Iron Ore Green Pellets Screening Solutions

Triple Deck Roller Feeder!

A solution that enables iron ore pelletizing plants to reach new higher levels of productivity and quality, while reducing energy consumption and overall production costs.

The Triple Deck Roller Feeder provides much more screening area for the same footprint. This increases screening efficiency by enhancing the capacity to remove over-and under-sized pellets, and by also recovering good size pellets more efficiently.

The Challenge

In most pelletizing plants, the induration process operates at its maximum capacity.

Increasing the furnace capacity through process fan capacity upgrading and/or adding more wind boxes involves major capital investments and long shutdowns. The return on investment is long and thus difficult to justify.

The current pellet beds are randomly packed. Consequently, the downdraft of hot air in the firing zone must be overheated to make sure that the remaining heat at the bed bottom is enough to fire big pellets, which are more difficult to fire.

The challenge is to optimize heat distribution during induration.

The Solution

IMPROVE BED PERMEABILITY

Improving pellet bed permeability is the best way to reduce pressure drops throughout the induration process the system. It is the key point in order to free extra capacity on the actual process fans at low CAPEX investment.

To improve permeability and thus improve gas flow, the best ways are feeding induration furnace with more uniform size pellets and minimizing pellet bed compaction. The proportion of good size pellets feeding the induration machine is higher, and a more uniform sized pellet improves bed permeability.

PRODUCTIVITY INCREASE: +7,5%

OPTIMIZE SEGREGATION

Metal7’s Triple Deck Feeder allows the pellets to be fed to the induration in a double layer bed with the biggest pellets on the top and the smallest ones at the bottom.

Since big pellets are more difficult to fire, with a segregated bed, the descending hot air during the induration process will transfer its maximum heat content to the biggest pellets first, precisely where it is most required.

At the bed bottom, the remaining available energy takes care of the smallest pellets, which are much easier to fire.

ENERGY COST SAVINGS: -10%

BENEFITS & FEATURES

Allow segregation concept
Eliminate bottlenecks
Better gas flow through the bed
Induration furnace capacity increase
Balling process efficiency and productivity increase
More uniform pellet size distribution
Smarter use of energy in the firing zones
Energy cost reduction

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TECHNICAL SPECIFICATIONS

The Triple Deck Feeder provides much more screening area for the same footprint. This increases the screening efficiency by enhancing the capacity to remove over and undersized pellets, and also recovering good size pellets more efficiently.

The proportion of good size pellets feeding the induration machine is higher, and a more uniform sized pellet improves bed permeability.

REDUCTION OF BED COMPACTION / EPSILON CHUTE ACHIEVE EVEN HIGHER PERFORMANCE LEVELS

REDUCTION OF BED COMPACTION / EPSILON CHUTE

The introduction of the Epsilon Chute is another key element to improve permeability. This chute reduces the pellets’ velocity by 25% during bed formation, therefore reducing bed compaction. Less compaction improves void fraction and balls’ sphericity in the pellet bed.

ACHIEVE EVEN HIGHER PERFORMANCE LEVELS

• Better bed permeability:

• Better gas flow through the bed

• Induration furnace capacity increase and/or energy cost reduction

• Reduction of recirculating load

• Balling process efficiency increase

• Higher balling productivity

• More uniform pellet size distribution

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With our world-class expertise in surface engineering and our proficiency in complex industrial processes, Metal7 built a solid reputation with multiple worldwide top mining companies in the metallurgical sector.

Our innovation team continuously addresses customers’ challenges and strives to develop and improve our products to help our clients increase the reliability and performance of their critical equipment and processes.

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