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Research & Development Enterprise NPVP TOREX 8 Osnovinskaya Street Yekaterinburg 620041 RUSSIA Fax/Tel. +7 343 253 06 53 [email protected]

NPVP TOREX LLC

Research & Development Enterprise

Company Profile

1. BACKGROUND

NPVP TOREX, LLC, a research-and-development enterprise (Yekaterinburg, Russia), was founded as a separate unit in August 1989. However, the company traces its roots back to the department of Heat engineering of metallurgical raw materials treatment of the ‘All-Union Research and Development Metallurgical Heat-Engineering Institute’ (under the auspices of Iron and Steel Ministry of the USSR). Leading experts of the Institute, who have been working there by now, started the business. Their experience in iron ore agglomeration (i.e. sintering and pelletizing) and its direct reduction, in non-metallic materials treatment (drying, grinding, classifying) makes up 40-50 years. They have developed the heat-engineering schemes and technical specifications for all the USSR straight-grate indurating furnaces produced by ‘Uralmash’. These specialists also took part in commissioning, started commercial production and performed further process upgrading at all the pelletizing plants of Russia, Ukraine and Kazakhstan from 1965 until 1990.

Main fields of activities are Process Engineering and Implementation of Revamping of mining, beneficiation, metallurgical plants, including sintering and pelletizing plants, blast furnaces, direct reduction units, metallurgical furnaces, etc. Company renders engineering services in the processes elaboration, in audit, retrofit and adjustment of different thermal metallurgical equipment, grinding and classifying equipment for the mining, metallurgical, machine building and construction materials industries. It also designs new processes, non-standard equipment and assists designing of modern automation systems. NPVP TOREX also accomplishes consulting, Supervision, Training.

Commissioning & Process Adjustment.

Mission is to find and develop optimal process technology related to specific properties of raw materials, oriented on minimal fuel requirements, maximum output and low environmental wastes.

NPVP TOREX (LLC) is a member of Metalloinvest group of companies covering biggest part of iron ore market of Russian Federation. NPVP TOREX is a main process expert company of Metalloinvest.

In 2002 NPVP TOREX was awarded with the Russian Federation Government Prize in the field of science and engineering for the project entitled ‘Development of Energy-Saving Environmentally-Safe Processes of Multipurpose Pelletizing Based on Indurating Straight Grates Upgrading’.

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Company Profile Page 2


1.1. Expertise

At present NPVP TOREX consists of 40 people, 31 of whom belong to the core staff, including 10 doctors of engineering science (PhD). 30 people have higher technical education.

6 experts possess an over-25-years-long experience of development and elaboration of the heat-engineering schemes, gas flows parameters and straight-grate indurating machines design, drying, grinding and classifying equipment, rotary and shaft furnaces for iron-ore induration and direct reduction.

1.2. Methodology

NPVP TOREX has a comprehensive set of techniques to perform the heat-engineering and technological examination of the equipment, as well as heat losses tests and commissioning. Most of the techniques are unique, and the specialists in the course of 30 years have developed them. The techniques have been extensively tested in the on-site examinations, commissioning of straight-grate indurating furnaces for pelletizing and sintering since the end of 1970s, and they have been refined recently due to the state-of-the-art instrumentation.

While processing the examination and heat-losses tests results, mathematical models are used. The latter describe physical and chemical processes and gas-dynamic characteristics of the processed material bed, as well as pyro equipment and gas ductwork.

1.3. Instrumentation

NPVP TOREX has the state-of-the-art instrumentation at its disposal for the heat engineering research and commissioning, including the microprocessor equipment (infrared imagers, Testo-300 and Testo-350 gas analyzers, electronic differential manometers, professional cameras, water-cooled pneumometric tubes and Pitot gages, various thermocouples). NPVP TOREX specialists introduced Thermologger, a device for measuring temperature characteristics in the moving bed of the material being processed, which enables continuous remote monitoring the data of a primary thermal sensor, installed in the processed material bed (i.e. sinter or pellet bed).

Investigation results are processed at site on personal notebook computers, where all the necessary calculations are performed (including those employing the unique mathematical models).

Competitive Edge

Highly skilled researchers and engineers who carry out the on-site measurements and estimatingevaluation of power and environmental parameters of the processes employing gaseous-, liquid- orsolid-fuel pyro-processing equipment, grinding and classifying systems for various materials andpowders production, including inflammable and explosive ones.

A set of process algorithms, mathematical models and programs for solving new research, designand optimization tasks in the metallurgical processes and equipment. This ensures designingoptimum heat-flows schemes, technological, heat-and-power, gas-dynamic and environmentalindices for metal-rich materials drying, heat hardening and reduction, sintering and iron making(shaft furnaces, kilns, straight-grate machines), for heat treatment of metals, alloys, powders.

Original investigation and estimation techniques, modern equipment, measuring and computermachinery for estimating power consumption, environmental condition, product quality indices;

A unique set of fundamental and experimental scientific findings, technical and engineeringsolutions, integrated programs and implementation techniques, proven at the pilot stage and widelyapplied at metallurgical plants of Russia, Ukraine, Kazakhstan, Uzbekistan, and beyond the bordersthe CIS.

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Scope of Services

On-site examination and analysis of a technological, power and environmental state of operatingfacilities, processing lines and equipment.

Development of concepts, technological and technical solutions for the reduction of powerconsumption and hazardous gaseous and solid emissions.

Development of the technical documentation, including that for the non-standard processequipment.

Elaboration of concepts, algorithms of the process technology automation and technicalspecifications for the pyro-processing equipment and processing lines automation, including thoseemploying mathematical models.

Technological supervision of the design conducted by Customers or by third parties.

Manufacturing of the non-standardized equipment and measuring instruments.

Assembling supervision, start-up and commissioning, scheduled and after-sales maintenance of thepyro-processing equipment and processing lines of mineral preparation and processing, of grindingand classifying facilities.

Calculation of the optimized operating parameters of equipment, development of the process flowsheets and regulations.

In-class and ‘hands-on’ personnel training.

Processes Development

Crushing, grinding, classifying and dedusting

Processes and equipment for crushing, grinding, classifying and dedusting of various materials, including inflammable and explosive substances (ferroalloys, coals, peats, etc.), have been developed by NPVP TOREX. The proposed processes allow producing polydisperse, fractionated powders of such materials as bentonite clays, limestone, lime, pulverized coal, etc. An efficient single-facility integration of grinding, classifying and drying processes is possible. If compared with conventional ones, the proposed unique processes and equipment assure lower power consumption and metal intensity, and they meet the up-to-date requirements of sanitary work conditions and environmental regulations.

Drying

Starting from the material properties data, NPVP TOREX designs drying parameters and selects the equipment, develops the process, estimates the power consumption taking into account the heat-carrier type, designs and manufactures the drying equipment, including burners and gas-purifiers. If desired, the whole processing line for drying various lump and disperse materials, including high-moisture ones, is designed. Subsequent procurement of the main process equipment and commissioning are available. At the operating processing lines NPVP TOREX carries out the technological and heat-engineering examination, develops options for the line upgrade and equipment revamp, which improves the process, heat-and-power and environmental indices.

Pelletizing and hardening of metallic and non-metallic materials and powders

NPVP TOREX experts possess the 40-years-long experience in studying iron-ore agglomeration (sintering and pelletizing), development and elaboration of agglomeration processes, upgrading of the heat-flows schemes of indurating and sintering straight-grate furnaces. Thus, they are capable of integrated upgrading of operating facilities, including the elaboration of process and equipment at any stage and automation implementation. As demonstrated by the experience of indurating furnaces upgrading at ore mining-and-processing facilities (Lebedinsky IRON ORE MINING AND CONCENTRATING PLANT, Mikhailovsky IRON ORE MINING AND CONCENTRATING PLANT (Metalloinvest Holding), Kachkanarsky IRON ORE MINING AND CONCENTRATING PLANT

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(EvrazHolding)), the upgrade invokes significant heat-and-power consumption reduction, as well as harmful environmental impact decrease, while increasing the production rate and finished product quality and making them more consistent.

While designing new agglomeration facilities and processing lines, NPVP TOREX carries out testing and develops processes for individual production stages, prepare the process specifications for new facilities. The company develops the heat-flows scheme and parameters of the indurating equipment zones and gas flows, selects such accessories as burners, fans, scrubbers; designs and manufactures the non-standard equipment.

Direct reduction of iron-ore materials

NPVP TOREX possesses the technological and heat-engineering expertise and patents, field experience, commercialization and elaboration methodology for commercial direct reduction facilities employing Midrex and HYL-III processes. NPVP TOREX has developed original direct reduction processes, heat-flows schemes for their implementation in shaft furnaces and grate facilities, while utilizing gaseous and solid reductants.

Cooling

NPVP TOREX has calculation techniques, technological and engineering solutions of cooling particulate and lump materials, including granular ones. These techniques allow the process development, process parameters optimization, equipment selection, facility design, etc. If necessary, cooling parameters are optimized according to the ultimate thermal stresses in materials. The proposed original coolers make provisions for the recycled gas (air) flows in the heat-treatment closed circuits.

Process Automation

NPVP TOREX develops and implements the state-of-the-art multilevel automation systems for various process technologies, employing the hardware of Siemens, ABB and other suppliers. Mathematical basis of control systems allow solving tasks of central control, parameters adjustment, as well as technological process optimization as per desired criteria (the power rate minimum, production rate maximum, etc.) with due consideration for the respective restrictions.

WE HAVE EXPERIENCE OF MODERNIZATION OF CONVENTIONAL INDURATING MACHINES (BY LURGI-OUTOTEC) AS WELL AS DEVELOPING ORIGINAL THERMAL CIRCUITS FOR INDURATING MACHINES FROM THE SCRATCH. OUR EXPERIENCE IS BASED ON MULTIPLE ON-SITE ENGINEERING STUDIES OF OPERATING INDURATING MACHINES AND DETAILED PROCESS MODELLING.

IN IRAN and BRAZIL

JOINTLY WITH AZARAN COMPANY AND RUSSIAN PARTNERS, WE ALREADY PARTICIPATE IN TWO SANGAN PROJECTS (TWO DIFFERENT 5 MTY PLANTS). IN BRAZIL TOREX IS IN CHARGE OF RETROFITTING AND REVAMPING OF THE EXISING PELLETIZING PLANTS (TUBARAO COMPLEX, VITORIA CITY).

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MAIN SHAREHOLDERS

NPVP TOREX (LLC) is a member of Metalloinvest group of companies. NPVP TOREX is a main process expert company of Metalloinvest. The scheme below shows main pellet and metallurgical plants of Metalloinvest with an application of the state-of-the-art TOREX technological solutions.

REFERENCES

Pelletizing plants modernization and development references are given below.

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Table 1

List of Operating Indurating Machines in USSR with thermal circuits developed by the specialists of NPVP TOREX

while at the metallurgical charge preparation department of the All-Union Research and Development Institute for Metallurgical Heat Engineering prior to 1990

* - before revamping of 1983** - 2000 IRON ORE MINING AND CONCENTRATING PLANT = GOK (abbrv.)

Facilities Location Start-up year

Reaction area of

indurating machine,

m2

Pellets type Number

of machines

Annual output, million tpy

Specific production rate, t/m2·h

furnace plant designed actual

1. Sokolovsko-Sarbaisky IRONORE MINING ANDCONCENTRATING PLANT

Rudny, Kazakhstan

1964-1970 108 oxide, fluxed

12 0.64* 7.70* 0.65 0.75

2. Tsentralny IRON ORE MININGAND CONCENTRATING PLANT

Krivoy Rog, Ukraine


8 0.78 6.20 1.00 0.91

3. Tsentralny IRON ORE MININGAND CONCENTRATING PLANT

Krivoy Rog, Ukraine

1999 324 oxide, fluxed

1 2.30 2.30 0.88 -

4. Kachkanarsky IRON OREMINING ANDCONCENTRATING PLANT

Urals, Russia 1970-1971 108 oxide, fluxed

4 0.80 3.20 0.92 0.93

5. Kachkanarsky IRON OREMINING ANDCONCENTRATING PLANT

Urals, Russia 1988-1993 228 oxide, fluxed

4 1.40 5.50** 0.82 0.84

6. Severny IRON ORE MININGAND CONCENTRATING PLANT

Krivoy Rog, Ukraine


2 2.00 4.00 0.86 0.84

7. Lebedinsky IRON ORE MININGAND CONCENTRATING PLANT

Gubkin, Russia 1975-1977 306 oxide, non-fluxed

4 2.25 9.00 0,90 0.92

8. Kostomukshsky IRON OREMINING ANDCONCENTRATING PLANT

Karelia, Russia 1982-1984 520/536 oxide, fluxed

3 3.38 10.00 0.80 0.82

9. Kazakhstan Chemical PlantShimkent, Kazakhstan

1990 520 phosphorite

2 - - - 0.22

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Table 2

Company Profile

Parameters of TOREX-Design Upgrading of Indurating Machines

Company Year of

Upgrade

area quantity

Production Rate Specific Rates

Per year

Per hour Production rate Natural Gas

Consumption Electric Power Emissions

m2 MTY tph t/m2·h % nm3/t % kW·h/t % th.m3/t %.

Sokolovsko-Sarbaisky

IRON ORE MINING AND

CONCENTRATING PLANT

1982 108 12 0,7 90 0,83 38 45 3,6

1983 116 12 0,8 98 0,84 1,2 34 -10,5 42,4 -5,8 3,1 -13,9

2004 120 1 0,9 110 0,92 10,8 15 -60,5 37,1 -17,6 2,5 -30,6

2009 120 1 1 126 1,05 26,5 14,5 -61,8 32,4 -28,0

Lebedinsky IRON ORE

MINING AND CONCENTRATING

PLANT

1985 306 4 2,2 280 0,92 19,7 34 3,9

1999-2002

310 3 2,7 340 1,1 19,6 11,2 -43,1 25 -26,5 2,5 -35,9

2001 310 1 2 250 0,81 14,6 -25,9 28 -17,6 3,2 -17,9

Mikhailovsky IRON ORE


PLANT

1977 520 2 3,7 470 0,9 17 37 3,8

2005 520 2 4,6 580 1,12 24,4 11,5 -32,4 25 -32,4 1,6 -57,9

2007 520 1 5 625 1,2 33,3 9,5 -44,1 22 -40,5 1,6 -57,9

Kachkanarsky IRON ORE


PLANT

2000 228 4 1,4 180 0,79 28 35 3,9

2005 228 1 1,5 192 0,84 6,3 21,2 -24,3 33 -5,7 3,8 -2,6

2007 228 1 1,6 205 0,9 13,9 17,6 -37,1 32 -8,6 3,7 -5,1

2008-2010

228 4 1,8 225 0,99 25,3 14,5 -48,2 28 -20,0 3,5 -10,3

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Parameters of TOREX-Design Upgrading of Indurating Machines

Company Year of Upgrade

area quantity

Production Rate Specific Rates

Per year

Per hour

Production rate Natural Gas Consumption

Electric Power Emissions

m2 MTY tph t/m2·h % nm3/t % kW·h/t % th.m3/t %.

Oskolsky Electro-Metallurgical Plant

1985 370 1 2,9 360 0,75 9,9 27 2,2

2004 420 1 3,3 415 0,86 14,7 9,2 -7,1 27 2,2 -

2006 480 1 3,6 450 0,94 25,3 9 -9,1 27 2,1 -4,5

Severny GOK, Ukraine, IM-306

2005 306 1 2,1 263 0,86 18,8 29 3,4

2008 306 1 2,3 285 0,93 8,1 16,4 -12,8 28,5 -1,7 2,8 -17,6

2009 306 1 2,5 310 1,01 17,4 14 -25,5 28 -3,4 2,8 -17,6

Severniy GOK, IM Lurgi-278

2006 278 1 1,9 236 0,85 20 23 4

2008 278 1 2,2 278 1 17,6 14,5 -27,5 22,4 -2,6 1,8 -55,0

Severny GOK, IM Lurgi-552

2008 552 2 4 505 0,91 17,5 24 3,5

2009 552 2 4,4 552 1 9,9 14 -20,0 22 -8,3 3,1 -11,4

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TOREX Projects Worldwide

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Table 3

Current Pelletizing Projects

Pellet plant Production rate Pellet type

Sangan (IMIDRO), Iran 5 MTY Hematite / Magnetite, DR grade

Sangan (Mobarakeh), Iran 5 MTY Hematite / Magnetite, DR grade

Crest Steel & PP Ltd, India 1,2 MTY Hematite BF grade

Minera Steel & Power, India 0,8 MTY Hematite BF grade

Stemcor, India 1,2 MTY Hematite BF grade

6 MTY Magnetite, DR grade

Mikhailovsky IRON ORE MINING

AND CONCENTRATING PLANT,

Russia

5 MTY Magnetite BF grade

Mikhailovsky IRON ORE MINING

AND CONCENTRATING PLANT,

Russia

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Production rate increase after retrofitting at the Lebedinsky, Mikhailovsky and OEMK plants

0

100

200

300

400

500

600

LEBEDINSKY MIKHAILOVSKY OEMK

before after current

21,4 %

23,4 %

25,0 %

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Gas rate decrease after retrofitting at the Lebedinsky, Mikhailovsky and OEMK plants

0

2

4

6

8

10

12

14

16

18

20

LEBEDINSKY MIKHAILOVSKY OEMK

before after current

-43,1 %

-34,7 %

-9,1 %

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Thermal diagram of the new generation induration machine (Russia, Mikhailovsky GOK)

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3-D Model of the indurating machine gas ducts

Щлk

Our competent and friendly team is always ready to share with its sophisticated engineering solutions tailored to your business needs. Do not hesitate to be innovative!

Sincerely yours TOREX

torex€¦ · npvp torex. the proposed processes allow producing polydisperse, fractionated powders...

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