THE DESIGN, COMMISSIONING AND OPERATION OF

THE BROKEN HILL PROPRIETARY CO. LTD. PELLET PLANT AT

WHYALLA -
SOUTH AUSTRALIA.

C. F. Kaiser
P e l l e t Plant Superintendent
The Broken H i l l P r o p r i e t a r y Co. Ltd. -
Whyalla South A u s t r a l i a
J . M. Van De P l a s s e
Chief Engineer
AlliscChalmers A u s t r a l i a Pty. Ltd. -Sydney, N.S.W. A u s t r a l i a
J. D. H i n r i c h s e n
P r o c e s s Engineer
A l l i s - C h a l m e r s Process Research & T e s t C e n t e r , Oak Creek
Wisconsin U.S.A.
,
! Introduction
I
I
I The Broken H i l l P r o p r i e t a r y Company Limited d e c i d e d i n t h e l a t t e r h a l f of 1964 t o
: b u i l d a p e l l e t p l a n t w i t h a nominal c a p a c i t y of 1.5 m i l l i o n t o n s p e r annum.
Allis-Chalmers A u s t r a l i a Pty. Limited was awarded t h e main c o n t r a c t on 1 1 t h J u n e ,
1965, t o d e s i g n , s u p p l y , c o n s t r u c t and commission, t h e o r e p r e p a r a t i o n , b a l l i n g and
i n d u r a t i o n s e c t i o n s of t h e p l a n t , w h i l e t h e B.H.P. Co. Ltd. s u p p l i e d t h e s c r e e n i n g
p l a n t , o r e b l e n d i n g p l a n t , p e l l e t s t o r a g e and l o a d i n g f a c i l i t i e s .

C o n s t r u c t i o n work commenced on s i t e i n September, 1965, and t h e p l a n t produced

f i r e d p e l l e t s f o r t h e f i r s t time on 1 3 t h May, 1968.

I n October 1968 B.H.P. commenced s u p p l y i n g 9.9 m i l l i o n t o n s of a c i d p e l l e t s over a n

8 year p e r i o d t o a group of Japanese Steelmakers. The members of t h e group a r e -
Yawata I r o n and S t e e l Co. Ltd., F u j i I r o n and S t e e l Co. Ltd.., Nippon Kokan Kabushiki
Kaisha, Sumitomo Metal I n d u s t r i e s Ltd., Kawasaki S t e e l C o r p o r a t i o n and Kobe ' S t e e l Ltd.
The balance of t h e p r o d u c t i o n from t h e p l a n t has been used i n b l a s t f u r n a c e s a t
A u s t r a l i a n I r o n and S t e e l Pty. Ltd., P o r t Kembla, a s u b s i d i a r y of B.H.P.

P l a n t Location

he p e l l e t p l a n t was c o n s t r u c t e d i n South A u s t r a l i a a t Whyalla, a n e s t a b l i s h e d

p o r t w i t h a n i n t e g r a t e d Steelworks and s h i p b u i l d i n g yards. The p l a n t was l o c a t e d on
a n a r e a of reclaimed l a n d next t o e x i s t i n g b i n s and j e t t y . These f a c i l i t i e s a r e used
t o l o a d c o a s t a l f r e i g h t e r s s u p p l y i n g i r o n o r e t o B.H.P. o p e r a t e d s t e e l w o r k s l o c a t e d a t
P o r t Kembla and Newcastle on t h e e a s t c o a s t of A u s t r a l i a . Two a d d i t i o n a l b i n s w i t h a
t o t a l c a p a c i t y of 200,000 t o n s were c o n s t r u c t e d f o r p e l l e t s t o r a g e .

V e s s e l s up t o 68,000 t o n s deadweight w i l l be used t o t r a n s p o r t p e l l e t s from

Whyalla t o Japan.

P l a n t Feed

The p l a n t f e e d is mined by open c u t methods a t t h e North I r o n P r i n c e Quarry a t I r o n

Baron Township and crushed t o minus 2 i n . a t t h e mine s i t e b e f o r e b e i n g r a i l e d 29
m i l e s t o Whyalla. . . ..

North I r o n P r i n c e o r e i s a mixture of h e m a t i t e and m a r t i t e and i t i s predominantly

s o f t and f r i a b l e . The main contaminates i n t h e o r e a r e decomposed a m p h i b o l i t e s , which
a r e i n t r u s i v e i n t h e d e p o s i t , and weathered g n e i s s e s and s c h i s t s which a r e t h e
basement rocks.

The grade of o r e from t h e q u a r r y v a r i e s between 65% Fe and 67% Fe. The o r e , which
had a v a r i a b l e f i n e s c o n t e n t i s s c r e e n e d a t Whyalla t o produce minus $ i n . f i n e s f o r
p e l l e t p l a n t feed. Because of i t s s o f t f r i a b l e n a t u r e , t h e s c r e e n o v e r s i z e i s n o t
c o n s i d e r e d t o be s a t i s f a c t o r y b l a s t f u r n a c e f e e d and lumps a r e p r o g r e s s i v e l y reduced
i n s i z e by c r u s h i n g u n t i l a t l e a s t 80% of t h e o r i g i n a l o r e has been recovered a s
minus 4 i n . f i n e s . The balance of t h e lumps i s t h e n used a s b l a s t furnace feed.

F i n e s from t h e o r e s c r e e n i n g and c r u s h i n g p l a n t a r e blended by l a y e r i n g i n t o a

covered s t o r a g e b u i l d i n g t o produce 15,000 t o n s of blended p l a n t f e e d w i t h an i r o n
c o n t e n t between 65.5% and 66.5% Fe.

The pe1,let p l a n t f e e d m a t e r i a l i s r e l a t i v e l y f i n e being on a n average 2070 minus

325 mesh i n s i z e . The moisture c o n t e n t v a r i e s between 0.8% and 2.81%.

The f e e d m a t e r i a l is recovered from s t o c k p i l e f o r p e l l e t p l a n t use a t a c o n t r o l l e d

r a t e by a bucket wheel r e c l a i m e r .

B a s i s of Design

B.H.P. s p e c i f i e d t h a t t h e ore from t h e North I r o n P r i n c e quarry would be v a r i a b l e

i n chemical and p h y s i c a l p r o p e r t i e s and t h a t t h e p l a n t was t o be c a p a b l e of producing
a c i d p e l l e t s , , o r f l u x e d p e l l e t s w i t h a maximum limestone a d d i t i o n t o t h e f e e d of 1 0
per cent.

The s i z i n g and s e l e c t i o n of a l l equipment was f i x e d by agreement between B.H.P. and

Allis-Chalmers. I t was a c c e p t e d t h a t t h e p l a n t would produce a v a r i a b l e tonnage of
p e l l e t s dependent t o some e x t e n t on t h e o r e t o be t r e a t e d . However, a minimum
q u a n t i t y of 1.5 m i l l i o n t o n s per annum of a c i d o r f l u x e d p e l l e t s was r e q u i r e d . T h i s
y e a r l y tonnage r a t e was o b t a i n e d by m u l t i p l y i n g t h e e x p e c t e d d a i l y p r o d u c t i o n r a t e of
4,574 t o n s by 328, t h e number of days t h e p l a n t was e x p e c t e d t o o p e r a t e per year.

B.H.P. s p e c i f i e d t h a t i f p o s s i b l e t h e o r e was t o be p r e p a r e d f o r b a l l i n g by dry

g r i n d i n g and w e t t i n g i n pug m i l l s . I n a d d i t i o n , b a l l i n g drums were s p e c i f i e d f o r t h e
b a l l i n g o p e r a t i o n and Wyoming b e n t o n i t e o r s l a k e d lime was t o be used a s a binder.

The cl.imatic c o n d i t i o n s a t Whyalla a r e shown i n Table 1.

Table 1. Climatic Conditions

- Whyalla.
F r e s h Water temperatures . Ambient a i r shade
temperature .Jan. July
Summer maximum 6 5 F.
0
0
Record maximum :121°F -
Winter minimum 52 F. Normal maximum :LO~OF -
Mean 5 8 ' ~ Average d a i l y
maximum 86'~ 59'~
Average d a i l y
minimum 6 1OF 553
Minimum - 32 F
 T e s t Work

.B.H.P. shipped 35 t o n s of v a r i o u s grades of i r o n o r e and 4 t o n s of limesands t o t h e

Allis-Chalmers Oak Creek L a b o r a t o r i e s i n Wisconsin, U.S.A. Extensive testwork was
c a r r i e d o u t a t t h i s c e n t r e and a l s o a t The EIMCO C o r p o r a t i o n and Barber Greene.

The aim of t h e t e s t work was t o determine -

1. The most s u i t a b l e method of g r i n d i n g and p r e p a r i n g f e e d f o r b a l l i n g .
2. The equipment t h a t would produce t h e optimum q u a l i t y green b a l l s from t h e ground
wet - m a t e r i a l .
3. The i n d u r a t i o n equipment t h a t would be r e q u i r e d t o h e a t harden f l u x e d o r a c i d
pellets.
4. The q u a l i t y of t h e f i n a l p e l l e t s t h a t would be produced from t h e i n d u r a t i o n s e c t i o n .

Ore P r e p a r a t i o n T e s t Work

There were two processes f o r t h e p r e p a r a t i o n of t h e I r o n P r i n c e o r e f o r b a l l i n g .

The f i r s t p r o c e s s involved t h e wet g r i n d i n g of t h e f e e d m a t e r i a l i n c l o s e d o r open
c i r c u i t t o t h e d e s i r e d s i z i n g , and f i l t r a t i o n of t h e f i n a l product t o s l i g h t l y l e s s
t h a n b a l l i n g moisture.

The second p r o c e s s used d r y i n g of t h e f e e d followed by dry g r i n d i n g i n c l o s e d o r

I open c i r c u i t , t o o b t a i n f i n e f e e d f o r b a l l i n g . A f t e r g r i n d i n g , t h e o r e had t o be
I w e t t e d . t o b a l l i n g moisture.

I n i t i a l i n v e s t i g a t i o n s showed t h a t wet g r i n d i n g was not f e a s i b l e because l a r g e

tonnages of f e e d could not be economically f i l t e r e d t o t h e d e s i r e d moisture c o n t e n t
f o r b a l l i n g . The h i g h e s t f i l t r a t i o n r a t e t h a t was o b t a i n e d was 75 l b s . of dry s o l i d s
per sq. f t . of f i l t e r a r e a per 24 hours.

Other f a c t o r s which caused open c i r c u i t dry g r i n d i n g t o be favoured over wet

g r i n d i n g were -
1. B a l l and l i n e r wear were p r e d i c t e d t o be lower.
2. Absence of c l a s s i f y i n g equipment would reduce maintenance c o s t .
3. Open c i r c u i t dry g r i n d i n g produced a product w i t h high percentage of f i n e s which
was i d e a l f o r b a l l i n g .
4. I t was p o s s i b l e t o pre-wet t h e o r e t o enable b a l l i n g t o be c a r r i e d o u t a t t h e
lowest p o s s i b l e moisture content. This would r e s u l t i n lower f u e l consumption i n
the induration section.

A f t e r t h e b a s i c d e c i s i o n had been made t o use dry g r i n d i n g i n s t e a d of wet g r i n d i n g ,

f u r t h e r t e s t work was c a r r i e d out t o determine -
1. The type and s i z e of d r i e r t o b e , u s e d t o dry t h e o r e b e f o r e grinding.
2. Whether t h e limesands was t o be ground s e p a r a t e l y from t h e o r e o r w i t h t h e ore.
! 3. The type and s i z e of t h e g r i n d i n g equipment.
!
; 4. The s i z e and type of w e t t i n g device t o be used.

A g r e a t d e a l of t e s t work was c a r r i e d o u t but t h e testwork t h a t was of p a r t i c u l a r

i n t e r e s t was t h a t work c a r r i e d out t o determine t h e t y p e of d r i e r t o be used arid t h e
grinding m i l l size.
Ore Drying T e s t s

A d e c i s i o n had been made t o use a k i l n t y p e d r i e r b u t because of t h e f i n e s i z i n g of

t h e f e e d i t was n e c e s s a r y t o c a r r y o u t l a b o r a t o r y t e s t s t o determine t h e d u s t l o s s e s
a t the expected operating conditions.

T e s t work was c a r r i e d o u t w i t h a p l a s t i c model of t h e d r i e r t o be used i n t h e p l a n t

and t h e s e t e s t s showed t h a t t h e d u s t l o s s e s would be l e s s t h a n 2% of t h e Feed. P l a n t
o p e r a t i o n has confirmed t h e accuracy of t h e t e s t .

G r inding T e s t s

Bond g r i n d a b i l i t y t e s t s were c a r r i e d o u t t o determine t h e work irtdex a t a B l a i n e

s i z i n g of approximate 1 , 6 0 0 sq. cm/gm.

T e s t r e s u l t s i n d i c a t e d t h a t t h e g r i n d a b i l i t y v a r i e d w i t h t h e grade of o r e and t h e
h i g h e s t grade o r e had t h e h i g h e s t work index. The r e s u l t s showed t h a t a mixture of
o r e and limesands c o u l d be ground. The maximum power requirement was c a l c u l a t e d a t
20.4 horsepower hours per l o n g t o n when g r i n d i n g a mixture of h i g h grade o r e and
10% limesands.

To e n a b l e w e t t i n g , b a l l i n g and i n d u r a t i o n t e s t work t o be c a r r i e d o u t , i t was

necessary t o use l a b o r a t o r y equipment t o produce ground product w i t h t h e same s i z i n g
a s could be expected from t h e g r i n d i n g m i l l s t o be i n s t a l l e d i n t h e p l a n t . The p l a n t -
m i l l s were t o be charged w i t h 2 i n . b a l l s i n t h e f i r s t compartment and a mixture of
1: in. a n d 1 i n . b a l l s i n t h e second compartment.

A Bond autogenous media t e s t e r was used t o g r i n d t h e o r e f o r t h e t e s t work. T h i s

m i l l was 6 f t . i n d i a m e t e r by 1 f t . i n l e n g t h and i t was charged w i t h a mixture of
3 in. t o $ in. b a l l s .

The p r o d u c t s from t h e l a b o r a t o r y m i l l and t h e p l a n t m i l l s when t r e a t i n g t h e same

f e e d a r e compared i n Table 2.

T a b l e 2. Comparison of G r i n d i n g
M i l l Products

6 f t . dia. x 1 f t . 11 f t . d i a . x 29 f t .
batch m i l l 2- . Cpt. b a l l m i l l
Blaine 1,580 sq. cm/gm. 1 , 6 1 4 sq. cm/gm,

Cum. % p a s s i n g

1 0 0 mesh
150
2 00
270
325

Pug M i l l T e s t s

A pug m i l l was s e l e c t e d a s t h e d e v i c e t o be used t o wet t h e groulnd o r e a f t e r dry

grinding.

Pug m i l l s i z i n g and power consumption were a r r i v e d a t w i t h t h e help of t e s t s

performed i n a s h o r t b a t c h pug m i l l u s i n g a c t u a l components of t h e :proposed machines.
The t e s t were performed by Barber-Greene i n Aurora, I l l i n o i s . A maximum power
 consumption o c c u r r e d a t 9% moisture c o n t e n t . Based on t h e t e s t r e s u l t s and a l l o w i n g
f o r t h e f a c t t h a t no p r e c e d e n t e x i s t e d f o r t h i s a p p l i c a t i o n , t h e twin s h a f t m i l l s
were s i z e d a t 1 2 f t . i n l e n g t h w i t h 1 8 p a i r s of 6 i i n . s q u a r e p a d d l e s p e r s h a f t on a
16 i n . r a d i u s , With a proposed paddle speed of 55 r.p.m. t h e m i l l s were powered w i t h
200 h.p. motors f o r a r a t i n g of 250 t o n s per hour.

I n p l a n t t r i a l s , t h e m o i s t u r e c o n t e n t was maintained a t 8%. The power drawn

seldom exceeded 6 0 horsepower a t a f e e d r a t e of 300 t o n s per hour. I t would a l s o
appear t h a t only h a l f t h e l e n g t h of t h e pug m i l l was r e q u i r e d t o p r e p a r e a c c e p t a b l e
b a l l i n g f e e d . Because of gear box problems one of t h e m i l l s was slowed down t o 37
r.p.m., and t h i s m i l l a l s o produced s a t i s f a c t o r y b a l l i n g feed.

Balling Tests

B a l l i n g t e s t work was conducted u s i n g p i l o t p l a n t b a l l i n g drums and b a l l i n g pans.

Feed was o b t a i n e d by pug m i l l i n g ground m a t e r i a l .

The t e s t work i n d i c a t e d t h a t p r e - b a l l i n g of t h e f e e d i n a pug m i l l was n o t l i k e l y

t o cause problems a s t h e p i l o t p l a n t b a l l i n g equipment performed normally. The g r e e n
b a l l q u a l i t y was a c c e p t a b l e and compared f a v o u r a b l y w i t h t h e g r e e n b a l l s produced
from p i l o t p l a n t t e s t work on f i l t e r e d c o n c e n t r a t e s t h a t were b e i n g p e l l e t i s e d i n
commercial p l a n t s .

T e s t a l s o i n d i c a t e d t h a t t h e h o t f e e d t h a t was e x p e c t e d from d r y i n g , g r i n d i n g and

pug m i l l i n g was not l i k e l y t o have a d e t r i m e n t a l e f f e c t on b a l l i n g .

From t h e b a l l i n g c h a r a c t e r i s t i c s of t h e o r e , i t was d e c i d e d t o i n s t a l l s i x b a l l i n g
l i n e s and a t B.H.P. r e q u e s t , p r o v i s i o n was t o be made f o r t h e a d d i t i o n of a s e v e n t h
b a l l i n g l i n e a t a l a t e r date.

Induration. Tests

, The i n d u r a t i o n s e c t i o n was s i z e d w i t h t h e a i d of pot g r a t e t e s t s u s i n g h i g h grade

o r e ground i n t h e b a t c h m i l l . I n Table 3 t h e p r e d i c t e d performance i s compared w i t h
t h e a c t u a l o p e r a t i n g r e s u l t s from a 52 hour p e r i o d from June 6 t h through June 8 t h
1968.

Table'3. Predicted P e l l e t Quality

vs. A c t u a l

Predicted Actual
Product Rate 233 t p h 246 t p h

I
I
Product S i z e
; + $ in. 38.0% 72.2%
! + 3/8 in. 98 -5% 97.7%

II Compression S t r e n g t h

Tumble T e s t - A.S.T.M.
631 l b s . 625 l b s .

I +gin. 91.9% 94.5%

! - 28 mesh 3.1% 3.5%

The g r a t e was i n i t i a l l y s i z e d w i t h s e v e n windboxes i n t h e d r y i n g f u r n a c e and e i g h t

windboxes i n t h e pre-heat f u r n a c e , However, a t t h i s s t a g e f u r t h e r t e s t work showed
t h a t lower grade o r e s tended t o form g r e e n b a l l s which were h e a t s e n s i t i v e i n t h e
d r y i n g f u r n a c e , For t h i s r e a s o n , B.H.P. r e q u e s t e d t h a t t h e g r a t e be i n c r e a s e d i n
s i z e from 1,436 sq. f t . t o 1,724 sq. f t . w i t h n i n e windboxes i n e a c h s e c t i o n . The
i n c r e a s e d s i z e was t o a l l o w r a t e d c a p a c i t y t o be o b t a i n e d when t r e a t i n g t h e lower
grade ores. The k i l n diameter was a l s o i n c r e a s e d from 1 7 f t . t o 1 8 f t . 6 i n . t o
enable higher t h a n r a t e d tonnage of h i g h grade o r e t o be processed. The a n n u l a r
c o o l e r was s i z e d a t 50 f t . j n diameter by 7 f t . i n width.

Fans and the o i l burner were s i z e d from t h e pot g r a t e t e s t work r e s u l t s .

P l a n t Design and C o n s t r u c t i o n

The o r i g i n a l t e n d e r documents were i s s u e d t o A l l i s - C h a l m e r s l a t e i n 1964. On June

1 7 t h , 1965, w h i l e t h e t e s t work was s t i l l i n p r o g r e s s , B.H.P. p l a c e d an o r d e r f o r t h e
p l a n t w i t h Allis-Chalmers. S e v e r a l B.H.P. Technical O f f i c e r s went to Allis-Chalmers
Head O f f i c e i n Milwaukee, Wisconsin, t o p a r t i c i p a t e i n t h e p l a n t design and lay-out
work.

Before t h e a c t u a l d e s i g n work commenced, v i s i t s were made t o s e v e r a l i r o n o r e p e l l e t

p l a n t s and cement p l a n t s w i t h d r y g r i n d i n g i n s t a l l a t i o n s , t o s t u d y .the 1 a . t e s t
o p e r a t i n g and p l a n t lay-out p h i l o s o p h i e s .

The t e s t work had e s t a b l i s h e d t h e equipment s i z e s f o r t h e indura.tion a.rea and a n

L-shape d e s i g n was adopted, where t h e b a l l i n g b u i l d i n g was a t right.-angles t o t h e
grate-kiln-cooler b u i l d i n g , t o reduce t h e number of drops t h e green b a l l s made b e f o r e
they reached t h e g r a t e .

I t was p o s s i b l e t o l o c a t e t h e g r i n d i n g m i l l s and a u x i l i a r y equipment i.n t h e vacant

a r e a i n t h e b u i l d i n g under t h e b a l l i n g drums. However,. i t was necessary t o p l a c e t h e
d r i e r p a r a l l e l t o and on t h e same l e v e l a s t h e r o t a r y k i l n . The d r i e r was t o be
s e r v i c e d and c o n t r o l l e d from t h e i n d u r a t i o n c o n t r o l panel.

The d i s c h a r g e of t h e d r i e r i s conveyed and d i s t r i b u t e d over each of f o u r 500 t o n

m i l l f e e d bins. Discharge from t h e b i n s i s c o n t r o l l e d by four v a r i a b l e speed DC d r i v e n
apron f e e d e r s , one t o each of the f o u r open c i r c u i t g r i n d i n g m i l l s which a r e l o c a t e d
under t h e b a l l i n g drum f l o o r . Each conveyor b e l t f e e d i n g t h e m i l l s i s equipped w i t h a
conveyor weightometer s o t h a t t h e o p e r a t o r can c o n t r o l t h e f e e d r a t e t o each m i l l .

The g r i n d i n g m i l l s a r e provided w i t h a waJer i n j e c t i o n system t o l i m i t t h e g r i n d i n g

m i l l product temperature t o a maximum of 212 F. Water i s not i n j e c t e d below t h i s
temperature. S h o r t screw conveyors a r e used t o form a n a i r s e a l a t t h e d i s c h a r g e
p o i n t of t h e g r i n d i n g m i l l s and t h e s e screw conveyors d i s c h a r g e o n t o one b e l t conveyor
which conveys t h e ground product t o t h e pug m i l l s f o r pre-wetting. Two pug m i l l s a r e
i n s t a l l e d , one a s standby. The pug m i l l s a r e followed by s e v e r a l Pekay niixers t o
f u r t h e r mix t h e o r e and water and break up any b a l l s formed i n t h e pug m i l l s . This
pre-wetted m a t e r i a l i s t r a n s p o r t e d t o t h e 6 -
450 tons c o n c e n t r a t e bins by a s c i s s o r
conveyor and f u r t h e r d i s t r i b u t e d over t h e b i n s by means of motorizeld plows. The l a s t
b i n i s not equipped w i t h a plow and r e c e i v e s only t h e s p i l l a g e from t h e b e l t conveyor
over t h e bins.

Equipment i s a l s o i n s t a l l e d t o pump dry o r e from one m i l l t o s e p a r a t e b i n s shown a s

s l a k e d lime b i n s s o t h a t i t i s p o s s i b l e t o -add dry o r e t o t h e b a l l i n g drum feed. This
pumping system i s t o be used f o r pumping s l a k e d lime t o t h e s e b i n s i n t h e event t h a t
s l a k e d lime i s r e q u i r e d i n s t e a d of b e n t o n i t e .

A b e n t o n i t e g r i n d i n g p l a n t i s i n s t a l l e d t o dry and g r i n d minus i n . Wyoming

b e n t o n i t e d e l i v e r e d i n bulk t o t h e plant.

To comply w i t h t h e l o c a l c l e a n a i r requirements many wet d u s t c o l l e c t o r s a r e i n -

s t a l l e d . The m i l l s each have t h e i r ownwet d u s t c o l l e c t o r drawing a i r through t h e
m i l l and c o l l e c t i n g d u s t from both t h e f e e d and d i s c h a r g e p o i n t s .

Dry cyclones a r e used t o c l e a n t h e gases from t h e pre-heat furnace of t h e g r a t e and

m u l t i c l o n e s a r e used t o c l e a n t h e e x h a u s t gases from t h e d r y i n g f u r n a c e of t h e g r a t e .
Bag t y p e c o l l e c t o r s a r e used f o r t h e b e n t o n i t e and s l a k e d lime b i n s .

Concrete washdown f l o o r s a r e provided i n a l l s p i l l a g e a r e a s . A l l clean-up i n t h e

p l a n t , i n c l u d i n g d u s t from a l l d u s t c o l l e c t o r s and g r a t e flumes, i s c o l l e c t e d c e n t r a l l y
and ground t o t h e ' d e s i r e d s i z i n g i n a b a l l m i l l - c l a s s i f i e r c i r c u i t . The c l a s s i f i e r
overflow i s pumped t o a t h i c k e n e r f o r recovery by two f i l t e r s , preceded by wet cyclone
c l a s s i f i e r s . The f e e d t o t h e cyclones c o n t a i n s 40% s o l i d s by weight and t h e underflow
as f e e d t o t h e f i l t e r s about 70% s o l i d s by weight. T h e , c y c l o n e overflow c o n t a i n i n g
t h e s l i m e s a r e piped t o a d i s t r i b u t o r f o r a d d i t i o n t o t h e d r y o r e i n t h e pug m i l l s .
T h i s f e a t u r e p r e v e n t s t h e c l a y f r a c t i o n from b l i n d i n g t h e f i l t e r c l o t h of t h e f i l t e r s .
These f i n e s a r e a l s o needed f o r good b a l l i n g And hence a r e r e - i n t r o d u c e d i n t o t h e
c i r c u i t i n t h e pug m i l l s .

The f i l t e r product and r e j e c t b a l l s from t h e b a l l i n g c i r c u i t a r e d i s c h a r g e d i n t o a

r e j e c t bin. The r e j e c t b i n d i s c h a r g e i s metered i n w i t h t h e w e t t e d o r e . The f e e d r a t e
i s c o n t r o l l e d by a DC d r i v e n v a r i a b l e speed t a b l e f e e d e r . The b e n t o n i t e o r s l a k e d lime
f e e d r a t e i s c o n t r o l l e d ' by g r a v i m e t r i c f e e d e r s .

There a r e f o u r major a i r c o n d i t i o n e d c o n t r o l p a n e l s f o r p l a n t c o n t r o l -
a. Ore p r e p a r a t i o n p a n e l
b. B a l l i n g p a n e l
c. I n d u r a t i o n p a n e l
d. B e n t o n i t e g r i n d i n g p l a n t

,Comprehensive i n s t r u m e n t a t i o n e n a b l e s t h e p l a n t t o be o p e r a t e d economically and

efficiently.

There i s ample space i n t h e p l a n t f o r a c c e s s and maintenance, and t r u c k s a r e a b l e

t o d r i v e through t h e p l a n t on t h e ground f l o o r t o c o l l e c t o r d e l i v e r m a t e r i a l s .

A l o t of time was s p e n t by A l l i s - C h a l m e r s i n c o n j u n c t i o n w i t h B.H.F. Technical

O f f i c e r s i n a r r i v i n g a t t h e u l t i m a t e d e s i g n w i t h r e g a r d t o product q u a l i t y , e a s e of
c o n t r o l , maintenance and a c c e s s i b i l i t y and we b e l i e v e t h a t t h e r e s u l t a n t p l a n t i s very
a t t r a c t i v e and w e l l l a i d o u t and t h a t t h e time and money has been w e l l ' s p e n t .

A u s t r a l i a n made components of t h e p e l l e t p l a n t amount t o about 92% of t h e i n s t a l l -

a t i o n and t h e o v e r a l l complex i s approximately 98% A u s t r a l i a n made.

For p e l l e t p l a n t s t a t i s t i c s - major equipment i t e m s and c o n s t r u c t i o n s t a t i s t i c s -

s e e pages 8 , 9 and 10.

F i g u r e s 1 t o 1 3 show s i m p l i f i e d f l o w s h e e t s and photographs of phases of t h e

c o n s t r u c t i o n work

Fig. 1 Ore p r e p a r a t i o n f l o w ' s h e e t .

Fig. 2 T y p i c a l commercial i n s t a l l a t i o n o f . Grate-Kiln system.
Fig. 3 Load-out f i n i s h e d product flow s h e e t .
Fig. 4 F i r s t p i l e being driven - 22nd J u l y , 1966.
Fig. 5 F i r s t column being e r e c t e d and showing m i l l p i e r s - 2 1 s t December 1966.
Fig. 6 Erection k i l n riding rings - 1 8 t h J u l y , 1967.
Fig. 7 E r e c t i o n d r i e r s h e l l - . 1 2 t h August, 1967.
Fig. 8 Panoramic view -1 9 t h September, '1967.
Fig. 9 A e r i a l view p l a n t under c o n s t r u c t i o n - 1 9 t h O c t o b e r , 1967.
Fig. 10 South E a s t e l e v a t i o n of p l a n t - 2 0 t h J a n u a r y , 1968.
Fig,. 11 Induration c o n t r o l panel - 1 5 t h A p r i l , 1968.
Fig. 12 A r t i s t impression of t h e p e l l e t p l a n t .
Fig. 13 A r t i s t impression of t h e p e l l e t p l a n t showing p a r t of t h e i n t e r i o r
of t h e p l a n t .
 Pellet Plant S t a t i s t i c s

Excluding B.H.P. Ore S c r e e n i n g , C r u s h i n g ,

Blending and P e l l e t Load-Out P l a n t

Major Equipment Items

10'-0" d i a . x 110'-0"'long counterflow two s u p p o r t r o t a r y d r i e r w i t h 200 hop.

v a r i a b l e speed DC d r i v e .
Weights: D r i e r s h e l l w i t h r i d i n g r i n g s t r a n s p o r t e d and e r e c t e d i n
one p i e c e -
82 l o n g tons.

D r i e r burner - Max. 75,000,000 BTU/hr. No, 6 f u e l a t l C l O p s i g and 2 1 0 ~ ~ .

Hot o i l h e a t i n g system t o h e a t t h e no. 6 f u e l o i l t o a s u i t a b l e temperature

through h e a t exchangers.

11'-0" d i a . x 29'-0" nominal l e n g t h 2 compartment b a l l m i l l s coup:Led through

diaphragm c o u p l i n g s t o twinducer gearbox d r i v e n by two 945 h.p. 600 r.p.m.
synchronous motors.
Weights: M i l l s h e l l e x c l . l i n e r s -
43 l o n g t o n s
M i l l with l i n e r s -
178 l o n g t:ons
T o t a l oper,ating weight -
327 l o n g t o n s
Twinducer w i t h c o u p l i n g s -
52 long t o n s
Twinducer c a s e 22'-6" l o n g x 12" wide x 11'-0" high.

Pug m i l l s each 144" long x 56$" wide x 403" deep d u a l s h a f t pug m i l l s l i n e d

w i t h Ni-hard l i n e r s , e a c h s h a f t w i t h 1 8 paddles which a r e a d j u s t a b l e and
r e v e r s i b l e w i t h r e p l a c e a b l e Ni-hard t i p s .

10'-0'' d i a . x 32'-0" l o n g b a l l i n g drums. Main d r i v e and c u t t e r b i d~r i v e

d r i v e n by v a r i a b l e speed DC motors and i n t e r l o c k e d .

6'-0" wide x 14'-0" long two b e a r i n g floormounted s e e d s c r e e n s wi.th s t a i n l e s s

s t e e l rod decks.

12'-2" wide x 164'-1" l o n g t r a v e l l i n g g r a t e w i t h two banks of cyclone d u s t

c o l l e c t o r s , one bank on each s i d e . G r a t e d r i v e n by v a r i a b l e speed DC d r i v e .
G r a t e d i v i d e d i n 9 windboxes f o r d r y i n g and 9 windboxes f o r pre-heating.

Multiclone d u s t c o l l e c t o r s , one on each s i d e of t h e g r a t e t o c l e a n t h e waste

g a s e s from t h e g r a t e b e f o r e going t o t h e waste gas f a n s and t o t h e s t a c k s .

G r a t e burner each max. 83,000,000 BTU/hr. no. 6 f u e l a t 100 p s i g and 210'~.

Waste gas f a n s - each 156,000 cfm a t 2 0 0 ~ ~18" . WG d i r e c t d r i v e n by

700 h.p. - 1,000 r.p.m. AC s q u i r r e l cage motor.

Pre-heat f a n s -
each 236,000 cfm a t 700'~. 15" WG d i r e c t d r i v e n by 900 hop.
r.p.m. AC s q u i r r e l cage motor and t u r n i n g gear.

18'-6" d i a . by 118'-8" l o n g two s u p p o r t r o t a r y k i l n w i t h d u a l 250 hop. DC

v a r i a b l e speed d r i v e and a u x i l i a r y d r i v e .
Weights: 2 -
Riding r i n g s h e l l s e c t i o n s each - 32 l o n g t o n s
1 -
Feed end s h e l l s e c t i o n - 47 l o n g t o n s
1 -
Discharge s h e l l s e c t i o n - 50longtons
3 -Intermediate -s h e l l sections
r e s p . 43, 46 and 50 t o n s
T o t a l s h e l l weight - 300 l o n g t o n s
 Weights: 2 - K i l n r i d i n g r i n g s 21'-8;" O.D.,

1 -
19'-22" I.D. and 3' width each
Spurgear 25'-6" O.D. 16" width
-- 53longtons
1 5 long tons
4 - K i l n s u p p o r t r o l l e r s 72" d i a . x 42"
w i d t h w i t h 26'" d i a . s h a f t - each - 39 l o n g t o n s

1 - Main k i l n burner max. 240,000,000 BTU/hr. no..6 f u e l a t 900 p s i g .

1 - 50'-0"' mean d i a . x 7'-0" wide r o t a r y type c o o l e r .

v a r i a b l e speed DC d r i v e and a u x i l i a r y d r i v e .
Cooler provided w i t h

2 - Cooler f a n s each 124,000 cfm a t 70'~. and 20" WG d i r e c t d r i v e n by 650 h.p.

1,000 r.p,m. AC s q u i r r e l cage motor.

2 - 4'-0" wide x 24'-3" long floormounted v i b r a t i n g g r i z z l y f e e d e r s f o r c o o l e r

product d i s c h a r g e .

2 - 6'-0" wide x 16'-0" long floormounted f i n i s h e d product s c r e e n s .

1 - 20" x 34" jawcrusher.

1 - 130'-0" d i a . t h i c k e n e r , p l a n t clean-up and r e c l a i m system.

1 -. 5'-0" d i a . x 8'-0"' 1 o n g . c e n t r i . x b a l l m i l l , p l a n t clean-up and r e c l a i m system.

1 - 60"'dia. x 32'-0" long c l a s s i f i e r , p l a n t clean-up and r e c l a i m system.

2 - 6'-9" d i a . x 5 d i s c f i l t e r s w i t h vacuum pumps, p l a n t clean-up and r e c l a i m

system.

3 - A i r compressors f o r pneumatic pumping system.

3 - A i r compressors f o r p l a n t and equipment requirements.

1 - A i r compressor f o r emergency supply.

1 - Water f i l t e r i n g and s o f t e n i n g p l a n t .

1 - Water c o o l i n g tower and h e a t exchanger.

4 - Main a i r c o n d i t i o n e d c o n t r o l rooms and 5 a u x i l i a r y remote panels.

2 . - A i r c o o l i n g system f o r supply of f i l t e r e d and cooled a i r t o s w i t c h g e a r rooms

- and m i l l motor room.

- 21 - Dust c o l l e c t o r s .

1 - B e n t o n i t e g r i n d i n g plank t o g r i n d 14,000 l b s / h r . minus bentonite with 12 t o

I
15% m o i s t u r e t o a product of 80% p a s s i n g 200 mesh complete w i t h r o l l e r m i l l ,
a i r h e a t e r , whizzer s e p a r a t o r , cyclone c o l l e c t o r s and d u s t f i l t e r .

2 - Pneumatic pumping systems t o be used f o r pumping, b e n t o n i t e , ground o r e o r

I s l a k e d lime.
83 - Conveyors -
T o t a l l e n g t h c e n t r e t o c e n t r e p u l l e y 5,580 f e e t h o r i z o n t a l from
30" t o 156" wide.

7 - 48" wide x 10'-6" c e n t r e s apron f e e d e r s , v a r i a b l e s p e e d DC d r i v e .

 7 - 8'-6" d i a . t a b l e f e e d e r s , v a r i a b l e ' speed DC d r i v e .

22 - Conveyor s c a l e s .

28 - Water s l u r r y pumps.

333 - Push b u t t o n s .

399 - Motors from 1/6 t o 945 h.p.

2 - 33.000/6.600 V. transformers.

8 - 6.600 V. transformer 415 V.

4 - 415 V. switchboards.

4 - S t a r t e r panels.

11 - Light and power d i s t r i b u t i o n boards.

61 - Hoist and t r o l l e y s (14 e l e c t r i c ) .

5 - Overhead c r a n e s (from 5 - 30 t o n ) .

1 - Engine g e n e r a t o r s e t - emergency power supply 333 kW. staridby r a t i n g , 4 1 5

V o l t , 3 phase 50 c y c l e .

1 - K i l n - d r i e r d r i v e MG s e t -
c o n s i s t i n g of 3 -
205 kW -
480 V. DC g e n e r a t o r
s e t s d r i v e n by a 850 - 1500 r .p.m. 6.600 V , AC s q u i r r e l cage motor.

A l l o t h e r DC d r i v e s have s i l i c o n c o n t r o l l e d r e c t i f i e r power u n i t s .

T o t a l i n s t a l l e d horsepower = 20,840.
18 - Communication s t a t i o n s .

8 - Telephones.

442 - Equipment items.

i 1 - Passenger e l e v a t o r w i t h 7 s t o p s and approx. 121'-6" travel.

Construction S t a t i s t i c s
I

T o t a l i n s t a l l e d l e n g t h of e l e c t r i c a l c a b l e i n c l u d i n g w i r e f o r l i g h t i n g and communicat-
i o n system = 206,860 yards.

T o t a l number of p i l e s 790 t h a t i s
286 - 130 ton; 398 -
100 t o n -
66 H s e c t i o n s t e e l 40-60 ton.

T o t a l s h e e t i n g 359,000 sq. f t . e x c l . r i d g i n g and c o r n e r mould.

I Total structural s t e e l = 6,074 ton.

I Bricks

Concrete
= 370,530.

= 12,200 yards.
C o n s t r u c t i o n drawings = 3,011.
B u i l d i n g s i z e 480 f t . l o n g x 216/126 f t . wide and 173/110 f t . high.
 P l a n t Commissioning

Before t h e Grate-Kiln system was s t a r t e d a l l a u x i l i a r y equipment had been t e s t e d ,

o r e h a d . b e e n d r i e d and ground, and t h e o p e r a t o r s had been t r a i n e d t o produce a c c e p t a b l e
green b a l l s from t h e ground p r o d u c t . On 9 t h May, 1 9 6 8 , t h e k i l n b u r n e r was l i t and on
13th May, 1968, a c i d p e l l e t s were produced on a continuous b a s i s a t r a t e d c a p a c i t y
i . e . 4,574 t o n s p e r day. Product q u a l i t y was a c c e p t a b l e .
I n t h e p e r i o d b e f o r e t h e 29th May, some 25,000 long t o n s of f l u x e d p e l l e t s were
produced a t r a t e d c a p a c i t y without u s i n g t h e g r a t e b u r n e r s and t h e p l a n t performance
was s a t i s f a c t o r y . However, t h i s s h o r t r u n d i d n o t y i e l d enough c o n c l u s i v e d a t a t o
p u b l i s h . For p r o d u c t i o n . r e a s o n s it was n e c e s s a r y t o r e v e r t t o t h e p r o d u c t i o n o f a c i d
p e l l e t s on 29th May and Allis-Chalmers were given t h e o p p o r t u n i t y t o c a r r y o u t a 48
... .,::;.-::
hour performance t e s t .
T h i s t e s t run was c a r r i e d o u t from 6 t h J u n e , 1968, t o 8 t h J u n e , 1968, and t h e
r e s u l t s from t h e 48 hour t e s t f a r exceeded t h e performance warranty. The r e s u l t s a r e
shown i n Table 4.

T a b l e 4. O p e r a t i n g Data Over 48
Consecutive Hours

, .. . . 1 Date 6-7 June 7-8 J u n e Warranty Description

8

: ., . .. 4' . 0300-0300 0300-0300

.;.: . . 7 ' '

.
,. ..
-
'
.,
1 ' Long t o n s 5,467 5,683 - 4,574 Dry s c r e e n e d minus 1 i n .
p l u s 3/8 i n . a c i d p e l l e t s .
% minus 1 i n . 97.4% 98.0% 90% Screened f i n i s h e d
P l u s 3/8 i n . pellets.
Compression
strength lbs. 631 500 Average c o l d c r u s h i n g
s t r e n g t h i n l b s . on a
p l u s 3/8 i n . minus 5/8
i n . p e l l e t on ,12 h r .
composite.
Tumb l e 3.1% av. 3.7% av. Not t o A.S.T.M. t e s t % minus
3.4 max. 3.9 max. exceed 6%. 28 mesh. Sample 3/4 i n . -
2.8 min. 3.6 min. p l u s 3 mesh on 12 h r .
composite.
Fue 1 Average 970,000 1,200,000 B.T.U. Screened minus 1 i n .
Consumption R.T.U. p e r long perlongton. p l u s 3/8 i n . a c i d p e l l e t s
t o n s o v e r 48 h r s .
Bentonite
Con sumpt i o n l e s s t h a n 0.5%

Power Consumption Measured on 7 t h June, 1968

Induration - 18.3 Kwh/L.ton + b a l l i n g - 2.7 Kwh/L.ton
Power consumption f o r t h e b a l a n c e . o f t h e p l a n t was n o t r e c o r d e d .

The compression t e s t r e s u l t s r e p o r t e d i n T a b l e 4 were e q u i v a l e n t t o t h e r e s u l t s

o b t a i n e d by t h e A.C. Milwaukee T e s t C e n t e r b u t were somewhat h i g h e r t h a n t h o s e
r e p o r t e d i n T a b l e No. 6 . A l l compression t e s t s c a r r i e d o u t a f t e r commissioning
were to Japanese requirements and these gave lower strength.

During commissioning a test was carried out to determine the percentage plus 1 in.
and minus 3/8 in. in the cooler discharge product, and at the same time the efficiency
of the product load-out screens was also established. The results were as follows -
The plus 1 in. and minus 3/8 in. fractions in the product from the cooler totalled
4.2%. Screening efficiency was 99%.
Features of the commissioning which warrant special mention are -
1. Rated capacity was reached during the first 24 hour period of operation.
2. From the commencement of operations, product quality was acceptable and
generally above the guaranteed levels.
3. All items of equipment and all instrumentation operated in a trouble free manner.
4. All operating and maintenance personnel underwent an extensive training programme
prior to start-up. The instruction was given by A.C. and B.H.P. personnel and
the thoroughness of the training greatly contributed to the trouble free start-up.
5. The personnel safety record during construction and operation was excellent.
Only one construction worker suffered a lost time injury and operati.ngpersonnel
completed the commissioning phase and the first four months of operation without
a lost time injury.
Plant Operation
Since commissioning and the plant acceptance, there have been steady improvements
in production rates, pellet quality and process efficiency. The operating statistics
over the last six months period are shown in Table. 5. Acid pellets were produced
during this operating period.
Table 5. Product.ionDate August 1968 -
January 1969.

Period Production Monthly Fue1 Plant

Rate of T.P.H. Production B.T.U. 106 fivailability
Fired Pellets Screened per ton %
Product

August 1968 245

September 1968 223
October 1968 256
November 1968 266
December 1968 272
January 1969 264
Average 257

The total production over the six months period was equivalent to a yearly
production rate of 1,863,000 tons per annum. The average quality of pellets
produced for shipment during the period October, 1968 to January, 1969 is shown in
Table 6.
 Table 6. P e l l e t Q u a l i t y Japanese C o n t r a c t
Shipment

Chemical A n a l y s i s Fe S i02 A1203 Mn . P. Ti02

Assay % 65.5 3.34 2.10 0.37 0.027 0.11

Screen S i z i n g + 16 mm -16+9 mm -9+5 mm - 5 mm Total

Weight % 4.3 89.4 5.5 0.8 100.0

lbs .
Compressive S t r e n g t h
968 max. 528 Ave. 242 mine

Tumble Index J.I.S. - M8712 - 1965 3.1% - 1 m.

General Comments

Ore Drying

S i n c e p l a n t s t a r t - u p i t has been necessary t o o p e r a t e t h e o r e d r i e r on a continuous

basis. The average moisture c o n t e n t of t h e f e e d t o t h e d r i e r is 2%. A t t h i s m o i s t u r e
0
t h e f u e l consumption i s 110,000 B.T.U. per ton. The e x i t gas t e m p e r a t u r e i s 550 F.
0
and t h e product c o n t a i n s 0.8% m o i s t u r e and has a n average temperature of 150 F.

Operating e x p e r i e n c e has s h o w n t h a t t h e f e e d t o t h e m i l l s may c o n t a i n as

' 0
much a s 1.0% m o i s t u r e provided t h a t t h e temperaturg of t h e f e e d i s over 1 5 0 F.
However, i f t h e ambient temperature d r o p s below 50 F. i t i s necessary t o i n c r e a s e t h e
). g r i n d i n g m i l l f e e d temperature t o 1 6 0 ~ ~ .

The product from t h e g r i n d i n g m i l l s i s c o n t r o l l e d t o a B l a i n e s i z i n g of 1650 sq.

cm/gm. by c o n t r o l l i n g t h e f e e d r a t e t o t h e m i l l s . Power consumption f o r g r i n d i n g
v a r i e s between 6 and 1 0 kWH per ton. Because of t h i s v a r i a t i o n i n power consumption
; t h e s c r e e n s i z i n g of t h e product v a r i e s even though t h e B l a i n e remains c o n s t a n t .

1
! However, a n average s i z i n g of t h e product is 0.8% c o a r s e r t h a n 20 mesh, 28.8% between
2 0 mesh and 325 mesh, and 70.4% l e s s t h a n 325 mesh.

iI Some c o o l i n g of t h e o r e - o c c u r s d u r i n g g r i n d i n g and t h e temperature of t h e g r i n d i n g

0
i m i l l product a v e r a g e s 140 F. under s t a b l e o p e r a t i n g c o n d i t i o n s . No d i f f i c u l t i e s have
j been e x p e r i e n c e d i n h a n d l i n g t h i s h o t m a t e r i a l .

! Wetting

The ground o r e i s conveyed t o t h e pug m i l l s and weighed by weightometer. Water i s

added t o t h e f e e d i n r a t i o t o t h e tonnage f e d t o t h e pug m i l l . The m o i s t u r e c o n t e n t
i s checked manually every hour.

F i l t e r cake w i t h a v a r i a b l e m o i s t u r e c o n t e n t i s added t o t h e pug m i l l product and

allowance i s made f o r m o i s t u r e l o s s by e v a p o r a t i o n due t o t h e h o t product from t h e
pug m i l l s . However, i n s p i t e of t h e s e v a r i a b l e s , t h e moisture c o n t e n t of t h e f e e d t o
t h e b a l l i n g drum f e e d b i n s i s maintained w i t h i n 2 0.2% of t h e d e s i r e d m o i s t u r e c o n t e n t .

Power consumption f o r pug m i l l i n g i s nominal and i t is g e n e r a l l y l e s s t h a n 0.2 kWH

per ton. Maintenance c o s t s a r e a l s o nominal.

P r e - b a l l i n g of t h e o r e i n t h e pug m i l l i s t o l e r a b l e provided t h a t t h e B l a i n e
s u r f a c e a r e a of t h e ground product i s kept below 1800 sq. cm/gm. It is preferable
t o maintain 1650 sq. cm/gm. Ores w i t h a h i g h c l a y c o n t e n t a r e not s u i t a b l e f o r pre-
w e t t i n g as t h e y b a l l e d i n t h e pug m i l l even when t h e o r e s i z i n g i s maintained a t
1650 sq. cm/gm.

T e s t s have shown t h a t i t i s p o s s i b l e t o add 1.5% moisture t o pre-wetted o r e i n

k k a y mixers. However, p r e - b a l l i n g a l s o occurs i n Pekay mixers when t h e o r e s i z i n g
is f i n e r t h a n 1650 sq. cm/gm.

Balling

Some d i f f i c u l t y has been experienced i n c o n t r o l l i n g t h e s t a b i l i t y of t h e b a l l i n g

operation. Even under i d e a l o p e r a t i n g c o n d i t i o n s minor b a l l i n g of t h e f e e d occurs i n
t h e pug m i l l s and t h e micro b a l l s causes h i g h c i r c u l a t i n g l o a d s i n t h e b a l l i n g c i r c u i t s .

Water cannot be added t o t h e conveyors c a r r y i n g t h e c i r c u l a t i n g l o a d of t h e b a l l i n g

c i r c u i t w i t h o u t forming t h i n o u t e r s h e l l s i n t h e f i n a l green b a l l product. These
s h e l l s t e n d t o break o f f d u r i n g d r y i n g and pre-heating c a u s i n g low y i e l d s of a c c e p t a b l e
f i r e d product from green b a l l s .

Water i s added t o t h e conveyors f e e d i n g t h e b a l l i n g l i n e s and a l s o added by s p r a y s

i n t h e b a l l i n g drums. Under i d e a l o p e r a t i n g c o n d i t i o n s 1.5% moisture i s added t o t h e
f e e d conveyors and a n a d d i t i o n a l 1.0% moisture i s added i n t h e b a l l i n g drums.

The average q u a l i t y of t h e product from t h e b a l l i n g l i n e s is a s follows -

Green b a l l compression s t r e n g t h 23 l b s
No. of 'drops - 1 8 inches 10
Green b a l l s i z i n g 90% between 16 mm and 9 mm
Moisture c o n t e n t 8.2%

B e n t o n i t e i s added t o t h e f e e d i n v a r i a b l e q u a n t i t i e s dependent on t h e alumina

c o n t e n t of t h e feed. S u f f i c i e n t b e n t o n i t e i s added t o t h e f e e d t o r e s t r i c t p r e s s u r e
drops i n t h e d r y i n g and pre-heat f u r n a c e s t o a riaximum of 9 in. and 8 in. r e s p e c t i v e l y .
The average q u a n t i t y of b e n t o n i t e r e q u i r e d has been 1 2 l b s / t o n of green b a l l s .
0

Induration

The i n d u r a t i o n s e c t i o n has o p e r a t e d i n a t r o u b l e f r e e manner s i n c e s t a r t - u p .

Average o p e r a t i n g c o n d i t i o n s d u r i n g t h e l a s t t h r e e mpnths have been a s follows -
Drying temperature 5 5 0 ~ ~ ~
Pre-heat gas temperature 2,200 F.
Drying p r e s s u r e drop '
8 i n . a t 360 l o n g t o n s per h r ,
Pre-heat p r e s s u r e drop 7 in.oat 360 l o n g t o n s per hr.
Max. temperature of p e l l e t s i n k i l n 2,420 F.
Waste gas s t a c k . t e m p e r a t u r e from c o o l e r 800 F.
B.T.U. consumption 960,000 per ton.

Although t h e p l a n t was performing w e l l w i t h i n t h e guaranteed f i g u r e s d u r i n g

commissioning and a c c e p t a n c e , B.H.P. was not s a t i s f i e d w i t h t h e y i e l d of c . o r r e c t l y
s i z e d , f i r e d p e l l e t s from green b a l l s . The low y i e l d was mainly due t o t h e break-up
of pre-heated p e l l e t s d u r i n g t r a n s f e r from t h e g r a t e t o t h e k i l n . Breakage of p e l l e t s
i n t h e f e e d c h u t e t o t h e k i l n has been l a r g e l y overcome by adding a l o c a l c l a y t o t h e
feed. T h i s c l a y is used i n t h e Whyalla a r e a t o make b u i l d i n g b r i c k s and i t a c t s a s a
bonding agent a t temperatures experienced i n t h e pre-heat furnace. Since c l a y has
been added t h e y i e l d of f i r e d p e l l e t s from green b a l l s has averaged 88%. The 12%
l o s s was made up a s f o l l o w s -
 Moisture l o s s 8.2%
Ignition loss 1.5%
Dust 10ss 1.0%
F i n e s and lumps from
product s c r e e n i n g 1.3%

Total 12.0%

Ring orn nation - Rotary Kiln

A l l h e a t r e q u i r e d i n t h e i n d u r a t i o n s e c t i o n i s s u p p l i e d by a n o i l burner i n t h e
r o t a r y k i l n . I n i t i a l l y , d i f f i c u l t y was experienced i n p r e v e n t i n g t h e r e d u c i n g
atmosphere near t h e flame from forming a magnetite r i n g i n t h e k i l n . B.H.P. developed
a n o p e r a t i n g procedure which causes t h e r i n g t o o x i d i s e and break away from t h e k i l n
before t h e r i n g became s o l a r g e t h a t p r o d u c t i o n r a t e was a f f e c t e d .

B l a s t Furnace Performance

B.H.P. b l a s t f u r n a c e s a t P o r t Kembla and Whyalla have used Whyalla p e l l e t s a s feed.

High p r o d u c t i o n r a t e s have r e s u l t e d and i n some c a s e s new d a i l y , weekly and monthly
p r o d u c t i o n r e c o r d s have been e s t a b l i s h e d . T e s t s t o d a t e i n d i c a t e t h a t t h e r e has been
very l i t t l e improvement i n b l a s t f u r n a c e p r o d u c t i v i t y u n t i l t h e p e l l e t burden has been
i n c r e a s e d above 60%. A f t e r t h i s l e v e l has been reached t h e r e has been a s h a r p i n -
c r e a s e i n p r o d u c t i o n r a t e , a l s o good f u r n a c e movement and s t a b l e o p e r a t i n g c o n d i t i o n s .
The maximum p r o d u c t i o n r a t e s have been o b t a i n e d w i t h 100% p e l l e t burden.

Conclusions

The p l a n t was designed from i n f o r m a t i o n o b t a i n e d from e x t e n s i v e t e s t work and

r e s e a r c h , and has performed a s planned. Due t o i t s complexity and unique d e s i g n
f e a t u r e s , t h i s has been a p l e a s i n g r e s u l t .

The p l a n t has produced a t p r o d u c t i o n r a t e s e q u i v a l e n t t o 1,863,000 t o n s of s c r e e n e d

p e l l e t s per annum. A t t h i s production r a t e t h e q u a l i t y of t h e product has been h i g h e r
t h a n expected.

S e v e r a l minor m o d i f i c a t i o n s have been made by B.H.P.. t o f u r t h e r improve p l a n t

c o n t r o l and ~ e r f o r m a n c e . S e v e r a l c o n d i t i o n s such a s o r e grade v a r i a t i o n s , moisture
a d d i t i o n and o t h e r s have had t o be c l o s e l y c o n t r o l l e d , but f u r t h e r e x p e r i e n c e i n
o p e r a t i o n and a r e f i n e d maintenance schedule may r e s u l t i n a f u r t h e r improvement i n
production r a t e .

Acknowledgment

We would l i k e t o thank a l l o f f i c e r s who have c o n t r i b u t e d t o t h e d e s i g n , c o n s t r u c t -

i o n and s u c c e s s f u l o p e r a t i o n of t h i s p l a n t and i t must be s a i d t h a t t h i s only has
been p o s s i b l e due t o t h e c l o s e co-operation between B.H.P. and Allis-Chalmers'
technical officers.

The :authors of t h i s paper a r e i n d e b t e d t o a number of B.H.P. and A l l i s - C h a l m e r s t

personnel f o r t h e i r c o n t r i b u t i o n s t o t h i s paper.
 SPLITTER

F I G . NO.l ORE PREPARATION FLOW SHEET

TYPICAL COMMFRCIAL INSTALLATIaN

FIG. No 2 OF GRATE -
KILN SYSTEM
 DISCUSSION

R. D. Frans

Asst. to Vice President - Domestic,Operations

The Hanna Mining Company, Cleveland, Ohio

The authors are to be complimented on the prompt and successful commissioning of

this plant. No doubt the close cooperation among all parties contributed very much
to their success. . Also, I want to thank them for the fine paper they have presented.
I'm sure that the detailed discussion of the various problems must necessarily be use-
ful to those engineers faced with designing and,building the next pellet plant for
natural ore processing.

The whyalla plant is the sixth in a group of plants that may be termed the third
generation of pelletizing plants.

The first generation of plants included the shaft furnace and straight-grate as de-
signed and used in the early 1950's to process the magnetite concentrates produced from
low-grade taconite-type ores. The main purpose was to beneficiate an unacceptable rock
and obtain a metallurgical composition of superior quality for the blast furnace. Pel-
letizing was only a necessary evil in this case and may never have been developed if
the well-established sintering process had been able to economically process the fine
concentrates.

The second generation of pelletizing plants included the grate-kiln and straight-
grate. These evolved in the late 1950's for the processing of flotation or gravity
concentrated specular hematites. The goal of this effort was much the same as before;
however, several new process innovations were necessary. The absence of exothermic
heat of oxidation during pelletizing and the different balling characteristics resulted
in a group of plants that were of significantly different process design.

This third generation of pellet plants came into being in 1965 and includes all
three
,.
designs of pelletizing processes, although the shaft furnace use has been quite
!imited. The major goal was the production of superior physical properties from high-
grade earthy hematite fines. The main metallurgical improvement lies in the removal
of small amounts of water of hydration which occurs during induration; however, a small
degree of beneficiation is accomplished by washing at one plant, and flotation is being
considered for others still in the planning stage.

On first thought it might appear that the third generation of plants was quite simple
to design. The contrary is true, however, and all of these plants have required exten-
sive experimental and test work. In a few cases, rather costly modifications have been
needed because small-scale test data was inadequate or not completely representative of
the full-scale operation.
 The s o u r c e of t h e problems i n t h e s e p l a n t s l i e s w i t h i n t h e o r e body. S i n c e a con-
c e n t r a t o r i s n o t used i n any of t h e e x i s t i n g p l a n t s , a l l of t h e p h y s i c a l and chemical
v a r i a t i o n s e x i s t i n g i n t h e e a r t h must somehow be c o n t r o l l e d i n t h e m a t e r i a l p r e p a r a t i o n
p l a n t s o a s t o produce a uniform and c o n s i s t e n t supply of g r e e n b a l l feed t o t h e i n d u r -
ation plant.

The g r i n d a b i l i t y of t h e o r e and t h e n a t u r a l s l i m e s and m o i s t u r e c o n t e n t a r e , per-

h a p s , t h e most important f a c t o r s i n f l u e n c i n g t h e c h o i c e of m a t e r i a l p r e p a r a t i o n flow
s h e e t s . Very l i t t l e knowledge of t h e d r y g r i n d i n g . o f i r o n o r e s e x i s t e d p r i o r t o t h e
c o n s t r u c t i o n of t h e s e p l a n t s , s t a r t i n g w i t h C l e v e l a n d - C l i f f s ' Pioneer P e l l e t Company
i n 1965. T h e r e f o r e , each of t h e e x i s t i n g g r i n d i n g c i r c u i t s h a s been s p e c i f i c a l l y d e -
signed t o s u i t t h e unique c h a r a c t e r i s t i c s of t h e o r e being processed. And, a s a r e -
s u l t , c o n s i d e r a b l e v a r i a t i o n i n approach e x i s t s . For example, Pioneer has a c e n t e r -
p e r i p h e r a l d i s c h a r g e , o p e n - c i r c u i t , rod m i l l o p e r a t i n g on a feed c o n t a i n i n g 5 t o 6 p e r -
c e n t m o i s t u r e ; Kobe s t e e l ' s Nadahama p l a n t i n Japan has b a l l m i l l s i n c l o s e d c i r c u i t
w i t h a i r c l a s s i f i e r s which d r y t h e o r e t o l e s s t h a n one p e r c e n t m o i s t u r e ; and a t Broken
H i l l t h e r e i s s t i l l a n o t h e r method of o p e n - c i r c u i t , compartment b a l l m i l l s o p e r a t i n g on
a previously d r i e d feed.

Dry g r i n d i n g advantages of low m e t a l wear r a t e a r e o f f s e t

by d i f f i c u l t m a t e r i a l h a n d l i n g and d u s t c o l l e c t i o n problems f o r t h e s e c i r c u i t s . How-
e v e r , t h e d e c i d i n g f a c t o r f o r d r y g r i n d i n g i s o f t e n determined by t h e poor f i l t e r -
a b i l i t y of t h e f i n e o r e . The one common c h a r a c t e r i s t i c among e a r t h y n a t u r a l o r e f i n e s
seems t o be a slimy n a t u r e which i s s t r o n g l y d e t r i m e n t a l t o use of p r a c t i c a l vacuum
filtering.

I t i s p a r a d o x i c a l t h a t t h e e x p e n d i t u r e of c o n s i d e r a b l e c a p i t a l equipment and pro-

c e s s i n g e f f o r t t o accomplish d r y g r i n d i n g s i m u l t a n e o u s l y c r e a t e s a new problem - t h a t
of r e w e t t i n g t h e d r y o r e t o a c o n s t a n t and uniform m o i s t u r e c o n t e n t s u i t a b l e f o r b a l l -
ing.

Two approaches t o r e w e t t i n g of t h e o r e have been used. A t Caland and S t e e p Rock

mines i n Canada and a t Hamrnersley i n A u s t r a l i a , d r y o r e i s f e d t o b a l l i n g pans and t h e
t o t a l m o i s t u r e a d d i t i o n i s made d u r i n g t h e b a l l i n g o p e r a t i o n . This approach a v o i d s t h e
pre-agglomeration problem mentioned i n t h e paper, b u t does i n c u r d u s t c o l l e c t i o n and
b a l l i n g c o n t r o l problems. The p r e w e t t i n g method used a t Whyalla s i m p l i f i e s t h e d u s t
problems b u t cannot be a p p l i e d t o a l l o r e s because t h e s l i m e s may pre-agglomerate t o
such an e x t e n t t h a t t h e r e s u l t a n t mixture a c t s a s a c o a r s e sand i n t h e b a l l i n g d e v i c e .
Green b a l l s produced under t h e s e c o n d i t i o n s do n o t have s u f f i c i e n t s t r e n g t h t o produce
a permeable bed on t h e i n d u r a t i n g machine.

The Broken H i l l p l a n t i s t h e f i r s t t o use drums commercially f o r b a l l i n g e a r t h y o r e

f i n e s - a l l o t h e r s use b a l l i n g pans, mainly i n open c i r c u i t e x c e p t f o r Pioneer and
Caland where t h e b a l l e d product i s s c r e e n e d . The d e t e r m i n a t i o n of t h e type of b a l l i n g /
w e t t i n g c i r c u i t f o r p r o c e s s i n g n a t u r a l o r e f i n e s i s laden w i t h i n h e r e n t r i s k . The
n a t u r e of t h e o p e r a t i o n does n o t lend i t s e l f t o a n a l y t i c a l e v a l u a t i o n , and s m a l l - s c a l e
t e s t r e s u l t s a r e always h i g h l y s u s p e c t because of t h e s c a l e - u p f a c t o r . S h o r t of an
o p p o r t u n i t y f o r f u l l - s c a l e t e s t s , t h i s problem can b e s t be r e s o l v e d by a l l o w i n g g e n e r -
ous s a f e t y f a c t o r s i n t h e c h o i c e of c i r c u i t s and equipment.

The d e s i g n problems of t h e i n d u r a t i o n p l a n t a r e v e r y s i m i l a r t o t h o s e of e a r l i e r
p l a n t s s o t h a t t h e accumulated background of e x p e r i e n c e can be a p p l i e d i n a meaningful
way. G e n e r a l l y , t h e major d e p a r t u r e w i l l be found i n t h e d r y i n g s e c t i o n of t h e i n d u r -
a t i n g p r o c e s s . The e a r t h y n a t u r e of n a t u r a l o r e f i n e s f r e q u e n t l y r e s u l t s i n t h e need
f o r prolonged, low-temperature d r y i n g t o prevent d e c r e p i t a t i o n of t h e g r e e n b a l l s i n
t h i s process zone, and i n some c a s e s , s p e c i a l a t t e n t i o n t o t h e dehydration and c a l c i n -
i n g p r o p e r t i e s of t h e o r e i s r e q u i r e d . F o r t u n a t e l y , t h e p o t - g r a t e furnace o f f e r s a
r e l i a b l e means of e s t a b l i s h i n g t h e d e s i g n c r i t e r i a f o r t h e f u l l - s c a l e p l a n t .
 It is a tribute to the planning and foresight of the Broken Hill Proprietary officers
and their supplier representatives that the many potential problems have been solved in
the planning stage.

We wish them continued success with their new plant.

 We wish t o thank M r . R. D. Frans f o r h i s kind words and good wishes. In
general, we would agree with t h e comments made by Mr. Frans, but p e l l e t i z i n g
cannot now be considered a s an unnecessary e v i l , as i t i s now an accepted process
i n i t s own r i g h t . Whyalla p e l l e t s havebeen well received by Blast Furnace
operators and i n t h e B.H.P. o r g a n i z a t i o n , they a r e considered t o be premium Blast
Furnace feed.

We would c e r t a i n l y agree t h a t it i s d i f f i c u l t t o design a p e l l e t p l a n t t o

t r e a t a n a t u r a l o r e . The v a r i a b i l i t y of a n a t u r a l o r e i s a hazard t h a t must be
faced, and i n our case, we were f o r t u n a t e i n t h a t only very minor plant modifications
were required t o b r i n g t h e p l a n t t o f u l l production.

We consider t h a t t h e main problem l i e s i n t h e - s e l e c t i o n of t h e sample f o r t e s t -

ing r a t h e r than the s c a l e of t h e t e s t work. I r r e s p e c t i v e of the thoroul;hness of t h e
t e s t work o r t h e s c a l e on which i t i s c a r r i e d out, t h e r e s u l t may be worthless i f t h e
sample i s not r e p r e s e n t a t i v e of t h e o r e t o be t r e a t e d during t h e complete l i f e of
t h e mine o r t h e p l a n t .

In some c a s e s , t h e c o s t of o b t a i n i n g a r e p r e s e n t a t i v e sample of the ore i s p r o h i b i t i v e

and i n t h e s e i n s t a n c e s , it appears t h a t a compromise must be reached between spending
money on building f l e x i b i l i t y i n t o t h e p l a n t o r i n c u r r i n g considerable expenditure on
obtaining a r e p r e s e n t a t i v e sample. Each p e l l e t p l a n t and mine p r e s e n t s a d i f f e r e n t
problem and each must be evaluated.

Prewetting an o r e a f t e r dry grinding i s a problem. We have not so:lved t h i s

problem a t Whyalla, but we a r e gaining experience a s t h e p l a n t becomes o l d e r . I f
we were t o b u i l d another p l a n t , we would not n e c e s s a r i l y use t h e same flow s h e e t ,
a s some changes appear t o be j u s t i f i e d .

The B .H.P. Company, Ltd. considered t h a t optimum p e l l e t plant operation occurs

when c l o s e l y s i z e d , high compression s t r e n g t h f i r e d p e l l e t s a r e produced. Closely
s i z e d p e l l e t s a l s o appear t o promote g r e a t e r production i n a Blast Furnace s o t h a t
improvement i n el let ~ l a n aerformancet usuallv r e s i ~ l t sin an i ~ r o v e dproduct for
Blast Furnace use.