HIsmelt 0208 Jamshedpur Conference

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    Direct Smelting Technology

    © HIsmelt Corporation 2008

     Alternative Process for Ironmaking without Coke Alternative Process for Ironmaking without Coke

     – – The HIsmeltThe HIsmelt®® Process & its relevance to IndiaProcess & its relevance to India

    28th February 2008

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    © HIsmelt Corporation 2008

     Agenda

    Introduction to Rio Tinto

    HIsmelt Technology Overview

    Kwinana HIsmelt Plant Update

    Future Technology Developments

     – CO2 Reduction Options

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    © HIsmelt Corporation 2008

    HIsmelt’s f it with Rio Tinto

     Aluminium (RT Alcan)

    Copper 

    Energy

    Diamonds & Gold

    Industr ial Mineral

    Iron Ore

    Technology & Innovation

    Exploration

    • Rio Tinto is a world leader in finding, mining and processing the earth’s

    mineral resources

    • The Group’s activit ies span the world…

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    © HIsmelt Corporation 2008

    Rio Tinto Group’s Operations – Rio Tinto Iron Ore (RTIO) has a global presence

    • Operations in 3 continents (Nth America, Sth America & Australia)

    • Development projects in Africa and India

    Operations

    Projects

    Markets supplied

    IOC

    Corumba   Pilbara Iron

    HIsmelt

    Simandou

    Orrisa

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    © HIsmelt Corporation 2008

    HIsmelt Technology OverviewHIsmelt Technology Overview

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    © HIsmelt Corporation 2008

    The Kwinana HIsmelt Plant: 0.8Mtpa Capacity

     – A small footprint

    2  5  0  m 

      3  0  0  m

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    © HIsmelt Corporation 2008

    Strong international interest in HIsmelt

    China’s top three poli ticians have visited the Kwinana plant

     – Hu Jintao, President of the PRC (Sept-07)

     – Wen Jiabao, Premier of the PRC (April-06)

     – Wu Bang Guo, Chairman of China’s NPC* (May-05)

    ~35 site visits by major Chinese steelmakers

     – Two licences signed with Laiwu Steel and Huaigang

    Site visits from major steelmakers including Indian, European,Japanese, Korean, North-American, ROW

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    © HIsmelt Corporation 2008

    The HIsmelt process is simple

    Offgas

    Raw Materials

    Injection Lances

    Oxygen Enriched

    Hot Air Blast

    Metal Bath

    Slag NotchForehearth

    Water cooled

    panels

    Ore & coal are injected into

    the molten bath

    Hot blast is injected into the

    top-space

    Metal flows out

    continuously, slag is batch

    tapped

    Smelt Reduction Vessel (SRV)

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    © HIsmelt Corporation 2008

    Coal Flux Injection

    Ore Preheater Injection

    System

    Oxygen Plant

    Waste Heat

    Recovery Unit

    Stoves

    Offgas

    Scrubbers

    Coolers

    Offgas Duct

    Hood

    Flue Gas Desulphurisation

    Hot

    Metal Handling

    Slag Pits

    Water

    Treatment

    Smelt Reduction

    Vessel

    The HIsmelt process is innovative

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    © HIsmelt Corporation 2008

    HIsmelt’s Advantages for India

    Flexibi lity in Raw Materials

    Lower Capital & Operating Costs

    Lower Environmental Impact

    High Quality Iron Product

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    © HIsmelt Corporation 2008

    Indian Raw Material Flexibili ty

    Iron ore

     –  Dry fines (-6mm) and slimes (ultra-fines) – used directly

     – High phosphorus content possible

     – No blending or agglomeration necessary

     – Can be pre-heated / pre-reduced to increase process efficiency

    Steel plant wastes

     –  Dry fine wastes and metallic fines – used directly – E.g. mill-scale, steel-making slag, reverts, coke breeze

    Coal

     –  Non-coking coals – ground to -3 mm and dried

     – From coke breeze (low volatile) high volatile thermal coal (40%)

     – No blending, briquetting or coking required

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    © HIsmelt Corporation 2008

    Carboniser 

     – Char = Rich carbon source for SRV

     – Offgas used for power generation

     –  Further investigation required

    Circofer (after 2015)

     – Future technology using full spectrum of coals

     – R&D in progress with Outotec (formerly Outokumpu/Lurgi)

    Higher Value from Indian Coals

    Indian Coal

    Fuel gas / Power generation

    Char Carboniser 

     Air/Recycle Gas

    Oxygen

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    © HIsmelt Corporation 2008

    Indian Coal Solutions: – Use of a carboniser will allow higher productivity to be achieved

    with local coals

    * Assumes use of: Local Indian coal containing 18% ash and 25-30% volatile matter; Imported coal containing 10% ash and 10% volatile matter 

    0

    100

    200

    300

    400

    500

    600

    700

    800

    900

    Preheater 

    100% Imported coal

    Preheater 

    50% Imported coal

    50% Local coal

    Carboniser + Preheater 

    100% Local coal0%Indian Coal

    (Imported)

    50%Indian Coal

    100%Indian Coal

    +

    Carboniser 

    Productivity

    (ktHM pa)

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    © HIsmelt Corporation 2008

    Lower Capital Cost for Greenfield Expansions

    -

    2.0

    4.0

    6.0

    8.0

    China India USA China India USA

    HIsmelt Blast Furnace

       R  e   l  a   t   i  v  e   C  o  s   t

    Coke ovens

    Power plant

    Iron ore pretreatment

    Core plant

    2Mtpa Greenfield Facility Comparison

    HIsmelt Blast Furnace

    Source: Rio Tinto analysis; 2006

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    © HIsmelt Corporation 2008

    Lower Operating Costs: Lower input costs

    Raw Material Prices - Reductants

    0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

    High Vol

    PCI Coal

    Coking Coal

    Coke

    Purch. Coke Non-coking coals

    Iron ore fines

    Single source feeds okay

    No need for blending yards

    Graphs are indexed values only on a per tonne basis

    Source: CRU averages (updated Jan 2008)

    Reductants

    Raw Material Prices - Iron Units

    0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

    Fines

    Lump

    Sinter 

    Pellets

    Iron Units

    Relative price

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    © HIsmelt Corporation 2008

    Lower 

    Operating 

    Costs: 

    Compared 

    to 

    blast 

    furnaces

    0.0

    0.2

    0.4

    0.6

    0.8

    1.0

    1.2

    1.4

    Blast Furnace HIsmelt 8m

       R  e   l  a   t   i  v  e   I  n   d  e  x

    Ore Coal Other 

    ~10-20% lower

    operating costs

    Source: Rio Tinto analysis

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    © HIsmelt Corporation 2008

    Recycle Wastes

     – Utilise iron ore slimes

     – Steel plant wastes

     – Other iron unit sources (e.g. steel-making slag)

    No Toxic Emissions

     – No dioxins, furans, phenols or tars

    Reduced Overall Emissions

     – Reduced CO2, SO2 and NOx – CO2 Emissions

    Now in line with BF

    Future plants (Circofer) reduced emissions

    Circofer CO2 can be sequestered

    Low Footprint

     – Less land disturbance

     – Power balanced0.0

    0.5

    1.0

    1.5

    2.0

    2.5

    CO2 SOx NOx Dioxines &Furanes*

    Lower Environmental Impact

    Emissions per thm

    B  e s  t  -i  n- c l   a s 

     s B F 

    HI    s m el     t   

    (t/thm) (kg/thm) (kg/thm) (ppm/thm)Source: Rio Tinto analysis

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    © HIsmelt Corporation 2008

    1420°C1430 - 1500°CTemperature

    0.1 ± 0.05% #0.04 ± 0.02%Sulphur 

    0.02 ± 0.01% **0.09 ± 0.02% *Phosphorus

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    © HIsmelt Corporation 2008

    HIsmelt Kwinana Plant UpdateHIsmelt Kwinana Plant Update

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    © HIsmelt Corporation 2008

    Located in Kwinana, Western Australia

    Capacity of 800,000tpa

    High quality merchant pig iron

    Experienced Joint Venture Partners:

     – Rio Tinto 60%

     – Nucor 25%

     – Mitsubishi 10% – Shougang 5%

    First HIsmelt Commercial Facility

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    © HIsmelt Corporation 2008

    Construction

     – Started January 2003

     – Completed April 2005

    Hot commissioning / Initial operations

     – May-September 2005

    Operation – 3 year ramp-up period beginning in November 2005

     – Ramp-up schedule:

    50% nameplate by 2006

    80% by 2007

    100% by 2008

    Path to Operation

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    © HIsmelt Corporation 2008

    Core technology is working well at commercial scale

    SRV close to design rates, reached ~80tph (77% of nameplate)

     – Flue Gas De-sulphurisation (FGD) capacity limited productivity to ~60%

     – FGD capacity upgraded in July-07 and new production records were set:

    1,700t in a day 9,600t in a week

    30,000t in a month

    Coal consumption has fallen to 810kg per tonne – on track for

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    © HIsmelt Corporation 2008

     Accumulated Hot Metal Product ion

    0

    20

    40

    60

    80

    100

    120

    140

    160

    180

    200

    220

      S  e  p -  0  5

       N  o  v -  0  5

      J  a  n -  0  6

       M  a  r

     -  0  6

       M  a  y

     -  0  6

      J  u   l -  0

      6

      S  e  p -  0  6

       N  o  v -  0  6

      J  a  n -  0   7

       M  a  r

     -  0   7

       M  a  y

     -  0   7

      J  u   l -  0

       7

      S  e  p -  0   7

       N  o  v -  0   7

       T   h  o  u  s  a  n   d

       t  o  n  n  e  s

    Cumulative production – Improving as bottlenecks removed

     Ave: 350 tpd

    Max 42 tph

     Ave: 450 tpd

    Max 48 tph

     Ave: 700 tpd

    Max. 68 tph*

     Ave: 830 tpd

    Max. 65 tph

     Ave: 1000 tpd

    Max. 85 tph

    •This maximum rate exceeded the capability limit of the FGD, and practical maximum production rate was 65 t/h until extra FGD capacity was added in 2nd quarter 2007

    •Source: HIsmelt Operation

    Flue Gas

    Desulphurisation (FGD)

    unit expansion

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    © HIsmelt Corporation 2008

    20

    30

    40

    50

    60

    70

    80

    90

    20 25 30 35 40 45 50 55

    Total Oxygen Input (kNm3/hr)

       H  e  a   t   T  r  a  n  s   f  e  r   t  o

       t   h  e   B  a   t   h   (   %   )

    HIsmelt Process indicators are excellent

    Heat Transfer Efficiency (%)Coal rate (t/thm)

    0.0

    0.4

    0.8

    1.2

    1.6

    2.0

    2.4

    2.8

    0 20 40 60 80 100

    Hot metal production (thm/h)

       C  o  a   l  r  a   t  e   t   /   t   h  m

    Target ~0.70t/thm

    Campaign C2-1 (April-06 to May-06)

    Campaign C2-5 (Nov-06 to Dec-06)

    Campaign C3-4 (Aug-07 to Sept-07)

    Increased rates transfermore energy to the bath

    •Source: HIsmelt Operation

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    © HIsmelt Corporation 2008

    Key

    Productivity = Average productivity when injecting ore (tonnes per operating hour)

    Utilisation = Time that ore was injected (%)

    Performance by Operating Period

     – Productivity and Utilisation Steadily Increasing

    48

    53

    77

    72

    62

    6867

    37

    45

    1923

    16

    2730

    22

    38 40

    72

    42

    4945

    62

    80

    46

    7369

    1348

    1041

    787

    1350 1258   1335 1184 1105

    15701712

    738704692

    0

    20

    40

    60

    80

    100

    120

    140

    Sep-05 Oct-05 Dec-05 Apr-06 Jul-06 Aug-06 Sep-06 Nov-06 Feb-07 Jul-07 Aug-07 Oct-07 Nov-07

    Month Operating Period Commenced

    %

    &

    tpoh

    -5000

    -4500

    -4000

    -3500

    -3000

    -2500

    -2000

    -1500

    -1000

    -500

    0

    500

    1000

    1500

    2000

    tHM/d

    Productivity

    Utilisation

    Peak daily production

    •Source: HIsmelt Operation

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    © HIsmelt Corporation 2008

    Commissioning issues being systematically eliminated

    Reliability issues have limited Kwinana HIsmelt Plant production – E.g. 30+ interruptions to ore injection for December ’07

    Significant causes of delays been: –  Preheater  - Refractory sub-optimally installed (rectified)

    - Unreliable ore feed system (rectified)

     –  WHRU - Process control / reliability (rectified)

    - Trips (50+) stop whole plant…• Integrated steam systems (Blower, Oxygen plant)

    • Will be replaced with electric drives next plant

     –  Flue Gas Desulphurisation- FGD unit under-designed (rectified)

     –  Hot Metal Handling- Desulphurisation & Pig Casting integrated with the SRV

    • Delays could quickly create a bottle-neck

    • Hot metal for steelmaking in future plants

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    © HIsmelt Corporation 2008

    Key Plans for 2008

    Optimise SRV to achieve 80 100tph

    Focus on improving plant reliabili ty / availabili ty

    Extend SRV campaign life

     – Installation of slag zone coolers

     – Installation of keyed SRV refractory bricks

    Couple Preheater to SRV

     – ~10% pre-reduction / Productivity increase

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    © HIsmelt Corporation 2008

    Future TechnologyFuture TechnologyDevelopmentsDevelopments

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    © HIsmelt Corporation 2008

    The Next Step: 2Mtpa – 8 metre diameter SRV

    Major Changes from 6m SRV

     – Hearth diameter from 6m to 8m

     – Production from 0.8 to 2.0 Mtpa

     – Redesigned hot air blast injection – improved process efficiency, simplermanufacture

     – Two 6m offgas hoods – single larger hood not feasible to manufacture,

    transport or erect

    Minimal Changes to:

     – Lances

     – Forehearth

     – Cooling Panels

     – Refractory

    Offgas DuctsOffgas

    Chamber 

    Forehearth

    8m SRV 6m SRV

    SRV Access

    Roof 

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    © HIsmelt Corporation 2008

    Circofer Pre-reduction

    add coal feed

    & oxygen

    Circofer 

     – Utilising full spectrum of coals & dramatically lowers CO2 emissions

    * Circofer is a trademark of Outotec GmbH

    Preheater 

    Hot Ore

    Circulating

    Fluidised Bed

    SRV Offgas

    Off Gas

    850

    °C

    Iron Ore

    Process Gas

    950

    °C

    Coal Feed

    Oxygen

    DRI & Char 

    Circulating

    Fluidised Bed

    Iron Ore Cl   e  an e  d  , S 

     c r  u b  b  e  d  & R e  c i  r  c  ul   a t   e  d 

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    © HIsmelt Corporation 2008

    Future developments wil l allow major reductions in GHG

    low vol coal

    ore

    10% prd

    oreSRV

    ore

    preheaterFGD

    stack

    HABwaste heat

    recovery

    CO2 Emitted

    1.7-1.9 t/thm

    Equal to world’s bestblast furnace

    oxygen

    ore

    highvol

    coal

    80%

    prd ore

    & char

    Circofer

    CFBFGD

    stack

    waste heat

    recovery

    CO2

    Scrubber 

    geo-sequestered CO2

    (30-35% of total output)

    HAB

    SRV

    CO2 Emitted

    0.9-1.1 t/thm

    5 0 % r e d u c t i o n  

    oxygen

    ore

    highvol

    coal

    80%

    prd ore

    & char

    Circofer

    CFB

    geo-sequestered CO2

    (90-95% of total output)

    ox

    SRV

    CO2

    Scrubber 

    CO2

    Scrubber 

    rich gas

    CO2 Emitted

    0.1-0.3 t/thm

    9 0 % r e d u c t i o n  

    HIsmelt Mark III (2012)

    N2-Free + Sequestration

    HIsmelt Mark II (2010)

    Circofer HIsmelt Mark I (2008)

    Kwinana Plant

    •Source: HIsmelt Technology Development

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    © HIsmelt Corporation 2008

    Developments to 2015: Mk I Developments 2015-2020: Mk II Developments 2020+: Mk III

    HIsmelt’s Technology Roadmap:

     – Step change improvement in capacity and emissions

    Geo-sequestered

    CO2

    6m SRV + Preheater 

    0.8Mtpa Capacity 8m SRV + Preheater 

    2Mtpa Capacity

    8m SRV + Circofer

    4Mtpa Capacity

    Geo-sequestered

    CO2

    8m SRV + Circofer + CCS

    4Mtpa Capacity

    6m SRV

    0.6Mtpa Capacity

    8m SRV

    1.6Mtpa Capacity

    Current

    Kwinana

    Plant

    Near net zero

    emissions profile

    6m SRV + Circofer

    2Mtpa Capacity

    6m SRV + Circofer + CCS

    2Mtpa Capacity

    •Source: HIsmelt Technology Development

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    © HIsmelt Corporation 2008

    The HIsmelt process is performing. Production achievements of:

     – 30,000t in 30 days

     – 9,600t in 1 week

    Coal rates on track with design

    Strong global interest in the technology

     – The 3 top politicians in China have visited Kwinana

     – Over 80 steel company visits

    Increasing injection & product ion rates to nameplate capacity in 2008

    Detailed engineering for 2Mtpa HIsmelt plant complete

    Circofer pilot plant test-work nearing completion

     – Pathway to lower CO2 emissions

    Preparing to deliver raw material flexibi lity to India…

    In Summary