Pellet Making Journey at ESSARESSAR Steel Ltd, Vizag Operations

Presented by –

Mr. M. RavindranathHead (GM) – Technical Services,ESSAR Steel Ltd.

Mr. Prakhar SharmaManager – Technical ServicesESSAR Steel Ltd.

ESSAR A Diversified Multinational Conglomerate

PortsSteel

Projects PowerOil & GasServices

EnergyShipping

Infrastructure

A Diversified Multinational Conglomerate

Upstream2,132 MMBOE reserves & resources

Midstream

Raw Material450 MT coal reserves

Generation1,600 MW

Raw Material1.4 billion tonnes of iron ore reserves27 MTPA pellet plants

OperationalDry Bulk30 MTPAWet Bulk46 MTPA

Under

Essar Projects IndiaEngineeringFabricationConstruction

Fully geared to

BPO50,000+ employees globally

38,000+

Shipping26 ships. 12 new ships on order.Oilfields Svs.1 semi-submersible rig14 MMTPA refining

capacity expanding to20 MMTPA

Downstreamc. 1,385 retail

operational capacity, to go up to 11,470 MW by 2014

Under construction –8 070 MW

plants188 MT coal reserves

Steel-making14 MMTPA steel-making capacity

Under ConstructionDry Bulk70 MTPAWet Bulk12 MTPA

Total Capacity

Fully geared to execute turnkey EPC projects in India and overseas

2nd largest equipment bank in India

,seats in 47 locations

TelecomEssar Telecom East AfricaThe Mobile Store

submersible rig 12 land rigs2 new jack ups on orderLogistics5000 trucks & offshore

outlets 8,070 MWDistributionEssar Hypermart

158 MTPA

Integrated company

spanning the oil & gas value

Over a decade’s experience in

the Indian power i d t

Integrated, global steel

producer

India’s 2nd

largest pvt. sector port

Leading EPC contractor with 40 years track

d

The Mobile StoreThe Electronic Store

Provider of multi-channel CRM solutions

to blue-chip

offshore lighterage assets

International logistics provider to steel, oil and

t& gas value chain industry producer company record to blue chip

clientspower sectors

ESSAR GROUPSTEEL BUSINESS

14 MTPA of Steel Making Capacity

Steel MakingMinerals & Pellets

1.4 billion tonnes of Iron Ore Reserve in Retail / Distribution thrust through Service Centers

Marketing

STEEL BUSINESS

g p y

10 MTPA at Hazira, Gujarat

4 MTPA at Algoma, Canada

Value Added Products

2.5 MTPA of CRC / Galvanized / ColourCoated

1.4 billion tonnes of Iron Ore Reserve in Minnesota, USA

Long term supply contract with NMDC for supply of Ore

20 MTPA of Beneficiation & Pelletization

8 MTPA in Vizag, Andhra Pradesh

Retail / Distribution thrust through Service Centers and Hypermarts (first time in India)

Building 4 MTPA Service Center capability globally

Existing Service Centers in Pune, Chennai, Delhi , Hazira and Indonesia

Building distribution netwrok of 2.5 MTPA under Coated

1. 5 MTPA, Plate Mill

0.6 MTPA, Pipe Mil

8 ag, d a ades

12 MTPA in Paradeep, Orissa

u d g d st but o et o o 5 u deEssar Hypermart brand

78 Hypermarts and 259 Expressmarts already operational

Acquisition of Shree Pre coated Steel, Pune

Adding Value to portfolio in line with market demand

Focusing on bringing the costs down

Internal mining and pelletization asset provides sustainable profits and insulates from volatilityContinue to pursue sourcing opportunities for iron ore in India and overseas

Gaining market share with superior products and services

Expanding the downstream operations in Asia, Middle East, Europe and USA

Key Highlight / Update y g g p

• On schedule to commission the 5 MTPA expansion at Hazira by Q4 of CY 2010. With this, Hazira will be a 10 MTPA integrated

steel complex

• Selling close to 100,000 tons of steel per month from Steel Hypermarts

• All new projects under construction are financially closed and we have firm visibility of commissioning datesAll new projects under construction are financially closed and we have firm visibility of commissioning dates

• Consolidating the Indian Steel operations under one Single entity, Essar Steel Ltd. – 10 MTPA

ESSAR STEEL (India) LTD.COMPANY OVERVIEW

♦ Production capacity of 4.6 MTPA at Hazira

ith dditi l t d l ti

COMPANY OVERVIEW

with additional 5 mtpa under completion

♦ Beneficiation & Pelletisation Plant with 8.0

MTPA capacity

♦ Raw material and energy needs secured ♦ Raw material and energy needs secured

through long-term contracts

♦ Power sourced through long-term contracts

with Essar Power Ltd and affiliateswith Essar Power Ltd and affiliates

♦ Distribution setup includes 4 service

centers, 78 Hyper marts & 259 Express

martsmarts

♦ Stand-alone FY2009 Revenues, EBITDA and

shipments of US$ 2.5 billion, US$ 525

million and 3 1 million tonnesmillion and 3.1 million tonnes

ESSAR STEEL (India) LTD.COMPANY OVERVIEW

KIRANDULKIRANDUL

• Iron Ore Beneficiation Plant[8mmtpy]• 267 km long Kirandul- Vizag Slurry Pipe line[

8mmtpy]

COMPANY OVERVIEW

py

VIZAGVIZAG

• 2 X 4 mmtpy Iron Ore Pelletization Plants• 25 MW Coal Based CPP.

l ] [ l ]

Operating Plants

Under Execution

HAZIRAHAZIRA

• 4.60 mmtpy SteelHBI+EAF+HSM+DSC] [ Plant A]• 5.00 mmtpy Steel Plant,[BF+Corex+EAF+HSM+

DSC[Plant B]

Dabuna

Visakhapatnam (Essar Steel Ltd)

Essar Steel Ltd

Paradeep(Essar Steel Ltd)

DabunaDabuna

• Iron Ore Beneficiation Plant [12mmtpy]• Iron Ore Slurry Pipe line – Dabuna to Paradeep

O ll i i l [ 6 ]

kirandul

ParadeepParadeep• Iron Ore Pelletization Plant[2 X 6 mmtpy]• Captive Power Plant

ParadeepParadeep• 6.0 mmtpy Integrated Steel Plant

pp

ESSAR STEEL (India) LTD.VIZAG OPERATIONS

5.365.45

6.00

VIZAG OPERATIONS

4.51

4.90

4.00

5.00

S d P ll t Pl t

2.47 2.64

2.93

2.93

3.133.44

3.00

Second Pellet Plant Commissioned.

Slurry Pipeline Damage

1.541.62

1.791.58

1.00

2.00

0.340.00

* Production Figures in Million MT

ESSAR STEEL (India) LTD.VIZAG OPERATIONSVIZAG OPERATIONS

01

ESSAR STEEL (India) LTD.VIZAG OPERATIONSVIZAG OPERATIONS

Slurry

Pipeline

Water Iron ore slurry

IOF f

Slurry

Pipeline

IOF from NMDC

BENEFICIATION PLANTBASIC FLOW SHEETBASIC FLOW SHEET

BENEFICIATION PLANTMASS BALANCE

ORE TYPE

MASS BALANCE

SLIMES -20%(1.76Mil.T)

FINES-80%Fe-64.50%

(7.04 Mil.T)

Chemistry (%on Dry basis)Fe 66.50%SiO2 2.25% Max

Combined feedFe-64.00%,

SiO2-3.50%, Al2O3-1.70%(8.8Mil.T)`

Al2O3 1.00%LOI 1.35% Max

Beneficiation

C 8 %

Physical Properties+150 Mic : 0.50% Max

Tails-20%Fe-45%

(0.8 Mil.T)

Concentrate-80%Fe > 66.50%

SiO2+Al2O3< 2.5%(8.0Mil.T)`

(-) 45 Mic : 80.00% MinBlaine No.:1750 sq.cm/gm

SLURRY PIPELINEGEOGRAPHICAL PROFILE

HY-GRADE PELLETS LIMITEDSlurry pipe line routeBailadila

0 k

BeneficiationPlant

GEOGRAPHICAL PROFILE

Sl k Fl St

0 km613 m

Main Pumping

Station

Water Pumping

Station

Rly Line

Slack Flow Stn.

113 km

Water Line

100 km434 m

113 km496 m

205km

Slack Flow Stn.

180km696 m

Booster Stn.

Valve stn.

91 m

267km0mts

Pellet plant

FromFrom[Km][Km] To[Km]To[Km] StateState

0 000 00 62 2962 29 Chh tti hChh tti h0.000.00 62.2962.29 ChhattisgarhChhattisgarh

62.2962.29 137.02137.02 OrissaOrissa

137.02137.02 267267 Andhra PradeshAndhra Pradesh

WHY SLURRY PIPELINE?FUTURE OF HYDROTRANSPORT

• Slurry pipelines have aesthetic advantages over other modes of solids transportation.• Minimum land is required for laying the under ground pipeline and the land is

restored to its Original condition. After the pipes are laid, agriculture and aforestation

FUTURE OF HYDROTRANSPORT

activities can be resumed. Hence it is the most environmental friendly mode of transportation available as of now.

• Slurry pipe lines are environmentally desirable, as they do not cause noise, dust pollution or negative visual impacts.

• This Mode of Transportation is extremely Economical /Cost effective.(ref: Pie Charts)• The cost of transportation by slurry pipeline is almost one-tenth of that by wagons.

Moreover, it ensure zero waste during transportation. • Low maintenance costs and higher availability.

SlurryPipeline

Railway Rake

Cost of Operations/Mt

70 Rs/Mt 700 Rs/MTOperations/Mt

*NOTE: THE DIFFERENCE IS ONLY ON THE ACCOUNT OF LOSS IN TRANSPORTATION COST (KEEPING ALL OTHER (FACTORS CONSTANT)

SLURRY PIPELINEGEOGRAPHICAL PROFILE GEOGRAPHICAL PROFILE

SLURRY PIPELINEGEOGRAPHICAL PROFILE

km Chattishgarh Orrissa Andhra Pradesh Total

Length km 63 74 130 267

GEOGRAPHICAL PROFILE

Forest Land Km 15 22 23 60

Non-Forest Land Km 48 52 107 207

CrossingsN.H - - 1 1RoadsRailwaysRivers

Nos 5-1

2-3

833

1537

Private Landowners

Nos 1800 2500 3500 7800owners

1. Annual Throughput – 8.0 million Tonnes2. Slurry is transported from Kirandul (613 MSL to Vizag 2.6 MSL), which is 267 km

South-East of Kirandul.Pi li h t i ti3. Pipeline characteristics

1. Length = 267 Km2. O.D. = 356-406 mm3. Wall thickness = 6.4 -15.4 mm

4. The equipment availability is 95% min.C t f I O T t ti th h Sl i li i / f th t f 5. Cost of Iron Ore Transportation through Slurry pipeline is 1/10 of the cost of transporting Iron Ore fines through rakes.

SLURRY PIPELINEPROJECTPROJECT

SLURRY PIPELINEGEOGRAPHICAL PROFILE GEOGRAPHICAL PROFILE

Orissa sector Chattisgarh sectorOrissa sector Chattisgarh sector

SLURRY PIPELINEGEOGRAPHICAL PROFILE GEOGRAPHICAL PROFILE

Slurry Pipe Line Passing through Eastern Ghats

PELLETIZATIONFLOW SHEETFLOW SHEET

PELLETIZATIONTECHNOLOGY PROVIDERS

S.No

Key Process Key Equipment Technology Providers

Sl Mi i S l ti USA IRON ORE FINES

A TYPICAL FLOW SHEET

TECHNOLOGY PROVIDERS

01 SlurryAgitation Slurry Mixers Mixing Solutions - USA

02 Filtration

Disc FiltersPressure FiltersCeramic Filters

Metal7Larox/ Metso

Larox /Russian

IRON ORE FINES

GRINDING/CONCENTRATE

Larox /Russian

03 Mixing Paddle MixerPlanetary Mixer

LudigeEirich

04 Pelletization Disc PelletizerDrum Pelletizer

Outotec / MetsoMetso

FILTRATION

MixingAdditivesDrum Pelletizer Metso

05 Screening Double Deck Screens

Metal7Abacus

Grate Kiln Kobe/ Metso

Pelletizing

06 Induration Straight GrateShaft Kiln

Aker/ OutotecItalian/Chinese

07 ProcessControl DCS/SCADA HONEYWELL

ABB/SIEMENS

Induration

Pellets

PELLETIZATIONPELLET QUALITY

Chemical Analysis Physical Properties

PELLET QUALITY

Fe Fe -- 66.0% Min66.0% MinSiOSiO22 –– 2.5% Max2.5% Max

Size 8 to 18 mm:90%Min(-)5 mm :5%Max22

A lA l22OO3 3 –– 1.25% Max1.25% MaxCaOCaO ++MgOMgO -- 1.00%1.00%

Tumble :94.50%minAbrasion :04.50% maxCCS (Kgs/Pellet) >275CCS (Kgs/Pellet) >275

Metallurgical PropertiesR d ibilit I d (J b Mid ) 94%Reducibility.Index (Jumbo-Midrex) 94%

CCS After Reduction - 30kg/p

Major Plant ModificationsESSAR Steel Ltd, Vizag Operations

Pellet Plant – 1INDURATION FURNACE MODIFICATIONINDURATION FURNACE MODIFICATION

1. The capacity of Pellet Plant 1 was limited to 8500 TPD (2.8 million MT) by the unstable operation of the cooling air fan, caused by an increased system resistance p g y yoffered by lower cooling area of the furnace.

2. Cooling air fan was operating very close to area of unstable operation, and minor fluctuations in process parameters slips the fan into STALL CONDITION.

3 System resistance can be decreased by enlargement of the cooling zone through 3. System resistance can be decreased by enlargement of the cooling zone through connection of one windbox from after-firing (windbox recuperation) to the cooling zone. Also, to reconnect one windbox from exhaust gas main zone to recuperation main zone.

Drying Section Heating Section Heat Recovery Section

Travel

Pre-heating (Ramp) Firing After Firing First

CoolingSecond Cooling

Updraft Drying (UDD)

Down-draft Drying DDD

36 m2 (8 58%)

54 m2 (12 85%)

66 m2 (15 71%)

120 m2 (28 57%)

36 m2 (8 58%)

84 m2 (20 00%)

24 m2(5 70%)(8.58%) (12.85%) (15.71%) (28.57%) (8.58%) (20.00%) (5.70%)

FURNACE AS DESIGNED

Pellet Plant – 1INDURATION FURNACE MODIFICATION INDURATION FURNACE MODIFICATION

ZONE Before Modification of CZ2 in sq.mts

% of total area

After Modification of cooling zone-2

% of total area

Modification

Up draft 36 8.58 36 8.58 SAMEp 3 5 3 5

Down draft 54 12.85 54 12.85 SAME

Preheating 66 15.71 42 10.00 DECREASED

Firing 120 28.57 120 28.57 SAME

After firing 36 8.58 36 8.58 SAME

Cooling 108 25.71 132 31.42 INCREASED

Total 420 100 420 100 SAME

Drying Section Heating Section Heat Recovery Section

Travel

Pre-heating Firing After Firing First Cooling Second

CoolingUpdraft Drying (UDD)

Down-draft Drying DDD

36 m2 (8 58%)

54 m2 (12 85%)

42 m2 (10 00%)

120 m2 (28 57%)

36 m2 (8 58%)

108 m2 (24 32%)

24 m2(5 40%)(8.58%) (12.85%) (10.00%) (28.57%) (8.58%) (24.32%) (5.40%)

AFTER MODIFICATION

Pellet Plant – 1INDURATION FURNACE MODIFICATION INDURATION FURNACE MODIFICATION

IMPROVEMENTS1. After modification production went up to 1o,000 tpd (3.3 million MT) on a

consistent basis with out any problems with the cooling air fan.2. Due to reduced preheating area by rearranging the wind boxes has lead to

higher pressures.C li i f fl h i f 8 / b f difi i3. Cooling air fan flow has increase from 180 cu.m/sec before modification to210 cu.m/sec after modification.

As a result of zone re-distribution the preheating / firing cycle was reduced by 5.7% and the cooling time was increased by 5 7%; Although this had resulted an increase in the cooling time was increased by 5.7%; Although this had resulted an increase in throughput, the decrease in firing cycle impacted heavily on the QUALITY of the pellets (low tumble and high cracked pellet %). To overcome this problem various schemes were suggested:

1. Install an after cooler to partially cool the pellets outside the furnace (was installed in PP1)

2. Rearrange the wind boxes as per design and increase the cooling zone length by 6mts to overcome the cooling air fan stall problem (was taken care in PP2)to overcome the cooling air fan stall problem (was taken care in PP2)

Pellet Plant – 1INDURATION FURNACE MODIFICATION

Drying Section Heating Section Heat Recovery Section

Pellet Plant 1

INDURATION FURNACE MODIFICATION

Section

Pre-heating (Ramp) Firing After Firing

First /Second Cooling

AFTER COOLERS*

Updraft Drying (UDD)

Down-draft Drying DDD

Travel

C g

36 m2 (8.58%)

54 m2 (12.85%)

66 m2 (15.71%)

120 m2 (28.57%)

36 m2 (8.58%)

108 m2 (25.71%) 24m2

IMPROVEMENTSIMPROVEMENTS1. After the modification the production rate of Pellet Plant 1 went up

from 3.3 million MT to 4 million MT.2 The percentage of cracked pellet reduced and physical properties 2. The percentage of cracked pellet reduced, and physical properties

such as tumble and CCS improved.3. The specific consumption of power and fuel went up by 20%

approxapprox.

Pellet Plant – 1INDURATION FURNACE MODIFICATION – AFTER COOLERINDURATION FURNACE MODIFICATION AFTER COOLER

Pellet Plant – 2INDURATION FURNACE MODIFICATION (at design stage)

In view of the improvements achieved in PP1 with after cooler, the similar cooling area was incorporated at the design stage of PP2.

INDURATION FURNACE MODIFICATION (at design stage)

IMPROVEMENTS1. Fuel and Power Specific Consumptions of PP2 are lower than that

of PP12. Design Capacity of PP2 is 4 million MT. 3. Consistent quality with lower standard deviations.

Drying Section Heating Section Heat Recovery Section

Travel

Pellet Plant 2

Pre-heating (Ramp) Firing After Firing First/Second CoolingUpdraft

Drying (UDD)Down-draft Drying DDD

36 m2 (8.2%)

54 m2 (12.16 %)

66 m2 (14.90%)

120 m2 (27.00%)

36 m2 (8.10%) 132 m2 (29.3%)

Pellet Plant – 2CERAMIC FILTERS

1. Filtration is a mechanical or physical operation which is used for the separation of solids from fluids (liquids or gases) by interposing a medium through which only the fluid can pass.

CERAMIC FILTERS

2. The most widely used filters in mineral processing application are VACUUM DISC FILTERS( which are operating in our Pellet Plant 1 from 1996).

3. However, conventional vacuum disc filters when in operation offer significant difficulties with respect to :

1. High Filter Cake Moisture,2. High % SOLIDS reporting in filtrate,3. High Maintenance Cost,4. Higher POWER Consumption.

4. Because of higher operating/maintenance costs for vacuum disc filters, ESSAR decided to try ceramic filtration technology in Pellet Plant 2 ; ESSAR became the first plant to operate Ceramic Filters on a large scale for Iron Ore application it in the

ldworld.

Pellet Plant – 2WHAT ARE CERAMIC FILTERS?

1. Ceramic Filters because of capillary action produces a very dry filter cake with an energy consumption of one

WHAT ARE CERAMIC FILTERS?

gy ptenth of the one required in conventional vacuum filtration.

2 Ceramic Filters provide low moisture 2. Ceramic Filters provide low moisture in filter cake than conventional Vacuum Disc Filters.

Ceramic filters operates on the pprinciple of capillary action. A capillary action filter operates according to the Young-Laplace law which states that the pores of law, which states that the pores of a certain diameter causes a capillary effect due to surface tension and the contact angle of the liquid.

Pellet Plant – 2CERAMIC FILTERS vs CONVENTIONAL FILTERS

P ti l C i Filt C ti l Filt

CERAMIC FILTERS vs CONVENTIONAL FILTERS

Particulars Ceramic Filters Conventional Filters

Tonnage/unit area 0.85 T/m2 1.00 T/m2

Power Consumption per tonne 0.80 Kwh/T 6.85 Kwh/T

Filter bags/Filtering media (Rs/t) 1.42 Rs/T 1.99 Rs/T

Spares (Rs/t) 0.75 Rs/T 2.0 Rs/T

Chemical (Rs/t) 3.06 Rs/T ---Chemical (Rs/t) 3.06 Rs/T

Total OPEX Cost/t 8.43 Rs/T 31.39 Rs/T

Beneficiation PlantPROCESS OPTIMIZATION

1. The Kirandul Beneficiation plant was designed to produce 8 MTPA (Million Ton Per Annum) of concentrate. During 2006, it was not giving the desired output.

PROCESS OPTIMIZATION

Sl. No Description Unit Design Actual1 Feed to Primary Mills Dry MT/hr 1390 9002 Operating Hours Hours 7200 72003 Wt. Recovery % 80 75

C t t P d ti D MT/h 6

2 Constraints as perceived at that time because of which designed out could not be

4 Concentrate Production Dry MT/hr 1112 6755 Annual Plant Capacity MMT 8.0 4.866 Fe content % 68 67.5

2. Constraints as perceived at that time because of which designed out could not be reached:

a. The feed quality (harder ore than what was envisaged during design)b. operational difficulties in intermediate and tailing thickeners above 900

h b f i l dtph because of coarser particles andc. HGMS problems limiting its availability

3 Plant audits were done by different agencies that include RRL Bhubaneswar (Now 3. Plant audits were done by different agencies that include RRL Bhubaneswar (Now IMMT), Metso, JK Tech, etc.

Beneficiation PlantPROCESS OPTIMIZATION – Before ModificationPROCESS OPTIMIZATION Before Modification

Fig. Flow sheet of Kirandul Beneficiation plant before modification (2006-07)

Beneficiation PlantPROCESS OPTIMIZATION – PROPOSALS

1. *Close Circuiting the Primary Grinding with Wet Screen.

2. *Hydro cyclone for Rougher Spiral Tails and Cleaner Spiral Middling

PROCESS OPTIMIZATION PROPOSALS

2. Hydro cyclone for Rougher Spiral Tails and Cleaner Spiral Middling

3. Derrick Screen for screening above Hydro cyclone Underflow for +300 micron and –850 micron

4. Vertimill to grind the above fraction in close circuit with the Derrick Screen.

5 Conversion of Existing HGMS matrix from Coarse to Medium 5. Conversion of Existing HGMS matrix from Coarse to Medium

6. Additional HGMS

7. *Third Regrind Mill with hydro cyclone

8. Stand Alone Intermediate Thickener for each Line / Stand Alone Concentrate Thickener for each LineThickener for each Line.

Beneficiation PlantACTUAL MODIFICATIONS

1. Addition Of Thickener For NMDC Slimes

ACTUAL MODIFICATIONS

2. Grinding Media in the Millsa. Before modifications, the grinding media used in the Primary ball mill was φ 60

mm balls. During modifications, φ 80 mm grinding media were added to the mill t tl d th t f ti l ti t i t di t to partly reduce the percentage of coarse particles reporting to intermediate thickener.

b. Addition of φ 40 mm & φ 25 mm grinding media were done to regrind ball mills to improve their grinding efficiency.

3. Close Circuiting of Primary Grinding Milla. Earlier Primary ball output was fed to Primary hydro cyclone. The overflow of

hydro cyclone was directed towards intermediate thickener for further processing hydro cyclone was directed towards intermediate thickener for further processing through HGMS. The underflow of hydro cyclone went to Rougher Spiral.

b. After the modification, the ball mill output goes to a vibrating screen of 1 mm aperture. The oversize from screen is re-circulated to mill, while the undersize is fed to Primary hydro cyclonefed to Primary hydro cyclone.

Beneficiation PlantACTUAL MODIFICATIONS

4. Rougher Spiralsa. Before modifications, the rougher spiral tailings were directly fed to intermediate

ACTUAL MODIFICATIONS

a. Before modifications, the rougher spiral tailings were directly fed to intermediate thickener. The coarser particles in those tailings caused operational difficulties for thickener.

b. hydro cyclone has been introduced in this route. The overflow of this hydro cyclone goes to intermediate thickener while the underflow is fed to Linear cyclone goes to intermediate thickener, while the underflow is fed to Linear Screen.

5. Cleaner Spiralsa. The tailings of Cleaner Spirals were earlier sent to Primary ball mill from sump

box. A hydro cyclone has been introduced and the part overflow & underflow goes to the Primary ball mill while the part overflow is directed towards the Concentrate thickener. This has been made to balance the slurry concentration in Primary ball mill.

Beneficiation PlantPROCESS OPTIMIZATION – After ModificationPROCESS OPTIMIZATION After Modification

Fig. Present flow sheet of Kirandul Beneficiation plant after modification

* The equipments and lines in red show the modifications carried out in original flow sheet

Beneficiation PlantSLON - TAILING RECOVERY

1. Traditional HGMS offers a magnetic field of 0.5 Tesla; SLON offers a higher magnetic field of 1 Tesla. Therefore SLON can be used to recover more Fe from the tailings

SLON TAILING RECOVERY

recover more Fe from the tailings.2. After the commissioning of SLON in 2008, ESSAR conducted

various experiments to reduce the Fe of Tailings.B f di th t il f HGMS t th SLON bl t d 3. By feeding the tails of HGMS to the SLON we were able to reduce the tail Fe from 48% to 40-42%. The overall weight recovery of the Beneficiation Plant went up from 80-85% to 90%.

Beneficiation PlantSLON - TAILING RECOVERY

1. SLON offers various advantages such as low maintenance, easy operations, higher recovery etc over conventional HGMS.

SLON TAILING RECOVERY

2. With the use of SLON our Tail Fe dropped form 47% to 40%, and our weight recovery went up from 80% to 90%.

3. The SLON was picking up Ultrafine-High Fe (1 mic -10 mic range) particles from the tailings. Resultantly the filtration productivity of our Vacuum disc Filters and Ceramic Filters went down drastically. The filter cake moisture went up above 11%.

4. The % of ultrafine (<10 mic) particles in the slurry went upto 30%, which was causing the loss in productivity of the downstream process.

IMPROVED PROCESS FLOW SHEETORISSA PROJECT

Iron Ore Fines

Filtration

10 mm Wet Screen

ORISSA PROJECT

Mixing

Additives &Grinding

Screen

+10 mm

Roll Crusher 2 mm Wet Screen

Primary Balling Mill -1

0 m

m

+0.15 mm

+2 mm

-2 mm

Feed Preparation

Balling DiscsScrew Classifier

De-sliming Hydro cyclone

Allflux

Medium -HGMS-0.15 mm Single Deck Roller

Screen

-8 mm

+8 mm

-8 mm + 18 mm

ne

Medium

arse

Induration

Hydro cyclone

Fines HGMS

Intermediate Thickener

Secondary Hydro cyclone

Secondary Balli Mill

Concentrate Thickener

Double Deck Roller Screen

fin Coa

Hearth LayerSeparation

Pellet StockyardSlurry Tanks Pumping

Station

Fines- HGMS

Tailings Thickener

Tailings Thickener

Slurry Tanks PELLETIZATION Slurry Pipeline (253 km)BENEFICIATION

TECHNOLOGICAL MODICIFATIONS ORISSA PROJECT

1. Allflux hindered separator in place of spirals2 Paste thickeners for tailings disposal as an alternative to

ORISSA PROJECT

2. Paste thickeners for tailings disposal as an alternative to conventional disposal in slurry form

3. Blender reclaimer in place of conventional reclaimer for ore blendingblending

4. Pressure filters in place of ceramic & vacuum filters5. Screening at discs in addition to the screening at feed end6 All process fans are provided with VFD’s for energy conservation 6. All process fans are provided with VFD s for energy conservation

and better process control7. Screening the feed to mill before grinding 8. High basicity pellet production (Addition of lime is as high as 8%) 8. High basicity pellet production (Addition of lime is as high as 8%) 9. One pumping station as against two in our existing plant10. Paste Thickening tailing disposal mechanism (first time in India).

THANK YOU