Suitable Pelletizing Technology to DRI - KOBELCO ... · PDF fileSuitable Pelletizing Technology to DRI ... ITmk3 EAF DRI Pellet ... Kobe Steel was licensed Grate-kiln process by Allis-Chalmers

Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document.

Kobe Steel, Ltd. (KSL)

August 1st, 2014

Suitable Pelletizing Technology to DRI

- KOBELCO Pelletizing System -

1

http://www.kobelco.co.jp/english/index.html

Kobe Steel, Ltd. retains copyrights and all other proprietary rights related to this document. 2

Contents

1. Corporate Profile of KSL and Iron Unit Division

2. KSL’s Service Capability

3. KOBELCO Pelletizing System

4. Consideration on Indian Conditions

5. Contribution to DR Operators

6. Collaboration between KSL and FLS

7. Project Reference












Name: Kobe Steel, Ltd.

Founded : September 1, 1905

Net Sales : USD 17.92 billion*

Capital： USD 2.48 billion*

Related Companies: 206 subsidiaries

64 equity-valued affiliates

Employees : 36,018* *Consolidated (KSL + subsidiaries , excluding affiliates)

*Ex-rate: JP¥ 94.05 / USD

Kobelco Construction

Machinery

Other Businesses

Kobelco Cranes

Corporate Profile

Engineering

& Machinery

13%

Iron & Steel,

Welding

49%

Others

7%

Aluminum & Copper

16%

Construction

Machinery

16%

KSL is composed of ;

4



IPP Unit

Power Generation IPP

(1,400MW)

Aluminum & Copper

Business Unit

Aluminum forgings for

automobile suspensions

Welding Business Unit

Various welding rods

Aluminum & Copper

Business Unit

Copper alloy sheet for

lead frame

Machinery Business Unit

- Various types of compressors

- Rolling Mills

Engineering Business Unit

Iron making processes

Iron & Steel Business Unit

High Strength Steel Sheet /

Wire rod products for

automobile

Kobelco Cranes

Crawler Crane

Products of Kobe Steel

Unique Products, Technology and Service



Processes owned by KSL

Molten Iron

Casted Pig Iron

DRI

Iron Nugget

Steaming Coal

Coal-Based DR

Plant FASTMET/ FASTMELT

ITmk3

EAF

DRI

Pellet Plant

Natural Gas

Shale Gas

Low-Grade

Iron Ore

BF Iron Ore

Scrap

Coking Coal

Beneficiation

Outline of Iron Making Processes

Gas-Based

DR Plant

Pellet

6



Business Foundation of Iron Unit Division

Knowledge & Experience Accumulated

in Engineering and Project Execution

Countries: 29

FTK/STK Plants: 51

FOB + SV: 25

Creation of

New Iron Making Technologies

Continuous R & D for New Iron Making Technologies

in cooperation with MIDREX Technologies Inc.

MIDREX® DR Process KOBELCO Pelletizing

System

FASTMET ® Process

Plant Supply: Since 1962 - Bangladesh Fertilizer Plant

Japan Standard Engineering Quality: Thoughtfulness and Seamless Engineering












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: FTK/STK Projects : FOB + SV Projects

Engineering Business - Overall Past Record

1. Fertilizer (Bangladesh) 17. Phenol Acetone (Korea) 33. Cement (Japan) 49. Polyethylene (Nigeria) 65. Cement (Italy)

2. Bar Mill (Bangladesh) 18. Polypropylene (Singapore) 34. Fertilizer (Indonesia) 50. Pelletizing (Venezuela) 66. FASTMET (Japan)

3. Pelletizing (Japan) 19. Cement (Japan) 35. Fertilizer (Malaysia) 51. Meltblown (Netherlands) 67. Iron Ore Beneficiation (Iran)

4. Pelletizing (Japan) 20. Bar & Wire Rod Rolling (Nigeria) 36. Coal Liquefaction (Australia) 52. Spunbond (Korea) 68. Direct Reduction (Qatar)

5. Integrated Mill (Bangladesh) 21. Cement (Japan) 37. LPG Recovery (Algeria) 53. Direct Reduction (Egypt) 69. Pelletizing (Iran)

6. Fertilizer (Zambia) 22. Vinyl Acetate (Taiwan) 38. Aluminum Mill (Bahrain) 54. Caustic Soda (Indonesia) 70. FASTMET (Japan)

7. Acrylic Fiber (Korea) 23. Cement (Indonesia) 39. Wire Annealing (Nigeria) 55. Direct Reduction (Venezuela) 71. Pelletizing (Bahrain)

8. Pelletizing (Japan) 24. Cement (Jordan) 40. Cement (Malaysia) 56. Iron Ore Beneficiation (Iran) 72. Direct Reduction (Oman)

9. Pelletizing (Japan) 25. Sulfuric Acid (Zambia) 41. Polypropylene (Thailand) 57. Cement (Vietnam) 73. FASTMET (Japan)

10. Pelletizing (Japan) 26. Bar & Section Mill (Libya) 42. Cement (Jordan) 58. Spunbond (USA) 74. FASTMET (Japan)

11. Pelletizing (Japan) 27. Sulfuric Acid (Iraq) 43. Direct Reduction (Iran) 59. Spunbond (Indonesia) 75. Iron Nugget (USA)

12. Polypropylene (Brazil) 28. Cement (Japan) 44. Direct Reduction (Egypt) 60. Pelletizing (Venezuela) 76. Direct Reduction (Bahrain)

13. Continuous Bar Mill (Qatar) 29. Cement (Japan) 45. Steel Casting (Australia) 61. Direct Reduction (Egypt)

14. Direct Reduction (Qatar) 30. Cement (Japan) 46. Refinery (Ecuador) 62. FASTMET (Japan)

15. Pelletizing (Chile) 31. Cement (Jordan) 47. Cement (Egypt) 63. FASTMET (Japan)

16. Oil Gathering (Kuwait) 32. Pelletizing (Bahrain) 48. Direct Reduction (Venezuela) 64. Direct Reduction (Korea)

9



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1. Acindar

2. ArcelorMittal Montreal 1

ArcelorMittal Montreal 2

3. ArcelorMittal Hamburg

4. ArcelorMittal Lazaro Cardenas

5. ArcelorMittal Pt. Lisas 1-3

6. ArcelorMittal South Africa

7. Antara Steel Mills

8. Arfa Steel

9. Comsigua

10.DRIC 1-2

11. ESISCO

12. Essar Steel 1-6

13. EZDK 1-3

14. Ferrominera Orinoco

15. Global Steel Holdings

16. Hadeed A - E

17. HOSCO 1-2

18. IGISCO

19. IMPADCO

20. JSW Ispat Steel

21. JSW Steel

22. Jindal Steel & Power

23. Khorasan Steel

24. Khouzestan Steel 1-5

25. LGOK 2, 3

26. Lion DRI

27. LISCO 1-3

28. Mobarakeh Steel A - F

29. Nu-Iron

30. OEMK 1-4

31. Qatar Steel Co. 1-2

32. Jindal Shadeed

33. SULB

34. Tenaris Siderca

35. Sidor 1

Sidor 2 A - C

36. Tuwairqi Steel Mills

37. Venprecar

38. voestalpine

Midrex - Midrex DR Plants all over the world Since 1969, Midrex has built more than 70 Shaft Furnace Modules in 21 countries worldwide.

Note: Projects written in blue were implemented by KSL (main contractor) with Midrex

38

10

Midrex DR Plants Overall Past Record



Comprehensive Project Development Capabilities

Project

Management

ISO9001

Training

Service

Spare Parts

Supply

Plant

Diagnosis Marketing,

Consultation &

Finance Arrangement

Plant Design

&

Engineering

Shipment

Haulage

Commissioning

&

Operation

Procurement

&

Inspection Service

Construction

&

Site Management

Technical

Assistance



KSL fulfills Customer’s requirement from multiple aspects;

Project Design & Development Stage

Project Study (Scoping / Conceptual / Preliminary Design)

(Conceptual Layout, Preliminary Financial Analysis, Sample Test etc.)

Feasibility Study & Finance Arrangement

Project Execution Stage

Plant Construction (Engineering, Procurement & Construction)

Project Management & Supervision

O & M, Training Services

Provision of Aftermarket Service: Technical Assistance, O&M, Training Service and

Spare Parts Supply for the smooth and timely operation of the plant.

12

Summary of KSL’s Service



Performance of KOBELCO Pelletizing System

Long and rich experiences in pelletizing

plant construction since 1966.

Delivery of the world largest grate kiln

pelletizing plant for Bahrain Steel (former

GIIC) No.2.

Capability to support operation &

maintenance aspects as a pelletization plant

operator.

Bahrain Steel No.2 (front side)

(Capacity: 6.0 MTPA)



Qatar Steel Company – HBI/DRI Combo plant

Jindal Shadeed DRI Plant - Oman

Pellet Plant – Vale Oman

RHF based technology

Fastmet - Japan

Pellet Plant – Bahrain Steel No2 (Former GIIC)

14

Recently Built Plants - Unique Technologies












KOBELCO Pelletizing System (KPS) - History

1965: Kobe Steel was licensed Grate-kiln process by Allis-Chalmers.

Since 1966 Kobe Steel has provided Grate-Kiln Process all over the

world.

Experience of Kobe Steel’s Own Plant

1966: 1st Pelletizing Plant (1mtpy) in Kobe Works, KSL Japan

1970: 2nd Pelletizing Plant (2mtpy) in Kakogawa Works, KSL Japan

1973: 3rd Pelletizing Plant (2mtpy) in Kakogawa Works, KSL Japan

1996: Kobe Steel acquired Grate-kiln Process, and

“KOBELCO Pelletizing System” was born.

Over 40 years experience of

Pelletizing Plant Supply and Operation.



F

FFF

F F

DRYING GRINDING

SLURRY

PRE-WETTING

BALLING

INDURATIONPRODUCTS

IRON ORE

LIMESTONE

BENTONITE

AIR HEATER

TRAVELLING GRATE

1100℃ 1100℃

1300 ℃

570℃ 400℃

400℃

AIRF

220℃

280℃

120℃

KILN BURNER

ANNULAR COOLER

ROTARY KILN

ELECTROSTATIC

PRECIPITATOR

Typical Flow of KOBELCO-Pelletizing Process

Pellet

17

Typical Process Flow



Typical Unit Consumption

Raw Material

Utility

Unit Consumption

Iron Ore 1,000-1,050 kg/t-pellet (depending on LOI)

(All spillages are recycled)

Limestone Depending on requirements

Bentonite 5 -8 kg/t-pellet

Anthracite

(or Coke Breeze)

5-10 kg/t-pellet (for hematite ore)

Fuel 190 Mcal/t-pellets (incl. Anthracite heat)

Power 23 kWh/t-pellets ( for induration area)

Water 0.07 m3/t-pellets

(In case of receiving wet concentrate)



Quality Items Criteria Method

for BF for DR

Size distribution (9-16mm) > 93% ISO2194

(- 5mm) < 0.5% ISO2194

Cold compression strength (Ave) > 300kg ISO4700

(-100kg) < 0.5% ISO4700

Tumble index (+ 6.3mm) > 97% ISO3271

Abrasion index (-0.5mm) < 3.5% ISO3271

Porosity > 24% JIS M8716

Swelling index < 16% --- ISO4698

Reducibility > 65% --- ISO7215

Metalization --- > 95% ISO11257

Fragmentation (+6.3mm) --- > 99% ISO11257

(-0.5mm) --- < 0.5% ISO11257

19

Note: Pellet quality is adjustable in accordance with the client’s requirement.

Typical Products Quality



1. Capacity Lineup

Small Range: 2.0 - 2.5 mtpa

Medium Range 3.0 mtpa

4.0 mtpa

5.0 mtpa

Large 6.0 mtpa (Largest KPS in operation in Bahrain)

2. Tailor-Made Design

In accordance with the customers’ requirements (capacity of the plant,

characteristics of raw materials, product quality, kind of fuel, etc.), KSL can

deliver tailor-made plant with the following standard equipment.

Traveling Grate Width: 4.716 m, 5.782 m

Rotary Kiln Shell i.d.: 5.8 m, 6 m, 6.6 m, 6.9 m, 7.2 m

Annular Cooler Nominal dia.: 17 m, 18.5 m, 20 m, 22 m

20

Capacity Lineup



Compact Layout

Typical Plant Layout (6mtpa KOBELCO Pelletizing System)

280m

190m

Balling Area Travelling Grate

Rotary Kiln Annular Cooler

21












Indian ore application

23

• Hematite

Less oxide heat than magnetite generates.

• High LOI (Crystal water content)

Crystal water needs to be dehydrated.

Porous pellet after dehydration

• High Al2O3 content

Higher melting temperature of high Al2O3

containing slag

Issues on Indian Iron Ore




• Hematite

Need more heat than magnetite

->> Addition of Anthracite or coke breeze

->> More heat recuperated from cooler

->> Additional heat source (Air Heater)

KSL has experiences of 100% hematite utilization.

• Bahrain Steel No.1 & No.2 (Bahrain),

• Vale Sohar (Oman)

• FMO (Venezuela)

Solutions for Indian Ore Application




• High LOI (Crystal water content)

Longer retention time in TPH is required for

de-hydration.

Need more heat to harden porous pellet after

de-hydration

->> Appropriate grate section design

->> Addition of Anthracite or coke breeze

->> More heat recuperated from cooler

->> Additional heat source (Air Heater)





• High Al2O3 content

Need higher temperature in induration

process

->> Kiln system can provide higher induration

temperature easily, because heat is

transferred by radiation of Kiln burner flame.




Flexibility in Fuel selection

1. COG, Heavy Oil or Natural gas is usable as the Kiln

burner fuel.

2. Coal (Bituminous coal, Anthracite Coal, and Charcoal)

and Coke Breeze are also usable as the Kiln burner fuel,

being different from Straight Grate Technology,

3. BFG and/or Mixed gas (COG & BFG) are usable;

As partial fuel of Kiln Burner, which reduces the main

fuel consumption according to the use of such lean fuel

gas.

As fuel of Air heater, which provides additional heat on

Travelling Grate.

27



Solutions for Indian Situation

4WB 8WB 4WB 9WB

25C 1055C 1320C505.1t/h

2WB 9WB 4WB 6WBSCREEN

4.716mW x 2.413mL/WB x 25 WB Traveling grate 6.6mD x 46mL Rotary kiln 20mD x 3.1mW Annular cooler

c

EP2 EP1

CN2 CN1

CN3

FN6

FN1FN2

FN3

FN4

FN5

CN4

FR1

BU2

FN7FN8

SK1

BU1

FN9SK2

c

Traveling grate Rotary kiln Annular cooler

Anthracite (CB) pre-mixture

Air heater

BFG utilization

NG, HFO, Coal, COG or

Mixed Gas utilization

Kiln burner












Quality Requirements

of DR Plant Operators

KPS can produce the most suitable pellets for DR operation.

Important elements of pellets for better

operation of DR plant

1. High Fe in pellets 2. Good CCS

3. Less fine generation

= Good CCS & Uniform Quality

4. Reducibility

Highly important

Source;

KSL’s independent research



Quality Requirements

of DR Plant Operators

High Fe in Pellets

1. High quality of pellet feed → Beneficiation

1. Less additives in pellet making

• Less limestone addition

• Binder less operation

KPS can produce the most suitable pellets for DR operation.



High Fe in Pellets

Oxide bonding

• Diffusion of core material

• Higher temperature required

Slag bonding

• Low melting temperature slag

Making bridge

• Lower temperature Fe2O3-SiO2-CaO slag

Less limestone addition case

Fe2O3

Better induration (such as Kiln) is preferable.

Limestone addition case



Reference:

Binder-less operation at Kakogawa pellet plant, KSL

Indirect feed

Direct feed

Ball mill

BOF Dust

Intensive mixer

Drum mixer

• Utilizing very fine BOF dust

• Part of ore is ground up to

higher Blaine

No binder is

mixed for

balling

Balling discs

High Fe in Pellets

thickener



Kobelco Pelletizing System

0

10

20

30

40

50

60

0 1 2 3 4 5 6 7 8

(%)

Comparison of Compression Strength Variation

Process Gas

Overheating

Proper Heating

Inadequate Heating

Pellet Layer

Hearth LayerD

バーナー火炎

輻射熱

ペレット

キルン回転方向

Radiation

Heat

Burner

Flame

Pellet

Kiln

Rotation

Straight-grate system

0

10

20

30

40

50

60

0 1 2 3 4 5 6 7 8

(%)

Weak pellets

(cause of dust)

Kiln Rotation

Burner Flame

Radiation Heat

Too strong pellets

(difficult for HBI)

Pellets produced by KPS have more uniform quality and high CCS

(= Less Fine Generation), which result in good DR plant operation.

34

Uniform quality & Good CCS pellet products

Uniform Quality

KOBELCO Pelletizing System Straight Grate System












Collaboration with FLS

• Rich experiences & know-how in the mineral

processing and cement plant

• Proven and Reliable in dealing with EPC projects

in India

• Global sourcing, supply chain team and dedicated

project management

High Capability of Project Execution in India

KSL and FLS made collaboration agreement

for sales and project execution of pellet plant

project in India.



● Collaboration with FLSmidth

Integrated Service to Customers from Beneficiation to DR production

● Pellet Plant & DR Plant Engineering & Supply

● Operation & Maintenance of Pellet & DR Plant

37

Note:

• Midrex is a KSL’s 100% subsidiary company.

• FLSmidth is a Licensee of KOBELCO

Pelletizing System.





Value to Customers - Smooth Project Execution in India

- Take Advantage of Local Procurement

- Keep High Quality

- Providing Integrated Service Around Pellet Plant

(Beneficiation – Pelletizing - Direct Reduction)












Reference List (1/4)

40

Location Name of

Customer

Plant

Capacity

（1,000tpy)

Raw Material Scope of

Work

Year of

Completion

(Completion

of Service)

Present

Status

Japan

Kobe Steel,

Ltd. Iron &

Steel Division

1,000 Mag.+ Hema. EPC 1966 Closed down

Japan Nippon Steel

Corporation 400 Mag.+ Hema. EP/SV 1967 Closed down

Japan Tetsugen

Corporation 165 Mag.+ Hema. EP/SV 1970 Closed down

Japan

Kobe Steel,

Ltd. Iron &

Steel Division

2,000 Mag.+ Hema. EPC 1970 Operation

(4,000ktpy)

Japan Nippon Steel

Corporation 2,500 Mag.+ Hema. EP/SV/TR 1973 Closed down

Japan

Kobe Steel,

Ltd. Iron &

Steel Division

2,000 Mag.+ Hema. EPC 1973 Closed down

Chile

Compañía de

Acero del

Pacífico S.A.

de Inversiones

3,500 Magnetite EP/SV/TR 1978 Operation

Bahrain Bahrain Steel

(former GIIC) 4,000 Hematite EPC/TR 1985 Operation

USA Inland Steel

Company - Magnetite OMA (1985) Closed down




41

Location Name of

Customer

Plant

Capacity

（1,000tpy)


Work

Year of

Completion

(Completion

of Service)

Present

Status

Australia BHP Steel

Whyalla - Hematite OMA (1986) Operation

Chile

Compañía

Minera del

Pacífico S.A.

- Magnetite WS (1988) Operation


(former GIIC) - Hematite OMA/TA (1988) Operation

Venezuela C.V.G.

Siderúrgica del

Orinoco, C.A - Hematite WS (1991) Operation

Iran Ahwaz Steel

Complex - Mag.+ Hema. WS/OMA/TR (1994) Operation

Venezuela

C.V.G.

Ferrominera

Orinoco, C.A.

3,300 Hematite EPC/TR 1994 Operation

Chile

Compañía

Minera del

Pacífico S.A.

- Magnetite WS (1995) Operation

Chile

Compañía

Minera del

Pacífico S.A.

- Magnetite OMA (1997) Operation




42

Location Name of

Customer

Plant

Capacity

（1,000tpy)


Work

Year of

Completion

(Completion

of Service)

Present

Status

Venezuela

C.V.G.

Ferrominera

Orinoco, C.A.

- Hematite MG/OMA (1998) Operation

Venezuela

C.V.G.

Ferrominera

Orinoco, C.A.

- Hematite TA (2002) Operation

Venezuela

C.V.G.

Ferrominera

Orinoco, C.A.

3,300 ⇒ 4,000

(Capa.

Increase)

Hematite Revamping

EPC 2007 Operation

Iran

Chador Malu

Mining &

Industrial Co.

(Ardakan)

3,400 Mag.+ Hema. EPCM 2008 Operation


(former GIIC) 6,000 Hematite EPC 2010 Operation

Malaysia

Vale

International

S.A

6,000 Hematite BE (2011) -

Oman

Vale

International

S.A

Vale Oman

Pelletizing

Company L.L.C.

9,000

(4,500×2) Hematite E/SV 2011 Operation




43

Location Name of

Customer

Plant

Capacity

（1,000tpy)


Work

Year of

Completion

(Completion

of Service)

Present

Status

Ukraine Ferrexpo AG - Magnetite WS 2011 Operation

Oman

Vale

International

S.A

Vale Oman

Pelletizing

Company L.L.C.

9,000 ⇒

11,000

(4,500×2 ⇒

5,500×2)

Hematite BE 2012 Under study

Oman

Vale

International

S.A

Vale Oman

Pelletizing

Company L.L.C.

6,000 Hematite BE 2012 -

BE: Basic Engineering

EPC: Engineering, Procurement and Construction

EPCM: Engineering, Procurement and Construction Management

OMA: Operation and Maintenance Assistance

WS: Works Survey and Basic Engineering

MG: Management Service

TR: Off-site Training Service

TA: Technical Assistance

SV: Supervisory Service



Kobe Steel, Kakogawa Works

• Year of Completion: 1970

• Capacity: 4.0 mtpa

• Iron ore: Mag. + Hema.

• Present status: In operation

44



FMO, Venezuela



(Upgraded by KSL from 3.3mtpa in 2007)

• Iron ore: Hematite


45



Ardakan, Iran



• Iron ore: Mag. + Hema.


46



GIIC No.1, Bahrain





47



GIIC No.2, Bahrain (1/2)





48



GIIC No.2, Bahrain (2/2)

No.2 Pellet plant

(6mtpa – Hematite) No.1 Pellet plant

(4 mtpa – Hematite)

49



Vale / Sohar, Oman


• Capacity: 4.5 mtpa x 2 lines



50



• KOBELCO Pelletizing system (KPS) is grate

– kiln system which has been supplied widely

all over the world for long years.

• Taylor made KPS design can adapt to Indian

ore to produce good quality pellet.

• KPS can produce suitable pellet for DR use.

• Collaboration between KSL and FLS realize

advantages for Indian customers.

Conclusion

51



Thank you very much for your kind attention!


Documents

Suitable Pelletizing Technology to DRI - KOBELCO ... · PDF fileSuitable Pelletizing Technology to DRI ... ITmk3 EAF DRI Pellet ... Kobe Steel was licensed Grate-kiln process by Allis-Chalmers