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Outotec`s Pelletizing Technology, Process Influencing Factors and Market Demands

54th meeting of Blast furnace and Sinter plant Operating committee at MECON, Ranchi21.-22.07.2011


Content

22.07.20112

Outotec’s recent Pellet Plants

Agglomeration of Iron Ores

Cost Comparisson Sinter Plant vs. Pellet Plant

Market Demand

Outotec’s Pellet Plant Developments


Pelletizing

Plant Capacities• Between 1.0 and 9.25 million t/a in one strand• Grate areas between 189 and 816m²

References• Total more than 60 pellet plants• Last contracts

• 2011 – Samarco 4, Brazil: LSTK indurating machine for the world‘s largest pellet plant with 9.25 million t/a plant

• 2011 – Stoilensky GOK, Russia: Technology Package for 6 million t/a plant• 2009 – BPSL, India: Technology package for 3.85 million t/a plant• 2008 – Tata Steel, India: LSTK with Indian partner for 6.0 million t/a plant• 2008 – Caofeidian, China: Technology package for 4.0 million t/a plant• 2006 – MBR, Brazil: EP contract for 7.0 million t/a plant• 2005 – Samarco 3, Brazil: LSTK indurating machine for the world‘s largest pellet plant

with 7.5 million t/a plant• 2005 – Vale, Tubarao 8, Brazil: Engineering and technical assistance for 7.0 million t/a

plant• 2005 – LKAB, Malmberget, Sweden: LSTK indurating machine for 4.0 million t/a plant• 2003 – Gol e Gohar, Iran: Engineering and supply of a 5.0 million t/a plant• 1998 – Vale, São Luís, Brazil: Engineering for 6.0 million t/a plant

Pelletizing plant Samarco 3, Brazil

Traveling grate based pelletizing

May 4, 20113


Content

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Market Demand



Screening

Why Pelletizing

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BF

Ore with high iron content

Fines

Sintering Pelletizing

Ore with low iron content

Beneficiation

Concentrate

DR

Lump ore


Why Pelletizing

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Conventional Sintering changes for the worse permeability and consequently decreased productivity if feed materials become finer than 100 µm.Transportation of Sinter over a large distance is irrational due to its degradation.1911: A.G. Anderson applied for Swedish patent for drum rolled iron ore balls, too fine for sintering, and their subsequent firing to harden them.

Sinter Feed: 10-15% > 10mm, 10% < 0,125µm

Pellet Feed: 100% < 150µm, 85% < 45µm


Content

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Market Demand



Sinter Plant Feed Material and Productivity

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Sinter Feed0,15 – 3,0 mm

Pellet Feed< 150 µm

Sinter Plant

Sinter Feed 35 – 40 t/d m²Mixture 28 – 32 t/d m²Pellet Feed 19 – 20 t/d m²

Pellet feed processing can drop productivity up to 50% !Specific operational cost per ton of sinter will exceed those of comparable pellet plant


Total Cost Comparison Sinter & Pellet Plant

Scenario: Capacity: 4.0 mtpyLocation: EURaw Materials: Brazilian Iron OreOptions: a) Sinter Plant without Recycle

Materialsb) Sinter Plant with 10% Recycle

Materialsc) Pellet Plantd) Import of Pellets and Lump Ore

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Plant Specifications

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Sinter Plant without recycle material

Sinter Plant with 10%recycle material

Pellet Plant Pellet import

Bedding and Blending to Product Screening

Grinding to Product Screening, incl. Raw Material Storage

Raw Material Storage

Gas Cleaning with MEEP Gas Cleaning with conventional ESP

---



Sinter Plant Pellet Plant

ElectricalEnergy 30 kWh/t 108 MJ/t 52 kWh/t 187 MJ/t

Thermal Energy 22 kWh/t 80 MJ/t 210 kWh/t 755 MJ/t

Carbon Carrier 50 – 52 kg/t 13 kg/t

350 kWh/t 1.255 MJ/t 91 kWh/t 327 MJ/t

Total Energy 402 kWh/t 1.443 MJ/t 353 kWh/t 1.267 MJ/t

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Total Energy Consumption of the Pellet Plant is approx. 12% lower than for the Sinter Plant



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Sinter Plantwithout recycle

materials

Sinter Plant with 10% recycle

materialsPellet Plant

Pellet & Lump import

Investment Cost 100% 100% 120% 5%

Average Capital Cost 100% 100% 120% 5%

depreciation allowance 100% 100% 100% 100%

Operational Cost

Ore 100% 90% 87% 146%

Energy 100% 97% 112% 0%

Others 100% 100% 71% 0%

Total Cost per annum 100% 93% 92% 92%

Total Cost per t 100% 93% 92% 92%



22/07/2011 Outotec`s sintering technology13

Sinter Plant Pellet PlantCAPEX lower spec. cost higher spec. cost

OPEX raw material depended

Raw Material Preparation processing of ore as delivered

grinding to pelletizing fineness

Raw Material Qualities high Fe content low Fe content possible with upstream beneficiation

Feed of Recycle Materials possible very limited

Product Quality acc. BF requirements standardized for global market

Transport very limitedCommodity, transport cost are substantial part of total cost

Enviromentallower spec. waste gas volumes with higher contaminant loads

higher spec. waste gas volumes with lower contaminant loads


Overview BF pellet properties

Pellet Type Compression Reducibility SwellingAcid ++ - -

Basic/fluxed + + +Olivine + + +

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Overview pellet properties for Blast Furnace:

Type Basicity2 Fe% SiO2 % MgO % Compressionstrength

Acid < 0.15 64 – 67 % 2 – 5 % <0.2 % 250 – 300Olivine <0.15 64 – 67 % 2.5 – 5 % 1.3 – 1.8 % 150 – 200Basic ~0.8 – 1.0 60 – 64 % 3.5 – 5.5% 1.3 % 200 – 250fluxed ~1.1 – 1.3 60 – 63 % 3.5 – 5.5 % 1.5 % 200 - 250


Content

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Market Demand



Global Steel Production 2005 - 2019

May 4, 201116 Source: MBR, 03.2011

-10 %

-5 %

0 %

5 %

10 %

15 %

20 %

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2005 2006 2007 2008 2009 2010e 2011f 2012f 2013f 2014f 2015f 2016f 2017f 2018f 2019f

Rest of world production (mt) Chinese production (mt) World growth rate

Source: MBR, IISI


Pellet Production 1999 - 2019

May 4, 201117 Source: MBR, 03.2011

0

100

200

300

400

500

600

700

capa

city

mt/y

World Pellet Capacity

Asia Pellet Capacity


Pellet Production 2005 - 2019

May 4, 201118 Source: MBR, 03.2011

050

100150200250300350400450500

Global BFI Pellet Demand (m tonnes) Global DR Pellet Demand (m tonnes)Source: MBR


Typical Blast Furnace Burden

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0%

20%

40%

60%

80%

100%

PelletSinterLump

Source: MBR, 03.2011


Blast Furnace Burden Development in India

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0%

20%

40%

60%

80%

100%

PelletSinterLump

Source: MBR, 03.2011


Content

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Market Demand



Typical flowsheet

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Wetgrinding

Homo-genization

Filtration

RegrindingDosing & mixing

Additivepreparation

Green pelletizing

Induration

Central plant dedusting

Process gas cleaning

Cooling system

Fuel oil system

Substation

Typical layout of a 7 million t/a plant


Typical Layout – 189m² Pellet Plant

Central PlantDedusting

Substation

Process GasHandling

Dosing andMixing

GreenPelletizing

Traveling Grate Induration Machine Pellet Screening

192 m

116 m


Typical Layout – 189m² Pellet Plant


Pelletizing plants built since 2003

Outotec's pelletizing technology26Tubarão VIII

7.0 million t/a

LKAB KK4 5.0 million t/a

BPSL3.85 million t/a

MBR7.0 million t/a

GIC 6.0 million t/a

CVRD Sohar2x4.5 million t/a

LKAB MK3 2.5 million t/a

BRPL4.0 million t/a

Caofeidian4.0 million t/a

Samarco 37.25 million t/a

Paradeep6.0 million t/a

Gol-e-Gohar 5.0 million t/a

WISCO5.0 million t/a

Plant size >3.5 million t/a, status 04/2011

Tata Pellet6.0 million t/a

JSPL Barbil4.0 million t/a

M-GOK5.0 million t/a

Essar MIS6.0 million t/a

Technology/supplier Installed annual capacity

Outotec traveling grates 54,6 million t/a

Other traveling grates 21,0 million t/a

Grate kiln 26,0 million t/a

Travelling Grate:

75,6; 74%

Grate/Kiln: 26,0; 26%

7/22/2011


Samarco 3 – pelletizing plant

22.07.2011 Outotec's pelletizing technology27


May 4, 201128

Thank you!

Sustainable use of Earth's natural resources.

Stefan MehlHead of Traveling Grate [email protected]

Ou Totec

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