Micro Pellet Plant

Background

• Reprocess and recycling the entire solid waste generated in the process of

steel making is feasible solution in aiming a clean, green and zero waste

technology leading to sustainable development of the steel industry .

• Their disposal depletes the natural resources more than necessary an poses

challenges to environment quality.

 Generation Source and Strategy

• Waste generated from Blast furnace, BOF, Rolling Mills, Lime Calcinations, Coke oven Plants have

valuable minerals like Iron, Calcium oxide, Magnesium oxide & Carbon etc.

• Recycling of the valuable components from the waste reduces production cost and improves the

environmental condition.

• Direct usage was restricted in pile making to sustain sinter quality due to its physical and chemical

characteristics.

• To overcome the above problem, JSW strategically developed a Micro palletising technology in

collaboration with HARSCO to maximize waste recycling in sinter making.

Definition-Micro Pellet

▪Micro pellets are 0~6mm granules produced by using all metallurgical wastes like

BOF sludge, LD slag, ESP dust, Lime & Dolo dust & Bag filter dust generated during

steel making.

▪Micro pellets are used in sinter making through base mix @ 55Kg per ton of sinter.
Micro Pellet-Input Raw Material Source

Blast Furnace Sinter plants

SMS RMHS

COREX CDQ

Other Dust
 BF Slag- Generation and Consumption
Total Generated
13200 T/day

Dry Pit Granulation

700 T/day 12500 T/day

Dumped to
Sultanpur
JSW Other Cement Slag Unprocessed
Cement Plants Sand sand
 Dry Pit Slag

Air Cooled Dry Pit Slag

• Water is sprayed over the molted slag to cool it fast.

• Results in foaming and porous slag. Not suitable.

Existing Water Cooled Dry Pit Slag
Application : Can be crushed to make fine aggregate/sand
Blast Furnace
Remarks :
➢Cast house dust
✓ Major Fe(T) & Carbon
➢Bag filter dust
Total generation:685 tpd percentages are recovered
➢Flue dust
from the BF dust, which

Source
directly impact the Sinter
LOI
Fe(T) SiO2 Al2O3 CaO MgO C (Including
C)
making.
BF4 Bag filter
38.67 8.69 4.45 7.53 1.30 26.47 21.32
✓ Flue dust: Now a days flue
dust
dust are using at cement plants
BF1,2 Bag
filter dust
35.73 7.63 4.23 7.84 1.24 23.47 26.42
due to high Zink percentage.
BF3 Bag filter
dust 40.69 7.13 4.52 6.5 1.02 20.09 22.57
 Sinter Plants

➢ESP dust Remarks :

➢Bag filter dust
Total generation:350 tpd ✓ During process dust generation from
machine and internal conveyor route are
diverted to ESP and bag filters

LOI
✓ Major Fe(T) percentages are recovered
Source Fe(T) SiO2 Al2O3 CaO MgO C (Includi
ng C)
from the SP, which directly impact the
Sinter making.
SP’s ESP
36.13 5.05 3.79 9.8 1.77 2.0 26.42
dust
Steel Slag

BOF/LD

Air Cooled Granulated

Steel Slag (95%) Steel Slag (5%)

Metal Recovery Plant Applications

Established
Steel Slag- Generation Source and Quantity

Total Generation
8030 T/day

HMPT/HMDS LHF Slag BOF + EAF Slag

Slag

707 T/day 680 T/day 6643 T/day

(SMS-1 + SMS-2) (SMS-1 + SMS-2 + SMS-3) (SMS-1 + SMS-2 + SMS-3)

To be Processed separately in Refractory

To be Processed separately
and Cement making
and used in Sinter Plant
HARSCO has Interest in processing
 Dumped at Sultanpur Used at BOF + Micro pellet

6600 T/day

Metal Recovery Plant

+ 30 mm 10 - 30 mm - 10 mm -10 mm 10 - 30 mm
Handling Loss/ filling
Non - Metallic Non - Metallic Non - Metallic Metallic Metallic

10 % 6% 55 % 13 % 6% 10 %

680 T/day
1088 T/day 3740 T/day 1292 T/day

As Coarse Aggregate
Requires Steam Ageing In Cement &
as Fine Aggregate

Need further studies

 Steel Melting Shop

➢ HMPT Bag filter dust

➢ SMS-1 & 2 Bag filter dust Total generation:60 tpd
➢ LD slag

LOI (Including ✓Remarks :

Raw Material Fe(T) SiO2 Al2O3 CaO MgO C
C) ✓ During process LD Slag and SMS
SMS-1 & 2 Bag bag filter dust are generated
24.35 3.94 1.73 38.50 5.16 1.70 10.94
filter dust
✓ LD slag replaces the flux
HMPT Bag filter
10.61 1.7 0.99 58.07 0.55 1.85 20.63 consumption in sinter making which
dust
reduce the Overall Sinter Cost by
5rs/t
10.4
LD slag 25.78 8.46 45.20 3.63 1.19 -
7
RMHS

➢Bag Filter dust

Total generation:540 tpd
➢ Dedusting
✓Remarks :
✓ Bag filter dust generated

LOI during raw material handing

Source Fe(T) SiO2 Al2O3 CaO MgO C (Including
C) in RMHS
✓ Major Fe(T) percentages
Bag filter
36.13 5.05 3.79 9.8 1.77 12.32 26.42
dust
are recovered from the dust
 Corex

➢Corex Bag Filter dust

Total generation:540 tpd
➢Corex Sludge

LOI ✓Remarks :
Source Fe(T) SiO2 Al2O3 CaO MgO C (Including
C) ✓ Corex bag filter dust and sludge’s are
generated during process and thickeners
Corex Bag
45.77 7.48 5.2 12.34 2.00 4.12 5.46 respectively
Filter dust
✓ Major Fe(T) percentages are recovered
Corex Sludge 51.33 5.82 3.25 8.89 3.08 9.89 - from the sludge
Coke Dry Quenching Plant

➢ CDQ DUST Total generation:110 tpd

Remarks :
✓ Coke dust (CDQ dust) is
generated while quenching
of
Source ASH VM FC coke with nitrogen

✓ CDQ dust directly replaces

the
CDQ 15.36 1.09 83.55 solid fuel consumption for
sinter making
Other Sources

HSM#1&2 - 20 tpd
• WRM&BRM - 10 tpd
• DRI sludge - 260 tpd Total generation: 250tpd
• Lime sludge - 10 tpd
• CRM#1&2 - 25 tpd

LOI Remarks :
Source Fe(T) SiO2 Al2O3 CaO MgO C (Including
C)
Sludge’s form various units like
HSM, DRI, Lime sludge, and CRM,
Lime sludge 0.45 4.15 0.124 25.48 7.50 8.61 60.97 which contains Fe(T) and CaO,
which increases Fe(T) In sinter
product
DRI sludge 51.33 5.82 3.25 8.89 3.08 9.89 -
Dust Usage in Micro Pellet Plant

Dust Generation

S.No Dust Source Kg/t Generation Destination

1. ESP dust SP#1-4 9.0 350

2. Cyclone dust BF#1-4 21.0 685

3. Bag filter dust All units 11.50 540 Micro Pellet Plant

4. SMS dust SMS#3 2.10 60

5. CRM Oxide CRM#1-2 0.40 50

Sludge Usage in Micro Pellet Plant

Sludge Generation

S.No Sludge Source Kg/t Generation Destination

1. BOF SMS#1&2 21.0 600 MPP & 250t dumped into Cement pond

2 HSM HSM#1&2 1.0 20 MSB

3 LP Mills WRM & BRM 1.80 10 MPP

2t to MPP, & 23 TPD of CRM ETP sludge

4 CRM CRM#1&2 2.08 25 dumped to Sultanpur,

5 Corex Corex#1&2 72.0 325 50 –MPP, 235 – MSB, 40- PP1

6 BF BF#1-4 1.73 60 WWP
7 DRI DRI 70.0 260 210- MPP, 50 - MSB
8 Lime RO plants 2.50 10 MPP
Slag Usage in Micro Pellet Plant

Slag Generation

S.No Slag Source Kg/t Generation Destination

700t of Dry pit is diverted to Sultan

BF Slag BF1234 440 13200 pur, & Remaining used in cement
1. plant & Slag sand
Steel 300t of slag is used in MPP, &
2. making SMS123 286 8030 Remaining are used in Refractory &
slag Cement making
Micro Pellet

1. Facilitate disposal of 1600 TPD of

dust/sludge from Air/water pollution
control equipment's.

2. Enhance Sinter plant production by 0.5%.

3. Reduced return fines generation.

4. Reduced emission from Sinter plants.

5. Estimated saving : Rs. 15 Cr/Year.

6. BOOT basis (HARSCO)

High Intensity Mixer (HIM)

High Intensity Mixer:

• Continuous mixer: 140 TPH
• Volume: 7200 lit
• Operation : Continuous
• Rotor – 2 X 200 kW
• Rotating pan- 1 X 30 kW
• Wear resistant material (bottom, walls,
rotors)
 Micro Pellet Plant Layout (0.6 MTPA)

Primary
Mixer

Other plants:
•Kosice (Slovakia),
Capacity: 0.2 MTPA Slag Screen
Secondary
Mixer
•Arcelor Dunkerque -6mm

(Europe), Capacity:
0.4 MTPA
Sludge

Water
Tank
MICRO PELLETISING PLANT
Process description
Blending of Raw material

Raw material Wet (tpd) Blending Dry (tpd) Moisture, %

BOF Sludge 600 33% 450 25.0
Pond Sludge 150 8% 144 4.0
COREX Sludge 50 3% 48 4.0
CRM dust 5 0% 5 0.0
DRI Sludge 6 0% 6 0.0
RMHS Dust 223 12% 222 0.3
ESP Dust 62 3% 62 0.3
BF dust 200 11% 200 0.0
SMS (BFD) 25 1% 25 0.0
-8mm Slag 250 14% 240 4.0
LCP dust 85 5% 85 0.5
Bentanite 43 2% 43 0.5
CDQ fines 115 6.3% 107 7.0
Recycled MP 0 0% 0 10.0
1814 99% 1636 9.8
Micro Pellet –Physical and Chemical Properties

Chemical Composition of Micro Pellets

Fe(T) FeO SiO2 Al2O3 CaO MgO LOI (Including carbon) C P
Constituent

% 40.00 37.00 6.50 2.50 27.00 3.90 8.07 6.50 0.18

Size distribution of Micro Pellets

Mean Size +8mm +6.3mm +5mm +3.15mm +1mm -1mm

% 27.16 10.30 11.41 17.35 21.69 12.09

Major Advantages of Micro Pellet

Parameters Before After Advantage Remarks

Fines generation during

-100# thro’ Metallurgical Reduced by
28.51 27.34 transportation & oversize receipt
waste in Base mix 1.14%
(>6.3mm: 35%)

Sinter bed permeability improved

Waste Gas Fan Speed, Reduced by
895 860 collective by micro pellet, Nodulizer
RPM 35rpm
and steam addition

Potential to Sinter Productivity restricted due to

Projected Productivity,
37.81 38.03 increase by low Base mix stock and lesser Sinter
t/m2/d
0.22t/m2/d requirement
Mett Waste Utilization, Increased by 6 Replaced Flux and Iron Bearings
59.0 65.0
Kg/t Kg/t proportionately

Anticipated to
Inlet dust load – Inlet dust load improved after
ESP Performance Not analyzed be reduced by
18.0% commissioning of MPP & Nodulizer
1.14%
Advantages…….

Effective dust evacuation from Bag filters, efficiency improved.

Avoid dumping of 500 TPD of high Fe dust.

Usage of dust in place of using low grade iron fines.

Sinter productivity improved by 0.5 %.

Metallurgical waste consumption rate after micro pelletization has increased from 45 Kg
to 65kg per ton of sinter consistently.

Reduction in stack emission in SP2,3 and 4, 250mg/Nm³ to < 100mg/Nm³

Fluctuation in sinter chemistry is reduced after micro pelletization due to homogeneous

mixing of micro pellets in base mix pile preparation.

In sinter plants by using micro pellets instead of using individual metallurgical waste
material in base mix pile preparation, increase in productivity is anticipated.
Micro Pellet Consumption in Base Mix Preparation

START
Micro pellet production

Micro pellet Shifting

Micro pellet heaping & reclaiming

Micro pellet transfer through 14No.s of discharge chute

Stacked in base mix blending yard along with other raw materials

A ready base mix pile

Reclaiming and feeding to sinter plants END

 Production Declaration Procedure

Total Consumption of Raw material + Water consumption (after curing) = Production

BOF Sludge, t 679

Slag from NCPL, t 296
ESP dust (SP1,2,3 &4) , t 0
Bag filter dust, t 375
Lime dolo dust (LCP) , t 63
Bentonite, t 36
Burnt Lime, t 0
CDQ fines, t 79
**Water consumption, t 116
Total, t 1644
** Water consumption (after Curing) is equals to 90% of Total water consumption
Thank You