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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IS MT IR TY AG

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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4- Induration Furnace 

1 

4 

3 

2 

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5- Product Classification 

1 

4 

3 

5 

2 

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6- Product Pile 1 

4 

3 

5 

2 

6 

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6- Product Pile 

7- Process Air Cleaning 

1 

7 

4 

3 

5 

2 

6 

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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 



2- Dosing & Mixing Building 

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1 

2 

3 




3- Green Balling 

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1 

2 

4 

3 






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1 

2 

4 

3 







5 

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1 

2 

4 

3 








6 

5 

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1 

2 

4 

3 








7- Product Intermediate Bin 

7 

6 

5 

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1 

2 

3 

4 

8 








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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