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TRANSCRIPT
Latest Developments and Installations
of Environmental Protection Measures
in Material Handling Solutions
Dr. Rainer Bertling
Latest Developments and Installations of Environmental Protection
Measures in Material Handling Solutions
1. Introduction
2. Developments in material handling improving environmental protection
I. Closed raw material storage
II. Clean unloading systems
III. Reduced maintenance and energy recovery in sinter production
IV. Energy recovery and capacity increase by hot DRI charging into EAF
V. HBI soft cooling without water treatment requirement
3. Examples of latest installations all over the world
4. Conclusion
Agenda
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AUMUND Metallurgy equipment
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1. Introduction
2. Developments in material handling improving environmental protection
I. Closed raw material storage
II. Clean unloading systems
III. Reduced maintenance and energy recovery in sinter production
IV. Energy recovery and capacity increase by hot DRI charging into EAF
V. HBI soft cooling without water treatment requirement
3. Examples of latest installations all over the world
4. Conclusion
Agenda
4
Latest Developments and Installations of Environmental Protection
Measures in Material Handling Solutions
I. Closed storage systems
Arrangement of Baosteel closed material storage (Source: Baosteel / MCCI)
Longitudinal
storage
buildings
Circular
storage
buildings
Silos
Features:
Avoid dust exposure resulting from open stockpiles especially in storage areas close
to the sea with high wind velocities
various systems for the stacking and reclaiming of the different raw materials such as
coal, iron ore, limestone or coke
No special dust control, no risk of material losses and no fugitive dust pollution or
ground water pollution can occur
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Storage
volume
per
footprint
I. Rotary Discharge Machines
Multiple silo arrangement using various rows of Aumund Rotary discharge machines
Features:
increased storage volume on significantly reduced foot-print
capacities of up to 4000t/h per machine with several machines per line possible
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compliance with safety
regulations to explosion
protection (self-combustion
by time) – avoidance of
solidification
by first in first out principle
blending by parallel rows /
number of machines per line
Easy maintenance by
moving out of the silos
I. Rotary Discharge Machine
Features:
Simultaneous Feeding and
Discharging
Low power demand
travelling length, depending on
stockpile length or number
and size of silos up to 400m
defined by type of power
supply system such as
power chain, cable reel or
festoon system
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I. Rotary Discharge Machine dedusting system
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material chute ~ 20mm
above belt conveyor guides
material from bunker table /
serves as dust cover
Optimized water spray
system by adaptation of
water droplet size to
grain size
Minimized operational costs
by adapted spray nozzles
(water / pressurized air
requirement)
Material free fall nearly zero, bulk of truck contents is
drawn into the body
~ 25% of the rate required for extraction on
conventional deep hoppers, thus saving capital cost
and long term operational costs
Benefits:
Surface Mounting without costly
Excavation.
Flexibility in Location / Easily
Relocated
Minimum Dust Generation
Easy Maintenance Access
Reduced Energy Demand
A Flexible Investment
II. Samson® Material Feeder for clean material unloading
Dust Filter
Module
Profiled
Steel
Enclosure
Dust
Curtain
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III. Hot Sinter Conveyor – replacement of vibrating feeders
Sinter discharge area with vibrating feeder Sinter discharge area after reconstruction
with Aumund pan conveyor Benefits:
Significantly reduced energy demand & noise emissions (and hence improved
working conditions)
Reduced wear and maintenance (no vibration (disintegration / recirculation), no
relative movement metallic pan conveyor with special wear protection caps
with proven lifetimes > 10 years
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Features and applications:
Sinter shaft cooler technology with improved heat and energy recovery and minimized
diffusive dust emissions (closed system)
counter flow principle is applied with increased height of the sinter bed for the most
effective heat transfer
lifting hot sinter to a higher charging level possible with inclinations of up to 60° (in case of
bucket apron conveyors)
III. Hot Sinter Conveyor – part of latest heat recovery sinter cooling systems
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Example of Primetals sinter shaft cooler system (Source: Primetals)
Features:
Instead of cooling DRI, the direct use in EAF significantly
reduces energy consumption / tap-to-tap times
EAF productivity increase up to 20% (or more)
DRI-EAF route = substantially lower CO2-emissions / ton
steel vs. BF route (mainly natural gas based)
Buckets = greatest possible volume = minimum contact area
to surrounding atmosphere / small potential reaction surface /
optimized thermal radiation for energy saving
Lifting height up to 110m
conveying capacities up to 400t/h – limited by chain strength
(increasing chain size would increase total weight) – specific
breaking strength of each single chain of 3000kN possible
dust losses << vs. pneumatic transport >> energy /
maintenance costs
IV. Energy-optimized hot DRI conveying
Bucket conveyor
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Source: Primetals
IV. Benchmark with Hot DRI input
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Increasing use of merchant HBI to
replace scrap charge in EAF for
high quality steel grades
increase steelmaking capacities
reduce CO2-emissions
With applications in EAF / BF
V. HBI Soft Cooling
voestalpine Texas LLC HBI plant
For further handling / transport HBI needs to be cooled after the DR furnace
Disadvantages of quenching with water directly after the briquetting process:
open quenching systems produce dust loaded steam clouds
resulting in dust pollution and equipment wear
Fast cooling process can cause cracks / potential fragmentation leading to additional
fines
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Source: Midrex
Patented HBI soft cooling conveyor to
achieve best quality HBI under the most
environmentally clean conditions
V. HBI Soft Cooling
Features:
Using water mist / vapor for a smooth cooling effect
Avoidance of sludge and dust generation in a closed system
vapor injected just according to the need to achieve the required HBI temperature,
typically to be ~ 100°C
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1. Introduction
2. Developments in material handling improving environmental protection
I. Closed raw material storage
II. Clean unloading systems
III. Reduced maintenance and energy recovery in sinter production
IV. Energy recovery and capacity increase by hot DRI charging into EAF
V. HBI soft cooling without water treatment requirement
3. Examples of latest installations all over the world
4. Conclusion
Agenda
16
Latest Developments and Installations of Environmental Protection
Measures in Material Handling Solutions
Rotary Discharge Machine (RDM) – Baosteel Meishan coal storage
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13 silos: 33m height, Ø 21m
Capacity: 400-550 t/h
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AUMUND Hybrid Feeder
New AUMUND BPB-SLP Hybrid Feeder, a technical combination of Samson® Material Feeder and heavy-duty AUMUND
BPB-SF Arched Plate Conveyor (example photos)
Combination of Samson® Material Feeder and a heavy-duty AUMUND Arched Plate
Conveyor = spillage-free heavy-duty process
• ERAMET Le Havre’s Sandouville Refinery, France
• Nickel Matte extremely difficult to handle – almost
spherical particles = challenges in reception, interim
storage and onward transportation
• Dust cover and top-mounted filter, slewing grate,
cleaning brushes and catching strips, for fine, spherical
bulk material.
• Essential no spillage of fine material in production area
= sealing Robust tractor-type chains required due to
high densities of material (2.8 to 4.3 t/m³).
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new permanently lubricated rollers after successfully testing in actual working conditions
in other sinter plants
Long trial sequences
Latest installation: 3,000 mm wide
capacity ~1,500 tons sinter /h
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Further references e.g. in
Brazil, Russia, Germany,
Austria, Netherlands
Hot Sinter Conveyor Japan
Patented HBI cooling lines for MIDREX Project at Cleveland Cliffs
New HBI works close to Lake Erie.
In December 2018: patented technology with 2 FPB-K pan conveyors with center
distances of 72 m.
AUMUND = subcontractor to MIDREX
HBI-Slow-Cooling process with HBI product to be conveyed and cooled from 750 to 90
°C, protecting the integrity of the product
Throughput of up to 285 tph at a nominal conveying capacity of 142 tph
First installation successfully completed by AUMUND in Venezuela in 2006
Example
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Regulatory drivers but also cost reductions through energy recovery and reduced
maintenance requirements have already been supporting different investments in
environmental protection measures worldwide.
AUMUND, together with its partners in steelmaking technologies and operation,
developed solutions to
minimize risk of material losses, fugitive dust pollution or ground water pollution by
means of covered storage areas or silos and unloading stations
allow modern sinter coolers to be connected in existing situations accompanied by
minimized energy demand and noise emissions.
handle other hot materials such as pellets, DRI or HBI
to improve energy consumption and environmental influences of the processes
to avoid / minimize equipment damages / high maintenance costs.
Conclusion
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Thank you for your kind attention!
Dr. Rainer Bertling