Scribd Logo
Upload

Welcome to Scribd!

    • 824 views

    Tata Steel

    Uploaded by

    patrik710
    The document discusses plans for a pelletizing plant at Tata Steel in India. Key points include: 1) The pellet plant will help increase steel production capacity and improve blast furnace performance. 2) Pellets are spherical agglomerates of iron ore fines that are better for blast furnaces than raw fines. 3) The pelletizing process involves three stages - raw material preparation, green pellet formation, and induration of pellets in a furnace. 4) The plant will have a capacity of 6 million tonnes per year and use iron ore, limestone, coal and other materials as inputs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Tata Steel

    Uploaded by

    patrik710
    824 views32 pages
    The document discusses plans for a pelletizing plant at Tata Steel in India. Key points include: 1) The pellet plant will help increase steel production capacity and improve blast furnace performance. 2) Pellets are spherical agglomerates of iron ore fines that are better for blast furnaces than raw fines. 3) The pelletizing process involves three stages - raw material preparation, green pellet formation, and induration of pellets in a furnace. 4) The plant will have a capacity of 6 million tonnes per year and use iron ore, limestone, coal and other materials as inputs.

    Original Description:

    tata steel

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses plans for a pelletizing plant at Tata Steel in India. Key points include: 1) The pellet plant will help increase steel production capacity and improve blast furnace performance. 2) Pellets are spherical agglomerates of iron ore fines that are better for blast furnaces than raw fines. 3) The pelletizing process involves three stages - raw material preparation, green pellet formation, and induration of pellets in a furnace. 4) The plant will have a capacity of 6 million tonnes per year and use iron ore, limestone, coal and other materials as inputs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    824 views32 pages

    Tata Steel

    Uploaded by

    patrik710
    The document discusses plans for a pelletizing plant at Tata Steel in India. Key points include: 1) The pellet plant will help increase steel production capacity and improve blast furnace performance. 2) Pellets are spherical agglomerates of iron ore fines that are better for blast furnaces than raw fines. 3) The pelletizing process involves three stages - raw material preparation, green pellet formation, and induration of pellets in a furnace. 4) The plant will have a capacity of 6 million tonnes per year and use iron ore, limestone, coal and other materials as inputs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 32
    At a glance
    Powered by AI
    The key takeaways are that a pelletizing plant is being established to increase steel production capacity, improve blast furnace performance, and extend the life of iron ore reserves. Pellets offer advantages over sinter such as uniform size, purity, and strength for downstream steelmaking processes.

    The main reasons for establishing a pelletizing plant are to increase hot metal output to meet higher steel production targets, improve blast furnace performance through increased productivity and reduced fuel usage and slag generation, and extend the usable life of iron ore reserves.

    The main advantages of pellets over sinter are their uniform size and quality, high strength and porosity, low degradation and impurity levels, and faster reduction rates in blast furnaces. Pellets offer more consistent metallurgical properties.

    Pelletizing Plant At Tata Steel (6.

    0mtpa 768m2 )
    RANCHI 22nd Jul Jul-2011 2011

    Pellet Plant Project

    Need of Pellet Plant for Tata Steel To increase hot metal output to meet 10 MTPA Crude Steel Production To improve blast furnace performance
    a. Increase in blast furnace productivity b. Decrease in blast furnace fuel rate c. Decrease in hot metal quality d. Decrease in Slag Rate

    Extending g the life of iron Ore Reserves

    Pellet Plant Project

    What are Pellets ?


    Pellets are approximately spherical lumps formed by agglomeration of crushed iron ore fines in presence of moisture and binder, on subsequent induration at around 1300C, which suit the requirements of downstream processes e e.g. g Blast Furnaces & Direct Reduction.

    Pellet Plant Project

    Advantages of Pellets
    Standardization uniform size range , generally within a range of 616 mm Purity 6368% iron iron, mainly FeO High and uniform porosity of 2530% Good bed PermeabilityDue to Spherical shape and open pores Cost-effectiveness Virtually no loss of ignition Fast reduction and high metallization rates Fine particles, not suitable for sinter making, are used Strength high and uniform mechanical strength even under thermal stress in reducing atmospheres Transportable low degradation under abrasive conditions

    Pellet Plant Project

    Pellet Vs. Sinter


    Parameters Iron Ore Fines Size Coal / Coke Size Limestone / Pyroxinite Agglomeration Process Product Size, mm Tumbler Index (TI),% Reduction Degradation Index (RDI), % Reducibility Index (RI), (RI) % Swelling Index, % Pellet 80% < 0.045 mm 80% < 0.045 mm 80% < 0.045 mm Induration 6-16 6 16 mm >92 < 12 65 < 18 Sinter < 8-10 mm < 3.15 mm < 3.15 mm Sintering 6-40 6 40 mm 65 27-30 65

    Pellet Plant Project

    Process Stages of Pellet Production


    Three process stages are involved to produce pellets from raw materials: 1. Raw material preparation 2. Formation of green pellets 3. Induration of green pellets

    Successful S f l pellet ll t production d ti calls ll for f an optimum ti efficiency ffi i and d harmony between all above three stages with preceding stage highly influencing the subsequent one.

    Pellet Plant Project

    Process Flow of Pellet Plant


    Noamundi
    Iron Ore Fines Limestone Anthracite Coal BF Gas Hot Air Generator Recirculation Load

    Dryer y

    Ball Mill

    ROKSH Separator

    Process Bag House


    Ground Ore Concentrate Materials Bentonite Powder Process Water Spiral Classifier Product Pellet e et Fines es Pellet

    Dense Phase Conveying System

    Roller Screen

    Disc Pelletizer
    Rejected Pellets

    Green Mix Materials

    Mixer

    Green Pellets Single Deck Roller screen CO Gas Coal Tar


    Pellet Plant Project

    Water from Drainage system Hearth & Side Layer pellets

    Indurating Machine

    Product Screens

    Process & Plant Dedusting ESPs

    Pneumatic conveying of ESP Dust


    7

    Details of facility, input & Output Requirements

    Major Units Facilities Input


    Iron Ore Fines Limestone Anthracite Coal Bentonite CO Gas BF Gas Coal Tar Power Process Water Grinding media 1. 2 Impact Mills (30 tph) 1 2. 2 Dryers (5 m X 35 m) 3. 2 Grinding Mills (6 m X 12 m) 4. 2 ROKSH Separators 5. 2 Process Bag Houses 6. 2 Mixers (620 tph each) 7. 10 Disc Pelletizers (156 tph each) 8 Single deck Roller Screen 8. 9. Induration Machine 10. Induration Machine Hood 11. 6 Process Gas Fans 12. 3 Process ESPs & 1 Plant Dedusting ESP 13. 2 Product Screens

    Output
    Product Pellet Pellet Fines

    Pellet Plant Project

    1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

    Pellet Plant Project

    Stage 1: Raw Material Preparation


    D G Dry Grinding i di V Vs W Wet tG Grinding i di of f Iron I Ore O Fines Fi
    SL No. 1 Parameters Production Cost Wet Grinding Grinding Cost Rs Rs. 275 275-325 325 /ton of IOF Dry Grinding Grinding Cost Rs Rs. 450 450-500 500 /ton of IOF due to higher consumption of fuel & electricity All raw materials like IOF, Limestone & Coal can be grounded together 0.03-0.05 Kg/t of IOF Thickening & Filtration not required 20-22 kwh/t of pellet Requirement of extensive pollution control measure to counter dust nuisance High

    2 3 4 5 6

    Grinding of Additives Grinding media consumption Filtration Eletrical energy Consumption Pollution Hazards Capital Cost

    Separate grinding facility for additives 1-1.2 Kg/t of IOF Required to bring down moisture to 9 % 16-17 kwh/t of pellet Nil dust hazard

    Lower than dry grinding

    T t Steel Tata St l has h gone for f dry d grinding i di process because b of f high hi h alumina l i content t t in iron ore fines. Here, wet grinding will have sluggish filtration rate.
    Pellet Plant Project 10

    Stage 1: Raw Material Preparation at Tata Steel A. Raw Materials Receiving Circuit B Additives (Limestone & Coal) Crushing Circuit B. C. Drying Circuit D. Grinding Circuit

    Pellet Plant Project

    11

    Stage 1: Raw Material Preparation at Tata Steel


    A Raw Materials Receiving Circuit A.
    Blended Iron Ore fines from Noamundi Track Hopper # 4 (5100 t) Paddle Feeder 1500 tph
    1500 tph

    Iron Ore Fines 850 m3 each

    LS S 200 m3

    C 200 m3

    Stacker Cum Reclaimer

    IOF 140,000 Tons

    LS 400 T

    Coal 400 T

    B Additives (Limestone & Coal) Crushing Circuit B.


    Impact Mill
    LS 200 m3 C 200 m3 Limestone 100 m3 Coal 100 m3 Limestone 100 m3 Coal 100 m3

    Pendulum Bucket Elevator Pellet Plant Project 12

    Stage 1: Raw Material Preparation at Tata Steel


    C Drying Circuit (2 Parallel Circuit) C.
    Raw Materials Iron Ore Fines Lim e Stone Anthracite Coal Consum ption Rate Tons/Hr Kg/ton of Pellet 1246.8 945 16.2 12.3 9.5 7.2

    Rotary Dryer 2 Circuit

    Iron Ore Fines 850 m3 each

    Limestone 100 m3

    Coal 100 m3

    Dryer Bag House 1

    Burner air dilution fan

    To Roksh Seperator1

    60 tph (12%)

    Vol. Flow 50000 Nm3/hr Cal Val 850 Kcal/Nm3

    BF Gas

    Rotary Dryer1
    Size 5 m dia X 35 m long Slope 4 degree Speed 2.5 RPM Residence Time 19.2 minutes

    Burner primary air fan

    To Grinding Circuit 13

    Pellet Plant Project

    Stage 1: Raw Material Preparation at Tata Steel


    D G D. Grinding i di Circuit Ci it (2 Parallel P ll l Circuit) Ci it)
    Dust from Rotary Dryer bag house ROKSH Separator 1st Process Bag Filter House

    Iron Ore + Additives from Rotary Dryer System

    2nd Process Bag Filter House

    Ground Ore Concentrate Bins 1500 m3 each

    Ball Mill #1 6 m X 11.6 m

    Pellet Plant Project

    14

    ROKSH Separator

    Pellet Plant Project

    15

    1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

    Pellet Plant Project

    16

    Purpose of green ball formation

    The purpose of the green ball formation is to obtain pellets of the desired size range ( 9 -16 mm) and having a mechanical strength which enable them to be safely transported from the b lli equipment balling i t to t the th induration i d ti machine hi

    Pellet Plant Project

    17

    Stage 2: Green Pellet Formation at Tata Steel


    A. Mixing Circuit (2 Parallel Circuit)

    Ground Ore Concentrate Bins 1500 m3

    Bentonite Bins 100 m3

    Process water & Slurry from dedusting scrubber

    Eirich Mixer

    2nd Mixing Circuit

    Green Mix Materials

    Pellet Plant Project

    18

    Stage 2: Green Pellet Formation at Tata Steel


    B Green Pelletizing Circuit (10 Parallel Circuit) B.
    Green Mix Materials from both Mixers Plough Scrapers

    Mix Material ate a Bins

    Green Mix Materials 55 m3

    Parallel 9 Mix Material Bins

    Parallel 9 Disc Pelletizers


    Disc Diameter 7.5 meter Disc Slope angle 44-53 degree Throughput Rate 154 tph Rotational Speed 4.7 to 7 rpm Roller Screens Disc Pelletizer

    Parallel 9 Roller Screens

    Green Pellets Rejected Pellets Pellet Plant Project 19

    Green Pelletising building (inside view)

    Pellet Plant Project

    20

    Green Pelletising Disc (side view)

    Pellet Plant Project

    21

    1.Raw Material Preparation 2.Formation of Green Pellets 3.Induration of Green pellets

    Pellet Plant Project

    22

    Induration of Green Pellets


    Green pellets G ll t h have l low mechanical h i l strength t th hence h need df for h hardening d i for further processes Method for hardening pellets is Induration in which pellets are heated to 1300 1350C i 1300-1350C in controlled t ll d manner

    Pellet Plant Project

    23

    Travelling Grate (TG) Vs Grate Kiln (GK)


    SL No. 1 2 3 4 5 6 7 8 Items Heat hardening cycle Grate bars Pellet movement Burners Fans Number of Passes Pellet grades Largest Machine Travelling Grate (TG) Drying, preheating, induration and cooling are done on a single grate Grate bars subjected to high temperature; side & bed layers necessary Pellet remains stationary throughout the process Large number of burners along the length of induration furnace. Several fans operating in series with multiple fan controls. Multiplicity of passes Both BF & DR grades 768 m2 (CVRD) and 744 m2 (Samarco) with capacity of 6 MTPA each. Grate Kiln (GK) Drying and preheating on a grate, induration in rotary kiln and cooling in annular cooler No side or bed layers necessary Bed depth is nearly half Pellets tumble continuously in rotary kiln Single burner is used in for the kiln. Less number of fans with single fan control. Grate generally of two pass design Both BF & DR grades LKAB-3, GIIC-Bahrain & Tildon-2 with capacity of 4 MTPA each.

    Pellet Plant Project

    24

    Stage 3: Pellet Hardening at Tata Steel


    A I A. Induration d ti Process P

    Pellet Plant Project

    25

    Temperature Profile of Indurating Machine

    Pellet Plant Project

    26

    Indurating Furnace Structure (outside view)

    Pellet Plant Project

    27

    Stage 3: Pellet Hardening at Tata Steel


    B Pellet Handling & Despatch Circuit B.
    Induration Machine
    Emergency stock Pile 10 KT

    Screening Building
    Pellet fines storage Bin 100 ton

    Luffing Stacker

    Pellet P ll t stock t k pile il 70000 Tons Stacker Cum Reclaimer IOF stock pile 140000 Tons

    Intermediate storage Bin 2200 ton each

    Blast Furnaces
    Pellet Plant Project 28

    Major Pollution Control Equipments


    Sl. No. Description Process ESP 1 (HR 41) Pellet plant Process ESP 3 (HR61) Process ESP 2 (HR51) Dedusting ESP (HR01)

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

    Vendor ESP size (m3) N of No. f field fi ld Waste gas volume (Nm3/Hr) Dust load (mg/Nm3) Emission Level (mg/Nm3) Inlet Gas temperature (Degree C) Design Temperature Allowable (Degree C) Collecting electrode thickness (mm) Discharge electrode type Discharge electrode thickness, mm Rapper system ESP Hopper volume (m3) ESP Controller Chain Conveyer System

    FLS Airtech 24*24*24 6 1140000 1500 30 175 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 80 m3 PIACS Redler

    FLS Airtech 24*24*24 6 918000 1500 30 210 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 80 m3 PIACS Redler

    FLS Airtech 23*12*24 3 840000 1500 30 115 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 50 m3 PIACS Redler

    FLS Airtech 23*12*24 3 306000 15000 30 60 250 for 24 hours 1.25 Fabulax 2.7 Tumbling Hammer 50 m3 PIACS Redler

    Numbers Chambers in Each Bag filter

    BAG HOUSE D&G System Ball Mill Sysytem 2 2 6(5opr+1standby) 6(5opr 1standby) 12(10opr +2standby) 2standby)

    Dust inlet gm/Nm3 216 1020 Dust outlet mg/Nm3 10 10* Gas Volume , m3/hr, each stream 335000 734400 Maximum Continous Temperature, Deg C. 250 140 St ti Pressure, Static P mmWg W -91 91 -357 357 Pressure Drop over fabric filter,mmWg 150 250 Fabric Filter Wooven Glass Polyester *Collected dust from Ball mill Bag filter pnuematically conveyed to Ground Concentrated Bins

    Pellet Plant Project

    29

    Pelletising Plant Layout

    Pellet Plant Project

    30

    Evaluation of Pellets

    Tests for p physical y p properties p


    Crushing Strength: 250 kg/pellet Tumble & Abrasion Index
    Tumble Index (TI) >92% for the fraction +6.3 +6 3 mm Abrasion Index (AI) <5% for the fraction -0.5 mm

    Size Distribution
    +16 mm < 3 % +6 mm to -16 mm >90 % -6mm < 3 %

    Tests for metallurgical properties


    Reduction Degradation Index (RDI), <12 % for -3.15 mm fraction Reducibility Index (RI), >65 % Swelling Index (SI), <18 %
    Pellet Plant Project 31

    THANK YOU

    Pellet Plant Project

    32

    You might also like