Siemens VAI

Circular Pelletizing Technology

General Presentation

We didn’t invent

Pelletizing…

We just made it better.

Delhi, 10 th 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

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Trends in

Iron Ore Mining

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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.

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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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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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Siemens VAI Sintering Technology

Mechanical design of a circular dip rail cooler

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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

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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 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

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The Induration Process in Circular Arrangement

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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.

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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.

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Circular Pelletizing

Technology –

Layout, Plant Options

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Standard Plant Layout CPT 1.2M

CPT Standard Plant Layout:

1- Dosing & Green Balling

1

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2- Additive Storage & Grinding

1

2

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3- Mixing Station

1

3

2

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3- Mixing Station

4- Induration Furnace

1

4

3

2

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3- Mixing Station


5- Product Classification

1

4

3

5

2

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3- Mixing Station



6- Product Pile 1

4

3

5

2

6

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3- Mixing Station



6- Product Pile

7- Process Air Cleaning

1

7

4

3

5

2

6

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3- Mixing Station



6- Product Pile


8- Coal Gasification Plant

1

4

7

8

3

5

2

6

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Dual Fuel Burner Principle Scheme

Indigenous

Coal

Flare

Primary

Air

Air

Coal

Gasif.

Ash

Fuels can be mixed in

every ratio.

HFO

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Coal Gas Operational Data

Minimum Properties of Coal

Coal composition

Lower heat-value at 10%

wet

Coal-grain size:

C 30-35%

H 4,64%

N 1,85%

S 0,95%

3,300

kcal/kg

25 - 50 mm

Ash content of coal 40% +/-2%

Lowest Ash melting

point

1,080°C

Data of Coal Gas per Gasifier

(typical)

Coal input

Coal gas output

HV of coal gas

1,76 t/h

1250 Nm³/h

1250 kcal/Nm³

Coal gas temp. 350°C

Coal gas

Dust content

Tar content

C0 25%

H2 9%

CxHy 2,5%

CO2 6,5%

N2 57%

300 mg/Nm³

25-30 g/Nm³

Ash amount

0,69 t/h

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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

50% of the Coal gasification plant

OPEX savings per year when substituting 50% of fuel

requirement with coal gas

~8,43 M€ ~3,00 M€

~5,43 M€

*The comparison has been prepared for India based on Indian unit rates.


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Top View of a CPT 1.2M in a Steelworks

1

CPT Plant Layout:

1- Iron Ore Grinding

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1

2

CPT Plant Layout:


2- Dosing & Mixing Building

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1

2

3

CPT Plant Layout:



3- Green Balling

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1

2

4

3

CPT Plant Layout:



3- Green Balling


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1

2

4

3

CPT Plant Layout:



3- Green Balling



5

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1

2

4

3

CPT Plant Layout:



3- Green Balling




6

5

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1

2

4

3

CPT Plant Layout:



3- Green Balling




7- Product Intermediate Bin

7

6

5

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1

2

3

4

8

CPT Plant Layout:



3- Green Balling




7- Product Intermediate Bin


7

6

5

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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.

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CPT in Figures

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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%

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Consumption Figures

Electr. energy requirement

Heat energy requirement

Water requirement

Compressed air

Bentonite

Coke

Limestone

Refractories

< 40 kWh / t pe

< 250 Mcal / t pe

< 0.2 m³ / t pe

< 25 m³ / t pe

< 7 kg / t pe

< 11 kg / t pe

< 11 kg / t pe

< 0.1 kg / t pe

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Environmental Figures

Dust in waste gas (mg dry / Nm³) < 50

Work zone dust content (mg dry / Nm³) < 5

Noise level (dB(A))

< 85 (at 1 m from source)

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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

• 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

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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

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Cooperation

Agreement

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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.

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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

• Design of Pelletizing Process

• Plant Performance

• Specification of Plant Equipment

+

SVAI India

Scope of Work

• Detail Engineering

• Supply of plant equipment

• Electrics and Automation



• Timely project execution

• Reliable E&A equipment based

on Siemens components

• After sales service and support

JIPL India

Scope of Work

• Detail Engineering

• Supply of plant equipment

• Project Execution



• High quality and economical

manufacturing of equipment

• Local expertise in engineering

and equipment procurement

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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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Siemens VAI

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