SEPTEMBER-2012/1

CHAIRMAN’S MESSAGE

Globally ninety percent iron is produced through BF route. India produces 65% of its iron through BF route and

35% through DRI route. India is the largest producer of DRI in the world with total installed capacity of 35 MTPA.

India’s DRI production has come down from 26.7 MTPA in 2010-11 to 21 MTPA in the year from 2011-12. Gas

based DRI capacity is 7.5 MTPA out of the total capacity and has been stagnating. Availability of quality raw materials

like iron ore, coal and natural gas has been the biggest bottle- neck. Innovative approach is required to counter the

ever increasing price of input materials and make the process more efficient.

We should continue to look upon the new avenues to reduce our cost of production and to maximize the use of

our installed production facilities. Keeping this in view, SIMA has taken a very pragmatic and bold step to organize

first time a true international technical conference with basic idea to bring all its stake holders together to discuss

and find out applicable innovative ideas. I am sure the forthcoming prestigious event – India International DRI

Summit 2012 will throw some light on the issues being confronted by the Indian DRI industry.

I express my thanks to the Organizing Committee members of India International DRI Summit 2012 for their support.

I congratulate Mr. Deependra Kashiva and his SIMA team for taking up the challenge to organize this event.

Alok Chandra

SEPTEMBER-2012/2

MESSAGE

I am glad to note that Sponge Iron Manufacturers Association is hosting first ever “IndiaInternational DRI Summit 2012” on 10

th September, 2012 in New Delhi. In spite of several

problems, Indian DRI Industry has been playing an important role in augmenting steel availabilityin the country. Indian steel industry is poised for rapid growth. DRI sector is undoubtedly goingto play an important role if it adopts an environment friendly technology.

I am sure conglomeration of International and Indian technical experts, technology & equipmentsuppliers, DRI producers, raw material suppliers etc. will provide an unique opportunities toensure sustainable growth of Indian DRI Industry.

I congratulate the organizers of this Summit for organizing this important event and wish thema grand success.

BENI PRASAD VERMAUNION MINISTER OF STEEL

SEPTEMBER-2012/3

MESSAGE

I am delighted to know that Sponge Iron Manufacturers Association (SIMA) is organizing “IndiaInternational DRI Summit 2012” on 10

th September 2012 at New Delhi. I understand that the

leading international technology and equipment suppliers for DRI/HBI process will also beparticipating in this Summit. I appreciate this initiative taken by SIMA to bring all the stakeholderson one platform.

Indian DRI Industry is passing through a crucial phase. While gas based DRI sector is highlyenergy efficient and eco-friendly, coal based DRI technologies have some inherent limitations.There are also reported incidences of environmental pollution being caused by coal basedplants, particularly the ones operating smaller modular capacities.

I am sure the deliberations in the Summit will lead to better utilization of our raw material resourcesand adoption of eco-friendly energy efficient technologies.

I wish SIMA a grand success in their endeavor.

DRS CHAUDHARYSECRETARY TO GOVERNMENT OF INDIA

MINISTRY OF STEEL

SEPTEMBER-2012/4

14th August. 2012

MESSAGE

I congratulate Sponge Iron Manufacturers Association for organizing first

ever international technical conference – “India International DRI Summit

2012” on 10

th

September 2012 in New Delhi. India has been the world leader

in the DRI production for last several years and has been playing an important

role in the steel production. Indian DRI industry is currently facing several

problems. Iron ore availability at affordable price is an issue agitating Indian

DRI industry. Government of India is promoting iron ore pelletisation and

substantial capacity is expected to be commissioned in next 2 years. I am

sure this will resolve to a great extent the iron ore problem of the DRI

producers.

Consistent innovation is the key for the sustainable growth of any sector.

Conglomeration of all stake holders like International and Indian technical

experts, technology & equipment suppliers, DRI producers, raw material

suppliers etc will provide an unique opportunity to explore innovative ideas

which will help Indian DRI Industry.

I wish organizers of this Summit all the success.

VISHWAPATI TRIVEDI

SEPTEMBER-2012/5

MESSAGE

Sponge lron Manufacturers Association (SIMA) is organizing lndia lnternational DRI Summit 2O12

on 10th September,2O12 in New Delhi. I believe this is dedicated lnternational Technical

Conference not only organized first time by SIMA but by lndia itself. I have been associated with

SIMA in its early stage and had the privilege to be its Chairman. lndian Sponge lron lndustry is an

important segment of lndian steel industry and play a very important role. Unfortunately, this

industry in lndia is passing through the crisis mainly due to non availability of main input of desired

quantity and quality. We need to focus to utilize the inferior grades of available raw materials in

lndia. This requires bold innovative actions.

I congratulate SIMA for the pro-active action taken by them to organize this world class Summit

and to bring all its stakeholders on one platform. I am sure the deliberations in this Summit will go

a long way for sustainable growth of lndian DRI lndustry.

I wish the organizers all the success.

Naveen Jindal

Chairman & Managing Director

SEPTEMBER-2012/6

SEPTEMBER-2012/7

SEPTEMBER-2012/8

SEPTEMBER-2012/9

SEPTEMBER-2012/10

SEPTEMBER-2012/11

SEPTEMBER-2012/12

SEPTEMBER-2012/13

SEPTEMBER-2012/14

SEPTEMBER-2012/15

SEPTEMBER-2012/16

With Best Compliments:With Best Compliments:With Best Compliments:With Best Compliments:With Best Compliments:

NOHAR CHAND & SONS STEELS PVTNOHAR CHAND & SONS STEELS PVTNOHAR CHAND & SONS STEELS PVTNOHAR CHAND & SONS STEELS PVTNOHAR CHAND & SONS STEELS PVT. L. L. L. L. LTD.TD.TD.TD.TD.

Y-164, Loha Mandi, Naraina, New Delhi- 110028

Tel No: 25897871 Fax: 45642994 Mobile No: 9811016521

Email: vasudev.goel@gmail.com

Trading in all type of sheets & Plates

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SEPTEMBER-2012/17

SEPTEMBER-2012/18

V R Sharma, Dy. MD & CEO(Steel Business)

Jindal Steel & Power Ltd

DRI PRODUCTION

IN

INDIA

l Direct Reduced Iron (DRI) is a reduced

Iron in Solid State reduction process

produced from iron ore which is

consequently used as a feedstock in EAF

and Induction Furnace for Steel Making.

Hot Briquetted Iron (HBI) is a

compacted form of DRI designed for

ease of handling, storage & shipping.

l In India the coal based kiln type DRI

plants became more popular because

of availability of coal and to meet out

the requirement of small steel plants. The

gas based DRI plants started coming up

with the availability of natural gas.

l As per the statistics available, in year

2011, 55 million ton DRI was produced

through gas based plants and 19 million

ton DRI through coal based rotary kilns.

What is DRI and HBI

Coal Based

DRI 24%

GAS Based

DRI

76%

SEPTEMBER-2012/19

DRI Production

l Methods of DRI production

l Coal based DRI (Rotary Kilns)

l Gas based DRI (Vertical Shafts)

l Natural Gas based DRI

l Synthesis gas Based DRI

l The natural gas based DRI plants are mainly based on Reforming of Natural Gas (NG), as

feedstock & two main predominant processes have come and now well established are

from Midrex, USA and HYL, Mexico.

l DRI plants based on Midrex Technology are equipped with conventional Reformer (with

Ni catalyst packed tubes) where both steam & CO2 reforming takes place with addition of

NG and produce reducing gases H2 & CO, which eventually convert iron oxide in the

form of lumps & pellets, to metallic iron in a shaft furnace.

l DRI plants based on HYL Technology have stand alone steam reformer in which NG is

reformed by steam generated by waste heat of reformer. Outlet spent gases from reactor

(furnace) is processed for CO2 removal by Amine/K2CO3 based Adsorption process or by

Pressure Swing Adsorption (PSA or VPSA) and is mixed back with Reformed Gas and

heated in process gas heater and fed to the reactor , which eventually converts iron oxide

in the form of lumps & pellets to metallic iron.

Gas based DRI Production

SEPTEMBER-2012/20

Typical Midrex Process

(natural gas based)

Typical HYL Process

(natural gas based)

SEPTEMBER-2012/21

Typical Midrex Process with Syngas

l First time in the world JSPL is putting up a 1.8 MTPY DRI

Plant based on Syn Gas produced from Indian High Ash

Thermal Coal.

l The Coal to Gas Plant of 2,25,000 Nm3/hr and DRI Plant

of 1.8 MTPY are under installation and expected to be

commissioned by December, 2012 at Angul, Odisha

Typical Midrex Process with Syngas

SEPTEMBER-2012/22

Chemical Value of COG for DRI Production

l Presently, worldwide the Coke oven gas is being used for reheating

purpose or steam production.

l First time in the world, JSPL recognizes the chemical value of

COG and has established a technical tie up with HYL to use COG

for DRI production. The engineering is completed and plant will be

commissioned by end of 2014.

l MIDREX is also offering a similar technology to produce DRI using

COG.

Coal Based DRI production in Raigarh

JSPL produces 1.3 MTPA DRI using rotary kilns based on coal.

The plant is rated as most efficient & environment friendly.

Parameters

l Coal consumption : 1.30 ton/ton of DRI

l Power Consumption : 78 kwh/ton of DRI

l Oxide Consumption : 1.49 ton /ton of DRI

l Specific Accretion Generation : 0.05 ton /ton of DRI

l Specific Char Generation : 0.218 ton / ton of DRI

We have experienced that Coal Based DRI production can be

environment friendly & efficient if proper selection and regular

maintenance of plant & equipment is done.

SEPTEMBER-2012/23

Raigarh Coal Based DRI

JINDALSHADEED (Shadeed Iron & Steel LLC) Sohar, OMAN:

l Midrex Technology :

l HBI production: 1.50 MTPY

SEPTEMBER-2012/24

l To reduce the dependence on lump ore , we are producing 4.0 MTPA

pellets at Barbil and putting another pellet plant of 4.5 MTPA capacity.

l Most of the production will be used for DRI making in house, balance

for the sale to other DRI manufacturers in the country.

l ADVANTAGES

l Sp.Iron Consumption is Reduced by 20-25 % as against of Iron Ore Lumps.

l Production of DRI increases by 10 -15% in rotary kilns .

l Specific Coal Consumption is reduced by 10-15%

l Specific Power Consumption is Reduced by 10% .

l Lumps & Fines Ratio is 90:10 as against 60:40 if Iron ore is used..

l Magnetic particles in char are reduced from 2.5% to 1%

l Accretion formation in DRI rotary kiln is reduced by 50%..

PELLET – A GOOD FEED FOR DRI PRODUCTION

RECOMMENDATIONS

l Future of Indian Steel Industry is pellet & DRI since it reduces

dependence on coking coal.

l We have found that using 50 % hot metal & 50 % DRI brings

better result in EAFs. We could achieve 40 heats /day /EAF.

l DRI can be produced using coke oven gas from coke oven plants.

l DRI can also be used as a chiller for BOF.

SEPTEMBER-2012/25

Technology & Market Conditions

l In the world of Direct Reduction, it has often beentrue that technologies existed but that marketconditions weren’t adequate until later.

• The ENERGIRON ZR (reformerless)process, perhaps the biggest breakthroughin the DR industry to date, was developed byHYL in the 1990’s, but was slow in taking offdue to market conditions.

• Tenova HYL successfully implemented theHYTEMP System and High-Carbon DRIproduction in 1998, yet years passed beforeadditional units were put into use, due todownturns in the industry.

• Developed DR modules from 200 kt/y toprovide metallics to small mills to 2,500 kt/yto enter into the size range of integrated steelmills

l The ENERGIRON ZR process opened the wayfor easily using natural gas or any other gassource such as syngas from coal gasification.

l In some markets, natural gas was too expensiveto use for Direct Reduction (North America), andin others the natural gas was simply not available(India).

• In the USA & Canada, all existing DR plantswere eventually shut down because theybecame too uneconomical to run.

• In India, most DRI production is coal-basedbut this means small capacity plants. Forlarge capacity DRI production, the alternativeseems to be via coal gasification.

MARKET SCENARIO FOR GAS-BASED DRI PLANTSAND ALTERNATIVE FUELS

Sponge Iron Manufacturers Assoc. - SIMAIndia International DRI Summit 2012Hotel Le Meridien, New Delhi, India

Sept. 10, 2012

ESI-UAE 2006

4M-Monterrey1998

SEPTEMBER-2012/26

Considerations for DR Plants

l Environmental considerations – Gas vs. Coal

l Need to upgrade or replace aging integratedfacilities

l If scrap prices are relatively high, and quality islimited

l Need for DRI as a clean source of virgin iron

l Larger ENERGIRON plant sizes

l Higher quality products:

l Hot DRI to EAF

l Metallization: 94-96% with high Fetot

l DRI Carbon ~ 4%

Current Scenario – Natural Gas

North America is now “king” in terms of natural gas:

l Shale gas phenomena

l “Fracking” is remaking the global energy scenario

l Prices at a 10-year low, and falling

l A big plus for industrial users and utilities:switching where possible from coal to natural gasfor power plants

l For areas where natural gas is not available, orprice is too high:

• Coal gasification is a viable option for DRIproduction if DRI plant capacity is sufficientlylarge to justify the capex of the gasificationplant

Current Scenario – Other fuels

l For integrated mills wanting to add DRI capacityto their ironmaking mix

• Coke Oven Gas can provide the necessaryreducing gases for ENERGIRON DRIproduction

Keying the Technology to the Market

l Tenova HYL and Danieli have joined know-howand technology for the design and constructionof gas based Direct Reduction Plants, offeredworldwide, under the ENERGIRON trademark.

l HYL and Danieli can offer any project approach– from any size DR plant to a complete integratedminimill facility; from technology packages to EPCturn-key projects.

l Our technology advances have made us theperfect choice for the new market conditions interms of virgin iron supply based on:

l PROCESS: Same, simple process scheme forall energy sources available, smaller in size yetlarger in capacity than any competing technology.

l PRODUCT QUALITY: Unique DRI quality: hot/cold with 94-96% Metallization and Carbon ~4%

SEPTEMBER-2012/27

l ENVIRONMENTAL IMPACT: The mostenvironmentally friendly: lowest NOx, andselective elimination of CO2 as integral systemto our technology, with lucrative by-productoptions (being currently commercialized invarious DRP’s), makes ENERGIRON thegreenest DR technology available.

l Higher DRI Energy content;

94%Mtz; high-C DRI (e” 3.5%C) For just 2.3Gcal/t DRI !!!!

l High DRI temperature

l Selective CO2 removal

ENERGIRON ZR DR Process:

SAME Scheme for ANY Application

l The basic process configuration is unchangedfor any energy source application and ischaracterized by its flexibility to process differentgas analysis .

l The “make up” gas can be of any mixture of H2,

CO, CO2 and hydrocarbons in any proportion..

l The selective removal of H2O and CO

2 optimizes

make-up requirements.

l The use of O2 depends on hydrocarbons content.

l DRI Metallization and Carbon are controlledindependently.

l EFFICIENCY: The ENERGIRON ZR scheme isthe most energy efficient in the market.

l The overall efficiency of the ZR scheme (83-87%vs. 75% of others) can be noticed when makinga benchmarking comparison:

SEPTEMBER-2012/28

ENERGIRON ZR DR Process: Efficiency

The overall energy efficiency of the ZR process isoptimized by the integration of high reductiontemperature (above 1050°C), “in-situ” reforminginside the shaft furnace, as well as by a lowerutilization of thermal equipment in the plant.Therefore, the product takes most of the energysupplied to the process, with minimum energy lossesto the environment.

just 60 to 80 kWh/ton DRI as electricity, with aremarkable low iron ore consumption of 1.36 to1.40 t/t DRI, mainly due to high operatingpressure. This makes the ENERGIRON plant,based on the ZR scheme, the most efficient directreduction method in the field.

It is important to note the efficient use of energy whileproducing a high-energy content DRI with 3.5% Cand 700°C.

ENERGIRON ZR: Overall Flexibility

ZR Overall EfficiencyHot DRI: 87%Cold DRI: 83%Others: < 75%

ENERGIRON DR Technology: Consumptionfigures

l For the production of high quality DRI, i.e. 94%metallization, 3.5% carbon and discharged at700°C, the thermal energy consumption is only2.30-2.4 Gcal/t DRI as natural gas or COG and

ENERGIRON DR Technology

High-Carbon DRI production

l Due to prevailing conditions of:

l Temperature

l Gas composition

the ENERGIRON-ZR Process favors the diffusionof Carbon in the Iron matrix and the precipitationof Iron Carbide (Fe

3C).

SEPTEMBER-2012/29

NEWSCarburization

3Fe° + CH4 ———> Fe

3C + 2H

2

l The DRI with a high content of Iron Carbideexhibits a much lower reactivity (no gasgenerated in any test conducted) than thestandard DRI.

l Additional energy required to produce 3.5-4%Carbon is marginal;

l In any case, by reducing Carbon in DRI, moreCO

2 will be taken out through flue gases/CO

2removal system

l Better option is to produce high-Carbon DRI andproviding additional chemical energy to EAF

High Carbon - hot DRI to EAF

l In general, as compared to scrap, melting DRI inEAF demands more power because of the DRIgangue content. However; the difference in powerconsumption almost become null whencomparing melting 100% scrap vs 100% high-Carbon, Hot DRI in the EAF.

l For both cases, the power consumption rangesfrom 360 - 400 kWh/tls.

l The combination of high-Carbon at hightemperature DRI yields power decrease of >160kWh/tls and productivity increase of up to 22%for a practice of 90% hot-10% cold DRI (ascompared to cold, low-C DRI).

ENERGIRON Plants

l Lowest Capex and Opex

l Smallest physical size due to pressurizedoperation

l Largest production capacities – also due topressurized operation

• 2.5 Million tpy and soon to be 3.0 Million tpy sizes.

• Nobody else can match this capacity.

DR Market Preference Change in Recent Years

Based on tpy contracted capacity

SEPTEMBER-2012/30

Sized to Compete With Integrated Iron Production

Two plants at 1.6 and seven plants from 1.9 to 2.5million tons each, using both Natural Gas andSyngas.

Gulf Sponge Iron, Abu Dhabi

l First HYL Micromodule

l 200,000 tpa

l ZR plant for high carbon DRI

l Started up 2010

l Ideal for US/Can small steel producers due tolow cost natural gas supply

Emirates Steel I and II, Abu Dhabi

l Twin plants

• 1.6 mtpa nominal capacity each

• Both use HYTEMP System to meltshop

• Module I started 2009

• Module II started 2010

• Project underway to increase capacity to 2.0 mtpaeach, for 4 mtpa total capacity

SEPTEMBER-2012/31

Ezz RMS and Suez Steel, Egypt

l Suez Steel-Egypt

• ENERGIRON ZR scheme

• 1.95 mtpa nominal capacity

l 94% Mtz; 3.5% Carbon

• HYTEMP System to meltshop

• Start-up scheduled end 2012

l Ezz Rolling Mill Steel-Egypt

• 1.90 mtpa nominal capacity

• Cold, high-Carbon DRI

l 93% Mtz; >3% Carbon

• Start-up scheduled: pending

Nucor Steel Louisiana, USA

• World’s largest single DR module underconstruction

• 2.5 million tpy capacity

• ENERGIRON ZR scheme

• 96% metallization

• e” 3.0% carbon

• Startup set for 2013

SEPTEMBER-2012/32

Jindal Steel & Power, India

• World’s largest single DR module with COG/Syngas (BOFG as fuel) under Engineering

• 2.5 million tpy capacity

• ENERGIRON ZR scheme

• 94% metallization

• e”2.5% carbon

• DRP can also operate with 100% NG ifconvenient

• Startup set for 2014

JSPL DR Project

Tenova HYL together with Danieli & C. signed acontract for the first of four ENERGIRON DR plantsfor Jindal Steel & Power of India. Main characteristics:

• DRP capacity: 2,5 million tpa of cold and hot DRIin any combination.

• Use of syngas from coal gasification and COGas source of reducing gases in any proportion,with energy consumption in the range of 2.2 Gcal/t DRI.

• DRI Metallization of 94% and carbon of 2-2.5%

• Use of BOF gas as fuel for the process gas heaterand other users.

ENERGIRON: Flexibility for the JSPL project

l COG and syngas, can be used from 0-100% inany proportion.

l Under typical operation, the DRP will use syngasfrom 0.6 – 1.2 Gcal/t DRI and COG from 1.0 –1.5 Gcal/t DRI in various operating modes andcombinations.

Total Process gas is ONLY 1.9 Gcal/t DRI as Syngas or COG

SEPTEMBER-2012/33

l Tail (purge) gas and BOF gas will be used asfuel in the Heater.

Final Remarks

l Shale gas has changed the world energyscenario, specifically for USA.

l Coal gasification presents a unique opportunityfor high-volume gas-based DRI production.

l ENERGIRON ZR plant sizes (2.5 Mmtpy) cancompete with BF for ironmaking capacities.

l ENERGIRON ZR Technology offers the mostflexible, efficient and environmentally friendlyoption for metallics production.

www.energiron.comwww.tenovagroup.com

Food for Thought

“Energy & Environment” will gain more prominence in the steel sector in

the very near future. The two critical issues– CO2 emission and specific energy

consumption are going to be the key parameters, influencing the future of the

steel sector, currently perceived to be energy inefficient and ecologically

hazardous. While the gas based DRI technologies in vogue, by and large, are

considered to be energy efficient and eco friendly vis-a-vis the conventional

integrated steel plants, the coal based smaller DRI modules pose serious

concerns on these two critical fronts. This is mainly due to the fact that the

direct reduction technologies, currently in practice, are very sensitive to the

quality of both iron ore as well as non coking coal. High grade iron ore and

non coking coal are very scarce materials in India now and are unlikely to be

available in the future also. Therefore, there is an imperative need to introduce

innovative, eco friendly and energy efficient technologies for the sustainable

growth of the DRI industry in India. Sooner the better!

Deependra Kashiva, Editor & Executive Director, SIMA

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SEPTEMBER-2012/34

SEPTEMBER-2012/35

ESSAR Group- A diversified multinationalconglomerate

Various iron making Routes at EStIL- Hazira

HISTORY OF HBI MAKING AT ESSAR“A BRIEF REVIEW OF TECHNOLOGICAL DEVELOPMENTS”

MIDREX 6 Modules 6.7 MTPA

COREX 2 Module 1.74 MTPA

SEPTEMBER-2012/36

BF-1.75 MTPA

History of HBI making at EStIL- Hazira

• 1981- NFW began early operations with twoMidrex 400 series plants producing DRI but dueto bad market scenario Module 1 operated forapproximately nine months and Module 2 forapproximately six months before the entireoperation was closed.

• 1982 to 1988- The plants were “mothballed”.

• 1988- In late 1988 Essar contracted with the courtreceivers in Emden Germany for the purchaseof the failed NFW direct reduction plants. Sitepreparation and civil work was taken up in earnestat Hazira with the first column for the Module 1furnace being erected in November 1988.

Erection and commissioning

• 1989- Hazira and Bombay became the focus ofthe project with civil works continuing and erectionof structures at Hazira. Hazira was the focus ofconstruction activities while procurement of newequipment was headquartered in the Bombayoffice. By the end of 1989 Module 1 was completemechanically and being commissioned inpreparation for starting the process.

Inception

• 1980-81- KORF Engineering of Germany led aconsortium to construct a Direct Reduced Iron(DRI) production facility, Nord Ferro Stahlwerke(NFW), at Emden, Germany.

SEPTEMBER-2012/37

• 1990- The first months of 1990 saw a flurry ofactivity as Module 1 was prepared for “start-up”.After months of around the clock activity Module1 achieved production status on March 28 1990.

SEPTEMBER-2012/38

• Module 2 was brought online in August 1990completing the major part of the project.

Expansion-I

• 1991- A process license was signed with thetechnology supplier, Midrex, for the Module 3project. Work began with the first furnace columnbeing erected in January 1991.

• 1992- Mod 3 was commissioned with productionbeginning in August of 1992 – only 19 monthsafter erection of the first column.

Innovations and improvements

• 1992- New hydrocarbon injection schemeinstalled in the furnaces to allow maximum Fe3Cproduction (In-house design)- Mod- 1,2,3.

• 1992- Reformer design modified duringconstruction to 336 tubes for a 16% increase inreformer capacity (In-house design) - Mod- 3.

• 1992- Liquid ring seal gas compressors replacedthe screw type compressors – (In-house design)Features both energy savings and lowermaintenance. - Mod- 3.

• 1992- Top gas duct redesigned to minimize oxidefines losses- (In-house design) - Mod- 3.

• 1996- Turbo expander, a second hand plant wascommissioned to take care of rich gas supply.

• 1997- For process monitoring, process softwarepackage, called FIXDMACS started for betterProcess evaluation with the help of historical data.

• 1997- Thin wall refractory liner installed in thefurnace increasing the furnace ID from 5.0 metersto 5.15 meters – Midrex design.- Mod-1

• 1999- Reformer expanded from 288 tubes to 336tubes providing 16% additional reforming capacity(In-house design)- Mod-1

• 1999- Oval Top Gas duct replaced standard off-take providing an additional 0.3 meters ofreduction zone height – Midrex design- Mod-1,2.

• 1999- Reformed Gas cooler was replaced bymodified temperature control system – Midrexconcept and (In-house design)- Mod-1,2,3.

• 1999- Oxygen injection equipment installed toallow operation at elevated reductiontemperatures to maximize production – Midrexconcept and (In-house design). Mod-1,2,3.

• 1999- Naphtha injection to the furnace cone trailswere carried out. The concept was a success andthe other modules have been similarly equipped.At this time naphtha can be utilized as a naturalgas substitute in all three modules.

• 1999- An additional set of heat recovery bundleswere designed in house and placed in serviceto. improve energy efficiency (In-house design).Mod-2

Breakthrough Concept of energy Saving

• 1999-2000- Module 3 – Hot DRI was taken fromthe furnace discharge upstream of the briquettersfor “hot charging” to an EAF. The trials were very

SEPTEMBER-2012/39

successful and the facility was built into the othertwo modules.

• Hot DRI (HDRI) development continues to be thetop priority project at Essar

• Energy saving at EAF (@ 100 to 120 KWH/tonof liquid steel).

• Zero %age moisture as against 1.5 to 2 % in HBI.

• Reduction in briquetting system maintenanceexpenses.

Expansion-II

• 2003 - Mod-4 erection started

• 2004- Mod-4 commissioned in July

• Capacity- 1MTPA

• Modified design of heat recovery system owingto better heat utilization.

• 2005 - Mod-5 erection started

• 2006- Mod-5 commissioned in October.

• Capacity- 1.6 MTPA

• Equipped with VPSA system to help in consumingCOREX gas

SEPTEMBER-2012/40

• 2008 - Mod-6 erection started

• 2010- Mod-6 commissioned in November.

• Capacity- 1.7 MTPA (CDRI)

• Equipped with VPSA system to help in consumingCOREX gas

• 2009 - VPSA erection started

• 2011- VPSA commissioned in November.

• Purpose — Designed for removal of CO2 andH2O from Top Gas Fuel.

• Capacity — 1,35,000 Nm3/Hr

• Power Consumption – 55 Kwh/t

Production across the Years

Major cost drivers across the years

Product quality across the years- Metallization

SEPTEMBER-2012/41

Product quality across the years- Carbon Highlights and way forward

• Crossed 50Mmt of production in FY 12-13.

• Startup of 19MW power generation facility byutilizing flue gas waste heat of MIDREX plant.

• Process tuned for safe use of BF grade pellets inour furnace.

• Fine tuning the operation of VPSA to optimizeit’s usage with the help of in-house talents anddeveloped concepts.

• Reduction in natural gas consumption per tonafter usage of COREX gas In reformer.

• Effective contribution towards ZERO waste policyof EStIL

With Best compliments:

Raj Kumar Jai Kumar Jain

Head Office: Z-156, Loha Mandi, Naraina, New Delhi- 110028

Tel No: 25897542,25897543 Tele Fax No: 011-47657542

Mobile No: 9811080533, 9810795895

Branch Office: Plot No. 151, Sector-24, Faridabad (Haryana)

Email: rkjkjain@gmail.com, lokant@gmail.com

Deals in DSQ Plates, M.S. Plates,Coil, G.P./G.C. Sheet, T.M.T & General Order Suppliers

* * *

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SEPTEMBER-2012/42

SEPTEMBER-2012/43

Introduction

Today most of the Direct Reduction Iron ( Gasbased) plants do not enjoy the privilege of getting the DR grade quality ( Total Fe as 67%) of Iron ore/pellets at all times. Most often, either such quality isnot available, or even if it is available, then there is apremium price to be paid to acquire this !! This is sobecause most of the mines around the world which used to provide such ore are now simply runningout of this ore and so the available low quality ore isbeing beneficiated , there by adding the cost ofbeneficiation. Moreover, the pellet manufacturers findit much profitable to produce pellets of BF grade(TFe less than 65%) with high yield for BF use insteel making.

Now the biggest challenge to DRI industry is that how to optimize the cost of DRI produced from suchhigh cost pellets to compete the Scrap cost, so thatSteel makers using Electric Furnace are able toprefer the DRI more and more. This can be madepossible through the use of a blend of Iron Oxides (Lumps and Pellets) with different quality andcommercial value in such a way that the quality andcost of DRI are at an optimum acceptable level tosteel maker.

We have done extensive work on this strategy in the2 Modules of DRIC plant at Dammam (Kingdom ofSaudi Arabia). DRIC plant is owned by ISPC ( IttefaqSteel Product Co.) which is the only Private sectorgroup as on date to have 2 Cold DRI Midrex modulesto produce 1.5 mtpy DRI. These Modules were

commissioned in 2007 after shifting and upgradingthem from Mobile, USA.

It has been observed by us that there are manysmall steel makers who are making steel thru smallElectric Arc Furnaces and Induction furnaces. As theDRI is not very safe to store in big volume and forlong time, so their need of DRI is normally in smallvolume of 5,000T -10,000 T and for a short time. Asa result they were least interested to purchase DRIin bulk of 25,000- 30,000 T.

We considered this as a marketing challenge forcommercial sale of Cold DRI and thereforedeveloped a method to transport DRI in small volumeas a containerized cargo of 25 Ton in each container.A process was developed to bag DRI in 2.5 Ton bagsin safe conditions, and bags were specially designedfor safe keeping of DRI in containers. This processof DRI transport not only provided a fast access ofsmall quantity of DRI to small consumers, but alsomade the transport most environmental friendly. SinceJanuary’12 we have marketed more than 90,000 Tof DRI thru containers as overseas cargo and alsothru trailers to inland customers.

The presentation contains a brief introduction inslides of ISPC subsidiaries in operation and in projectstage, along with some overview of DRIC plant. Mostof the slides show the performance of various Lumps and Pellets which have been tested by DRICin the running modules, to produce an optimum costDRI with desired chemical analysis to suit Electricarc furnaces . Some of the slides show the safe bagging and transport of DRI in container for export.

PRESENTATION ONDRI PRODUCED FROM

VARIOUS IRON OXIDE LUMPS AND PELLETSIN

MIDREX MODULES OF DIRECT REDUCTION IRON CO. (DRIC)DIRECT REDUCTION IRON COMPANY (DRIC)

A Subsidy ofIttefaq Steel Product Company (ISPC)

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ISPC NETWORK AT2

ND INDUSTRIAL CITY, DAMMAM

Product Silos

Direct Reduced Iron Company

Two MIDREX DRI modules built to produce 1.5million tons of low residual metallic iron for theproduction of high quality steel in NASCO & ARABSteel of ISPC.

Modules

DRIC PRODUCT – COLD DRI

DRI IN BAGS FOR SALE

COLD DRI

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DRI BAGS IN 20 FEET CONTAINER

DRI BAGS LOADED ON TRAILER

(1) KURUMBA ORE ( 30;70)

Chemical Analysis of Basket DRI

Conclusion – Very Good Reducibility :But more Fines generation

( Ore TFe – 67.7%)

(2) Yaman Ore (50;50)

Chemical Analysis of Basket DRI

Conclusion- No Reducibility observed.(Ore TFe – 68.2% )

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(3) Iran pellets ( 20:80)

(5) Nml PELLETS (50:50)

Chemical Analysis of Basket DRI

Conclusion- Poor reducibility: High Finesgeneration in DRI ; Low Carbon Potential ( Pellets

TFe – 66.16% )

(7) POLTAVA PELLETS (50:50)

Chemical Analysis of Basket DRI

Conclusion- Very Good Reducibility : Very GoodCarbon Potential

(Pellet TFe – 66.81% )

Chemical Analysis of Basket DRI

Conclusion- Good Reducibility : Good CarbonPotential :High Acid gangue(Pellet TFe – 65.51% )

(8) KUMBA LUMP (30;70)

KUMBA LUMP ( 30;70)

Conclusion;— Very Good reducibility; Low carbonpotential; High MFe

(Ore TFe – 66.61% ; GIIC Tfe – 66.3% )

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TSML, KARACHI.

TSML- Advantage to ISPC ?

l TSML HAS ;—l Special permission to export 100% of its

production as EPZ.l Full ownership rights to foreign investor.l Full Repatriation of capital and profits.l No minimum or maximum limit for investment.l Duty free imports of machinery, equipment and

material.l No sales tax on electricity and gas bills.l Freedom from national import restrictionsl Foreign Exchange Control Regulations of

Pakistan not applicablel Being EPZ unit, TSML is only required to pay tax

@ 1% at the time of export. No other taxes areapplicable on import or export of any part of theplant, production including utilities.

Contract Signing Ceremony 25 - 06 - 2006

DUST COLLECTION – ARAB STEEL

ATC FURNACES - ARAB STEEL

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Only the ‘FIT” organizations survive in this competitiveworld. Defining fitness of organization takes severaldimensions. In the business driven by marketdynamics, both for selling products and purchasingraw materials, the only tool available withmanufacturing unit to be “FIT” is to be efficient in allits internal processes. This would mean improvementin productivity, cutting cost, scrapping wastefulprocesses, focus on human resources, safety etc,among others.

Tata Sponge has adopted multipronged approach tobe internally efficient. It has embraced Total QualityManagement and works through improvement inProductivity, Quality, Cost, Delivery, improving Moraleof the workforce and managing Environment; TotalQuality Management through each of its element inPQCDME.

Another approach is to bring in improvements byadopting Total Productive Maintenance (TPM) andworking through its eight pillars of Continuousimprovement, Autonomous maintenance, Plannedmaintenance, Quality maintenance, Skilldevelopment (Training), Initial Flow Control , Safety,Health & Environment (SHE) and Office TPM.Whereas the approaches may appear to be differentin two philosophies, the activities and action convergeto improve the internal processes.

This paper illustrates some of the small and biginitiatives taken by Tata Sponge Iron Limited toenhance its internal processes and survive in thechallenging environment. The examples given hereare in the TQM format but largely implementedthrough various TPM pillars.

By implementing various improvements, the companyhas been able to increase its productivity as given inFig. 1 below.

INNOVATIONS AT TATA SPONGE IRON LTDSuresh Thawani and Partha Chattopadhyay

Many small improvements lead to ExcellenceExcellence is not a small thing.

JRD Tata

Fig 1. Increase in the productivity (Index)

1. Productivity: Productivity of each resourceinvested in the business counts in its success;be it man power, sweating the capital assets,getting more finished product out of each unit ofraw material purchased and so on. Some suchinnovative steps taken by Tata Sponge are:

1.1 Focus on reducing the generation of finesin multiple handling of iron ore by changingthe process of handling of iron ore uponreceipt.

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1.2 To ensure that the percentage of fine oreand coal going to kiln is restricted withindesired limits, the company experimentedand invested in changing the screens in theraw material handling circuit to get mostefficient screening.

1.3 To improve and sustain the rate of feedingof the raw materials in the Kilns, companyhas done a Modeling Study in collaborationwith Tata Consulting Services for definingkiln operating parameters with different rawmaterials. This model is under patenting.

1.4 The Indian coals available to the companyfrom Coal India Ltd have deteriorated inquality; especially the ash percentage. Tomaintain the productivity of the kilns, TataSponge has experimented with non cokingcoals from various sources abroad and hasstabilized the operations with a particularcoal from South Africa. This coal is used ina predetermined manner. Tata Sponge wasamong the first companies to buy expensiveimported coal and yet be cost competitive.

1.5 The company has embraced the process ofCritical Chain Project Management even formanaging kiln shutdowns. Thismethodology was popularized by Dr.Goldratt for in time completion of projectsand at Tata Sponge the same has beentailored to suit the kiln shut down jobs.

1.6 Tata Sponge focuses on ramp up of iron orefeed rate after the kiln shutdown by speciallydesigning the coal mix/heating cycle byliquid fuel to get ideal kiln production rampup as given in Fig. 2 below:

2. Quality: Although sponge iron is an intermediateproduct and loses its identity as soon as chargedfor melting in Electric Furnace, Tata Spongeemphasizes on quality of sponge iron, includingpacking, to enhance the customer experiencewith its product. Some of the in-process stepstaken, among others are as follows:

2.1 To reduce the variability in the productquality by suitably adjusting the process ofreduction of iron ore in the kilns, thecompany has introduced online continuousthermal scanning of kiln shell temperature.This indicates the state of process withinthe kiln and helps operators to adjust theparameters of operations.

2.2 Sponge iron picks up sulphur from coalduring the process of reduction. Sulphurbeyond a limit is difficult to remove from themelt in the Electric Furnaces withoutincurring excessive cost. Tata Sponge hascarried out optimization studies on meanparticle size of dolomite to have control onsulphur content in sponge iron.

2.3 Tata Sponge does not compromise onmetallization of iron ore and supplies onlyspecified quality of sponge iron to thecustomers. In the event of increase in themean particle sized (MPS) of iron ore, themetallization tends to fall. Tata Sponge hasimproved installed equipments in thefinished product handling system tosegregate higher size of sponge iron pieceswith lower metallization so as to deliver tocustomers sponge iron of consistent quality.

2.4 Despite best efforts in the kiln to producematerial of consistent metallization, theproduct has high standard deviation. Inorder to supply sponge iron to customerswith less variability, Tata Sponge hasintroduced blending in the finished producthandling system to even out the variationsin the quality parameters and supply spongeiron with controlled standard deviation inmetallic Fe content.Fig. 2 Days to reach full capacity

in different Kiln campaigns

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3. Cost: For Tata Sponge cost containment is ofprime importance for its survival. The companydoes not have its own captive sources of rawmaterials, both iron ore and coal, which thecompany buys at the market prices.

3.1 To reduce the consumption of lubricants invarious gear boxes, the company has doneoptimization studies. The number oflubricants used in the company has beenreduced. Further by testing of lubricants atpredetermined intervals, the lubricants areused to their maximum potential in terms oftheir properties.

3.2 The kilns are heated after shutdown byusing high speed diesel. Tata Sponge hasadopted innovative method to reduce theconsumption of high speed diesel aftershutdowns.

3.3 To cut labour costs, Tata Sponge hasredesigned its handling system afterbagging that number of workmen requiredto load the bags in trucks for transportationis reduced.

3.4 A significant percentage of trucks carryingfinished product for loading into the wagonswere sent for weight adjustment (reduce orincrease). This expensive rework wasavoided by taking several small butsignificant improvements to load correctweight of sponge iron in bags.

Fig.3 below gives the results.

4. Delivery: One of the factors that customersconsider in their buying decision is getting thematerial on time and that too without incurringany additional cost in delivery. Tata Sponge meetson time delivery commitment in 98% cases.

4.1 Tata Sponge delivers sponge iron in baggedcondition. The company controls the weightof the material in the bag in a very narrowrange so as to reduce any trouble in manualhandling of the bags. The customers cancharge material in their electric furnaces bycounting the bags instead of physicallyweighing the material. This also helps thecompany in reducing the cost intransportation by avoiding rework.s

4.2 One of the complaints of customers used tobe shortage of material in the wagons.Detailed analysis revealed that there wasactually no shortage on rake basis butshortage was caused by loading morematerial in one wagon and short in anotherwagon. By controlling the weight of materialper bag and innovative methods in stacking&handling sponge iron for loading into rakes,it became possible to totally eliminate theshortage. This also helped in eliminatingcustomer complaints.

5. Morale: It is said that Human Resource is thebest asset of any organization. Employees withhigh moral and engagement deliver unexpectedbenefits to the organization. To keep the moralehigh, besides adopting standard HRmanagement processes, Tata Sponge has takenfollowing steps:

5.1 e-associate programme: This signatureprogramme for associates (called workmenelsewhere) was to empower them bymaking them knowledgeable and improvingtheir skills. A set of chosen associates weremade mentors after due training, who in turnwrote all the processes and then went onto educate their colleagues in thoseprocesses; both in class room and impartingon the job training. This has raised not onlyskill level of the associates but has alsoraised their morale.

Fig.3. Percentage of trucks returned forweight adjustment

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5.2 A huge emphasis was given to clean up theplant and improve the working environmentunder programme Halla Bol. Tata Spongetakes pride in having cleaned up theenvironment to the extent it is possiblewithin the rotary kiln process using iron oreand coal. The company has proved that itis a myth to say that the sponge ironproduction process through the rotary kilnsis an environmentally unfriendly process.Several innovative measures have beentaken in the organization by employeesthemselves. This has improved workingcondition, cleaned up the environment andhas raised morale of the entire workforce.

6. Environment: At the cost of repetition, it is worthmentioning that Tata Sponge operates the rotarykilns in as environmentally friendly manner asprocess can support. Some of the othermeasures taken by the company are:

6.1 For past seven years the company hasbeen utilizing part of its fly ash to producefly ash bricks and market in the nearbyvicinity. The entire income from these bricks

is ploughed back as charity in the villagesnearby.

6.2 Despite there being no shortage of water,the company has invested in rain waterharvesting equipments and processes. Thishelps to actively raise the ground watertable.

6.3 To reduce the dust nuisance, the companyhas Electro Static Precipitators and de-dusting system covering entire plant.Further, the company has redesignedmaterial unloading spouts to cut down onfugitive dust emission.

6.4 Tata Sponge has greened up the entire plantand township. The company has plantednearly 160,000 trees and has convertedover 80,000 sq. ft of vacant space in theplant into gardens.

All these efforts have delivered expected results.Tata Sponge is well on its way to be the firstSponge Iron manufacturing plant to be conferredwith coveted TPM Excellence award.

Do not go where the path may lead, go instead where there is no path and leave a trail.

Ralph Waldo Emerson

There are three things extremely hard: steel, a diamond, and to know one’s self.

Benjamin Franklin

By three methods we may learn wisdom: First, by reflection, which is noblest; Second,by imitation, which is easiest; and third by experience, which is the bitterest.

Confucius

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Rakesh Steel Industries Pvt. Ltd.

Sobit Metal Pvt. Ltd.

Iron & Steel Merchants

Specialist in : G.P. COIL / SHEET & G.C. SHEET

Y – 248, Loha Mandi, Naraina, New Delhi – 110028

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P

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ABSTRACT

Mineral processing is characterized by a constantadaptation to changing raw materials and marketconditions. It is the link between the mined rawmaterial and a marketable product. As a lot of highgrade reserves are exploited, a steady deteriorationof raw material quality can be observed. At the sametime, the customers´ requirements for product purityand consistent quality increase.

Indian iron ores are characteristically friable in naturethat results in generation of sizeable quantity of fines(0-10mm) every year during various stages of miningand processing in the country with grade varying from50-60% Fe(T) and are high in silica/alumina (Al2O35-8%). The fines generated cannot be directly usedfor iron making (blast furnace/DRI units) in the countrydue its physical and chemical properties; thereforelarge portion of it gets exported or dumped.

Value addition to iron ore fines through variousactivities such as beneficiation & palletisation is theneed of the hour which will not only be economicallybeneficial to the mining sector in the long run butalso generate value addition & employmentopportunities. Incentives may be given for adoptinglatest technologies for direct use of fines in ironmaking by agglomeration of fines in the form of Pelletsand Sinters, as fines forms considerable part of ironore resources. Due to selective mining, although theiron content of the ore is high but the alumina(Al2O3)content in iron ore is also significantly high whichdemands for beneficiation as high alumina will create

problem during iron making like higher fuelconsumption, poor quality of slag produced, reducedproductivity of B.F.

allmineral has been engaged in hematite iron orebeneficiation with its gravity and magnetic separatorssince the mid-nineties. The delivery of jigs started forthe upgrading of iron ore for its utilization in a DirectReduction Plant in Australia. Since then, various otherinstallations with jigs for lumps and fines as well asupstream separators for fines are in operation inBrazil, Australia, India and South Africa. Low graderun of mine and/or dump ores are being processedwith alljig®-, allflux®- and gaustec®-WHIMS as thecore equipment.

The article describes the technology in use, thecharacteristics of various iron ores and the productqualities achieved.

The data presented shows the specific advantagesof jig application on iron ore upgrading due to thepossible high gravity cuts and the easy and low costoperation. The allflux®- technology provides the bigadvantage of high capacities and a two-step process,both in a single unit. The gaustec®-wet high intensitymagnetic separators offer high capacity incombination with unsurpassed process flexibility.

Keywords

Iron ore, Gravity separation, Jig, upstream classifier,wet high intensity magnetic separation (WHIMS),Pelletization, Sintering

ADVANCED IRON ORE BENEFICIATION TECHNIQUESFOR SINTER & PELLET FEED

Author – Dr. Ing Heribert Breuer,Managing Director, allmineral GmbH

Chairman, allmineral Asia Private Limited

Address : allmineral Asia Pvt LimitedEco Space Business Park,6th Floor, Block-B, Premises No. IIF/11, Action Area-II,New Town, Rajarhat, Kolkata-700 156.Telephone : +91 33 4017 4100 to 4109Fax : +91 33 4017 4110E Mail ID : breuer@allmineral.com

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1. Introduction

According to Ministry of Steel, Indian crude steelcapacity is projected to reach 140 million tons by year2017 and 200 MT by 2020. For production of 140million tons of crude steel the iron ore required wouldbe close to 250 million tons. Indian iron ore reserveis approximately 25 billion tons and our current ironore production is just above 200 million tons withexports of iron ore in the recent years nearing almost100 million tons per annum have raised seriousconcerns about future availability of iron oreresources to meet fast rising domestic steel demand.The mismatch between domestic production andconsumption of iron ore fines is mainly due to theinadequate sintering and pelletization capacity in thecountry lead to the heavy exports rather thandomestic usage until now.

Indian iron ore is good mix of all grades of iron orefrom low to high grade fines, lumps and slimes whichif properly processed or beneficiated could beefficiently used in steel making. The new export taxhike to 30% the future of exports of medium to highgrade iron ore fines is also quite uncertain and theywould be making their way into the domestic marketwith exports likely to be come down nearly to 60million tons in year 2012. With this projection theamount of iron ore remaining in the country after aproduction of nearly 200 million tons would be 140million tons in year 2012.

The overall picture suggests that for Indian steelindustry to conquer its dream production capacitiesin the coming years, a good utilization plan has to bedrawn for the available iron ore else by not usingcertain grades and only harnessing the good gradedore, our country’s reserves will deplete in less than40 years. The only way to utilize all types of iron orewithin the country and add value to our valuable non-renewable resource is by bringing in new mining,beneficiation & agglomeration technologies.

Sintering

Sintering is the agglomeration technique of finematerials (0.15-10mm) to produce clusters byincipient fusion at high temperature (2350 0F-26000F). Raw material required for sintering process are

Iron ore fines (-10+0.15mm), coke breeze (3-6mm),fine limestone/dolomite (-3mm) and sand. The qualityof iron ore concentrate used for sintering process isas mentioned below:

Grade- Fe: 63+%, Al2O3+SiO2: 6-8%, Size- 0.15-10mm

Pelletization

Pelletization process consists of forming green ballsout of a very finely ground mixture of Iron orefines(<325#), flux, coke breeze and a binderbentonite, then fired in an indurating furnace (800-1300 0C) to get hardened called pellets. The firedpellets are then segregated for size and the fractionbetween 9-16mm is sent to blast furnace & DRI forIron making. The quality of iron ore concentrate usedfor pelletization process is as mentioned below:

Grade- Fe: 64%, Al2O3+SiO2: 4-5%, Size- -45¼

2. Modern Beneficiation Process & Flow sheetDevelopment

Beneficiation process basically involvesComminution, classification, gravity separation &magnetic separation of lumps, fines and slimesseparately to produce concentrate suitable as lumpand fines for Sinter & pellet making. The quality ofiron ore is essentially defined as Fe contents, levelof SiO2 and Al2O3 contamination. Modernbeneficiation process allows effective and low costupgrading of lumps, fines and slimes. The processalso aims at maximizing Fe recovery by subjectingthe rejects/tailings generated from coarser sizeprocessing to fines size reduction and subsequentprocessing to recover iron values.

Based on a lot of test work on a wide variety of IronOres and the brought industrial experience a typicaliron ore beneficiation consists of the following processsteps:

l Low grade fines 0-10mm

l Scrubbing, to remove clay from particle surfacesand dissolve agglomerates, if required;

l Classification prior to beneficiation;

l Gravity separation of Lump ore by jigging;

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l Gravity separation of Sinter feed ore by jigging;

l Gravity separation and classification in fluidizedbed separators;

l Wet high intensity magnetic separation of fines(0.1 -1mm);

l Wet high intensity magnetic separation of ultra-fines (-0.1mm);

l Optional Crushing/Grinding of rejects from gravityseparation processes for further liberation andsubsequent beneficiation to have increasedrecovery of iron values ;

Fig 1: shows typical beneficiation flow diagram formaximum recovery of iron values. The beneficiationprocess involves jigging of +1mm fraction, and of 0-1mm fraction in fluidized bed separator. Grinding ofjig rejects is done to recycle it to 0-1mm stream forfurther beneficiation, the slimes and middling (aftergrinding) from the allflux(fluidized bed separator) aretreated in magnetic separation and the product fromallflux(R) and magnetic separation(Gaustec(R)) isused for pellet making.

Fig.1 Flow Diagram depicting Iron OreFines Beneficiation

For beneficiation of iron ore, with the objective pelletor sinter feed concentrate, all efforts should be madeto upgrade the sample in the coarsest possible size

and in stages. The straightway grinding the sampleto less 100 mesh (in case of pellet feed) and thenupgrading would be a comparatively costlier route,since grinding process involves major chunk of costin any beneficiation plant. Apart from this, the straightaway grinding to finer sizes and up gradation isalways prone to generation of high grade liberatedultra-fines which reports to tailings, i.e. results in yieldlosses.

3. Jigging technology | alljig®

Separation of minerals in jigging machines is basedon the fact that particles will stratify in pulsating water.The upward and downward currents fluidise andcompact the grains into relatively homogenous layers.Low density pieces stratify on the surface, whilespecifically heavy grains settle to the lower level ofthe bed.

alljig® jigging machines are air-pulsed, because thepulsation of the water can be generated practicallywear-free and so the stroke-motion (frequency,amplitude and shape) can be adjusted within a widerange, easily during operation.

After the stratification the discharge of heavy productis done by an automatic, PLC- controlled dischargesystem. The discharge is the second criteria essentialfor an excellent jig performance. In this regard aprecise detection of the stratified density horizons and

Fig. 2: alljig® for beneficiation of iron ore

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a continuous discharge of high grade product areneeded, with a product discharge rate depending onfeed characteristics, but guaranteeing a constantproduct quality independent of feed characteristics.

alljig® are in operation for the cleaning of differentraw and recycling materials. The only prerequisite isa difference in particle density.

More than 450 alljig® have been delivered so farworldwide. They are in use for various applicationsranging from iron ore to coal, sand and gravel, aswell as the recovery of metal from slag.

Because of the low operating costs compared toheavy media plants and the possibility of higherseparation densities (> 4.0 g/cm³) jigs are consideredas state of the art equipment for iron ore beneficiation.

Depending on the arrangement of the air chambers,side- and under bed-pulsed jigs are available.allmineral supplies both types. In terms of processefficiency, there is no difference between the twotypes of jigs since the same stratification is achievedwith the same water movement.

The following diagrams explain the technical basicsof iron ore upgrading in jigs. Fig. 3 and 4 show thedensity resp. Fe distribution vs. yield for feed, productand rejects. In this example the feed grade was 57% Fe, which could be upgraded to 65 % Fe at a yieldof 51,2 %. The rejects contain 48,6 % Fe.

From these distribution curves it can be seen thatabout 50 % of the feed has a SG of > 4,5 g/cm³ resp.a Fe- content of > 65 %. The product contains nomaterial with a SG of less than 4,5 g/cm³ resp. lessthan 62,5 % Fe. The rejects contain as little as less

than 10 % of such heavy material. Fig. 4 shows thecorresponding Tromp- curve which results in anImperfection of 0,054 resp. an Ecart probable of0,182. Cut point is at 4,40 g/cm³.

With such type of ore these high cut points arerequired to achieve the specified Fe % of > 64 with acorresponding reduction in SiO2 and Al2O3 tocombined values of about 4 % from 14 % in feed.

The jigs are widely used in iron ore beneficiation toreduce the amount of silica and alumina. While inSouth Africa, Australia and Brazil the silica content isin the focus, in India the challenge is more on thereduction of the alumina content. While the jiggingtechnology has been in use in Australia, Brazil andSouth Africa since the mid-1990, the Indian iron oreproducers have discovered the value of thistechnology about five years ago only. Neverthelessthere are more than 30 jigs in operation now.

Figs. 3 and 4 showing examples of the operation ofjigs in iron ore beneficiation.

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Fig. 6: Iron ore jig plant, Sishen, South Africa

Key Figures

4000 t/h plant 25-0.8 mm

Coarse Jig 8-25mm 320 t/h 8 alljig(R) G(UB) 4000*3000

Medium Jig 3-8mm 165 t/h 8 alljig(R) MUB) 3500*3000

Fines Jig 0.8-3mm 60 t/h 8 alljig(R) F(UB) 2200*3000

Performance

Feed- 52-60% Fe Product- 64% Fe Yield – 50-70%

Performance

Feed- 58-61% Fe Product- 64% Fe Yield – 60-80%

4. Fluidized bed technology | allflux®

The allflux®-process makes sophisticated use of thelaws of physics: the method is based on the fluidizedbed principle. The allflux® separator separateslightweight material made of fine-grained substances;e.g. sand, iron ore fines. The allflux® treats thematerial in a two-step process, eliminating the needfor pre-thickening. One single system combines highefficiency and high throughput.

The system is very simple: the allflux® generatesan upward current in the coarse fraction chamber.Light and fine particles rise while coarse, heavyparticles sink and are drawn off automatically fromthe bottom of the coarse chamber. In the fine fractionchamber, which is the second stage of the process,fine particles form an autogenously fluidized bed onwhich the light weight material to be separated floatsand spills over a weir. The fine product is dischargedautomatically from the bottom of the fines chamber.The flow and control equipment facilitates thegeneration of three highly selectively graded productsby one machine. Process control is automatic.

Technical Description- allflux®

The allflux® separator is a round, centre feedprocess vessel that is sized according to the hydraulicload. The process uses a unique combination of risingcurrent and fluidized bed techniques and can bedivided into three stages. The principle of an allflux®separator is schematically shown in Fig. 4.

The allflux® separators are used in iron orebeneficiation to classify and simultaneously reducethe amount of silica, alumina and slimes. Theclassified products are prepared for optimizedprocessing in the following upgrading process. Whilethe allflux® technology has been in use for morethan ten years in South Africa, the Australian andIndian iron ore producers have discovered the valueof this technology and are in the process

Fig. 7: Iron ore jig plant, Barbil, India (JSPL)

Key Figures

1500 t/h plant 30-0 mm

Coarse Jig 5-30mm 110 t/h 6 alljig(R) G 2200*3000

Fines Jig 1-5mm 125 t/h 3 alljig(R) F 2500*3000

Reject Fines Jig 1-5 mm 70 t/h 2 alljig(R) F 2500*3000

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Fig. 8: allflux®-Schematic

The following tables in Fig. 9 show typical results ofallflux® applications in iron ore beneficiation. Size-and Fe- distributions are shown for the feed and thethree products, coarse, middlings and overflow. Inthe coarse product the feed Fe of 60,4 % can beupgraded to 65,1 % at a yield of 37,9 %. The coarseproduct contains practically no fines < 0,125 mm. Thehighest grade of 67,8 % Fe is achieved in the sizefraction 0,125-0,25 mm. This corresponds to thetheory. The same applies to the Fe grades in themiddlings where the highest grade of 65,4 % Fe isfound in the size fraction 0,063-0,125 mm, while tocoarser sizes the Fe% decrease to values of as lowas 30 Fe% in the > 0,5 mm fraction. The overflowcontains more than 90 % of ultrafines < 0,063 mm.

Fig. 10 shows the corresponding Tromp curves forthe two cuts coarse/ middlings and middlings/overflow. The higher Ecart probable for the coarse/middlings cut results from the overlapping of size anddensity effect on the classification as mentionedabove already, i.e. coarse light particles end up inthe middlings product which reduces the efficiencyof classification. But that´s exactly what is requiredto get an upgrade of Fe in the coarse product. Onthe other hand the middlings/ overflow cut is verysharp with an Ep of 0,02 only, i.e. a very effectivedesliming takes place.

Fig. 9: Size-/ Fe- Distribution of allflux®feed and products

Fig. 10: Tromp curves of iron oreclassification in of allflux®

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Figs. 11 to 13 show examples of the operation ofallflux® -separators in iron ore beneficiation.

Key Figures

1360 t/h plant 0 – 1 mm

8 allflux®-750 8 x 170 t/h

Start up January 2011

Feed: 53 - 55 Fe %

Product: 60 - 61 Fe %

Yield: 50 - 60 %

Key Figures

540 t/h plant 0 – 2 mm

3 allflux®-1000 3 x 180 t/h

start-up March 2004

Feed 56 - 60 Fe %

Product 64 - 65 Fe %

Yield 30 - 40 %

Fig. 11: allflux® plant, Sishen, South Africa

Fig. 12: allflux® plant, Cloudbreak Mine,Western Australia

Key Figures

1200 t/h plant 0 – 1 mm

allflux®-1000 6 x 200 t/h

Exp. Start up 2012

More than 120 units are in operation worldwide outof which more than 50 are supplied to the iron oreindustry. Since the introduction of the allflux®technology to the concrete sand industry about twentyyears ago, many more applications have beendiscovered. Fine coal recovery from ponds, iron oreand mineral sand concentration and high quality glasssand sizing are just a few examples of this uniquetechnology.

Advantages of the allflux®

- high separating efficiency

- high capacity reaching 2000 m3/h

Fig. 13: allflux® plant, Solomon Mine,Western Australia

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FEED

- consistent high product quality

- automatic operation and control of dischargesystems and water feeds

- high solids content of discharged products

- low wear

- low energy consumption

- lesser area requirement compared to spirals

- lesser operating cost compared to spirals

- classification and concentration in a single unit

Another benefit results from the relativelyindependent processing of coarse and fine material.It allows either fraction to be processed or stockpiledseparately, or they may be blended to meet specialapplications. Even with variations in raw materialcomposition, the ability to offer a consistent productis greatly enhanced.

Perhaps the most important advantage of the allflux®-separator is an economic one. By combining highefficiency and high capacity with multiple processingstages, a reduction in specific production cost isrealized. Overall plant size is minimized and henceinvestment and operation costs are reduced. Theefficiency of the allflux® extends the boundaries forfeasible fine particle processing, it may allow somepreviously uneconomic reserves to be mined.

5. Wet High Intensity Magnetic Separation |gaustec®

The gaustec® wet high intensity magnetic separator(WHIMS) has been designed and improved by skilledengineers based on their practical experience of morethan 20 years. The gaustec® is a Wet High IntensityMagnetic Separator that offers a maximum offlexibility in magnetic separation.

The gaustec® separates ores and otherparamagnetic and feebly magnetic minerals with aparticle size up to 3mm.

The matrix is made of grooved plates. The gap of thegrooved plates is designed according to the processrequirements. The flow through the matrix is verticaland unhindered eliminating the risk of blockage by

Ferro magnetic particles. This allows for smallquantities of magnetite in the feed when treatinghematite ore. The high gradient magnetic field isindependently adjustable for each rotor through AC/DC converters, in the operational ranges. This allowsfor a rougher and cleaner/scavenger process step inone single machine. The rotor speed is adjustablefrom 3 to 7 rpm through a frequency inverter.

Several features introduced to the standardequipment led to the best possible operationalflexibility and easy maintenance.

A wide range of sizes starting from the smallest unitfor research and process design applications with arated feed capacity of 0.3 t/h, to the biggest equipmentof its kind ever constructed, the GX3600 with a ratedfeed capacity of up to 700 t/h.

The principle of a gaustec® GX separator isschematically shown in Fig.14.

Fig. 14 gaustec ®GX-Schematic

Major improvements in the gaustec® technologycompared to traditional Jones WHIMS led to:

• Higher flexibility

• Higher capacity in a single unit

NON-MAGMAG

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• Magnetic field is independently adjustable foreach rotor

• Rougher and Cleaner/Scavenger operation in asingle gaustec® WHIMS possible

• Increased matrix area at constant rotor diameters

• Width of magnetic poles is adjustable

• Reduced energy consumption

• Higher operation reliability

• Easier access for maintenance by increaseddistance between the rotors

The individual adjustment of the magnetic fieldstrength for both rotors of the gaustec® allows forprocessing of different particle size fractions withoptimized settings in a single machine.

The WHIMS are widely used in iron ore beneficiationworldwide to reduce the amount of silica and aluminain fines. The gaustec® WHIMS as a Braziliantechnology has been successfully gained marketleadership in Brazil and is now headed for worldwidemarket leadership with more than 80 units sold inthe last 7 years, thereof 20 in India so far.

Figs. 15 to 17 show examples of the operation ofgaustec® -separators in iron ore beneficiation.

Key Figures

800 t/h 0 – 1 mm

4 gaustec®-3600 4 x 200 t/h

Start up January 2011

Feed 58-59% Fe (T)

Product 64-65% Fe (T)

Tailings 48-50% Fe (T)

Fig. 15: gaustec® plant, JSPL, Barbil, India

Key Figures

700 t/h 0 – 1 mm

gaustec®- GX3600

Start up August 2010

Feed 54% Fe (T) | 23% SiO2

Product 64% Fe (T) | < 5% SiO2

Tailings 18% Fe (T) | 60% SiO2

Fig. 16: gaustec® plant, Itaminas, Brazil

Fig. 17: gaustec® GX plant, Usiminas, Brasil

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Key Figures

480 t/h 0 – 1 mm

gaustec®- GX3600

Start up November 2010

Feed 38% Fe (T)

Product 66% Fe (T)

Tailings 22% Fe (T)

6. Conclusion

The prime function of Beneficiation of Iron Ore is notonly to improve the Fe content but also to decreasethe alumina / silica ratio which affects economics infuel consumption & increase the productivity indownstream Steel Making process. The nature of Ironbearing Minerals & associated gangue mineralsdecides the method of beneficiation to be adoptedand needs extensive laboratory test to ensure thequality and recovery of the concentrate.

The increased demand for iron ore concentrates inthe last years as well as the mining of low gradedeposits leads to a growing demand for separationtechnology for lump ores, sinter feed and pellet feed.Because of the low operating costs compared toheavy media plants and the possibility of higherseparation densities (> 4,0 g/cm³) alljig® areconsidered as state of the art equipment for thebeneficiation of iron ore lumps & fines.

The allflux® two stage fluidized bed separators areused to recover a part of the fines concentrate whileclassifying and desliming the fines for the followingprocess step. The gaustec® wet high intensitymagnetic separators (WHIMS) are frequently usedfor a particle size < 1mm. The individual adjustmentof the magnetic field strength for both rotors of thegaustec® allows for processing of different particlesize fractions with optimized settings in a singlemachine.

With Best compliments:

STEEL INDIA CORPORATION

X- 57/D, Loha Mandi, Naraina, New Delhi- 110028

Tel No: 25708800 / 25896564 Fax No: 41418131

Mobile No: 9811062302

Email: pradeep@steelindia.net

Trading in all type of iron sheets / coils like CR / HR / GP / G.C

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Experts and colleagues, my dear friends:

Good morning!

As a director unit of DRI Professional Committee ofChina Association of Metal Scrap Utilization, HZK isone of the largest DRI tunnel kiln manufacturingenterprises in China. The company has Nationalsecond-level kiln construction qualification and safetyqualification, also has a number of DRI technologypatents and DRI utility model patents. HZK has strongtechnical strength, provide scientific research design,machinery manufacturing, installation,commissioning, technical advice integrated services.

HZK conduct extensive exchanges and cooperationwith Chinese universities and well-known experts,DRI tunnel kilns designed and manufactured by usis throughout China’s 28 provinces, cities, andautonomous regions. Quality of more than 100 DRItunnel kiln production lines which have been built byus is highly recognized. Having summed up thesetunnel kiln production line equipment technology Imake a brief introduction here for you.

I. DRI tunnel kiln equipment characteristics

1. Short process, simple process, easy operation.

2. It is of high efficiency, large output, energy savingand environment protection.

3. Suitable for use with low added value of coal andiron ore powder.

4. Less labor, a high degree of mechanization, lowlabor intensity.

5. Tunnel kiln belongs to an un-high altitude, un-high temperature and un-high pressure. Theproduction process is safe.

6. It is of low investment, more suitable for largeand medium-sized enterprises in constructionproject.

This process is suitable for mining iron powder; ingeneral requirements for iron ore grade is up toTFe65%~70%, as well as requirements for oxidationof iron grade is about TFe72%, it will be able toproduce direct reduction sponge iron.

A combination of the above materials, the factoryarea, investment scale and other factors, it will bedecided to invest in DRI tunnel kiln production line.

The length of the kiln made by above processdepends on the output size, kiln trolley size, reductiontime, raw material types, thermal system stability,easy operation and energy saving shall also beconsidered.

Domestic and foreign manufacturers could select DRIkiln devices suitable for their own development.

WORKING FOR THE PROMOTION OF NEW TECHNOLOGY OF DRI KILNChen Zhengdong

1

II. DRI Process parameters and cost analysis

Next I take 20,000T/Y & 30,000T/Y as example and list representation, it helps investors to enhance theunderstanding of DRI tunnel kiln production line then recognize it.

Table 1. DRI tunnel kiln section parameter

No. Name 20000 T tunnel kiln 30000 T tunnel kiln remarks

1 The length of the kiln 130M 150M

2 Inner width 2.6M 3.3M

3 Loading height 1.8M 1.8M

4 Fuel type: Producer gas or other gas

5 Combustion-supporting air preheated temperature is 350 !(can save the producer gas 600Nm3/h)

1The speaker is HZK General Manager & Senior Engineer.

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Table 2. DRI tunnel kiln main equipments

NO. Name Device configuration(includes)

1 Raw materials processing Iron ore powder dryer0reducing agent drier0Conveying equipmentand so on

2 Tunnel kiln equipment tunnel kiln steel structure parts0kiln trolley transportsystem0combustion system0fan system0trolley caresystem0transportation system of out of kiln and electrical controlsystem and so on

3 Loading system Loading and mold transporter0raw material conveying0 feedingsystem transmission line equipment and so on

4 Unloading system Unloading sand cleaning equipment0dust suction recoverysystem0the cover0cover position equipment and so on

5 Broken cold Multi roll reversible conveyor0cutting machine0storage pressingsystem bin0raw materials delivery machine0briquetting machine

6 Gas generating station 20,000T/Y & 30,000T/Y DRI tunnel kiln, each is equipped with a gasfurnace, diameter is respectively 2.6 meters and 3 meters

Table 3. Main cost structure of 1ton sponge iron (TFe65%Iron ore powder as an example)

NO. the main cost form item tons of consumption

1 ore fine 1.4T

2 producer gas 900Nm³

3 power consumption 60kw

4 anthracite coal (reducing agent) 0.53T

5 limestone (reducing agent) 0.12T

6 Si C tank 12kg (according to the cycle number allocation)

III. DRI material balance

1. For exampleÿiron ore powder in 65%, 67%, 70% three magnetite and sponge iron physicochemical indexafter roasting reduction:

No. Name TFe(Total iron) Impurity (Si0S0P and so on)

1 TFe65% 86.44% 10.2%

2 TFe67% 89.93% 7.46%

3 TFe70% 95.47% 3.32%

Iron ore powder TFe65% of 2% moisture content asan example:

1. With an annual output of 20,000 tons of DRI, itneeds 28,000 tons of iron ore powder and 13,000tons of reducing agent.

2. With an annual output of 30,000 tons of DRI, itneeds 42,000 tons of iron ore powder and 19,500tons of reducing agent.

3. After reduction, the reducing agent could be usedone or two times according to the carbon content.

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2. Physical properties

The raw material that tunnel kiln produce reducingsponge iron is used ore powder, using siliconcarbide tank canning, with good reducingatmosphere and high metallization rate, qualityof DRI is good and stable. After being broken DRIparticles or powder will be pressed block thendensity will be increased to more than 4.0t/m3, itcan be used for steelmaking.

3. Coal raw material and Calcium oxide index

As a reducing agent and fuel, it is request for thecoal such as the volatile, calorific value, ashmelting point. Higher index of coal is in favor ofenergy saving and consumption reducing, is goodfor reducing the equipment failure rate. Anthracitecomposition: ash is less than 20%, volatile matteris less than 15%, fixed carbon is greater than60%, and sulfur is less than 0.5%, ash meltingpoint is greater than 1250!. Limestonecomposition: calcium oxide is greater than 50%.

IV. DRI production process flowchart

The picture of rod shape sponge iron products

the picture of cold press sponge iron products

V. A group of drawings below are some detaildrawings of tunnel kiln process equipmentdesigned by HZK

Tunnel kiln production process plane layout

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The front of the tunnel kiln side (From right to left)

The rear of the tunnel kiln side (From right to left)

Tunnel kiln profile

Canning structure profile

VI. A group of pictures below are someproduction and construction pictures

Two 136.8 m tunnel kiln

Two 161.12m tunnel kiln

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Two 190m tunnel kiln

loading and unloading system

Broken cold pressing system

Construction site

VII. Brief description of new technology about DRItunnel kiln

1. Efficient energy-saving heat exchanger

On the top of preheating section of kiln flue heatexchanger is arranged and in the middle ofcooling section rapid cooling /heating exchangeris arranged, hot air which temperature is300!~350! degrees out from cooling /heatingexchanger can be used for combustion-supporting directly, it can save fuel 20%~25%, atthe same time it reduces both waste gastemperature and the temperature of coolingsection.

2. Rational layout of the combustion system

Gas burner with multi points by small flowarrangement in the roasting section are “goods”– type distribution which are in upper and lowerdislocationÿso, combustion gas injected into thekiln can also stir air, let reduction temperature ina kiln reaches unanimity, the maximumtemperature difference is no more than plus orminus 10 degrees.

3. Comprehensive utilization of circulating watersystem

In the rear of cooling section circulating watercooling system is arranged. For further reducethe temperature in the kiln, meanwhile the outputof the hot water can meet the various needs ofthe factories such as heating or bath hot waterand so on.

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4. Safe and stable trolley foot structure

Trolley foot ÿ made by radiation type big wheelwith high temperature resistant bearingÿcoupledwith kiln trolley frame body connected with abearing seat, run safely and steadily.

5. Automated material load& unload system

It has such characteristics as simple operation,low amount of repair, a high degree ofmechanization. It improves the labor intensity ofworkers and operating environment and increasethe economic benefit of enterprises.

6. Automatic control

The electrical appliance control equipment andswitch are centralized installed in the controlcabinet. In the both ends of the tunnel kiln,including the back trolley line, video surveillancesystem is equipped.

Economic development always accompanied bypeople’s new technology and new processinnovation. A mature innovation process shouldbe from simple to complex, from complexity tosimplicity ÿ the company’s innovative seriesfurnace has such characteristics. Welcomefriends to choose the coal based tunnel kilnequipment suitable for their own development. Itwill bring investors great economic benefit andsocial benefit to construct DRI tunnel kilnproduction line which is low investment and quickreturns.

Welcome you to visit HZK!

Thank you!

With Best compliments:

Madhusudan Chokhani

Managing Director

JCO Gas Pipe Limited

D-3/2, Okhla Industrial Area, Phase-II, New Delhi-110 020

Tel: 91-11-47105100, 26389150, 26384122 Fax: 91-11-41615273

Email: msc@chokhani.in contact@chokhani.in

Website: www.jcopipe.com

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JANKI CORP LIMITED, Steel Division.Works : Sidiginamola, Bellary – 583 138, Karnataka.

Correspondence : #17/95, Vishal Nagar, Anantapur Road, Bellary-583101, Karnataka. Web : www.jankicorp.com mail: info@jcl.co.in

With

Best

Compliments:

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LLOYDS GROUPLloyds Group started with the modest beginning withfabrication unit in the year 1974 and thereafterexpanded rapidly. The group companies are ; LloydsSteel Industries Limited and Lloyds Metal and EnergyLtd. The growth has been resulted with backward andforward integration within the group companies usingmodern technology so to bring in high levels ofefficiency. The group has diversified interest in Steeland Heavy engineering fabrication.

Lloyds Steel Industries Limited is situated at LloydsNagar, Bhugaon Link Road, Wardha, Maharashtraand has started its production activities in the year1994.

Products

l Hot Rolled Products

l Cold Rolled Products

l Galvanised Products

l Engineering Products

Lloyds Steel – Engineering Division is establishedin the year 1974 at Andheri, Mumbai and subsequentlyshifted its shop and converted into heavy fabrication,machine building unit at Murbad, Thane Dist.Maharashtra.

Products

l Process Plant Equipment & Systems

l Power Plant and Equipment

l WHR and FBC Boilers

l Steel Plant Equipment & Steel Projects

l Marine / Truck / Wagon Loading/ Unloading Arms

l Marine Projects For Indian Navy

l Turnkey Projects

Lloyds Metals & Energy Ltd. (formerly known asLloyds Metals and Engineers Limited) is a unit ofLloyds group is operating 2,70,000 TPA capacitySponge Iron Plant. LMEL has installed their plant atGhugus near Chandrapur (M.S.).

Corp. Office : Trade World, “C” Wing, 16th Floor, Kamala City, Senapati Bapat Marg,

Lower Parel, Mumbai-400 013. Tel. No. 3041 8111. Fax No. 3041 8260

Product

l Manufacturers of Direct Reduced Iron (DRI) whichis well known as Sponge Iron)