INTERNATIONAL SEMINAR ON ’ START UP’ AND …mist2016.in/presentations/Session_1/Paper1 by...

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

Technical Session-1

Managing Indian Iron Ore Fines - Beneficiating for improved yield

© Metso Minerals, Inc.

Sunil Yadav

VP - Projects & System ( Mining )

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 Outdated Technology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

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

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

UNCLASSIFIED

Magnetic attraction

© Metso Minerals, Inc.

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

UNCLASSIFIED

Magnetic system

© Metso Minerals, Inc.

UNCLASSIFIED

Types of MatricesMetso-Expanded MetalFor Iron Ore etc

Competetion

© Metso Minerals, Inc.

Competetion Metso-Steel WoolFor Clay Minerals etc

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

UNCLASSIFIED

HGMS – Operating Principle

© Metso Minerals, Inc.

UNCLASSIFIED

HGMS – Operating principle

© Metso Minerals, Inc.

UNCLASSIFIED

HGMS – Operating Principle

© Metso Minerals, Inc.

HGMS and WHIMS - Working range

© Metso Minerals, Inc.

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

UNCLASSIFIED

HGMS – Competing Equipment

© Metso Minerals, Inc.

Jones Eriez

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

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

Fomento

Goa

ESSAR-KirandulBMM Ispat-Hospet

Some HGMS References in India

© Metso Minerals, Inc. 19

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

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

Cleaner Stage

Rougher Stage

© Metso Minerals, Inc. 22

Scavenger Stage

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)

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

Benefits of Metso Column Flotation

• Improved Recovery

• Optimized Grade

• Increased Throughput

© Metso Minerals, Inc.

• No Plugging

• On-line Replacement

• Reduced Wear & Maintenance

© Metso Minerals, Inc.

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

”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

Sedimentation

29

© Metso Minerals, Inc.

Date/Title/Aut

© Metso Minerals, Inc.

24 M Dia Tanks –LTC 4200 at NMDC Bailadila- 2 Nos

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

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

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

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

�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

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

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

© Metso Minerals, Inc.

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

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

DREDGE PUMPSDREDGE PUMPS

© Metso Minerals, Inc.

TAILING RECLAMATION BY DREDGE

© Metso Minerals, Inc.

TAILING RECLAMATION BY DREDGE

© Metso Minerals, Inc. Date Author Title43

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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