Transcript Document

Pelletisation- A way Forward
for sustainable steel
Making…..
21.07.2010
Steel Production…………….
Current and future capacities after planned/projected expansions
(million tons pa of 'Crude Steel' Capacity)
Sl
Producer
2006-07
2011-12
2019-20
15
20
40
1
SAIL
2
TATA steel
6
11
25
3
JSW
4
14
30
4
Ispat Industries
3
5
7
5
Essar
4
7
15
6
RINL
3
6
10
7
JSPL
3
15
24
8
Bhushan
1
6
10
9
POSCO
0
4
12
10
Arcelor Mittal
0
3
12
11
Others
5
5
12
44
96
197
Total
Secondary & Tertiary producers not considered for yr 2006-07
2
Copyright © 2010 Jindal Steel & Power Ltd.
Indian Steel Industry On High Growth Phase
200
180
160
140
120
100
80
Million
tons (MT) 60
40
20
0
200
140
124
58
28
2000
3
2007
Copyright © 2010 Jindal Steel & Power Ltd.
2012(E)
2015(E)
2020(E)
Per Capita Steel Consumption…………….
•
•
•
•
•
4
World- 150 Kg
Developed World- 350 Kg
INDIA – 50 Kg
CHINA – 250 Kg
The estimated India per capita consumption is expected to reach
approximately 165 kg in 2019-20.
Copyright © 2010 Jindal Steel & Power Ltd.
Requirement for Iron making…
• Fe %
• SiO2 %
• Al2O3 %
• LOI %
•P%
•S%
Effect:-
≤1%
-
> 65 %
≤ 1.5 %
≤1%
< 0.005 %
<0.003 %
• Slag rate in Iron making ~ 200 kg/T of Hot Metal
5
Copyright © 2010 Jindal Steel & Power Ltd.
Chemical properties of Iron Ore
(Hematite) mostly available
Cause:-Typical
• Fe %
• SiO2 %
• Al2O3 %
• LOI %
•P%
•S%
Effect:-
-
61 – 63 %
3.5 % - 4.5%
2.5% - 3.5 %
3-4%
< 0.009 %
<0.005 %
• Slag rate in Iron making = 350-400 kg/T of Hot Metal
6
Copyright © 2010 Jindal Steel & Power Ltd.
Types of Indian iron Ore Deposit
» Hematite
» Magnetite
 Hematite is the main producing iron ore in India.
 Hematite ores are found in the form of hard massive , hard
laminated, semi friable / soft laminated , powdery type.
 Goethite, limonites and laterites are also found in the form of
associated with Hematite minerals.
7
Copyright © 2010 Jindal Steel & Power Ltd.
Types of Indian iron Ore Deposit
 Our Iron ore is fragile in nature and contain good amount of
goethite and kaolinite in association with hematite ore.
 During beneficiation of these low grade hematite iron ore goethite
enriches along with hematite, which remain associated with the iron
ore concentrate even after beneficiation.
 As the liberation of iron phase mineral is below 200 microns, the
generation of fines are more during size reduction which causes high
Blaine number
 Causes high LOI and high Blaine number in iron ore concentrate after
beneficiation.
8
Copyright © 2010 Jindal Steel & Power Ltd.
Types of Indian iron Ore Deposit
• The presence of deleterious gangue mainly Alumina and Silica are
highly undesirable as they adversely increase the cost of hot metal
produced.
• SiO2 - 1.5 % will reduce Slag volume - 65 kg / Tonne
• Al2O3 – 1.0 %, will reduce Slag rate - 30 kg / Tonne
• Coke / Flux rate reduced - 6 kg / Tonne
• Productivity (Hot metal) increased – 2.75 %
• Reduction of 1 Tonne of Alumina load through Washing /
Beneficiation from ore will give savings of Rs.1 Lakh in steel making
process
• Note :1 % reduction of Alumina, benefit is around 100 crores per
annum for 3.0 MTPA steel plant.
9
Copyright © 2010 Jindal Steel & Power Ltd.
Iron Ore Demand-Supply Matrix
For the year 2009-10
Demand* (in million tonnes)
102 MT
Note: For producing 1 Tonne of crude steel/ sponge iron, 1.6 tonnes of iron ore
consumption has been assumed.
Supply
Production of iron ore
226
Mine-head stocks
73
(IBM Nagpur)
Total
Surplus
Demand-Supply matrix= 299-102
Exports
= 299
= 197.00
= 117.37
*** Surplus available (including stocks at mine- heads)= 79.63
10
Copyright © 2010 Jindal Steel & Power Ltd.
Resource…………….
•
•
•
•
•
India has 25 billion tons of iron ore reserve
India produces 222 MT with avg. recovery @27% lump ore
Huge fines/ultra fines generation
More than 60% of good quality ore is exported
By 2020
– 200 MT Steel
– 480 MT Iron ore
Low grade
Lumpy ore
Low grade
Fines/Slimes
BHJ/BHQ/BMQ
Beneficiation/
Agglomeration
LOW GRADE RESOURCE
Low grade iron ore, iron ore fines and iron ore tailings/slimes accumulated
over the years at mine heads and generated during the existing washing processes,
need to be beneficiated to provide concentrates of required quality to the Indian
steel plants.
11
Copyright © 2010 Jindal Steel & Power Ltd.
Agglomeration
Briquette
Sinter
Pellet
Use of Pellets - Conservation of mineral by use of
fines / ultra fines to agglomerate, making it usable in the
steel industry.
Pellet making through …………..
Innovative Technology “Coal Gasification”
12
Copyright © 2010 Jindal Steel & Power Ltd.
Different Ore Types
Iron Ore Pellets
are made from
a variety of
different ores.
13
Copyright © 2010 Jindal Steel & Power Ltd.
Purpose of Pelletising……
Why Pelletising….?
Why not used fines directly ???
The design and operation of Blast Furnace makes it necessary to
agglomerate the fines by either Sintering or Pelletising….
14
Copyright © 2010 Jindal Steel & Power Ltd.
Blast Furnace Operation
Process
Chemical Reactions
Charge Distribution
3Fe2O3 + CO  2Fe3O4 + CO2
250 C
Fe3O4 + CO  3FeO + CO2
CO+N2
o
Low Temperature Distribution
Indirect Reduction
Stack
FeO + C  Fe + CO
Swelling and Softening
MnO + C  Mn + CO
P2O3 + 5C  P2 + 5CO
SiO2 + 2C  Si + 2CO
Coke Solution/ Direct Reduction
o
1200 C
primary Slag Formation
Bosh
Flood Phenomena
Hot Blast Air
C + O2  CO2  CO2 + C  2CO
Slag Tap Hole
o
1700 C
Tuyeres
o
1500 C
Effect of raceway conditions
⅓SiO2, ⅓CaO, ⅓Al2O3, MgO, MnO
o
1350 C
Pig Iron tap hole
Fe, C, Si, S, P, Mn- 93% Iron
Hearth
15
Copyright © 2010 Jindal Steel & Power Ltd.
Pellets in Blast Furnace
Gas to Solid Reactions
Permeability of Furnace Burden
Strength of Pellets
Porosity of Pellets
16
Copyright © 2010 Jindal Steel & Power Ltd.
Steps of Pelletising
17
Copyright © 2010 Jindal Steel & Power Ltd.
Indurating Furnace
Seven Processing Zones
Drying Section
Heat Recovery
Section
Heating Section
Travel
Updraft
Drying (UDD)
Down- draft
Drying
(DDD)
Pre-heating
(Ramp)
Firing
After Firing
First
Cooling
Second
Cooling
1
2
3
4
5
6
7
Copyright © 2010 Jindal Steel & Power Ltd.
Pelletisation Process Flow with Dry Grinding
Iron Ore Bins
Dryer
Ball Mill
Bentonite Grinding
Mixing
Paddle Mixture
Burners
19
Balling Discs
Green Pellets
Osciilating Conveyor
Roller Screen
Thickener & ESP
Copyright © 2010 Jindal Steel & Power Ltd.
Fired Pellets
Pellet Discharge
Process Gas Flow
20
Copyright © 2010 Jindal Steel & Power Ltd.
Key Equipment for Process Control
21
Copyright © 2010 Jindal Steel & Power Ltd.
Indurating Machine
Direct Recup
Header
Downcomer
Furnace Hood
Top Strand
Burners
Windbox
Rails
Air Passage
Bottom Strand
Double Dump
Valve Copyright © 2010 Jindal Steel & Power Ltd.
Typical Arrangement of Pellet
Bed of green pellets on pallets
Hearth layer and side layer protects the pellets
and ensures uniform pellet quality
23
Copyright © 2010 Jindal Steel & Power Ltd.
Pellet Quality
PELLET QUALITY COMPARISION FOR THE YEAR 2010-11
JSPL
ARYA
JSW
GIIC
VALE
PHYSICAL
CCS
TUMBLER INDEX
ABRASION INDEX
270
95.02
3.83
249.65
93.9
3.33
243
93.93
4.73
300
92
6
230
92
7
POROSITY
23.64
17.85
17.17
Not Available
Not Available
8-16MM
-5MM
91.23
0.41
83.86
1.16
98.42
0.85
88
2
90
4
CHEMICAL
Fe
FeO
64.55
0.58
65.24
Not Available
62.25
67
Not Available
67.5
Not Available
SiO2
Al2O3
CaO
MgO
P
S
3.65
2.28
0.8
0.19
0.05
0.005
3.28
1.96
0.66
0.18
0.047
Not Available
5.16
2.62
2.1
0.37
0.04
SiO2+Al2O3 =2.6
1.45
0.75
0.9
0.5
0.035
0.01
Degree of Metalisation
Not Available
Reductivity
Not Available
PARAMETER
24
0.7
0.05
0.01
Not Available
0.01
94.21
Not Available
Not Available
96.78
Not Available
Copyright © 2010 Jindal Steel & Power Ltd.
Not Available
Present Pellet Manufacturing Capacity
SL NO
COMPANY
CAPACITY
1
ESSAR, VIZAG
8
2
JSW, VIJAYNAGAR
4.5
3
JSPL, BARBIL
4.5
4
KIOCL, MANGALORE
4
5
ARYA, BARBIL
1.2
6
MANDVI, GOA
1.8
7
BMM, HOSPET
1.2
8
CHOWGLEY & OTHERS
4
9
TOTAL
28.6
Another 30 million ton under commissioning by 2013
25
Copyright © 2010 Jindal Steel & Power Ltd.
Direct Cost reduction on Coke head
 For a 1mtpy plant Rs.3.8 Cr can be saved per annum
26
Copyright © 2010 Jindal Steel & Power Ltd.
Benefits of using of Pellets…………….
• Good Reducibility:
Because of their high porosity that is (25-30%), pellets are usually reduced
considerably faster than hard burden sinter or hard natural ores/lump ores.
• Good Bed Permeability:
Their spherical shapes and containing open pores, gives them good bed permeability.
Low angle of repose however is a drawback for pellet and creates uneven binder
distribution.
• Less heat consumption than sintering.
Approx. 35-40% less heat required than sintering.
• Uniform chemical composition & very negligible LOI:
The chemical analysis is to a degree controllable in the concentration processing
within limits dictated by economics. In reality no LOI makes them cost effective.
• Easy handling and transportation.
Unlike Sinter, pellets have high strength and can be transported to long distances
without fine generation. It has also good resistance to disintegration.
27
Copyright © 2010 Jindal Steel & Power Ltd.
Benefits Contd…….
The other Advantages of using iron ore pellets are:
1. The rotary kiln can produce 20% more without any changes in the design.
2. Specific consumption of coal will come down by 10%.
3. Campaign life will increase to almost 60%.
4. Metallization will be better compared to lump ore.
5. Reduce the generation of fines to 5% in the finished product against 35
to 40%, when produced with lump ore.
6. There are no losses of handling iron ore, as pellets will not break during
transport or handling because of high cold crushing strength.
7. Finally, we will have better environment to work.
28
Copyright © 2010 Jindal Steel & Power Ltd.
Benefits of Using Iron ore Pellets in JSPL
•
•
•
•
•
•
•
•
coke / coal consumption - 25 %.
Productivity of Sponge - > 20 %.
carbon content - 20 %.
Sulphur content - 5-10 %.
Phosphorous content - 5 – 10 %.
Iron content - 64.5 %.
Porosity - 18.5 - 24 %.
Direct cost saving around Rs.1800 / Tonne of pellet used in steel
making process.
• Refractory repairing cost
• Stable blast furnace operation.
• Environmental conditions.
29
Copyright © 2010 Jindal Steel & Power Ltd.
JSPL-Barbil Pellet Plant
30
Copyright © 2010 Jindal Steel & Power Ltd.
JSPL-Barbil Pellet Plant
31
Copyright © 2010 Jindal Steel & Power Ltd.
JSPL’s drives towards sustainable growth…
 Straight Grate Technology based Pelletising
JSPL operating 4.5mtpy pelletizing plant at Barbil
 Gas based DRI
JSPL has worlds largest coal-based sponge iron manufacturing facility, which
uses indigenously developed rotary kilns. JSPL leads the Indian market in this
sector and has the world’s largest coal-based sponge iron plant, with a
capacity of producing 1.32 MTPA DRI.
 Pipe line transportation for slurry
JSPL is laying 178km cross country pipeline from Barbil to Angul for transport
of Pellet feed concentrate.
 Micro Pelletised Sinter
JSPL- Patratu is Mapping Eirich and HPS technologies
– Technology and process
– On parameters like productivity, coke usage, power consumption,
lime consumption etc.
32
Copyright © 2010 Jindal Steel & Power Ltd.
JSPL’s drives towards sustainable growth…
 The DRI-BF-EAF route technology would be adopted for steel production at
Angul.
The DRI plant has a unique feature of using Syn Gas from the coal gasification
plants as reductant. The DRI-Gasification route is being used for the first time
in the world and has the advantage of using high ash coal which is
predominantly available in the vicinity of the project site. JSPL has signed an
agreement with Lurgi Sasol Technology Company, South Africa, for providing
technology for coal gasification.
Hot DRI charging in SMS
 Coal washery
JSPL has 6.0 million TPA coal washery at Tamnar, where 47-48% ash coal is
washed down to 26% ash. This washery meets the requirements of coal for
the sponge iron plant and in addition produces middling's for generation of
captive power of about 300 MW.
33
Copyright © 2010 Jindal Steel & Power Ltd.
JSPL’s drives towards sustainable growth…
 Coal injection in BF to reduce the dependency of Coke
 Organic Binder used replacing Bentonite & resulting less gangue in Pellet
 High efficiency by high volume BF installation
 Pelletising with Zero waste generation at Barbil
 R&D & Institute ,Industry partnership
JSPL has developed Column Floatation technology for Iron recovery from Tailings with
IMMT, Bhubaneswar & for recovery from BHJ, BHQ..
 HESS m/c from Germany for making high quality fly ash brick at Angul
 Infrastructure development
JSPL is setting up a captive port in Ganjam district. It involves a capital cost of Rs
1,424 crore, while the operational cost of running the port would be Rs 152 crore per
annum. The first phase is scheduled to be operational by 2017.
34
Copyright © 2010 Jindal Steel & Power Ltd.
35
Copyright © 2010 Jindal Steel & Power Ltd.
36
Copyright © 2010 Jindal Steel & Power Ltd.