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Pelletisation 1.0

Overview

The Iron and Steel sector has been looking at alternative methods to utilise the low grade iron ore fines for steel making so that there is optimal utilisation of the available iron ore resources. The growth of the Global Steel Industry over the years, especially in China, despite the depletion of high-grade Iron Ore, has taken a speedy pace on the strength of technologies such as Iron Ore Beneficiation, Sintering and Palletisation. These technologies enhance the productivity of the blast furnaces in Steel making and hence, lower the cost of steel production.

The Indian steel industry which predominantly uses expensive coarse or lumpy ore is gradually moving towards the usage of sintered ore and pellets. MSPL Ltd forayed into pellet making, with a modest start of 1.2 million tonnes per annum pellet plant near Koppal. We cater to the requirements of sponge Iron manufacturers in South India, by providing customers with premium quality pellets that will yield higher metalized Sponge Iron with reduced production costs.

MSPL Limited has used proven new process flow and advanced Grate Kiln technology of pelletising plant with reasonable economic index to ensure stable and reliable process technology.

MSPL ltd has also commissioned a 1.4 MTPA Iron ore beneficiation plant to utilize the low-grade Iron Ore Fines and upgrade to Fe 63.5% to feed to the pellet plant suitably.

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Production


Production capacity:

The capacity of the pelletising plant is 1.2 MTPA (million tonnes per annum) finished pellets per year by using Grate–Kiln technology supplied by MECC Sino Steel China.

Plant Commissioned

Commissioned on 19th March 2011 and production started on 21st March 2011.

Products

A perceptible improvement in productivity of iron making through blast furnace route is seen. There is a uniformity of pellets which results in better permeability. There has been a wholesome percentage increase in sponge iron-making

Quality of Final Pallet
Sl. No Chemical Combination UOM Grade
1 Fe % 63.5 / 65
2 FeO % 0.5 max
3 SiO2 % 4.00
4 Al2O3 % 2.75
5 Sulphur % 0.01
6 CaO % 0.90
7 Phosphorus % 0.06
8 Basicity (CaO+MgO/SiO2+Al2O3) Ratio 0.15
Physical Properties
9 Bulk Density T/m3 2.1
10 Tumbler Index % 95.00 min
11 Abrasion Index % 3.00 max
12 Cold Crushing Strength ( Avg ) Kg/P 200 ~ 250
Size Analysis
13 8 – 16mm % 95 min
14 -5 mm % 3.00 max
15 +20 mm % 1.00 max
Metallurgical Properties
16 Porosity % 23 – 27
17 Reducibility % >65.00

Benefits of Pellets

  • Pellets are uniformly sized, with purity of + 63% contributing to faster reduction and high metallisation.
  • Pellets with their uniform mechanical strength and high abrasive strength increase production of sponge iron by 25% to 30% with same amount of fuel.
  • Product Standardisation: Uniform size range, generally within a range of 8-16 mm.
  • Quality of Pellets: + 63% mainly (Fe2O3).
  • Cost-effectiveness – There is no loss of handling iron ore, as pellets will not break during transport or handling. Reduces coal consumption in sponge iron making with lower fines generation. Maintenance cost is low as there is no need for crushing and screening of iron ore lumps.