SVAI Circular Pelletizing Jun12 LR

Circular Pelletizing Technology
General Presentation
We didnt invent
Pelletizing
We just made it better.
Linz, June 2012
Protection notice / Copyright notice
Circular Pelletizing Technology (CPT)

Introduction
1
2
Trends in Iron Ore Mining
Circular Pelletizing Technology = A Smart Combination
Circular Pelletizing Plant Walk Through
Circular Pelletizing Plant Plant Details
Advantages of Siemens VAI Circular Pelletizing Plant
CPT in Figures
Siemens VAI A Long History in Pelletizing Business
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Trends in
Iron Ore Mining
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Trends in Iron Ore Mining
Strong tendency towards production of fine ore and ultra fine ore grades
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From Ore to Iron

Process Routes in Ironmaking
Ore with high iron content
Ore with low iron content
Screening
Beneficiation
Lump ore
Fines
Concentrate
Sintering
Pelletizing
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Why Pelletizing?
Good Bed Permeability
Due to the spherical shapes and the high porosity of
the pellets a high bed permeability is achieved, which is
beneficial in shaft-type ironmaking processes.
Good Reducibility
The high reducibility of pellets is leading to less energy
consumption in the downstream processes.
Low energy consumption
Pelletizing process requires less heat than sintering.
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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Pellet Production 1999 - 2019
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A Long History in
Pelletizing Business
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Siemens VAI 40 years experience

in straight grate pelletizing
1978
Mandovi Pellets
India
1.8 Mt/a
Limonite
1978
SIDOR
Venezuela
2 x 3.3 Mt/a
Limonite
1969
Tubarao 1
Vale, Brazil
2.0 Mt/a
Hematite
1973
Tubarao 2
Vale, Brazil
3.0 Mt/a
Hematite
1970
1966
Siemens VAI enters
pelletizing business
(VOEST-Alpine)
References
2001
Pelletizing Plant
modernization studies
1981
Delta Steel
Nigeria
1.5 mt/a
Hematite
1980
2011
First Circular
Pelletizing Plant
implemented in India
1976-2011
Primary focus
on Sinter Plants
1990
2000
1977
License Agreement with
LURGI (today Outotec)
2005
2010
2004
LURGI Pelletizing
License terminated
2015
2010
Acquisition of Circular
Pelletizing Technology
Milestones
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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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Temperature and Processing Zones
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Siemens VAI Sintering Technology

Mechanical design of a circular dip rail cooler
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A SMART combination
Mechanical Principles applied:
Straight grate induration process
Pallets move through the different process zones

of the induration furnace on circular rails
Pallets are connected to carrying rings and pulled
through the induration furnace by means of a
drive mechanism which is located at the feed area
At the end of the induration furnace, pallets are
tilted to discharge the cooled pellet product
Pallets can be easily removed and exchanged
during short term maintenance intervals
+
=
Mechanical system of SVAI circular dip rail cooler

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Characteristics and Design Criteria
Circular Grate technology is based on proven design of straight grate
Plant and Process Characteristics
Proven process technology utilized in straight grate pelletizing plants
Experiences from Siemens VAI circular sinter coolers utilized
Induration furnaces for capacities between 0.8 and 2.5 mt/a considered
The induration cycle is identical to straight grate and the induration
process is designed based on pot grate tests for each ore type
Small footprint of induration furnace with efficient and optimized
equipment utilization
Fully automated process control and plant operation
CPT combines proven process with reliable mechanical system
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Characteristics and Design Criteria
Circular Grate technology is based on proven design of straight grate
Design Criteria
Simple and robust design of equipment and gas flow
Circular design and light building structure lead to light weight
and low CAPEX
Optimized process for excellent plant performance and quality as well as
low energy consumption
Location of Circular Pelletizing Plant not necessarily at mine site, but also
at steel works or direct reduction plants
Produces high quality Blast Furnace and Direct Reduction grade pellets
as well as Manganese pellets
CPT combines proven process with reliable mechanical system
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The induration process in a circular arrangement
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Typical Plant Layout
CPT Plant Layout:

1- Dosing & Green Balling
2- Mixing Station
3- Induration Furnace
4- Product Classification
5- Product Pile
6- Process Air Cleaning
7- Coal Gasification Plant
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IS MT IR TY AG

Typical Plant Layout
CPT Plant Layout:
1- Dosing & Green Balling
2- Mixing Station
3- Induration Furnace
4- Product Classification
5- Product Pile
6- Process Air Cleaning
7- Coal Gasification Plant
2
6
3
7
4
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Plant Walk Through
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Pictures
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Plant Plant Details
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Feeding Area
Wide belt conveyor
Reciprocating conveyor
Roller screen for

separating fines and
equalizing pellet feed
Fines return belt

conveyors
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Firing Area
Furnace hood
Burner
Pallet grate
Wind box
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Dumping and Service Area
Service area
Pallets are tilted along this rail for pellet discharge

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Drive System
Pallets are pulled by carrying rings (inner and outer),

which are driven by lantern wheel drive
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Induration Machine - Cross Section - Firing Zone
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Advantages of CPT
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Advantages
Benefits of CPT
Compact plant layout, low building profile, short process air ducts, completely
standardized equipment
Specific investment costs comparable with large pellet plants, low overall CAPEX
Flexibility to define plant location: at mine or in steel plant site
Efficient use of expendable traveling grate components = 25% of pallets cars not
inside the furnace)
Maintenance friendly: short shut-down time for pallet grate exchange
High environmental standards applied
Excellent pellet quality as produced in straight grate induration machines
Low OPEX due to use of various energy source for firing process (e.g.
indigenous coal via gasification)
No waste materials 100% recycling loops for all input materials, high
environmental standards applied
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CPT in Figures
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Production and Consumption Figures
Productivity at 1.2 Mtpy
> 150 tpe / h
Electr. energy requirement
< 40 kWh / tpe
Heat energy requirement
< 250 Mcal / tpe
Water requirement
< 0.2 m / tpe
Compressed air
< 25 m / tpe
Bentonite
< 7 kg / tpe
Coke
< 11 kg / tpe
Limestone
< 11 kg / tpe
Refractories
< 0.1 kg / tpe

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IS MT IR TY AG

Environmental Figures
Dust in waste gas (mgdry / Nm)
< 50
Work zone dust content (mgdry / Nm)
<5
Noise level (dB(A))
< 85 (at 1 m from source)
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Thank you for your attention!
CPT: a Technological evolution that

will change the World of Pelletizing
Siemens VAI
Changing the World.

Contact:
Andre Fulgencio
Global Marketing Manager Ironmaking
+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
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June 12
IS MT IR TY AG

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Circular Pelletizing Technology

We just made it better.

Linz, June 2012

Protection notice / Copyright notice

Circular Pelletizing Technology (CPT)

Trends in Iron Ore Mining

Circular Pelletizing Technology = A Smart Combination

Circular Pelletizing Plant Walk Through

Circular Pelletizing Plant Plant Details

Advantages of Siemens VAI Circular Pelletizing Plant

Siemens VAI A Long History in Pelletizing Business

Protection notice / Copyright notice

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

From Ore to Iron

Ore with high iron content

Ore with low iron content

Protection notice / Copyright notice

Circular Pelletizing Technology

Circular Pelletizing Technology

Pellet Production 1999 - 2019

Protection notice / Copyright notice

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

Siemens VAI 40 years experience

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

The Challenge of making iron ore pellets

Protection notice / Copyright notice

Circular Pelletizing Technology

Straight Grate Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

Temperature and Processing Zones

Protection notice / Copyright notice

Circular Pelletizing Technology

Siemens VAI Sintering Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

Circular Pelletizing Technology

Straight grate induration process

Pallets move through the different process zones

Circular Pelletizing Technology

Circular Pelletizing Technology

Circular Pelletizing Technology

Circular Pelletizing Technology

Circular Pelletizing Technology

Circular Pelletizing Technology

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology

Circular Pelletizing Technology

CPT Plant Layout:

Protection notice / Copyright notice

Circular Pelletizing Technology

Circular Pelletizing Technology

Protection notice / Copyright notice

Circular Pelletizing Technology