Minitec Sintering Technology

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MINITEC Sintering technologyMINITEC Sintering technologyMINITEC Sintering technologyMINITEC Sintering technology

www.minitec.eng.br


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VALE MANGANS SA, Simes Filho, Brazil, has MINITEC sinter plant in operation since 2007.

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

Ore fines agglomeration in the form of sinter or pellets becomes more and more important, as quality of natural ores

deteriorates, demanding concentration. Furthermore, sintering improves the performance of the blast furnace and ameliorates the

smelting behavior of ore in the non ferrous smelting furnaces, lowering specific power consumption and increasing the yield.

The Mini Sinter Plant - SKPProcess was developed by MINITEC MINITECNOLOGIAS LTDA, aiming at low capital investment as well

as low operating and maintenance cost. Even very small plant sizes are economical e.g. 50,000 tpy.

The SKP process features the flexibility of all sintering processes, offering the possibility of agglomeration of all kinds of ores,

like iron, manganese, nickel, tin, chromite, among other ores and materials. Ultra fine raw materials (below 100 mesh) also can be

sintered, with a simple introduction of an intensive mixer in the process route.

Industrial residues such as mill scale, dusts collected in bag filters, sludge, dust from dust catcher of blast furnaces, slag etc can

be recycled in this process, blended with ores or separately, producing sinter of predefined characteristics.

This new sintering system is a semi-continuous process, consisting of a number of pans disposed side by side in a carousel type

arrangement, successively fed, ignited, processed and discharged. The entire process is controlled by a supervisory station makingthe operation fully automatic.


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RawRawRawRaw material handling systemmaterial handling systemmaterial handling systemmaterial handling system

RawRawRawRaw material binsmaterial binsmaterial binsmaterial bins

For the proportioning of the raw mix, MINITEC develops the

best solution for each case. The bins are designed according

to each material and its characteristics and properties toavoid bridging within the bins, to provide proper mass flow

and to reduce the segregation of coarse and fine particles

during charging and discharging.

Specially designed bins for storage and handling very fine

ores and other materials preventing bridging and

minimizing potential outflow problems.

Segregation in the bins during charging and discharging

occurs in different ways at different bin filling levels. A

higher number of bins allows for the simultaneous discharge

of a single ore type from at least two bins with differentfilling levels, which compensates for the varying segregation

of the coarse and fine ore particles during charging and

discharging.

The discharge of raw materials by dosing weigh feeders

from the bins is controlled by the real-time dosing system.

With this control system, the desired mixture composition

will conform to predetermined ratios throughout the entire

operation.

In some cases, mainly for lower production and cost,

batching feeding system can be adopted, where dosingweigh feeders are replaced by weighing bins and mixing

drum is of batching type.

CCCConveyor systemsonveyor systemsonveyor systemsonveyor systems

MINITEC specifies and works only with robust and powerful

equipment for belt conveyor systems to ensure a reliable

and efficient transfer and handling of different bulkmaterials (including iron ore, iron concentrate, limestone,

coke, sludge, dust etc) to or from the sintering process. All

material handling systems are designed to minimize and

optimize the overall handling operation.

The result: a significant decrease in investment costs,

improved overall logistic process, and homogenized material

quantities. The ability to blend different products gives plant

operators much more flexibility in securing their plants

future. And all solutions are available from a single source.

Main benefits:Main benefits:Main benefits:Main benefits: Excellent homogeneity of the raw mix Higher precision in the proportioning of raw materials Greater flexibility in changing raw material Recipes in the shortest possible time


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MiMiMiMixing andxing andxing andxing and micro pellmicro pellmicro pellmicro pelletizingetizingetizingetizing systemsystemsystemsystem

For mixing and micro pelletizing of sinter raw mix, MINITEC

develops the best process route according to materials to be

used, to meet required productivity and final product quality.

Excellent homogeneity and high permeability of the sinter

raw mix are decisive factors in achieving high sinterproductivity and quality with reduced consumption of energy.

With a conventional mixing drum, only a very limited

homogeneity of the sinter raw mix can be obtained and

materials grain size are restricted in a very specific range.

For these cases, MINITEC selected the intensive mixing and

micro pelletizing system, which consists of an intensive

mixer and micro pelletizing drum.

The sinter raw materials (like coarse as well as fine iron ores,

ultra-fine ores/pellet feed, additives, dusts, solid fuels,

return fines, recycled materials from the steel plant andothers) are continuously fed into a high-speed intensive

mixer where macro- and micro-mixing of the sinter raw mix

takes place. After the intensive mixer, the material is

transported to the micro pelletizing drum where the material

granulation takes place. The mixing devices can be

individually adjusted to changing requirements.

The required amount of process water will be added to mixer

in predetermined ratios by means of spray nozzles, in order

to adjust the optimum moisture/permeability of the feed mix.

According to the plant configuration required, mixing andmicro pelletizing drum can be of continuous or batching

type.

Main benefits:Main benefits:Main benefits:Main benefits:

Excellent homogeneity as a result of turbulent mixing andimproved preparation of the sinter raw mix

Capacity to mix higher ratios of iron ore ultra-fines (pelletfeed) and other ultra-fines materials

Improved sinter quality with reduced standard deviations(greater homogeneity)

Reduced coke consumption Pre-blending/blending yards are not needed Nodulizing phase at the micro pelletizing drum is

possible

Intensive mixer


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Sinter machineSinter machineSinter machineSinter machine

CarouselCarouselCarouselCarousel

The Mini Sinter Plant SKP process is marked by the side by side arrangement of pans on a rotating carousel. On this carousel,

which rotates intermittently, pans are fed and the raw mix is ignited, sintered and discharged into a single system intended for

crushing, cooling and screening product sinter and return fines.

In the first phase of the process the bedding is fed into the pan, covering uniformly the grate bars. In the second step, the raw mixis also fed uniformly over the bedding, assuring the correct layer thickness and proper leveling. The pan is then positioned under

the ignition chamber, where ignition of the raw mix takes place. During the subsequent step by step rotation of the machine the

sintering process is completed. Finally the pan is tilted and the sinter cake is fed into the crushing station, where it is crushed and

then conveyed to the sinter cooler to be cooled. The cooled sinter is conveyed to the screening station, in order to separate

product sinter, bedding and return fines.

Suction systemSuction systemSuction systemSuction system

The suction system consists of a set of ducts, individually connected to the bottom of each pan, and rotates with the carousel. At

the center there is a collector, connected to a fixed pipe by means of a rotating water seal. From this collector the exhaust gas

passes through the dedusting system, the ID fan and is discharged to the atmosphere. Each individual duct is outfitted with a

control valve, allowing presetting of any desired depression and flow profile. The supervisory station automatically controls all

steps in the Sinter Machine.


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FeedingFeedingFeedingFeeding sssstatiotatiotatiotationnnn

As pans are circular, their feeding is made by two rotating bins, one for bedding and

one for raw mix.

Bedding bin The hearth layer is discharged via a conical finned roller. The rotation of

roller and bin determine the height of hearth layer on the grid.

Raw mix bin The material is discharged by means of a conical finned roller. Raw mixflow is adjusted by rotation of roller and bin. The design is in accordance with the flow

characteristics of each raw mix in order to control segregation and allow a perfect

leveling of raw mix surface.

IgnitionIgnitionIgnitionIgnition chamberchamberchamberchamber

Ignition chamber operates with intensive top burners for better heat distribution on the

sinter surface: and, due to its special design, it also requires lower fuel consumption

compared to the conventional sinter strand design.

The intensive ignition chamber with state-of-the art top burners features an advanced

flame monitoring and gas control and regulation. This enables steady and constant

ignition with temperatures of approximately 1,200C or above.

The main features are:

Uniform ignition Highly flexible operation in response to fluctuations in material bed permeability Possibility of operation with a high rate of excess air High safety standards

Discharge stationDischarge stationDischarge stationDischarge station

The pan is tilted, once it reaches the discharge station, and discharges the sinter onto a

crash deck, specially designed and equipped with wear resistant material, from where it

slides into a spiked roll crusher whose arms crush it to a maximum size desired, usually

75 mm.

The Discharge Station consists of:

Crushing deck, specially designed and equipped with wear resistant material forlong service life

Spiked roll crusher fitted with crushing arms Crusher drive with AC motor, safety coupling and special gear box Hydraulic tilting system


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SinterSinterSinterSinter ccccoolerooleroolerooler and screening stationand screening stationand screening stationand screening station

Sinter coolerSinter coolerSinter coolerSinter cooler

The most common sinter cooling is done at circular coolers. For smaller units, for reasons of cost-effective, cooling of hot sinter is

accomplished either/on a metallic cooling conveyor or in a cooling bin, of special design, by blowing air through the bed of

crushed sinter, in counter-current to be cooled down.

The necessary cooling air is delivered by the blower system connected to the metallic bin.

An alternative for the Cooling Bin is an air cooled Metallic Conveyor, which cools down the crushed sinter while conveying same to

the screening station.

ScreeningScreeningScreeningScreening sssstationtationtationtation

After being cooled, the sinter is fed to the crushing and screening station. There the material is downsized to be used in three

different applications: return fines to the sinter process, hearth layer, and product sinter, either for blast furnace burden or for

charging to the submerged arc smelting furnace.

The small particles are recirculated to the sinter process, the mid-size particles are usually used as hearth layer to protect the

grate bars, and the larger-sized particles are transported to the smelting furnace.


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Dedusting systemDedusting systemDedusting systemDedusting system

MINITEC sinter plants are designed to meet the most stringent environmental regulations.

For effective dust collection, bag filters and/or electrostatic precipitators dedust the sinter waste gas. Processes for limiting SOX,

NOX and organic hydrocarbons/VOC emissions are available, as well as more elaborate flue treatment processes whenever

required, while incorporating noise attenuation equipment to meet local regulations.

For dust collecting from material handling system, sinter cooler and screening station, a bag filter or electrostatic precipitator is

installed in order to achieve high dust collection efficiency.


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Electrics and automation for sinter plantsElectrics and automation for sinter plantsElectrics and automation for sinter plantsElectrics and automation for sinter plants

Operation of the sintering plant is remotely controlled and monitored from

a central control room. This concept allows:

A continuous observation and assessment of the process and theoperational status of the main equipment.

A correction or adjustment, if necessary, of the actual conditions to setpoint or other required values.

Plant operation with a minimum of personnel. The automation system is based on micro-processor equipment (PLC).At the level of process/technological controls, the primary applications are:

Raw material bin filling Free configurable raw mix proportioning system Return fines ratio control Water addition and sinter mix moisture control for constant

permeability

Mix buffer bin level control Sinter mix charging control for constant and compression free material

charge Air and gas flow control for ignition burners Temperature and pressure stabilization for accurate ignition BTP and sinter machine speed control Cooler speed control Control of off-gas system


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Plant design and main figuresPlant design and main figuresPlant design and main figuresPlant design and main figures

The Mini Sinter Plants are designed for continuous product supply, but also aiming the flexibility to cape with fluctuating demands

on production requirements. It is even possible to operate the carousel type MSP for one or two shifts per day only.

The Mini Sinter Plants are available in the following sizes and capacities:

ModelModelModelModelSintering AreaSintering AreaSintering AreaSintering Area Rated productionRated productionRated productionRated production (1(1(1(1))))

m2 tpd tpy

SKP 50 7.3 150 50,000

SKP 100 13.5 300 100,000

SKP 150 16.6 450 150,000

SKP 200 22.8 600 200,000

SKP 250 29.1 750 250,000

SKP 300 35.3 900 300,000

SKP 350 41.5 1,060 350,000

(1) Based on iron ore sinter feed and only for reference. Production depends on raw material characteristics.

Production capacity shown above is based on sintering of iron ore. For other materials, and even for iron ore itself, the production

rate may change due to their specific characteristics.

Carousel dimensionsCarousel dimensionsCarousel dimensionsCarousel dimensions

7.3 to 41.5 m sintering area

CapacityCapacityCapacityCapacity

Product sinter: 50,000 to 350,000 tpy (1)

Availability: 330 to 345 days/year

Specific production rates up to 45 t/24 h/m

Typical cTypical cTypical cTypical consumption figures (per t of product sinter)onsumption figures (per t of product sinter)onsumption figures (per t of product sinter)onsumption figures (per t of product sinter)

Iron ore fines (- 8mm): 930 kg

Limestone (-3 mm): 100 kg

Coke breeze (-4 mm): 70 90 kg

Flue dust: > 30 kg

Return fines (-6 mm): 420 kg

Gaseous fuel: 40,000 50,000 kcal

Electric energy: 65 kWh

Process water: 0.1 0.5 m

OperOperOperOperaaaationaltionaltionaltional laborlaborlaborlabor (4(4(4(4----shift basis)shift basis)shift basis)shift basis)

16 men per day

Process parametersProcess parametersProcess parametersProcess parameters(2(2(2(2))))

Basicity (CaO/SiO2): 1.2 2.9

Bed height: 500 630 mm

Suction: 1300 1900 mmWC

Return fines rate: 18 25 %

Product qualitiesProduct qualitiesProduct qualitiesProduct qualities(2(2(2(2))))

Shatter index (+9,52): 7585 % (coke) and 6580 % (charcoal)

RDI (- 2,83 mm): 2830 % (coke) and 3032 % (charcoal)

FeO: 58 % (coke) and 711 % (charcoal)(2) All above data are indicative and may change case by case.

Pot tests determine the key ore mix parameters (specific sinter

output as a function of the applied suction and required sinter

quality) for use together with the flux and solid fuel. These

parameters form the basis of sinter plant design. Our pilot

plant tests sinter properties to meet international standards,

such as ISO, ASTM, JIS and DIN.

Implementation scheduleImplementation scheduleImplementation scheduleImplementation schedule

Due to the equipment simplicity of the SKP Sintering Process,

the total implementation time, including engineering and

designing phases, is 18 months.

Our service portfolio includes:Our service portfolio includes:Our service portfolio includes:Our service portfolio includes:

Raw-material and sinter pot tests Operational consultation and plant assessment (including

startup and shutdown support)

Cost-efficiency measures Economical and technical feasibility studies Research and analysis services Expert training on- and off-site Utilization of waste materials (residuals)


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Reference listReference listReference listReference list

Customer: MAMOR

Local: Pirapora do Bom Jesus, BrazilProduction: 80,000 tpy

Raw material: Cassiterite

Start up: 1999

Customer: USIMAR

Local: Marab, Brazil

Production: 250,000 tpyRaw material: Iron ore

Start up: 2006

Customer: VALE MANGANS

Local: Simes Filho, Brazil

Production: 165,000 tpy

Raw material: Manganese oreStart up: 2007

Customer: SBQ STEELS

Local: Nellore District, India


Raw material: Iron ore

Start up: 2010

Customer: SATKA

Local: Satka, Russia


Raw material: Manganese ore

Start up: 2014


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PartnerPartnerPartnerPartnerssss

Company: STG Group S.p.A.

Headquarter: ItalyActuation region: Ex-Soviet Union countries e Middle East

Site: www.stggroup.it

E-mail: [email protected]

Company: Ghalsasi Group

Headquarter: India

Actuation region: India

Site: www.ghalsasigroup.com


Company: Tenova Pyromet

Headquarter: South Africa

Actuation region: Sub-Saharan Africa

Site: www.tenovagroup.com



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Headquarters:Headquarters:Headquarters:Headquarters:

MINITEC MINITECNOLOGIAS LTDA

Rua Bananal, 405, 5 Andar, Santo Antnio

Divinpolis, Minas Gerais, Brasil

CEP: 35500-036Phone: +55 37 3085-7113


www.minitec.eng.br

MINITEC EQUIPAMENTOS SIDERRGICOS LTDA

Rua Minas Gerais, 1.901, Ipiranga

Divinpolis, Minas Gerais, Brasil

CEP: 35502-026

The information provided in this brochure contains merely general descriptions or characteristics of

performance which in actual case of use do not always apply as described or which may change as a

result of further development of the products. An obligation to provide the respective

characteristics shall only exist if expressly agreed in the terms of contract.

All rights reserved. Subject to change without prior notice.

SKP is trademark of MINITEC MINITECNOLOGIAS LTDA.

August, 2013

Minitec Sintering Technology

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