Fluidization technology

Innovative solutions for fine grained materials

n Calcination n Oxidation
n Roasting n Gas cleaning
n Reduction n Heat recovery
n Gasifi cation n Cooling
n Combustion n Drying
n Decarbonization n Spray granulation
002 More out of ore!

Alumina CFB calciner, Worsley Alumina, Australia.

50 years of technology evolution

For over 50 years Outotec has developed and commercialized fluidized bed

technology for a variety of industrial applications.

Lurgi constructed the first reactor for roasting of sulfur bearing materials
in 1950, based on the principles of fl uidized bed technology. The new
system was quickly adopted by industry; multiple hearth furnaces and
rotary kilns were increasingly replaced by fluidized bed roasters,
thereby ensuring enhanced product quality and signifi cantly reduced
plant emissions.
Fluidized bed combined with effi cient heat recovery and offgas
treatment, including the process of converting the offgas to sulfuric
acid, became state-of-the-art technology for processing sulfur bearing
ores. We have delivered more than 260 plants to date.
Signifi cant process improvements have been achieved by using
Early FB pyrite roasting plant, BASF, Germany.
fl uidization technology, for example in the production of alumina. The
circulating fl uidized bed (CFB) was developed over 40 years ago for the
high temperature treatment of fi ne and light particles. A whole variety
of other CFB applications followed, with more than 170 industrial plants
worldwide. The CFB has been successfully applied for coal combustion,
roasting of gold containing ores, direct reduction of iron ore fi nes
and other uses. In the early 1990s we introduced a new variation of
fl uidization technology, the annular fluidized bed (AFB).
With the aquisition of Lurgi Metallurgie in 2001, Lurgi's
fl uidization know-how was transferred to Outotec. The development
of fl uidized bed technology continues and we are working on new
processes utilizing solid mixtures, such as ore and coal, with different
properties for industrial application.
 More out of ore! 003

Fluidized bed types

Bubbling fl uidized bed (FB) Circulating fluidized bed (CFB) Transport or flash reactor (FR)

The classical bubbling fl uidized At higher gas velocities the slip With further increase of the gas
bed is operated at relatively low velocity increases and the fl uid- velocity, the solids are approaching
gas velocities with the particles ized bed changes its behavior. The the velocity of the gas. In the fl ash
kept in balance against their own defi ned boiling surface disappears (transport) reactor the slip velocity
gravity. Most of the particles do not with the expansion of the fl uidized between gas and solids is consi-
leave the surface of the fl uidized solids. The fl uidization gas has derably decreased compared to
bed, typically characterized by a enough energy to entrain solids the circulating fl uidized bed. At
defi ned surface between gas and particles. The entrained particles the same time the advantages
solids. The surface may show a are separated from the gas by a of homogeneous temperature
behavior similar to a boiling liquid, cyclone and recirculated via an ex- distribution and ideal heat and
depending on size and density of ternal loop back into the fl uidized mass transfer are decreased. This
the particles. From the mixing point bed reactor. In addition an internal type of reactor is used in selected
of view, the FB is a continuously recirculation of the solids in the fl u- applications where low gas and
stirred tank reactor with a defi ned idized bed reactor takes place. Both solid retention times are suffi cient.
solids residence time distribution. internal and external circulation re-
The mean solid velocity is close to sults in a homogenous temperature
zero with the slip velocity almost distribution in the CFB system.
identical to the gas velocity.
Velocity

"Slip
velocity" Increasing
solids density
Gas
Solids
Increasing expansion

Annular fluidized bed (AFB ®)

This new type of fl uidized bed improves the introduction and mixing of hot dust laden
process gases. These gases enter the reactor through a large central nozzle, with
additional fluidization gas introduced through an annular nozzle ring. As a result, a
very intense mixing zone is achieved within the reactor above the central nozzle,
comparable to the conditions achieved by an external loop of a CFB. Further
advantages are excellent process control and improved mass transfer conditions.
The AFB can be combined with any other fluidized bed type.
004 More out of ore!

Milestones in fluidized bed development

Bubbling fluidized bed
01 1950 First pyrite roaster, BASF, Germany, 40 tpd
02 1956 First zinc roaster, Nikon Kogyo, Japan, 40 tpd
03 1958 Sulfate decomposition roaster, Imperial Smelting, UK, 140 tpd
04 1962 First sulfating roaster for copper ores, Chambishi, Zambia, 118 tpd
05 1965 Hydrogen based reduction plant for NiO, Inco, Canada, 150 tpd
06 1965 First single-stage dearsenifying pyrite roaster, Boliden, Sweden, 350 tpd
07 1968 First double-stage dearsenifying pyrite roaster, Bayer, Germany, 450 tpd
08 1969 First slurry feed to pyrite roaster, Gold Fields, South Africa, 2 x 125 tpd
09 1971 First partial roaster for copper ore, Noranda, Canada, 900 tpd
10 1973 First 123 m 2 zinc roaster, Pasminco, Australia, 800 tpd
11 1994 Largest coarse pyrite roaster, Wengfu, China, 2 x 1,200 tpd
12 1996 Circored direct reduction plant, CAL, Trinidad, 1,500 tpd
13 1999 Largest zinc roaster, Asturiana de Zinc SA, Spain, 1,000 tpd
14 2004 Largest pyrite concentrate roaster, Tongling, China, 1,130 tpd
15 2005 Ni chloride pyrohydrolysis roaster, Goro Nickel, New Caledonia, 3 x 380 tpd

Circulating fluidized bed

16 1959 First laboratory CFB plant at Metallgesellschaft, Germany, 0.5 tpd
17 1961 First pilot plant for alumina calcination, VAW Lünen, Germany, 24 tpd
18 1968 First industrial alumina calciner, VAW Lünen, Germany, 500 tpd
19 1973 First laboratory tests for iron ore reduction using CFB technology, R&D Center, Germany
20 1979 Signifi cant capacity increase of alumina calciners, Interalumina, Venezuela, 3 x 1,400 tpd
21 1982 First coal combustion plant, VAW Lünen, Germany, 84 MW
22 1987 First gold ore roasting plant, KCGM, Australia, 575 tpd
23 1990 First alumina calciner with hydrate bypass, Worsley Alumina, Australia, 1,850 tpd
24 1991 Circodust demonstration plant, Thyssen, Germany, 120 tpd
25 1992 Largest roaster for gold ore, Newmont, USA, 2 x 3,800 tpd
26 1993 Largest CFB (11.5 x 14.7 m) based power plant, Soprolif, France, 650 MW
27 1996 Circored direct reduction plant, CAL, Trinidad, 1,500 tpd
28 2001 Oxidizing ilmenite roaster, Iscor, South Africa, 1,000 tpd
29 2002 Ore preheater, HIsmelt Corporation, Australia, 4,000 tpd
30 2003 Signifi cant capacity increase of alumina calciners, Alunorte, Brazil, 2 x 3,300 tpd
31 2005 Reducing ilmenite roaster, Kenmare Resources plc, Mozambique, 1,200 tpd
32 2005 First preassembled module supply of alumina calciners, Alcan Gove, Australia, 2 x 3,500 tpd

Flash reactor
33 1985 Flash reactor for high temperature alumina production, VAW Schwandorf, Germany, 250 tpd
34 1993 Flash reactor for ilmenite preheating, Namakwa Sands, South Africa, 625 tpd
35 1996 Circored direct reduction plant, CAL, Trinidad, 1,500 tpd

Annular fluidized bed

36 1992 Waste heat boiler pilot plant, 1 tpd
37 1996 Circored direct reduction plant, CAL, Trinidad, 1,500 tpd
38 2002 Ore preheater, HIsmelt Corporation, Australia, 4,000 tpd
39 2005 Reducing ilmenite roaster, Kenmare Resources plc, Mozambique, 1,200 tpd

Development in the Lurgi and Outotec companies, indicating the year of order.
 More out of ore! 005

Numbers refer to the development stages of the list of milestones.

References

Bubbling fluidized bed Flash reactors

n Zinc roasters 74 n Ilmenite preheating 2
n Pyrite, copper, gold, nickel n Circored, Trinidad 1
concentrate roasters 190 Total 3
Total 264
Annular fluidized bed
Circulating fluidized bed n Boiler pilot plant 1
n Alumina calcining plants 51 n Circored, Trinidad 1
n Power plants* 82 n Circoheat, Kwinana 1
n Gold ore roasting plants 5 n Ilmenite roaster, Mozambique 1
n Sulphur adsorption 16 Total 4
n Calcining of clay/lime 3
n Fluorine adsorption 10
n Coal based reduction (Elred) 1
n Gas based reduction (Circored) 1
n Ore preheating (Circoheat) 1
n Circodust (demonstration plant) 1
n AlF 3 synthesis (demonstration) 1

Total 172 * No longer part of Outotec's offering

006 More out of ore!

Fundamentals
Fluidization systems are ideal for the treatment of fine grained materials. For processing ultra
fine materials, Outotec has developed and patented a microgranulation process. The treatment

of oversized material has to be evaluated depending on its behavior during processing.

Flexibility in feed Fluidized bed phase diagram

particle size
The so-called Reh* diagram illustrates the different phase behavior
of gas-solids interactions. The yellow region represents the fixed
bed operating domain. The blue region indicates the domain of
the bubbling fluidized bed where gravity and drag forces on the
particles are in balance. The grey section represents the pneumatic
transport domain. The orange triangular region represents the
area of the circulating fluidized bed. As the diagram is calculated
for ideal spherical homogeneous particles it provides an indication
only. However, coupled with experience from industrial plants the
CFB operating range can be extended to area a of the diagram. This
knowledge gained from operational experience is applied to the design
of new plants and processes.
f [v G², d P]
Particle Froude Number

Important design criteria

n Particle size and density

n Decrepitation behaviour
n Retention time
n Process temperature
n Process energy
requirement Particle Reynolds Number Re P
n Production rate
n Demand on product quality
* Diagram developed by Prof. Dr.-Ing. Lothar Reh
 More out of ore! 007

Application in exothermic and endothermic processes

Chemical reactions occurring between the solid particles and the fl uidi-
zation gas can either be endothermic or exothermic. Endothermic pro-
cesses require energy input, provided either directly by the combustion
of fuels or indirectly by the introduction of hot gases and/or preheated
solids. All types of fl uidized bed systems can be used for both endother-
mic and exothermic processes. A typical example of an exothermic pro-
cess is the roasting of sulfi de ores. An example of an endothermic pro-
cess is the calcination of alumina. Whether the process is endothermic
or exothermic, tight control of temperature in a fl uidized bed reactor is
more easily achievable. Fluidized bed based plants may include heat re-
covery systems, which allow for the effective utilization of heat from off-
gas and solids streams to decrease operating costs and emissions.

Use of 3D design tools

Outotec uses modern 3D design systems as planning and design tools

also for fl uidized bed based plants.

The main advantages of such systems are:

n High planning reliability
n Improved drawing quality
n Reduced modifi cation work on site
n Shorter job execution time
n Reduction in overall cost

AFB of ilmenite roaster,

Kenmare Resources plc, Mozambique.
008 More out of ore!

R&D and scale up competence

Outotec's pursuit of new fluidized bed applications for customer needs is supported by experimental work in the
company's in-house R&D Center. For example development of neural networks, in-situ monitoring systems and

modern mathematical methods, including computational fl uid dynamics modeling, are key elements of research.

Outotec has developed theoretical

models of fl uidized bed systems and Outotec's largest CFB based test facility is the Circofer demonstration
specialist scale up know-how over plant at the R&D Center in Frankfurt. This plant is equipped with a
many decades. A unique set of pilot 700 mm diameter CFB, recycle cyclone, integrated heat generator,
plants, suitable for processing of char separator, magnetic separator, gas cleaning system, and all
feeds in the range of 100 g batches necessary ancillary equipment.
up to 1,000 kg/h continuously, is
available to develop and improve
existing technologies for customer
applications. These pilot plants are
designed to be fl exible with respect
to temperature, pressure, gas and
fl uidization conditions and can be
confi gured either as single or
multistage units. However, the data
gained in laboratory scale fl uidized
bed systems are not suffi cient to
provide design and performance
criteria of industrial plants without
the experience of operating
facilities.

700 mm Circofer demonstration plant, R&D Center, Germany.

Scale up experience
With Outotec's experience in many state-of-the-art fluidized bed technologies the customers do not need a
large scale demonstration plant as an expensive interim step. Examples of the scale up figures:

Process, year From pilot plant size To industrial plant size Scale up factor
Alumina calcination, 1970 D=1,000 mm/24 tpd D=3,600 mm/500 tpd 1:20
Coal combustion, 1982 D=360 mm/20 kg/h D=5,000 mm/500 tpd 1:1,000
Gold ore roasting, 1990 D=200 mm/22 kg/h D=3,800 mm/2,000 tpd 1:4,000
Circored, 1999 D=200 mm/18 kg/h D=5,000 mm/1,500 tpd 1:3,500
 More out of ore! 009

Applications
Outotec's portfolio related to fl uidized bed technology can be classifi ed as follows.

Diagram for fluidized bed applications.

Reducing conditions Oxidizing conditions

n Dearsenifying pyrite roasting n Alumina calcining

n Circored (gas based fi ne ore n Roasting of pyrite, copper and zinc
reduction) concentrates
n Circofer (coal based fi ne ore n Roasting of gold ore
reduction) n Oxidizing ilmenite roasting
n Circodust (processing of n Heat recovery by fl uidized bed cooling and
steel plant residues) Circotherm
n Circosmelt (prereduction n Circoheat (preheating of ore fi nes)
and smelting of ilmenite) n Circoroast (improved pyrite roasting system)
n Reducing ilmenite roasting
n Heat recovery by fl uidized
bed cooling and Circotherm
n Circoheat (preheating of ore fi nes)
n Circochar (coal charring)
n Circonickel (prereduction
of lateritic nickel ore)
n Partial roasting of copper concentrate
010 More out of ore!

Alumina calcination
The fi rst industrial plant for the Preheating stage I Electrostatic
calcination of alumina was de- precipitator
Waste gas
signed in 1968. Calcination is the
fi nal stage of the Bayer process, Preheating stage II
Hydrate
in which bauxite is digested with
caustic soda to fi rst extract and Cooling stage I Cooling stage II
then precipitate a pure aluminum
hydroxide (hydrate). The hydrate
CFB
from the Bayer process is then reactor
Hydrate Cooling water
calcined to alumina in a CFB. This bypass
Alumina
step was earlier carried out in
Calcining stage
rotary kilns, but today all new capa-
Fuel Fluidized bed cooler
city is installed as fl uidized bed Secondary air
calciners. Primary air
Cooling water

CFB calcination process

Alumina calcination in the CFB.

The CFB calciner uses a two-stage

venturi preheating system to recover Some energy of the hot alumina Due to the homogeneous temperature
the waste gas heat by preheating is also used for direct calcination in the CFB reactor, product qualities
and de-watering the hydrate. Final of incoming hydrate in a so-called regarding specific surface area, loss
calcination to alumina (Al 2 O 3 ) is ”hydrate by-pass”. This effi cient on ignition and alpha content in the
accomplished in the CFB reactor heat recovery system leads to an alumina can fulfi ll the demands of
in which the energy is provided by overall fuel energy consumption of today’s aluminium smelters. We
direct combustion of fuel (oil or gas). less than 3 GJ/t of alumina for the have installed more than 50 CFB
The energy of the hot alumina is calcination process. CFB calciners calciner units worldwide, which
recovered to the incoming air in a operate in a range from 900 to represents approximately one third
multistage cooling system including 1,000 °C depending on product of the world's production of smelter
cyclones and a fluidized bed alumina quality demands. grade alumina.
cooler.

Outotec's preassembled module (PAM) technology reduces capital cost and meets the challenges of
plant construction in remote areas. The fi rst PAM delivery of two large calciners took place in 2006
to the Northern Territory in Australia. The calcining units were preassembled in South East Asia and
transported by ship to Alcan's Gove operation.

3,500 tpd preassembled calciner module being delivered to Alcan Gove, Australia.
006 More out of ore! More out of ore! 011

Roasting of sulfide ores

The roasting of sulfide ores and concentrates is an important process step in the production of metals and
chemicals. Sulfides of iron, zinc, copper and other metals are oxidized with air at temperatures between
600 and 1,000 °C into metal oxides and gaseous sulfur dioxide. After cleaning and cooling, the sulfur dioxide
contained in the roasting gas is further processed to sulfuric acid. Both FB and CFB types of fluidized bed
reactors are commonly used depending on the material properties and specific process requirements.

FB roaster

The optimum reactor for roasting of

extremely fine flotation concentrates
of copper, pyrite and zinc is a highly
stable FB. These reactors, charac-
terized by relatively low fluidization
velocities, are well suited to treat
such fine materials with grain sizes
down to approximately 20 microns.
The established concept of a roast-
ing plant consists of a FB roaster,
waste heat boiler, gas cleaning and
calcine handling systems. Dry feed
throughput rates of over 350,000 tpa
per unit are achievable. The generated
SO 2 gas is recovered in a dedicated
Pyrite roasting plant, ETI Holding, Turkey.
sulfuric acid plant.

Gold ore roasting in the CFB.

CFB roaster
Waste heat
boiler
Gold CFB ore Hot electrostatic The CFB roaster is the appropriate
ore preheater CFB precipitator
reactor reactor for special roasting pro-
Gas cleaning +
sulfuric acid plant
cesses or higher throughput rates
of over one million tpa. An example
Pyrite
is the gold refractory ore roasting
process, where sulfur and carbon
Sulfur Fluidized removal are essential to obtain ac-
bed cooler
Fuel ceptable gold recoveries in the sub-
Quench sequent calcine leaching steps.
tank
Fuel

02 make up
Calcine
slurry
Fuel

Tailgas acid plant

012 More out of ore!

Iron ore preheating and direct reduction

Circored ®

Recycle Process gas

cyclone heat exchanger
The drivers for the development of Offgas
scrubber Process gas
compressor
the Circored process in the early CFB Reduction
stage system Multi-
1990s were the growing demand for To thickener I clone Process gas
Suspension scrubber
direct reduced iron (DRI) coupled Iron preheater
Feed
system
ore To thickener
with the advantages of using iron Bleed
as fuel
ore fi nes directly in the steelmaking
FB stage II Cyclone
value chain, avoiding the agglomer- CFB
Product handling
preheater
DRI system
ation step. The Circored process, us- Fuel discharge

ing hydrogen as the only reductant, Bucket

elevator Flash
Air heater
Natural Hot Hot
applies a two-stage CFB/FB reactor gas briquetting charging
Preheating option option
confi guration for reduction. In addi- system Steam Hydrogen
reforming make up
tion, a single CFB is utilized for ore Fuel Air
EAF
preheating and an AFB based fl ash Process gas heater HBI Steel

heater is used to achieve the DRI Fuel Air

briquetting temperature. The fi rst Circored direct reduction in the CFB/FB.
commercial Circored plant, with an
annual capacity of 500,000 t of hot
briquetted iron (HBI), commenced
operations in 1999 in Trinidad.

Ore preheater, HIsmelt Corporation, Australia.

Circoheat™

The first commercial Circoheat plant, operating

at HIsmelt's Kwinana facility in Western
Australia is capable of preheating approxi-
mately 1,300,000 tpa of iron ore fines to 850 °C
using offgas from the HIsmelt smelt reduc-
tion vessel (SRV). In the Circoheat process,
wet iron ore fi nes are fed to a suspension
preheater system where they are preheated
to approximately 500 °C prior to introduction
into a CFB reactor. Hot combustible SRV offgas
at a temperature of 1,000 °C is introduced
into the CFB reactor via an AFB system. The
offgas is partially combusted with air to gen-
erate the necessary energy for preheating the
iron ore. Since the SRV gas is not completely
combusted, a reduction of the iron ore to the
magnetite/wuestite stage is achieved. The
preheated material is subsequently pressurized
in a lock hopper system and injected at high
temperature into the SRV via a new pneumatic
hot ore conveying system.
006 More out of ore! More out of ore! 013

Latest developments
Based on the wealth of experience gained in the field of fluidization technology, Outotec is continuously working
on improving existing processes and developing new processes and applications to meet the demands of an

industry pursuing sustainable solutions.

Circofer ®

The Circofer process has been

developed to reduce iron ore fines
utilizing coal as reductant. Similar
to the Circored process, Circofer
uses a two-stage CFB/FB reactor
configuration to obtain a highly
metallized product. A heat generator
is integrated into the CFB prereduction
circuit to provide the energy necessary
for the endothermic reduction reaction
by partially combusting the introduced
coal with oxygen. The process
operates at reduction temperatures
of approximately 950 °C in a closed
gas circuit without the production of
export gas.
Circored plant, CAL, Trinidad.

Circofer CFB prereduction step for HIsmelt.

One possible application of Circofer
Dolomite
Iron ore

Multiclone Process gas scrubber is as a single stage prereduction step

Char
Coal

Stand pipe
for the HIsmelt ® process, replacing
Stage I the Circoheat ore preheater. This
CO2
Preheating Thickener leads to a signifi cant increase in the
Ore
dryer
Stage II
Reduction
Smelting CO2 throughput of the HIsmelt SRV.
Hot air absorber
Steam
Hot air Prereduced
Coal crushing CFB iron and Offgas
reactor Recycle char
char Coal

Pneumatic Hot
Heat injection
coal feeding gene-
rator Slag
O2 Char Hlsmelt Hot
separator SRV metal
with 4% C

Process gas
Process gas compressor
heater
Bleed gas
Air
014 More out of ore!

Circosmelt ®

The combination of ilmenite prere-

Ilmenite
Char
duction in a single stage Circofer Multiclone Venturi scrubber

Goal
CFB unit with an electric smelting
Stage I
furnace allows for the production CO2
Hot Thickener
Preheating Dust magnetic
of a high quality TiO 2 slag and pig separation CO2
Stage II absorber
iron, resulting in signifi cant energy Gas Prereduced
Ilmenite Steam
lift
Recyle
savings. char
CFB
Process gas
Offgas compressor
Pneumatic Heat
Circochar ® transport gene-
O2 rator
Smelting
furnace
The CFB based Circochar Process
gas heater
process, a spin-off from the Pig iron Titania Air
slag
circofer development, produces
metallurgical char and a valuable
Circosmelt: Ilmenite preheating, prereduction and smelting.
fuel gas from fi ne grained high
volatile coals. The gas quality can
be adjusted to meet the requirements Clay calcination
for power generation by adding
steam or oxygen to the process. Calcined clay can be mixed in a
ratio of up to 40% with Portland
Circoroast ® cement to supplement production
whilst maintaining quality. The
The next generation of sulfi de ore calcination temperature for the
roasting processes will have an clay is signifi cantly lower than the
environmental and maintenance production of equivalent Portland
friendly reactor design. The compact cement leading to considerable
combination of roaster reactor, energy savings. Using the CFB
recycle cyclone, waste heat boiler calcination process, organic and
and fluidized bed cooler provides inorganic compounds are removed
maximum efficiency in heat recovery to achieve a homogenous high
and reduced investment and quality intermediate product for
operating costs. further downstream processing.
 More out of ore! 015

Circotherm ®

Where applications require inten-

sive mixing between solids and hot
dust laden gases, a special reactor
design is needed. Circotherm is
ideally suited for the quenching of
hot offgases with solids, as well
as condensing vapors contained in
offgas streams that are diffi cult to
handle. The core system comprises
an AFB with integrated heat reco-
very systems and a solids recovery
cyclone.

Circonickel

Outotec has developed a process

where the calcination and reduction
of lateritic nickel ores to the wues-
tite/metallic state is performed in
a combination of a CFB and a FB
system. Coal and natural gas can
be used as reductants. Through im-
proved process control of the prere-
duction, considerable energy savings
in smelting of lateric nickel ores to
ferro-nickel can be achieved. The
new process avoids the production
of excessive fine dust as currently
generated in existing production
plants. Furthermore, dust deposits
of existing plants can be processed
recovering its nickel content.

Circotherm pilot plant, R&D Center, Germany.

 3055EN. Pinta/Libris, Helsinki, Finland. May 2007
Outotec, formerly Outokumpu Technology, is a worldwide technology
leader in minerals and metals processing, providing innovative and
environmentally sound solutions for a wide variety of customers in
minerals processing, iron and steel, aluminum and non-ferrous metals
industries. Outotec Oyj is listed on the Helsinki Stock Exchange.

[email protected]
www.outotec.com

Copyright © 2007 Outotec Oyj. All rights reserved.

Outotec and More out of ore! are registered trademarks of Outotec Oyj.