INTERNATIONAL SEMINAR ON ’ START UP’ AND …mist2016.in/presentations/Session_1/Paper1 by...
Transcript of INTERNATIONAL SEMINAR ON ’ START UP’ AND …mist2016.in/presentations/Session_1/Paper1 by...
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MIST-2016
INTERNATIONAL SEMINAR ON ’ START UP’ AND ’STAND UP’INDIA SEMINAR ON ’ START UP’ AND ’STAND UP’INDIA FROM MINES TO STEEL
MECON, RANCHI
29th,30th & 31st January,2016
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Technical Session-1
Managing Indian Iron Ore Fines - Beneficiating for improved yield
© Metso Minerals, Inc.
Sunil Yadav
VP - Projects & System ( Mining )
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Preamble1. India is poised to produce 300 Million Tonnes of Steel in near future
2. To meet this target around 700 Million Tonnes of Iron Ore will be required.
3. Raw Material Quality plays a vital role and more so in the future.
1. The Indian Steel Industry is consuming 6.9 Giga Calories per tonne of crude steel ( gcal/tcs) against a Global average of 4.5 gcal/tcs. We use 50% more energy compared to the world average.
Challenges
2. The Indian Steel industry emits 2.7 tonnes of CO2 per tonnes of crude steel produced ( ton/tcs ) against Global average of 1.75 ton/tcs. Again we pollute 50% more compared to the world average.
3. The factors affecting higher specific energy consumption and higher pollution are
1. Outdated Technology
2. Inferior Raw Material Quality
3. High Alumina to Silica Ratios in Indian Iron Ores
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5-FIVE-Major Challenges in Managing Indian Iron Ore Fines
1. Increasing Recovery of Iron Values
through Magnetics
2. Increasing Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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5-FIVE-Major Challenges in Managing Indian Iron Ore Fines
1. Higher Recovery of Iron Values
through Magnetics
2. Higher Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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UNCLASSIFIED
Magnetic attraction
© Metso Minerals, Inc.
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Relative Magnetic Susceptibility Classification of selected minerals
Maghemite 100000
Magnetite 20000 - 80000Franklinite 7000
Pyrrhotite 1500 - 6100
Valleriite 1100
Cubanite 400
Hematite 170 - 290Ilmenite 110 - 270
Rhodochrosite138
Rhodonite 127
Braunite 120 - 145
Fe-tourmaline 22 - 31
Epidote 24
Sphene 22
Goethite 21 - 25
Hornblende 19 - 23
Fe-grossularite 13 - 47
Fe-pyrope 11 - 56
Lepidolite 10 - 46
Monazite 19
Fe-sphalerite 10 - 25
Fergusonite 16
Marcasite 1 - 4
Rutile 2
Smithsonite 1 - 2
Platinum 1
Dolomite 0,9
Cobaltite 0,9
Beryl 0,7
Spinel 0,6
Chalcopyrite 0,4 - 7
Iridium 0,2
Pyrite 0,2
Selenite -0,32
Celestite -0,34
Corundum -0,34
Galena -0,35
Orthoclase -0,38
Calcite -0,38
Bismuthite -0,39
Aragonite -0,41
Topaz -0,42
Quartz -0,46
Ferromagnetic
Upgrade by LIMS
Paramagnetic
Upgrade by
HGMS
© Metso Minerals, Inc.
Aegirine 85
Ferrowolframite 66 - 95
Almandite 60 - 124
Siderite 56 - 64
Hausmannite 58
Chromite 53 - 125
Andradite 51 - 93
Manganite 51
Fe- amphibole 38 - 120
Melanterite 42
Melonite 36
Pyrolusite 25 - 32
Fe-pyroxene 26 - 130
Biotite 23 - 80
Azurite 10 - 19
Dioptase 9
Malachite 8 - 15
Molybdenite 8
Bornite 8 - 14
Phlogopite 5 - 8
Palladium 5
Zinnwaldite 4
Niccolite 3 - 12
Arsenopyrite 3 - 8
Tourmaline 1 - 9
Muscovite 1 - 6
Scapolite 2 - 3
Cinnabar 0,2 - 2
Zircon 0 - 130
Pyrophyllite 0
Osmium 0
Copper -0,04
Cassiterite -0,08
Orpiment -0,1
Lead -0,1
Gold -0,14
Chalccite -0,18
Covellite -0,2
Silver -0,21
Fluorite -0,29
Barytes -0,29
Arsenic -0,31
Strontianite -0,32
Sulphur -0,49
Diamond -0,49
Carnallite -0,6
Antimony -0,87
Gypsum -1,0
Sphalerite -1,2
Sylvanite -1,2
Bismuth -1,35
Anhydrite -1,6
Halite -1,8
Antimonite -1,9
Graphite -6,2
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UNCLASSIFIED
Magnetic system
© Metso Minerals, Inc.
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UNCLASSIFIED
Types of MatricesMetso-Expanded MetalFor Iron Ore etc
Competetion
© Metso Minerals, Inc.
Competetion Metso-Steel WoolFor Clay Minerals etc
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Magnetic SeparationWet high gradient
10
MATRIX
FEEDRINSE WATER
RING
MAGNET
HEAD
MAGS
MAGNET COIL
FLUSH STATION
by method by equipment
© Metso Minerals, Inc.
Date/Title/Aut
NON MAGSFLUSH WATER
Homogeneous field
Filament
Inhomogeneous field
Filament matrix
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UNCLASSIFIED
HGMS – Operating Principle
© Metso Minerals, Inc.
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UNCLASSIFIED
HGMS – Operating principle
© Metso Minerals, Inc.
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UNCLASSIFIED
HGMS – Operating Principle
© Metso Minerals, Inc.
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HGMS and WHIMS - Working range
© Metso Minerals, Inc.
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UNCLASSIFIED
HGMS - Processing of iron ore
Product Weight Grade Grade Recoverytph % Fe % SiO2 % Fe
Feed 175 64 - 65 5 - 6 100
Concentrate 150 - 155 67 - 68 1,5 - 1,7 92
© Metso Minerals, Inc.
Concentrate 150 - 155 67 - 68 1,5 - 1,7 92
Equipment HGMS 350-7
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UNCLASSIFIED
HGMS – Competing Equipment
© Metso Minerals, Inc.
Jones Eriez
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UNCLASSIFIED
Metso HGMS technique vs. WHIMS Comparison
Metallurgical / Economical comparison
Yield Grade Recovery No. of Total Est. RelativeEquipment Product weight % % Fe % Fe units weight equipment*
tons cost, %
© Metso Minerals, Inc.
The above is based on an Indian project * excluding installation and foundation cost.
Svedala HGMS Hematite 80,0 67,5 84,9 1 110 100
Jones WHIMS Hematite 75,2 67,6 79,3 3 360 141
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UNCLASSIFIED
HGMS - Features and Benefits
• Broad range of applications
• High separation efficiency
• Unsurpassed efficiency in recovery of fines
• Rugged design
• Patented vacuum assisted back flush for magnetic products
• Available in a wide range of sizes and field ratings
© Metso Minerals, Inc.
• Available in a wide range of sizes and field ratings
• Long component life
• Low operator attendance
• Easy adjustable and automatic control of operation
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Fomento
Goa
ESSAR-KirandulBMM Ispat-Hospet
Some HGMS References in India
© Metso Minerals, Inc. 19
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IRON ORE REFERENCES
1. Metallurgimport,USSR HGMS 120-15 1 Unit 1980
2. EDMA,Portugal HGMS 120-05-05 1 Unit 1980
3. Austromineral, Sierra Leone HGMS 480-05-05 1 Unit 1981
4. I.O.C Canada HGMS 350-05 1 Unit 1992
5. Chador Malu, Iran HGMS 350-05-05 3 Units 1992
6. ESSAR, India HGMS 350-05-05-05 2 Units 1995
7. Fomento, India HGMS 250-05 1 Unit 1996
© Metso Minerals, Inc.
7. Fomento, India HGMS 250-05 1 Unit 1996
8. LKAB, Sweden HGMS 250-07-07 2 Units 1997
9. Chador Malu, Iran HGMS 350-05-05 1 Unit 2004
10.Fomento, Goa-Extra Head HGMS 250-05 1 Unit 2005
11.BMM Ispat, India HGMS 250-07-07 1 Unit 2005
12.ESSAR, India HGMS 350-07-07-07 1 Unit 2012
13.JSW, India HGMS 250-07-07-07 3 Units 2012
14.Bhusan Steel, India HGMS 350-07-07-07 3 Units 2013
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5-FIVE-Major Challenges in Indian Iron Ore Fines
1. Higher Recovery of Iron Values
through Magnetics
2. Higher Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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Cleaner Stage
Rougher Stage
© Metso Minerals, Inc. 22
Scavenger Stage
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Bubble Size Measurement
50
60
70
80
90
100C
um
ula
tiv
e v
olu
me
(%
)
© Metso Minerals, Inc. 23
0
10
20
30
40
50
0 1 2 3 4 5 6 7 8
db (mm)
Cu
mu
lati
ve
vo
lum
e (
%)
CISA/Microcel™ Sparger (Average17 tests)
Air-only Sparger (Average 19 tests)
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The Metso ColumnTechnology
Yie
ld (
%)
Product Grade / Yield Relationship
Same Product Grade
Increase in YieldIncrease in Yield
© Metso Minerals, Inc.
Product Grade (%)
Yie
ld (
%)
Conventional Spargers
Metso-Cisa (Microcel™) sparger
Increase in YieldIncrease in Yield
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Benefits of Metso Column Flotation
• Improved Recovery
• Optimized Grade
• Increased Throughput
© Metso Minerals, Inc.
• No Plugging
• On-line Replacement
• Reduced Wear & Maintenance
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© Metso Minerals, Inc.
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5-FIVE-Major Challenges in Managing Indian Iron Ore Fines
1. Higher Recovery of Iron Values
through Magnetics
2. Higher Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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”Compact” Sedimentation - Inclined Plate Settlers
28
By using sliding instead of free sedimentation the settling speed is increasing dramatically.
This effect is mainly used in clarification.The thickening effect is not too impressive.
© Metso Minerals, Inc.
Date/Title/Aut
Applications: Effluent treatment when
space is a shortage.
Comparing compact and
classical clarifiers
Compact means ”doing
the same job in a smaller
space!”
Comparison compact and classical clarifiers
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Sedimentation
29
© Metso Minerals, Inc.
Date/Title/Aut
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© Metso Minerals, Inc.
24 M Dia Tanks –LTC 4200 at NMDC Bailadila- 2 Nos
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Process
Building
Old Process Plant with Large and Ground Conventional Thickener
Pump House
@ 3-4 M below ground
Less Green Cover
© Metso Minerals, Inc.
Date Author Title31
New Process Plant with Compact and Above Ground Lamella Thickener
Process
Building
@ 3-4 M below ground
Pump House
above ground
More Green Cover
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Some References in India
© Metso Minerals, Inc.
Date Author Title32
LTE 440-9.3 in ESPL Coal WasheryAt Jaduguda
LTC 4200-24 in NMDC Bailadilafor Iron Ore- 2 nos.
LTE 1140-12.5 in JPL Coal WasheryAt Tamnar, Raigarh
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5-FIVE-Major Challenges in Managing Indian Iron Ore Fines
1. Higher Recovery of Iron Values
through Magnetics
2. Higher Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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Costs per metric tonne milled for a100,000 t/d copper concentrator
Item Cost- US$ Percent costper tonne
Crushing 0.088 2.8
Grinding 1.482 47.0Flotation 0.510 16.2Thickening 0.111 3.5Filtration 0.089 2.8
Tailings 0.161 5.1
Reagents 0.016 0.5
© Metso Minerals, Inc. 34
Reagents 0.016 0.5
Pipeline 0.045 1.4
Water 0.252 8.0
Laboratory 0.048 1.5
Maint support 0.026 0.8
Mgmt support 0.052 1.6
Administration 0.020 0.6
Other expenses 0.254 8.1
Total 3.154 100
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�Huge quantity
concentrated in
Karnataka, Odisha
and Chattisgarh
�Hard to grindConstituents,
%
BHQ,
Karnataka
BHQ/BHJ
�Hard to grind
� Liberation size is
quite small
�Can only be used for
pellet making
% Karnataka
Fe(T) 37.9
Fe2O
354.2
SiO2
44.6
Al2O
30.50
LOI 0.42
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100
1000E
ne
rgy
(k
Wh
/t)
ball mill
stirred mills
© Metso Minerals, Inc. Title/AuthorDate36
1
10
1 10 100 1000
Product 80% passing size (µµµµm)
En
erg
y (
kW
h/t
)
conventional grinding
regrindingfine grinding
very f ine grinding
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How to Reduce the Grinding Costs
• Energy Efficiency
• Sustainability
• Low Capital
• Minimize Maintenance
• Ease of Operation
•
Metso’s Design Goals
© Metso Minerals, Inc.
• Long mill life
• Lowest Total Cost of
Ownership
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© Metso Minerals, Inc.
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Vertimills in Iron Ore
Installation List
SITE/USER LOCATION MILL SIZE QTY PRODUCT SIZE CAPACITY (EACH)
BHP Samarco
Brazil VTM-1500-WB 1 88% passing 45 microns 141 MTPH
Laiwu Steel China VTM-125-WB 1 95% passing 37 microns 5 MTPH
CP Mining Australia VTM-1500-WB 5 80% passing 28 microns 90 MTPH
Anglo American Brazil VTM-1500-WB 16 85% passing 45 microns 152 MTPH
© Metso Minerals, Inc.
Anglo American Minas Rio
Brazil VTM-1500-WB 16 85% passing 45 microns 152 MTPH
Accelor MittalSicartsa
Mexico VTM-1500-WB 1 80% passing 40 microns 90 MTPH
Hyllsa Las Encinas Mexico VTM-1500-WB 2 80% passing 45 microns 142 MTPH
Pena Colorada Mexico VTM-1500-WB 2 80% passing 25 microns 202 MTPH
CliffsHibbing Taconite
USA VTM-1250-WB 2 90% passing 44 microns 100 MTPH
Vanadium Australia PTA Ltd Australia VTM-800-WB 1 80% passing 75 micron 67 MTPH
14 September 201039
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5-FIVE-Major Challenges in Managing Indian Iron Ore Fines
1. Higher Recovery of Iron Values
through Magnetics
2. Higher Recovery of Iron Values
through Flotation
3. Close Water Circuit
Challenges
Metso HGMSIncrease Grade & Recovery
Solutions
Microcel Column Increase Grade & Recovery
Lamella thickener3. Close Water Circuit
4. Lowering of Grinding Costs
5. Tailing Re-treatment
Lamella thickenerSave space by 60%
VertimillReduce Power by 40%
Dredge Technology
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DREDGE PUMPSDREDGE PUMPS
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TAILING RECLAMATION BY DREDGE
© Metso Minerals, Inc.
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TAILING RECLAMATION BY DREDGE
© Metso Minerals, Inc. Date Author Title43
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Conclusions
1. Low Grade Iron Ores will be increasingly used for Steel Making after beneficiation.
2. Outdated Technology needs to be phased out to reduce the energy consumption in the steel sector.
3. Extensive Beneficiation of Iron Ore needs to be done so that we minimise the Iron losses in the Tailings.
4. Tailings reclamation needs to be adopted for resource 4. Tailings reclamation needs to be adopted for resource conservation.
5. Space optimisation should be done by adopting modern compact Thickeners ( Inclined Plate Settlers )
6. Close water should be adopted in all plants to minimise the water requirement.
7. Technology should be adopted to minimise the CO2 emission.
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company/metso metsogroup metsoworldmetsoworld metsogroup
www.metso.com
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Any Questions ?
Thank You for your timeThank You for your time