and Sintering Colloquium 17-18 September 2008 SAIMM - Pretoria

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The Steel making Routes

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Steel Production
World crude steel production (in million tons)

1400 1200 1000 800 600 400 200 0 2000 2002 2004 2006 2007 188,3 127,2 106,4 98,5 134 193,3 203,1 280,5 182,2 107,7 101,2 121,6 188,3 112,7 113,4 132,7 202,3 116,2 119,8 130,4 206,8 120,2 124 130,1 210,3 227,3 422,7 489,2 269,2 254,3 other China Japan GUS NAFTA EU 27

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Steel Consumption in kg per Capita

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Development of raw material prices

Iron Ore Price [US$ / t dry]
Sources : CVRD, Wall Street Journal, US Steel and other steel producers.

140,00 120,00 100,00 [US$ / t dry] 80,00 60,00 40,00 20,00 0,00 1999

fines lump ore pellets

2000

2001

2002

2003

2004

2005

2006

2007

2008

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[US$ / t] 100 120 20 40 60 80 0

Development of raw material prices

Coking Coal Export Price [US$ / t]

Source: www.s teelonthenet.com

20 00 Q1 20 00 Q3 20 01 Q1 20 01 Q 20 3 02 Q 20 1 02 Q 20 3 03 Q 20 1 03 Q3 20 04 Q 20 1 04 Q 20 3 05 Q 20 1 05 Q 20 3 06 Q 20 1 06 Q 20 3 07 Q 20 1 07 Q 20 3 08 Q1

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Development in transport charges

Sea Freight Charges (Tubarao/Rotterdam) [US$ / t]
source: Erzkontor, Germany

50 45 40 35 [US$ / t] 30 25 20 15 10 5 0 2005Q1 2005Q2 2005Q3 2005Q4 2006Q1 2006Q2 2006Q3 2006Q4 2007Q1 2007Q2 2007Q3

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Environmental Regulations
Emission Limits
Country Germany Dust Emission 20 mg/m ntp 24h Immissionaverage 120 g/m Emission 100 mg/m ntp Emission 150 mg/m ntp SO2 Emission 500 mg/m ntp 24h Immissionaverage 200 g/m NO2 Emission 400 mg/m ntp 24h Immissionaverage 150 g/m Source TA Luft

Australia

WHO, USEPA, WAEPA local regulations

Brazil

India

Immission 120 g/m ntp

Immission 120 g/m ntp

Air Act 1981

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Consumption of Reductants

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CO2 emitents in BF steel production

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Pellet Market: New Projects 2008

LKAB KK4 5.0 Mill. t/a New Millennium 2x7.5 Mill. t/a QCM 7.5 Mill. t/a Northland 5.0 Mill. t/a Vest Alpine 2.0 Mill. t/a

M-GOK 5.0 Mill. t/a

~ 64 Pellet P ~ 17 Mill. t/ roje cts a 8M ill. t under 2008 /a u nde execut i r ev alua on tion
S-GOK 6.0 Mill. t/a Zhuhai YPM 1.5 Mill. t/a Baosteel 4.0 Mill. t/a WISCO 5.0 Mill. t/a

Essar MIS 6.0 Mill. t/a

Essar Trinidad 6.0 Mill. t/a

Gol-e-Gohar 5.0 Mill. t/a Sangan 2.4 Mill. t/a Gohar Zamin 2x5.0 Mill. t/a

SSGPO 6.0 Mill. t/a Ferrexpo 5.0 Mill. t/a

Caofeidia 4.0 Mill.

CVRD JV 4x1.5 Mill.

Caofeidian 4.0 Mill. t

MBR 7.0 Mill. t/a CSN 2x3.0 Mill. t/a

Tubaro VIII 7.5 Mill. t/a MMX Amap 3.5 Mill. t/a Samarco 4 7.5 Mill. t/a

SNIM/Sphere 7.0 Mill. t/a

JSW 3.5 Mill. t/a Brahmani River 4.0 Mill. t/a Essar Paradeep 6.0 Mill. t/a Tata Pellet 6.0 Mill. t/a Gua & Bolani

Amsteel 5.0 Mill. t/a Grange 6.0 Mill. t/a

GIC 5.0 Mill. t/a CVRD Sohar 4.5 Mill. t/a Al Tuwairqi 5.0 Mill. t/a Hadeed

Minas-Rio 7.0 Mill. t/a Ferrous 6.0 Mill. t/a Usiminas

CITIC 5.0 Mill. t/a

Gerdau 7.0 Mill. t/a

JSW West Bengal

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Sinter Market: New Projects 2008

8 200 tion ts je c execu ation ro r P nder valu te Sin l. t/a u der e Mil . t/a un 3 ~ 5 Mill 197 ~
P.R. China 33 plants 140.0 Mill. t/a Dragon Steel 2.5 Mill. t/a

Krivoi Rog 10.0 Mill. t/a Nucor 2.5 Mill. t/a Kardemir 2.8 Mill. t/a

Isdemir 3.4 Mill. t/a Formosa 5.0 Mill. t/a Tata KPO 5.75 Mill. t/a

CSA 4.8 Mill. t/a Aominas 2.5 Mill. t/a Belgo Min. 3.0 Mill. t/a Baosteel 7.0 Mill. t/a Usiminas 6.3 Mill. t/a Vallourec 1.2 Mill. t/a Kalahari 2.5 Mill. t/a Pecm 4.2 (5.3) Mill. t/a CSV 5.0 Mill. t/a

Tata SP4 2.3 Mill. t/a JSW 2 2.3 Mill. t/a

JSW 3 5.75 Mill. t/a Vizag Steel JSPL 3.6 Mill. t/a 7.2 Mill. t/a IISCO 4.6 Mill. t/a Rourkela Bhushan 4.6 Mill. t/a Durgapur Bhilai

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Typical flow sheet

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Typical layout of a 7.5 million tpa plant

Green Pelletizing Induration

Central Plant Dedusting

Substation Process Gas Cleaning

Cooling System Fuel Oil System

Additive Preparation

Dosing & Mixing

Regrinding

Filtration

Homogenization

Wet Grinding

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Plant Sizes vs. Investment Costs

100

90

80

70 Specific Investment Costs [%].

60

50

40 Limonite/ Whethered Ores Hematite 20 Magnetite 10

30

0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Plant Capacity [mtpy]

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Development of pellet plant size

Capacity in million t/a
8 7
Plant capacity (single strands) [mtpy] Samarco 3

7.5 Million t/a

6 5 4 3 2 1 0
1950 Samarco 1 Tilden Ijmuiden Hamersley Krivoi Rog Eagle Mountain Wabush Carol Lake Republic Eagle Mills Malmberget 1 1960 1970 1980 1990

Samarco 2

2000

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Samarco 3 with 768m and 7.5 Mtpy Worlds largest Pellet Plant

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Steel belt plant general layout

Pellets

Concentrate

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Steel belt process concept

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Simplification of Plant Design Roller Presses vs. Ball Mills

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Simplification of Plant Design Roller Presses vs. Ball Mills

Slurry Storage Grinding Roller Presses Bins Bins

Filtration

Thickening

Grinding and Filtration Section of a 4,000,000 t/a Pelletizing Plant

Comminution Section of a 7,000,000 t/a Plant

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Simplification of Plant Design

Conventional Vacuum Disc Filters Ceramic Filters
standard equipment for pellet feed dewatering

high investment costs (170 %), significant energy savings (-95%) => pay back in 3 5 years, larger sizes possible, few references with iron ore simplified plant layouts due to large sizes (up to 132m filtration area), significant energy savings, improved moisture control

Vertical Filter Presses

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Improvement of Operating Costs

Conservation or introduction of thermal energy to pellet feed/green pellets Improved green pellet qualities with narrow size distributions Improved screening concepts for hearth- and side layers Increased pellet bed heights Optimized heat balances and gas flow schemes External cooling areas Frequency controlled drives

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Specific Capacities

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Ore

Fluxes

Coke Return Lime Material Bins Fines

Sinter plant typical flow sheet

High Intensity Mixer

Granulator

Sinter Machine Waste Gas Fan and Gas Cleaning Sinter Cooler

Cold Crushing

Screening Hearth Layer

Product Sinter Return Fines

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Typical layout

Plant Dedusting

Sinter Machine with Ignition Furnace

Sinter Cooler

Mixing

Coke Raw Material Grinding Dosing

Screening

Waste Gas Cleaning

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Principle of EOS process

Sinter Emissions Residual Gas Volume Dust NOx SO2 CO CO2 Dioxines

LBS -40% -50% -35%

HBS -45% -60% -45% -30%

-45% -25% -70%

-50% -30% -65%

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Sinter plant with EOS hood

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EOS process principle compared to conventional sintering

Conventional sintering
Ambient air longitudinal sealing Evaporation Calcining C combustion with O 2 of air to CO 2 Formation of CO, S ox etc. Ambient air inleak cross and longitudinal sealing Evaporation Calcining C/CO combustion with O 2 Formation of CO, S ox etc. Recirculated gas Residual air Residual gas to be exhausted Ambient air inleak cross sealing only

EOS Process
Ambient air

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LEEP waste gas recycling process

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EPOSINT waste gas recycling process

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Bag filter technology

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High intensity mixer for sinter mix

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Dust mixer/granulator

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Space requirement for drums vs. HIM

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Future developments in Sintering

Use of pellet fines in the sinter mix Fine grinding of additives and coke Granulation process with pelletizing discs and/or drums Mixing/granulation with HIM Modified sinter machine feeding arrangements Frequency controlled drives Use of other solid fuels Modified process gas cleaning systems

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Thank you for your attention!

Walter Gerlach Outotec GmbH walter.gerlach@outotec.com