Iron ore is the main source of iron and steel and our world is made of it. The computers we use, the chairs we are sitting on, the cars we are driving with, the buildings we are working in, the schools, we are learning in and the cell phones we are communicating with – everything contains iron ore. Iron ore is so present in our everyday lives that it is practically impossible to imagine a world without this mineral resource.
All modern methods of energy generation and transmitting consist of iron and steel. Thus, we cannot renounce iron ore mineral processing, even though iron and steelmaking sector is one of the largest energy consumers in the world. It is our duty to improve the iron ore beneficiation in order to implement sustainable solutions to minimize CO2 emissions and to improve resource efficiency by better process and product performance.
The undiminished demand of iron ore leads to mining of even lower-valued deposits. The reduced quality of the natural resources stands in opposition to the economic, ecological and technological restrictions, which require an intensive mineral processing of the iron ore. An enrichment of iron components is achieved by separation of undesirable components.
However, for this it is necessary to crush the ore to the decomposition grain size and to supply sorting processes such as magnetic separation and flotation. To improve the process- and product properties of the fine-grained iron ore concentrates, it is necessary to agglomerate these concentrates. Pelletizing of iron ore concentrates in pelletizing discs leads to narrow grain size distributed pellets with smooth surface.
The process chamber of a pelletizing disc is made by an inclined, rotating, flat cylindrical pan. Due to rotation of the pan, the fine material is pulled along to the disc uppermost point and then rolling down onto a material bed. Caused by the special movement of the material itself and the addition of water onto the material, nucleation and growing occurs as a result of the settings of the pelletizing disc.
Typically, final pellets with a very tight particle size distribution are discharged continuously over the board of the SCARABAEUS® 7500.
HAVER & BOECKER NIAGARA supports you to develop and optimize your processes, machines and plants. In our test facility are various tests equipment for pelletizing available. The objective of HAVER Process Engineering is to meet your technical requirements and economic benefits. To achieve this, it is necessary to concentrate on the whole pelletizing process, starting with raw materials preparation, dosing and mixing and binder treatment. The core-components of pelletizing are focused in detail to minimize the efforts of final product classification, material circulation as well as de-dusting, safety and environmental protection. Applying recognized technical norms and standards with tailor-made processing leads to a production process that saves energy and resources.
These balls roll off a discharge chute and onto a belt conveyor that leads to a roller screen. The roller screen classifies the pellets into oversize, undersize and correct-sized grains.
The process chamber of a pelletizing disc forms a horizontally inclined, rotating, flatcylindrical vessel. The fine iron ore concentrates are agglomerated with use of sprayed water into green balls with 9 to 16 mm.
Innovative quality control of the pellets with Haver & Boecker Niagara’s camera system
Haver & Boecker Niagara integrates camera systems to the pelletizing discs THE SCARABAEUS® 7500. The analyses because you can only manage what you can measure.
Scarabaeus pelletizing discs provided by HAVER & BOECKER NIAGARA are used for sustainable and efficient production of iron ore pellets. The unit’s design minimizes circulation, increasing productivity and profitability. The pelletizing discs used for agglomerating iron ore concentrates into pellets are remarkable for their very narrow particle size distribution with a target size of 10 to 14 mm, important for DR-Processes: “It is the direct iron ore reduction process, enabled by those uniform size pellets, which finally leads to the tremendous reduction in greenhouse gases. This innovative pellet based solution avoids the traditional blast furnace route and, hence, the energy intensive smelting of the ore and ensures the production of 97% pure iron at the end. This is such a great contribution to protect our climate through technology innovation ” (Prof. Holger Lieberwirth, Director of Institute of Mineral Processing Machines, Technical University Bergacademie Freiberg).
The powder-type feed material is formed into pellets with use water as the liquid binding agent. The optimum operating parameters can be set by changing the inclination, the rotational speed, mass flow rate, and now also the rim height thanks to our innovative automatic pelletizing disc control system. The integrated camera ensures continuous monitoring of the quality of the pellets: the analyses because you can only manage what you can measure. In order to develop the best solutions for our customers and to determine which process is the best for their iron ore and pellets requirements we are conducting iron ore tests in our Associated-Institute of TU Bergakademie Freiberg – HAVER ENGINEERING GmbH and proving the possibility of achieving the desired parameters with the main aim – to create added value for our customers through sustainable technically sound solutions, perfect quality, guaranteed reliability and absolute flexibility!
Automatic adjustment of the sidewall height
Stepless rotary speed adjustment during operation
Automatic inclination adjustment during operation
Completely automated inline analysis system
Measuring of pellet size distribution of unconsolidated material on the conveyor belt
Real time measurement without disrupting the production
Continuous target/actual comparison of key performance indicators based on Expert System
Automatic readjustment of process parameters
The The Scarabeus process creates pellets so high in quality that they can be utilized for the direct reduction process. This in return can create enormous CO2 emission savings, thus minimizing the mine’s impact on the environment.