Pelletizing Plant At Tata Steel (6.

0mtpa 768m2 )
RANCHI 22nd Jul Jul-2011 2011

Pellet Plant Project

Need of Pellet Plant for Tata Steel To increase hot metal output to meet 10 MTPA Crude Steel Production To improve blast furnace performance
a. Increase in blast furnace productivity b. Decrease in blast furnace fuel rate c. Decrease in hot metal quality d. Decrease in Slag Rate

Extending g the life of iron Ore Reserves

Pellet Plant Project

What are Pellets ?

Pellets are approximately spherical lumps formed by agglomeration of crushed iron ore fines in presence of moisture and binder, on subsequent induration at around 1300C, which suit the requirements of downstream processes e e.g. g Blast Furnaces & Direct Reduction.

Pellet Plant Project

Advantages of Pellets
Standardization uniform size range , generally within a range of 616 mm Purity 6368% iron iron, mainly FeO High and uniform porosity of 2530% Good bed PermeabilityDue to Spherical shape and open pores Cost-effectiveness Virtually no loss of ignition Fast reduction and high metallization rates Fine particles, not suitable for sinter making, are used Strength high and uniform mechanical strength even under thermal stress in reducing atmospheres Transportable low degradation under abrasive conditions

Pellet Plant Project

Pellet Vs. Sinter

Parameters Iron Ore Fines Size Coal / Coke Size Limestone / Pyroxinite Agglomeration Process Product Size, mm Tumbler Index (TI),% Reduction Degradation Index (RDI), % Reducibility Index (RI), (RI) % Swelling Index, % Pellet 80% < 0.045 mm 80% < 0.045 mm 80% < 0.045 mm Induration 6-16 6 16 mm >92 < 12 65 < 18 Sinter < 8-10 mm < 3.15 mm < 3.15 mm Sintering 6-40 6 40 mm 65 27-30 65

Pellet Plant Project

Process Stages of Pellet Production

Three process stages are involved to produce pellets from raw materials: 1. Raw material preparation 2. Formation of green pellets 3. Induration of green pellets

Successful S f l pellet ll t production d ti calls ll for f an optimum ti efficiency ffi i and d harmony between all above three stages with preceding stage highly influencing the subsequent one.

Pellet Plant Project

Process Flow of Pellet Plant

Noamundi
Iron Ore Fines Limestone Anthracite Coal BF Gas Hot Air Generator Recirculation Load

Dryer y

Ball Mill

ROKSH Separator

Process Bag House

Ground Ore Concentrate Materials Bentonite Powder Process Water Spiral Classifier Product Pellet e et Fines es Pellet

Dense Phase Conveying System

Roller Screen

Disc Pelletizer
Rejected Pellets

Green Mix Materials

Mixer

Green Pellets Single Deck Roller screen CO Gas Coal Tar

Pellet Plant Project

Water from Drainage system Hearth & Side Layer pellets

Indurating Machine

Product Screens

Process & Plant Dedusting ESPs

Pneumatic conveying of ESP Dust

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Details of facility, input & Output Requirements

Major Units Facilities Input

Iron Ore Fines Limestone Anthracite Coal Bentonite CO Gas BF Gas Coal Tar Power Process Water Grinding media 1. 2 Impact Mills (30 tph) 1 2. 2 Dryers (5 m X 35 m) 3. 2 Grinding Mills (6 m X 12 m) 4. 2 ROKSH Separators 5. 2 Process Bag Houses 6. 2 Mixers (620 tph each) 7. 10 Disc Pelletizers (156 tph each) 8 Single deck Roller Screen 8. 9. Induration Machine 10. Induration Machine Hood 11. 6 Process Gas Fans 12. 3 Process ESPs & 1 Plant Dedusting ESP 13. 2 Product Screens

Output
Product Pellet Pellet Fines

Pellet Plant Project

1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

Pellet Plant Project

Stage 1: Raw Material Preparation

D G Dry Grinding i di V Vs W Wet tG Grinding i di of f Iron I Ore O Fines Fi
SL No. 1 Parameters Production Cost Wet Grinding Grinding Cost Rs Rs. 275 275-325 325 /ton of IOF Dry Grinding Grinding Cost Rs Rs. 450 450-500 500 /ton of IOF due to higher consumption of fuel & electricity All raw materials like IOF, Limestone & Coal can be grounded together 0.03-0.05 Kg/t of IOF Thickening & Filtration not required 20-22 kwh/t of pellet Requirement of extensive pollution control measure to counter dust nuisance High

2 3 4 5 6

Grinding of Additives Grinding media consumption Filtration Eletrical energy Consumption Pollution Hazards Capital Cost

Separate grinding facility for additives 1-1.2 Kg/t of IOF Required to bring down moisture to 9 % 16-17 kwh/t of pellet Nil dust hazard

Lower than dry grinding

T t Steel Tata St l has h gone for f dry d grinding i di process because b of f high hi h alumina l i content t t in iron ore fines. Here, wet grinding will have sluggish filtration rate.
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Stage 1: Raw Material Preparation at Tata Steel A. Raw Materials Receiving Circuit B Additives (Limestone & Coal) Crushing Circuit B. C. Drying Circuit D. Grinding Circuit

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Stage 1: Raw Material Preparation at Tata Steel

A Raw Materials Receiving Circuit A.
Blended Iron Ore fines from Noamundi Track Hopper # 4 (5100 t) Paddle Feeder 1500 tph
1500 tph

Iron Ore Fines 850 m3 each

LS S 200 m3

C 200 m3

Stacker Cum Reclaimer

IOF 140,000 Tons

LS 400 T

Coal 400 T

B Additives (Limestone & Coal) Crushing Circuit B.

Impact Mill
LS 200 m3 C 200 m3 Limestone 100 m3 Coal 100 m3 Limestone 100 m3 Coal 100 m3

Pendulum Bucket Elevator Pellet Plant Project 12

Stage 1: Raw Material Preparation at Tata Steel

C Drying Circuit (2 Parallel Circuit) C.
Raw Materials Iron Ore Fines Lim e Stone Anthracite Coal Consum ption Rate Tons/Hr Kg/ton of Pellet 1246.8 945 16.2 12.3 9.5 7.2

Rotary Dryer 2 Circuit

Iron Ore Fines 850 m3 each

Limestone 100 m3

Coal 100 m3

Dryer Bag House 1

Burner air dilution fan

To Roksh Seperator1

60 tph (12%)

Vol. Flow 50000 Nm3/hr Cal Val 850 Kcal/Nm3

BF Gas

Rotary Dryer1
Size 5 m dia X 35 m long Slope 4 degree Speed 2.5 RPM Residence Time 19.2 minutes

Burner primary air fan

To Grinding Circuit 13

Pellet Plant Project

Stage 1: Raw Material Preparation at Tata Steel

D G D. Grinding i di Circuit Ci it (2 Parallel P ll l Circuit) Ci it)
Dust from Rotary Dryer bag house ROKSH Separator 1st Process Bag Filter House

Iron Ore + Additives from Rotary Dryer System

2nd Process Bag Filter House

Ground Ore Concentrate Bins 1500 m3 each

Ball Mill #1 6 m X 11.6 m

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ROKSH Separator

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1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

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Purpose of green ball formation

The purpose of the green ball formation is to obtain pellets of the desired size range ( 9 -16 mm) and having a mechanical strength which enable them to be safely transported from the b lli equipment balling i t to t the th induration i d ti machine hi

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Stage 2: Green Pellet Formation at Tata Steel

A. Mixing Circuit (2 Parallel Circuit)

Ground Ore Concentrate Bins 1500 m3

Bentonite Bins 100 m3

Process water & Slurry from dedusting scrubber

Eirich Mixer

2nd Mixing Circuit

Green Mix Materials

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Stage 2: Green Pellet Formation at Tata Steel

B Green Pelletizing Circuit (10 Parallel Circuit) B.
Green Mix Materials from both Mixers Plough Scrapers

Mix Material ate a Bins

Green Mix Materials 55 m3

Parallel 9 Mix Material Bins

Parallel 9 Disc Pelletizers

Disc Diameter 7.5 meter Disc Slope angle 44-53 degree Throughput Rate 154 tph Rotational Speed 4.7 to 7 rpm Roller Screens Disc Pelletizer

Parallel 9 Roller Screens

Green Pellets Rejected Pellets Pellet Plant Project 19

Green Pelletising building (inside view)

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Green Pelletising Disc (side view)

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1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

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Induration of Green Pellets

Green pellets G ll t h have l low mechanical h i l strength t th hence h need df for h hardening d i for further processes Method for hardening pellets is Induration in which pellets are heated to 1300 1350C i 1300-1350C in controlled t ll d manner

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Travelling Grate (TG) Vs Grate Kiln (GK)

SL No. 1 2 3 4 5 6 7 8 Items Heat hardening cycle Grate bars Pellet movement Burners Fans Number of Passes Pellet grades Largest Machine Travelling Grate (TG) Drying, preheating, induration and cooling are done on a single grate Grate bars subjected to high temperature; side & bed layers necessary Pellet remains stationary throughout the process Large number of burners along the length of induration furnace. Several fans operating in series with multiple fan controls. Multiplicity of passes Both BF & DR grades 768 m2 (CVRD) and 744 m2 (Samarco) with capacity of 6 MTPA each. Grate Kiln (GK) Drying and preheating on a grate, induration in rotary kiln and cooling in annular cooler No side or bed layers necessary Bed depth is nearly half Pellets tumble continuously in rotary kiln Single burner is used in for the kiln. Less number of fans with single fan control. Grate generally of two pass design Both BF & DR grades LKAB-3, GIIC-Bahrain & Tildon-2 with capacity of 4 MTPA each.

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Stage 3: Pellet Hardening at Tata Steel

A I A. Induration d ti Process P

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Temperature Profile of Indurating Machine

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Indurating Furnace Structure (outside view)

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Stage 3: Pellet Hardening at Tata Steel

B Pellet Handling & Despatch Circuit B.
Induration Machine
Emergency stock Pile 10 KT

Screening Building
Pellet fines storage Bin 100 ton

Luffing Stacker

Pellet P ll t stock t k pile il 70000 Tons Stacker Cum Reclaimer IOF stock pile 140000 Tons

Intermediate storage Bin 2200 ton each

Blast Furnaces
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Major Pollution Control Equipments

Sl. No. Description Process ESP 1 (HR 41) Pellet plant Process ESP 3 (HR61) Process ESP 2 (HR51) Dedusting ESP (HR01)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Vendor ESP size (m3) N of No. f field fi ld Waste gas volume (Nm3/Hr) Dust load (mg/Nm3) Emission Level (mg/Nm3) Inlet Gas temperature (Degree C) Design Temperature Allowable (Degree C) Collecting electrode thickness (mm) Discharge electrode type Discharge electrode thickness, mm Rapper system ESP Hopper volume (m3) ESP Controller Chain Conveyer System

FLS Airtech 24*24*24 6 1140000 1500 30 175 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 80 m3 PIACS Redler

FLS Airtech 24*24*24 6 918000 1500 30 210 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 80 m3 PIACS Redler

FLS Airtech 23*12*24 3 840000 1500 30 115 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 50 m3 PIACS Redler

FLS Airtech 23*12*24 3 306000 15000 30 60 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 50 m3 PIACS Redler

Numbers Chambers in Each Bag filter

BAG HOUSE D&G System Ball Mill Sysytem 2 2 6(5opr+1standby) 6(5opr 1standby) 12(10opr +2standby) 2standby)

Dust inlet gm/Nm3 216 1020 Dust outlet mg/Nm3 10 10* Gas Volume , m3/hr, each stream 335000 734400 Maximum Continous Temperature, Deg C. 250 140 St ti Pressure, Static P mmWg W -91 91 -357 357 Pressure Drop over fabric filter,mmWg 150 250 Fabric Filter Wooven Glass Polyester *Collected dust from Ball mill Bag filter pnuematically conveyed to Ground Concentrated Bins

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Pelletising Plant Layout

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Evaluation of Pellets

Tests for p physical y p properties p

Crushing Strength: 250 kg/pellet Tumble & Abrasion Index
Tumble Index (TI) >92% for the fraction +6.3 +6 3 mm Abrasion Index (AI) <5% for the fraction -0.5 mm

Size Distribution
+16 mm < 3 % +6 mm to -16 mm >90 % -6mm < 3 %

Tests for metallurgical properties

Reduction Degradation Index (RDI), <12 % for -3.15 mm fraction Reducibility Index (RI), >65 % Swelling Index (SI), <18 %
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THANK YOU

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