winner novel agglomeration process for ferroalloy fines

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Tata Innovista 2013 - Winner Novel Agglomeration Process for Novel Agglomeration Process for Ferroalloy Fines Ferroalloy Fines

Receiving the award from Mr Cyrus Receiving the award from Mr Cyrus MistryMistry, , Chairman Tata Sons, Chairman Tata Sons, MymbaiMymbai, 26, 26--AprApr--1313

Novel Agglomeration Process for Ferroalloy Fines

for use in bulk Steel Making Processes

P509613121840 Core Process Innovation

Mr. Veerendra Singh Principal Researcher, R&D, Tata Steel Mr. Prabhash Gokarn Head, Raw Material Projects, Tata Steel Mr. Bibhu Nanda Head, FAP Joda, Tata Steel Mr. Amitabh Bhattacharjee Head, KVHS, Tata Steel Mr. Ashuosh Kumar Head, Steel making LD1, Tata Steel

Tata Innovista, Finals 25th April, 2013

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1. Ferroalloy Production Process 1 slide

2. Problems Caused by Ferroalloy Fines 1 slide

3. Challenges in Agglomeration of Fines 1 slide

4. Finding a Solution 2 slides

5. Establishing Agglomeration Flowsheet 1 slide

6. Plant Scale Trials 1 slide

7. Commercialization & Stabilization 1 slide

8. Customer Feedback 1 slide

9. Results 1 slide

P509613121840 Novel Agglomeration Process for Ferroalloy Fines

Presentation Structure

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Background

Steel @ World Production :1.5 billion tons

@ Tata Steel production :26 million tons

Ferroalloys 30 MT produced in the world 350 kTPA produced by Tata Steel

* Bulk – FeCr(incl ChCr), FeMn, SiMn, FeSi… Noble - FeTi, FeNb, FeV, FeMo, FeB …

Ferroalloys used in steel making for deoxidation & alloying

Contributes 5 % - 30% of steelmaking cost

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Ferroalloy Production Process

Ferroalloy Cake

Ferroalloy Casting in Pans

Ferroalloy production

Smelting-reduction (@ 1500o C)

Casting of liquid ferroalloy (1m x 2m pans)

Sizing (2m→300mm→80mm)

Packing and Despatch

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High Carbon FeMn fines Silico Manganese fines

Lumps

(10-80mm)

Bulk Steel Making Process

Fines & Chips (0-3,3-10mm) 5% to 15% generation

Lower Realization Handling Difficulties

http://images.google.co.in/imgres?imgurl=http://www.jint-manganese.com/upload/20093181534.jpg&imgrefurl=http://www.jint-manganese.com/ecataproduct.asp&usg=__oYsR88fFFKT_pwWfz2NctLi8GQ0=&h=542&w=714&sz=99&hl=en&start=13&um=1&tbnid=8VSjDyHa93GF8M:&tbnh=106&tbnw=140&prev=/images?q=ferromanganese&hl=en&um=1

http://images.google.co.in/imgres?imgurl=http://product-image.tradeindia.com/00250829/b/Ferro-Manganese.jpg&imgrefurl=http://shivamiron.tradeindia.com/Exporters_Suppliers/Exporter16482.250829/Ferro-Manganese.html&usg=__BxUJTHgc1EsNoIZPl0PATvC5T4w=&h=338&w=450&sz=119&hl=en&start=12&um=1&tbnid=5xpal-UwWakAFM:&tbnh=95&tbnw=127&prev=/images?q=ferromanganese&hl=en&um=1

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Fines co-generated during sizing :

Unsuitable for bulk steel making (eg LD)

Environmental hazard

Transportation & handling difficulties

Contamination during handling & storage

No technology to reduce fines generation

Can we establish agglomeration of fines ?


Trigger

Lower Realization Rs 10,000 – 20,000

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(b) FeMn Particle


Challenges

Size : <3mm

Challenges

C1 : Metallic fines behave differently

C2 : No existing established process

C3 : Binder Selection

• Unwanted ingredient (P, S etc)

C4 : Agglomerate quality

• High Cold Compressive Strength

• High Hot Compressive Strength

C5 : Agglomeration process should be economical

(a) Mn Ore Particle

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Finding a Solution – Research efforts

Chemical analysis of FeMn Lumps & Fines

Size analysis of fines

Element (%) FeMn Lumps (>10mm)

FeMn Fines (0-3mm)

Mn >70 >67

Si 1.5 1.4 – 2

P 0.3 0.25

C 6-8 6 - 8

SEM analysis of FeMn Lumps & Fines

Lab Studies : Characterization of Fines

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• Molasses +Lime • Cement • Lignosulphate • Coal tar • Sodium Silicate • Resins

o Phenol-formaldehyde Resin o Acrylic Resin

Binder Selection

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Finding a Solution – Research efforts

Resin works as a best binder for alloy fines

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Establishing Agglomeration Flowsheet

Key Questions : Safety Recovery Operational Performance

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Lab Studies : Product Validation

Lab Testing

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Slag Analysis


Plant Trials

Metal Analysis

No increases in P,S and N in the steel.

Mn and C pickup in steel was similar for lumps and briquettes.

Charge Quantity remain same.

NO other operational problem was faced during the trial.

Establish for both SiMn and FeMn fines

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(a) Vendor Development (250tpm)

(b) Process for handling & addition in vessel


Commercialization & Stabilization

Vendor Capacity being increased Vendor Capacity being increased

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Customer Feedback

Appreciation from EIC (FA&MD)

Appreciation from Chief LD2-SC

Appreciation from Chief LD1

Appreciation from Chief BPE & KVHS

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Impact

• Tangible (Rs)

• Rs 0.3 Crore (till now)

• Rs 1.5 Crore/ Year (current rate)

• Rs 1.8 Crore/Year (next year)

• Intangible • Reduces Environmental pollution

• Reduces storage & handling issues

• Provides jobs to ~15 semiskilled workmen (currently)

0.3

1.5 1.8

Till Date Current Rate

From Next Year

Rs Crore/year

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Way Forward

Future • Scope to shift from manual sizing to use of crushers*

• New plants of FAMD (Joda & Gopalpur) with crushers

• Saving sizing cost by Rs 150/MT ~Rs 1.2 Crs/year

• Increase in Capacity Plan to briquette all Mn fines produced at FAMD plants as capacity increases ~Rs 3 Crs/year

• Rollout at TSKZN being explored

* Crushers generate higher fines than manual sizing - briquetting makes use of fines possible

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Projected Volume & Cost Savings With Increase of Capacity

SiMn (MT) FeMn (MT)

Cost Saved(Rs lakh)

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Questions ?

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Thank YouThank You

KVHSKVHS

Mr. Pankaj Lochan and team

OperationsOperations Mr D Das & colleagues

at LD1

Mr JB Singh & colleagues at LD2

FerroAlloy Yard colleagues

winner novel agglomeration process for ferroalloy fines

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