Minera Steel and Power Pvt

Ltd
Pellet Plant
Pelletization Process
By
SUNIL K

1
 SL NO. CONTENTS PAGE NO.

1. About Company

2. Introduction

3. General Layout of the Pellet

Plant
4. Pelletizing Feed Preparation,
Grinding, and Mixing
5. Balling Process

6. Induration Process

7. Product Handling

Pelletization Process 2
About Company

 Minera Steel & Power Pvt. Ltd. is a Steel manufacturing company, which was
incorporated in Feb’2006.
 Manufacturing Iron ore pellets, Sponge Iron, MS Billets & it also have a captive 12MW power plant.
 The company is promoted and managed by Mr. H Noor Ahmed and Mr. Tanveer Ahmed.

Different plants installed capacity of the company:

Name of the Plant Installed Capacity
Iron ore Pellet plant 0.8 MTA
Sponge iron 0.15 MTA
Steel melting shop 0.15 MTA
Captive power plant 12 MW

Pelletization Process 3
Introduction

 Iron ore Pelletization: is a process in which Iron ore fines are agglomerated into pellets and then
indurated using a furnace to create iron ore pellets. The pellets are then fed into a blast furnace or DRI
plant as part of the steel-making process.

The iron ore pelletizing process consists of three main steps:

1. Pelletizing feed preparation and mixing
2. Balling process
3. Induration process

Pelletization Process 4
General Layout of the Pellet Plant

Pelletization Process 5
Areas Involved In The Pelletization Process

 Raw Material Handling.

 Dump Hopper.
 Dryer Feed Bin.
 Rotary Dryer.
 Additives Filling.
 Ball Mill.
 Mixer.
 Balling Disc.
 Indurating Furnace.
 Product Handling

Pelletization Process 6
Material Preparation, Grinding and mixing

1. Material Handling
 Raw material is the Iron Ore in the form of
fines which is taken from the mines
consisting of different iron ore grades.
 Here the high and low grade iron ore fines
are mixed together in a pre-determined
percentages to get the good quality of Fe
content i.e., 63 % or above for proper use of
it.

Pelletization Process 7
 2. Dump Hopper
 The pelletization process mainly starts from
here.
 The proper blended of different grades of iron
ore is dumped into the hopper using trucks.
 Vibro feeder is used for feeding material to
conveyor.
 The iron ore is passed to the dryer feed bin
through IF-1 (Iron ore feed conveyor-1) and IF-
2 (Iron ore feed conveyor-2)

Pelletization Process 8
 3. Dryer Feed Bin
 It is also known as storage bin which is
having storage capacity of 500 MT.
 Its consists of weigh feeder below it which
is of 125 TPH, so we can control/ set the
value of feed coming from bin.
 From The feed bin we are transforming the
iron ore fines through the DF-1 (Dryer Feed
-1 Conveyor) to the Rotary Dryer.

Pelletization Process 9
4. Rotary Dryer
 The main principle of dryer is to remove moisture
from the iron ore fines by providing hot air with the
help of hot air generator Dryer has the supporting
wheels at the both the ends to support the dryer
while rotating.
 HAG system is run by the use of Coal gas.
Temperature in the dryer outlet will be 60 - 70 oC.
In HAG system the temperature will be in the
range of 700 – 900 oC.
 Near the discharge chute of the dryer there are

Pelletization Process
CYCLONE , BAG FILTERS, and AIR SLIDERS. 10
 5. Additive Filling
Additives means some other materials were
added such as binder, limestone, coke/anthracite
coal is used to form high grade iron pellets,
which enhance the needed physical and chemical
properties of pellet to process further.

1. Limestone + Dolomite
2. Bentonite
3. coke/anthracite coal

Pelletization Process 11
 6. Ball Mill
 A ball mill is a grinding machine used to crush
and grind iron ore into a uniform size. The mill
contains a rotating cylinder with chromium steel
balls that collide, rub, and wear against the ore
to crush it into the desired particle size.
 Here we are reducing iron ore size to a 45
microns.

Pelletization Process 12
7. Paddle Mixer
 In mixer, water is added to the substance
which is taken from the ball mill. In the ball
mill the powered material will be in dry
state it looks like powder soil, so we add
water to the dry material and feed to mixer.
 Mixer looks like a drum with shaft which is
having shovels. With the help of motor the
shaft inside the mixer starts rotating and
water is added on the material and it is
mixed evenly there after this mixed ore will
be sent to next
Pelletization stage.
Process 13
Balling Process

1. Disc pelletizer (Pan Granulator)

 The disc pelletizer is an inclined pan having
6.5 m diameter. It rotates at around 5.70
(rotations per minute) to 8.60 rpm. The
inclination of disc is around 45 degrees and it
can be adjusted in the off-line position
between 43 degrees to 53 degrees.
 The pre wetted mix is fed into the disc at a
controlled rate. In the disc, ball forming will
takes place due to the continuous rotation.

Pelletization Process 14
  Pellet growth is controlled by the small amount of water sprayed in the disc
and the adjustment in the disc rotational speed.
 These pellets are called green pellets as they do not have the required
strength.
 The green pellets are then screened in a roller screen and the required size
material is fed to the traveling grate of a pelletizing machine.

Pelletization Process 15
Indurating Machine

Pelletization Process 16
  In this process, a double deck roller screen ensures right size of green pellets
(8 mm to 12 mm in size) is evenly distributed across the width of the travelling
grate.
 The grate carries the green pellets on a bed having a height in the range of
300 mm to 550 mm through a furnace having several zones.
 These zones are with up drafting, down draft drying, preheating, firing, after
firing and cooling zones.
 There are six process fans Cooling air fan 1 & 2, Up Draft Drying fan,
Recuperation fan, Hood Exhaust and Wind box Exhaust fan.

Pelletization Process 17
Product Handling

 The pellets are discharged from Indurating machine to

discharge hopper.
 Then the pellets are sent to segregation bin with the
help of product conveyor -1.
 From segregation bin some of the pellets are send
back to hearth layer bin to create hearth layer and
side layer on cars to protect the grate bars of car .
 Rest of the pellets are send to dispatch.

Pelletization Process 18
Pelletization Process 19