Circular Pelletizing Technology General Presentation: We Just Made It Better

Circular Pelletizing Technology
General Presentation
We didn’t invent
Pelletizing…
We just made it better.
Delhi, 10th of September 2012 Protection notice / Copyright notice

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
Protection notice / Copyright notice

Page 2 Sept‘12 Circular Pelletizing Technology IS MT IR TY AG
Trends in
Iron Ore Mining

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.
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

Circular Pelletizing
Technology
A Smart Combination

The Challenge of making iron ore pellets
Typical Flow Sheet of a Pelletizing Plant

Straight Grate Pelletizing Technology
Induration Process

Siemens VAI Sintering Technology
Mechanical design of a circular dip rail cooler

A SMART combination
Straight grate induration process 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.
+
Mechanical system of SVAI circular dip rail cooler
= Circular Pelletizing Technology
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 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
CPT combines proven process with reliable mechanical system

The Induration Process in Circular Arrangement

Technical Challenges during Engineering
Development of Indurating Machine
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.
Technical Challenges during Engineering
Development of Process Gas Flow
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 –
Layout, Plant Options

Page 15 Sept‘12
Mar ‘12 Circular Pelletizing Technology IS MT IR TY AG
Standard Plant Layout CPT 1.2M
CPT Standard Plant Layout:

1- Dosing & Green Balling


2- Additive Storage & Grinding


3- Mixing Station


3- Mixing Station
4- Induration Furnace


3- Mixing Station
5- Product Classification
1
3
5
2


3- Mixing Station
6- Product Pile 1
3
5
2


3- Mixing Station
6- Product Pile 1 7
7- Process Air Cleaning
3
5
2


3- Mixing Station
6- Product Pile 1 7
8- Coal Gasification Plant
4 8
3
5
2

Dual Fuel Burner Principle Scheme
Indigenous
Primary
Coal
Flare Air
Coal
Air
Gasif.
Ash
Fuels can be mixed in
every ratio.
HFO

Coal Gas Operational Data
Data of Coal Gas per Gasifier

(typical)
Minimum Properties of Coal
Coal input 1,76 t/h
C 30-35% Coal gas output 1250 Nm³/h
H 4,64%
Coal composition HV of coal gas 1250 kcal/Nm³
N 1,85%
S 0,95%
Coal gas temp. 350°C
Lower heat-value at 10% 3,300 C0 25%
wet kcal/kg H2 9%
Coal-grain size: 25 - 50 mm Coal gas CxHy 2,5%
CO2 6,5%
Ash content of coal 40% +/-2% N2 57%
Lowest Ash melting Dust content 300 mg/Nm³
1,080°C
point
Tar content 25-30 g/Nm³
Ash amount 0,69 t/h

Coal Gas OPEX Benefit
The OPEX comparison considers 50% utilization of Coal Gas
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
~8,43 M€ ~3,00 M€
50% of the Coal gasification plant
OPEX savings per year when substituting 50% of fuel
~5,43 M€
requirement with coal gas
*The comparison has been prepared for India based on Indian unit rates.
Top View of a CPT 1.2M in a Steelworks
CPT Plant Layout:

1- Iron Ore Grinding

1
2
CPT Plant Layout:

2- Dosing & Mixing Building

1
2
CPT Plant Layout:

3- Green Balling

4
1
2
CPT Plant Layout:

3- Green Balling

4
1
2
CPT Plant Layout:

1- Iron Ore Grinding 5
3- Green Balling

4
1
2
CPT Plant Layout: 6

3- Green Balling

4
1
2
CPT Plant Layout: 7 6

3- Green Balling
7- Product Intermediate Bin

4
1
2
8
3
CPT Plant Layout: 7 6

3- Green Balling
7- Product Intermediate Bin
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.

CPT in Figures

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%

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

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)

Advantages of CPT

Advantages
Benefits of CPT
 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
Advantages
Benefits of CPT
 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

Cooperation
Agreement

CPT Project Setup for India
Cooperation JIPL + Siemens VAI
+
Siemens VAI GmbH, Austria
Siemens VAI India Pvt. Ltd.
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 - 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 JIPL India

• Design of Pelletizing Process
SVAI India
• Plant Performance Scope of Work Scope of Work
• Specification of Plant Equipment • Detail Engineering • Detail Engineering
• Supply of plant equipment • Supply of plant equipment
• Electrics and Automation • Project Execution
• Advisory Services • Advisory Services
Key Responsibilities Key Responsibilities

• Timely project execution • High quality and economical
• Reliable E&A equipment based manufacturing of equipment
on Siemens components • Local expertise in engineering
• After sales service and support and equipment procurement

Thank you for your attention!
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


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Circular Pelletizing Technology

Delhi, 10th of September 2012 Protection notice / Copyright notice

1 Trends in Iron Ore Mining

2 Circular Pelletizing Technology – A Smart Combination

3 Circular Pelletizing Technology – Layout, Plant Options

5 Advantages of Siemens VAI Circular Pelletizing Plant

Protection notice / Copyright notice

Protection notice / Copyright notice

Global Decrease of Lump and Sinter Feed Ores

Good Bed Permeability and Reducilbility

Uniform chemical analysis

Easy handling and transportation

Lump ore Fines Concentrate

Protection notice / Copyright notice

Protection notice / Copyright notice

Protection notice / Copyright notice

Protection notice / Copyright notice

Protection notice / Copyright notice

Straight grate induration process Siemens VAI combines the well-

Circular Grate technology is based on proven design of straight grate

 Simple and robust design of equipment and gas flow

CPT combines proven process with reliable mechanical system

Protection notice / Copyright notice

Development of Indurating Machine

Development of Process Gas Flow

Protection notice / Copyright notice

Protection notice / Copyright notice

CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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CPT Standard Plant Layout:

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Data of Coal Gas per Gasifier

Ash amount 0,69 t/h

The OPEX comparison considers 50% utilization of Coal Gas

CPT Plant Layout:

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CPT Plant Layout:

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CPT Plant Layout:

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CPT Plant Layout:

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CPT Plant Layout:

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CPT Plant Layout: 6

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CPT Plant Layout: 7 6

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CPT Plant Layout: 7 6

CPT Plant Combinations: