Essar Projects

Making Mega Projects Possible….

RESURGENT INDIA- VISION 2020 IN METALS AND MINERALS SECTOR

Utilization of Iron Ore Fines /

Pellets in Iron Making

28-09-12, Delhi
Contents

• India – Steel Production and Iron ore scenario

• Why - Utilization of Iron ore fines

• Essar’s contribution in utilization of iron ore fines & slimes

• Benefciiation
• Agglomeration
• Slurry pipeline transport
• Essar’s BF operation with pellets in burden

• Brief details of Essar’s iron ore Beneficiation plants, Slurry pipelines and
Pellet plants

• Initiatives required from Industry in usage of iron ore fines

• Essar Projects India Ltd – Brief EPC capabilities in Minerals & Metals
India – Steel Production & Iron Ore Scenario
• Annual production of steel In India is expected to reach close to 200 million
tonnes mark by the year 2020 making India world’s second largest steel
producer
Current Scenario of Iron ore reserves
• India has about 28.5 billion tonnes of Iron ore reserves
• Around 60% of Indian ore mined is in the form of fines with relatively lower
grade of iron
• India is amongst the highest consumers of CLO for its steel production. About
25% - 30% of India’s steel production is through sponge iron route which is
excessively dependent on CLO as feed
• With the projected steel production, requirement of iron ore is expected to be
around 350 to 400 million tonnes per year. At this rate of consumption, the
available good quality reserves would probably not last more than a few
decades
 Why - Utilization Of Iron Ore Fines
• Improving the resource base and exploitation of Mineral resources remains one
of the most important geological and economical tasks in India and is the need of
the hour

• The conventional iron ore processing generates slimes to the tune of 10 to 15%
of run-off-mine (ROM)

• It is estimated that more than 600 million tonnes of Iron ore fines dumps are
available across India and this needs to be clearly assessed.

• Fines/ Slimes occupy huge space and cause environmental and ecological
problems

• It is essential to beneficiate and recover the additional iron values from these
fines & slimes, not only to earn additional revenue to iron ore industries but also
from the view point of conservation of mineral wealth
Utilization Of Iron Ore Fines

• Beneficiation process is generally customized as per the ore mineralogy and

has to be established through laboratory and/or pilot scale tests

• Locating Beneficiation plant

Close to the mine head or at a place with good connectivity from mines,
sustainable source of water & power, safe and easy disposal of tailings

Nearby pellet plant / slurry transportation by pipe line to port based pellet
plant

• Beneficiated concentrate would need to be further processed for facilitating

its use in Iron making process

• Agglomeration processes of Sintering and Pelletizing enable the usage of

fines / concentrate in Iron making
ESSAR’S CONTRIBUTION TOWARDS IRON ORE
BENEFICIATION & PELLETISATION UTILISING
LOW GRADE FINES & SLIMES
Essar’s Strategy
• By installation of Iron ore beneficiation plants at mine head, Essar is able to
utilize low grade fines & Slimes(< 58% Fe Hematite ore) and impart value
addition
• Adoption of slurry pipe line for concentrate transportation eases logistics
and environmental issues
• Conversion of iron ore concentrate / pellet feed to pellets at port based
plants facilitates easy shipment to its ISP
• Essar group has gained good experience in Beneficiation and Pelletization,
reducing dependence on foreign technology providers and equipment
suppliers
• Essar is already operating its Blast Furnace with ~55 % Pellet in burden
• Essar is in discussions with R&D institutes for building up a 100 kg/h pilot
scale Beneficiation & Pelletization plant using BHQ ores, high blaine index
and higher LOI concentrates for Pelletization
Essar’s Pioneering Value Addition To Iron Ore
Fines/ Slimes

Facility Feed quantity

2X4 MTPA Beneficiation Plant in Kirandul,

10-11 MTPA of fines & slimes
Chattisgarh with Pellet Plant in Vizag
3X4 MTPA Beneficiation Plant in Dabuna,
Odisha with 2 X6 MTPA Pellet Plant in 17 MTPA of fines & dumps
Paradip
1X7 MTPA Integrated Pellet Plant in
About 23 MTPA of ROM
Minnesota, USA

to support Intergraded Steel Plants at

• 10 MTPA ISP at Hazira, Gujarat

• 4 MTPA ISP at Algoma, Canada

Integrated Steel Plant @ Hazira - Process Flow
r1
Slide 9

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ryellepeddi, 26-Sep-12
Advantages Of Beneficiation

• Utilization of available dumps

• Reduction in smelting cost due to reduction in quantity of feed processed

• Unwanted material is discarded at the site of ore processing reducing

logistics related costs and concerns

• Consistency in quality and uniformity in size of product obtained after

processing improving the efficiency of smelters

Advantages Of Slurry Transportation By
Pipelines
• Slurry transportation ensures zero wastage as there is no in-transit material
loss

• Pipelines have high availability and low maintenance requirement

• Pipelines are techno- economically more viable when compared to other

transportation modes. It gives considerable savings on transportation,
specific to locations

• Eliminates dependency on logistics providers like Railways, Road, etc.

• Slurry pipelines are environment friendly, as they do not cause noise, dust
pollution or negative visual impacts

• Minimum land is required for laying the under ground pipeline and land can
be restored to its original condition
Sintering

• Sinter feed

Ideal feed size range is 90% of material between10mm to 1mm

Feed size below 1 mm is generally restricted to 10%

• Micro pelletization

Imparts flexibility in the usage of ultra fines in the sinter feed mix

Augments usage of ultra fines by additional 10 - 15%

• 100% utilization of ultra fines/Pellet feed as sinter feed through
micro Pelletization is not possible as it adversely impacts the
operation, productivity and quality of sinter
• Test works are being carried out to use pellet feed in sintering and
assess the impact on quality/ production parameters
Pelletization

• The limitation in the utilization of beneficiated ultrafine concentrates in

Sintering could be overcome through the process of Pelletization
• In fact, it is desirable to have concentrates in the size range of 45 micron for
effective Pelletization
• Pellets have high resistance to abrasion and facilitate transportation over
long distances. This makes Pelletization an attractive option of
agglomeration either for captive consumption or as a merchandised product
• Lesser heat consumption than sintering
• The industry is gaining operational and economic advantages by the usage
of pellets in the Iron making process as compared to lump ore
• Sponge Iron Kilns have reported an increase in production by 25% due to
the utilization of pellets instead of CLO. Reduction in fines generation and
reduction in coal consumption by 10% is also experienced
Advantages Of Pellets In Iron making

• Spherical shape of pellets gives better & uniform permeability resulting in

smoother furnace operation

• Pellets have very high cold crushing strength resulting in negligible

generation of fines in stock house

• High porosity (i.e. ~ 20%) leads to faster reduction

• High strength of pellet (180 - 250 kg/cm2) provides good resistance to

disintegration during the descent of burden

• Uniform chemical composition compared to lump ore

• Benchmarked Blast Furnaces have 50% pellets in their BF burden.

14
BF Operation At Essar, Hazira
Description Unit Design With 30% pellet With 50% pellet
Hot metal prod. (Avg.) t/d 5000 4800 5200

Productivity (U.V.) thm/cum/day 2.27 2.18 2.36

Sinter % 55.0 42.0 40.0

Pellet % 30.0 30.0 54.0

Iron ore % 15.0 28.0 6.0

Slag rate kg/thm 380 328 324

Fuel rate kg/thm 530 564 540

Coal rate kg/thm 150 133 121

Si in hot metal % 0.8 0.6 0.66

Hot blast temperature 0C 1150 1165 1130

Oxygen enrichment % 3.0 3.2 – 3.4 2.8 – 3.0

Top pressure bar(g) 1.76 1.52 1.45

Essar’s Long Term Plans In India

• Essar is proposing to install ISPs at the following locations as a part

of its long term plans, with maximum utilization of pellets in Blast
furnace burden, thereby further usage of low grade fines in these
areas.

6 MTPA ISP at Paradip

3 MTPA ISP in Chattisgarh

6 MTPA ISP in Jharkhand

 BRIEF DETAILS OF ESSAR’S

IRON ORE BENEFICIATION PLANTS,

SLURRY PIPELINES AND PELLET PLANTS

12 MTPA Beneficiation Plant At Dabuna
3x4 MTPA Beneficiation Plant At Dabuna

• Conceptualized the process flow

based on the lab & plant scale
tests
• Plant based on “modular design”
concept
• Equipment selected based on
latest technologies and
operational expertise
• Equipment sized based on
availability & operational
flexibility to process wide range of
quality of ores
Usage Of Slimes At Kirandul
Beneficiation Plant
7 MTPA Beneficiation Plant At Minnesota

• Crusher

Primary crusher

Scalping grizzly

Secondary crusher

• Concentrator

AG mills

Ball mills

Magnetic separators

Floatation cells

Thickeners

Slurry pipe line
 Essar’s Beneficiation Plants-Summary
Dabuna (under Minnesota (under
Particulars Kirandul
implementation) implementation)
Capacity 8 MTPA (2x 4 MTPA ) 12 MTPA (3 x 4 MTPA) 7 MTPA (3 x 2.17 MTPA )

Butler Taconite mine

Bailadila range iron ore Pvt. Mines around Barbil-
Source near Nashwauk,
fines & slimes of NMDC Joda sector
Minnesota
Hematite fines and slimes, Hematite, 58-60%(BF) Total Fe, % 30.36
Iron ore & nature
58%Fe Hematite, 62-64%(DR) Magnetic Fe, % 20.46

Concentrate,63.8%(BF) 68.5 to 69.5 % (DR)

Plant output Concentrate, 66.5% (DR)
Concentrate,66.2%(DR) 66.0 – 66.3 % (BF)

29.75% (DR)
Yield 80% to 84% ~70% /75%
30.8% (BF)
Scrubbing, Gravity Magnetic separation,
Gravity separation,
Key processes separation, Magnetic Hydro-cyclones &
Magnetic separation
separation flotation
NMDC slimes feed along All flux hindered
with fines separator & small Dry cobber & flotation
Benchmark operability
Recovery of Fe units from capacity SLONs, future circuits
plant tailings plans to process BHQ
Kirandul – Vizag Slurry Pipe Line
Kirandul to Vizag Slurry Pipe Line
Essar Slurry Transportation Facilities-Summary

Particulars Kirandul - Vizag Dabuna – Paradip Minnesota

Distance 267 km 253 km 3.5 km

Benchmark India’s longest slurry 2nd longest iron ore

--
operability pipeline slurry pipeline in India

Control Supervisory control and data acquisition systems (SCADA)

Diaphragm type Diaphragm type

Differential Head
Pumps positive displacement positive displacement
pumps
pumps of GEHO make pumps of GEHO make

Pipeline passes
through 3 states in
Coverage within
Coverage area India (Chattisgarh, Across Odisha
plant premises only
Odisha, Andhra
Pradesh)
2X6 MTPA Pellet Plant At Paradip
Flow Sheet Of Pelletization Plant At Paradip
Consistent Value Addition In Pelletisation-Summary

Particulars Vizag Paradip Minnesota

8 MTPA (1 x 420 m2 &
Capacity 12 MTPA (2 x 744m2) 7 MTPA (1 x 744 m2)
1 x 444 m2)
Lurgi’s Straight grate Aker Solutions’ Aker Solutions’
Technology
process straight grate process straight grate process

Processing taconite
Capacity enhancement Customized process
ore, Improved
through zone based on previous
Process environmental
rearrangement and learning, multi-staged
improvement performance – SOx,
introduction of after screening of green
NOx and Mercury
cooler pellets
emission control

Grade of pellet BF & DR grade BF & DR grade BF & DR grade

64 % (BF) 63.8% (BF) 60.5- 61% (BF)

Fe Content
66.5% (DR) 66.2% (DR) 66.5- 67 %(DR)
 Essar’s Unique Initiative
• Essar’s unique initiative – Environmental regulations at Minnesota
• NOx mitigation at source

Collaborated with FNAC, USA
• Treatment of gaseous emissions

Collaborated with FLSmidth to implement solutions for
treatment of Hg and SOx emissions in the process exhaust
 INITIATIVES REQUIRED -

USAGE OF IRON ORE FINES/DUMPS/SLIMES

Technology Look Ahead
• Develop indigenous & viable technology to improve yield and effective
utilization of low grade iron ore including BHJ/BHQ/BMQ, fines & slimes to
produce quality concentrate by deep beneficiation.
• Use of tailings as building/construction material, ceramics, etc.
• New blast furnaces should have design provision to maximize pellet
utilization in their feed burden
• Upgrade the existing blast furnaces to accept higher pellet in burden
• Commercialization of alternate iron making technologies that directly use
low grade fines or concentrates as feed
Initiatives To Encourage Fines Utilization

• Significant steps have to be taken by the Ministry of Steel to encourage the

establishment of beneficiation and pellet plants

Ascertain proven reserves of fines/dumps and allot the resources to

pellet or pellet feed producers – Mine owners/integrated steel producers

Ensure long term securitization of ore linkage of a specific range of

quality to entrepreneurs so that periodical capital infusion is avoided

Improving the infrastructure and logistics support at mine head

Encourage rotary kiln based DRI producers to use pellets instead of

CLO
Initiatives To Encourage Fines Utilization

Providing tax incentives

Facilitate easy sanction of right of way for slurry pipelines

Establishing dedicated pipeline corridors for trouble free and safe

operation of slurry pipelines

Developing pellet hubs close to consumer points / seaports

The technologists, R&D institutions and the steel industry as a whole,

need to support the development of cost effective and environmentally

friendly solutions and processes

EPC Capabilities
EPC Capabilities

• Essar has a mixture of Design & Engineering, Operating, Maintenance and

Construction/Project knowledge. As a result the plants designed will be
operator friendly taking in to account all practical aspects

• For Iron & Steel plants Essar has the exposure to alternate routes of various
processes and ready access to operating plants

• With in-house operating plants, Essar has ready made access to all
operating data useful for improving successive designs.

• Having the practical knowledge of the plant, Essar is in better position to

select technology and equipment (giving better OPEX & CAPEX).
Expertise In Iron & Steel Making
Beneficiation And Pellet Plant Projects

• Pellet plants executed by EPIL on EPC basis

Vizag – Essar Steel Limited, 8.0 MTPA

Paradip – ESOL, 12.0 MTPA

Minnesota, USA – 7.0 MTPA

Vale, Oman – 8.0 MTPA (Engineering and procurement assistance)

• Other Beneficiation and Pellet plant activities

Front end loading studies for 6.0 MTPA pellet plant project of Vale,
Malaysia

Process audit of Sarda Mines Pvt. Limited Beneficiation plant
EPC capability in Beneficiation & Pellet
Plants

Sl. Slurry
Description Beneficiation Plant Pellet Plant
No. Pipeline
Only Induration area by a
Technical know- Flow sheet development Tech
1 Tech Supplier
how & lab testing by laboratories supplier

Basic EPIL EPIL

2 EPIL
Engineering (excl Induration area)

Detail
3 EPIL EPIL EPIL
Engineering
Supply of
4 EPIL EPIL EPIL
equipment

Construction &
5 EPIL EPIL EPIL
commissioning
EPIL Advantage…. Creating Enduring Value
• Group with experience of executing projects from concept to commissioning
• Pan India presence with offices at all key locations
• Hands on experience of setting up & operating Iron & Steel, Power, Refinery
and Ports in India & overseas locations
• State of the Art Engineering Centre & Reference Engineering Data available
from operating plants
• Construction infrastructure with modern tools & a large fleet of construction
machinery
• Global Procurement team conversant in dealing with steel plant equipment –
ongoing sub-vendor relations & logistics support
• Steel available for EPIL on priority from the Essar’s plant
• Strategically located fabrication / manufacturing facility along the waterfront
@ Hazira for efficient & hassle free shipment
• “A Positive Attitude Powered by Positive Action”
LET’S BEGIN …..
THANKS