06coking Coal Ironore

Coking Coal and Iron Ore -
Comparisons & Contrasts
Dave Osborne
Global Coal Technologist
Anglo Coal, Brisbane
Iron Ore 2005 Conference,

20/10/2005 1
Fremantle, Sept 2005
Introduction
Although the products present themselves at
opposite ends of the (beneficiation) spectrum…..
……numerous fascinating synergies exist in the
preparation of (coking) coal and (hematite) iron ore
products for their common export markets.
A 5-year sojourn in WA with Hamersley Iron,

following highly diversified coal experience provided
the opportunity for comparing and contrasting the
supply chains of both bulk products
This presentation covers some of the more
interesting of these synergies and raises some
potential opportunities for the future.
20/10/2005 2
Topics of Discussion
Comparisons and Contrasts
Resources
ROM to Plant
Beneficiation
Product Assembly and Blending
Quality Assurance
Value in Use
Next Steps
Presentation Take-aways

20/10/2005 3
Comparisons include:
¾ Resource evaluation (especially quality
aspects)
¾ Run-of-mine handling & preparation
¾ Beneficiation
¾ Product handling, blending & transportation
¾ Quality assurance & customer awareness
¾ Supply Chain Management and systems
¾ Value-in-use & impacts on ironmaking
Inherent within these are several notable

contrasts
20/10/2005 4
Contrasts include:
¾ “Black and brown”

¾ Seams and Orebodies
¾ Minerals and Macerals
¾ Floats and Sinks
¾ Products and rejects
¾ Solid-liquid separation
¾ Oxidation and weathering
¾ Emissions and pollution
¾ Sales and marketing!

20/10/2005 5
Resources
Resources are “ore bodies” or “coal seams”
Iron ore
¾ Iron ore deposits in the Pilbara are 2500M years old
and iron mineralisation proceeded from sedimentary
deposits of (laminated) banded iron formation
Coal
¾ Coal deposits from Bowen basin and Sydney basin
coal-fields are much younger (250-295M years) and
comprise numerous distinctive seams of differing
thickness and quality characteristics

20/10/2005 6
Resources
Iron ore
¾ Iron mineralisation proceeded from sedimentary
deposits of (laminated) banded iron formation (BIF)
¾ Collectively, known as the Hamersley province
¾ Composed of 5 major BIF units; 2 economic deposits
¾ Marra mamba iron formation (oldest and 238m thick)
¾ Brockman iron formation (youngest and 620m thick),

20/10/2005 7
Resources
Iron ore.
¾ 3 main genetic groups & 5 major ore types.
¾ Genetic groups differ from each other in terms of origin.
¾BIF-derived iron deposits (BID) – primary deposits
formed in situ.
¾Channel iron deposits (CID) – secondary deposits in
mesa and river courses, and.
¾Detrital iron deposits (DID) - secondary deposits in
basins.
¾ BID group includes 3 differing ore types:
¾Low phosphorus Brockman ores (LPB) - P <0.05% (note:
BIF has P~0.10%).
¾High phosphorus Brockman ores (HPB) - P~0.12%, and.
¾Marra mamba ores (MM) – P~0.04%.
20/10/2005 8
Resources
A – Low Phosphorus Brockman
Iron ore B – High Phosphorus Brockman
C – Marra Mamba
Photos of ore types D - Pisolite
D
Courtesy: Pilbara Iron Iron Ore 2005 Conference,
20/10/2005 9
Resources
Coal
¾ Maceral content and characteristics determine quality
Vitrinite
(grey) Inertinite
(white)
Liptinite
(dark grey)
Semi-
Inertinite
(mottled
grey)
¾ Two main regions have high quality deposits and supply

to metallurgical applications:
Bowen basin coal deposits
Sydney basin coal deposits

20/10/2005 10
Resources
Coal.
¾ Bowen basin coal deposits.
¾ 4 coal-bearing intervals comprising 10
formations,
¾ 5 commercially mined - oldest to youngest.
¾ Blair Athol coal measures (BACM);
¾ Collinsville coal measures (CCM),
¾ Moranbah/German Creek coal measures
(MCM/GCM).
¾ Rangal coal measures (RCM).

20/10/2005 11
Resources
Coal.
Sydney basin coal deposits.
¾ Main coal-producing formations
¾ Illawarra coal measures (south and west).
¾ Newcastle coal measures.
¾ Tomago coal measures (east).
¾ Singleton coal measures in the Hunter Valley.
¾ Newcastle & Tomago coal measures.
¾ Singleton coal measures & Gunnedah
sub-basin (40 seams).

20/10/2005 12
Bowen-Sydney Basin Coals
Rank and Vitrinite Content
©
The Quinn Coking Coal Diagram
100 Very Bright

Coals
90
NEWCASTLE CM Bright
80 Coals Zone of Thermal Coals
GERMAN CREEK CM
70 SINGLETON CM
% VITRINITE
Zone of Coking Coals

RANGAL & MORANBAH CM Intermediate
60
GRETA CM
Coals
COLLINSVILLE CM
50
ILLAWARRA CM
SOUTH COAST
ILLAWARRA CM Dull
40 WESTERN SHELF Coals
30
1.0 1.5 2.0 2.5 Publish ed in:
Callcot t, Callcot t & Quinn, 1990.
Rv (max) % Proc.Bowen Basin Symp osium.

20/10/2005 13
ROM to Plant Feed
Iron Ore.
¾ Primary crushers (250 – 150mm), now mainly jaw (instead
of gyratory) - a cost-based decision.
¾ Feeders need to be robust – apron types are preferred.
¾ Secondary crushers (150 – 100mm) are cone/gyratory
types, but some attempts to use mineral (double-roll)
sizers have had mixed success.
¾ Tertiary crushers (32mm) almost all are cone-type.
¾ Multi-slope screens with non-blinding/non pegging decks
are mostly used for the ~6.3mm dry sizing.
¾ Sampling of resultant lump and fine ore strands normally
carried out prior to treatment or stockpiling.

20/10/2005 14
ROM to Plant Feed
Coal
¾ Primary crushers (to 300 -150mm), now mainly jaw or
feeder/breaker types; A cost-based decision
¾ Feeders – apron and vibratory types preferred
¾ Secondary crushers (150 – 50mm) either rotary breakers
(less common), or double-roll sizers, recent trend.
¾ Tertiary crushers (to 50mm) almost all double-roll type
¾ Multi-slope screens widely used for the ~50 x 10mm range
dry sizing applications – roller screens are also used.
¾ Raw coal sampling is normal after crushing prior to
beneficiation.

20/10/2005 15
Beneficiation
Density differential is a major contrast.
¾ Iron ores:
¾ S.G. ~4.5-5.0.
¾ Associated rocks and minerals - gangue/mineralised
elements are: silica 2.7, alumina 3.2, shales, tuff and
dolerite 1.8 – 2.4.
¾ Coals:
¾ S.G.1.3 to 1.6;
¾ Compared with sandstones, S.G. 2.5-2.7 limestone,
shales and mudstones, S.G. 1.6 – 2.5.

20/10/2005 16
Beneficiation
Process selection.
¾ Similar gravity equipment used for iron ore
and coking/ thermal coal.
¾ Similar plant flowsheet designs exist, eg Mt Tom Price and
Moranbah North, i.e. DM bath & cyclones, spirals, etc.
¾ Iron ore & coal applications have benefited from
enhancements in design and scale.
¾ Gravity separators are still capable in iron ore to ~50mn.
¾ WHIMS has also been used for fines, but largely replaced.
¾ Spirals are common and hydro-separators now being tried.
¾ Flotation of hematite is technically feasible, but not applied
¾ Flotation in coking coal is widely practised and technology
has advanced to use of columns for improved recovery
and control.
20/10/2005 17
Beneficiation Plants
Application of beneficiation – another contrast

¾ Iron ore – introduction of a hematite “concentrator” is rare
and only justified by value of the (low phos. Hematite)
resource.
¾ Only Hamersley (Mt Tom Price 1976) and BHP (Mt Newman
1978 and port Hedland – HBI plant) have built them in
Australia.
¾ Only other examples of wet processing are the Paraburdoo
fines processing plant (1996) and barrel washing of pisolites
(Robe River 1999)
¾ Coal – comprehensive cleaning (down to zero) is the norm
and a dense medium, spiral & flotation combination is
common
20/10/2005 18
Beneficiation Plants
Dewatering is also a contrast

¾ Iron ore moistures are generally low as most of the final
product is a blend of mainly dry and some washed ore.
¾ Lump ores usually achieve ~3-4% TM & fine ores 6-9% TM
¾ Dewatering is by drainage screens and stockpiles
¾ Coking and thermal coals at 50mm top size need to be
<10% TM to avoid penalty and handling problems
¾ Dewatering in iron ore is generally by screens plus solar
¾ Dewatering in coal will involve coarse, small and fine coal
centrifuges and vacuum filters (mainly HBF trend)
¾ Some screen-bowl centrifuges are used.
¾ Most recently, recessed plate filter presses have been
selected Iron Ore 2005 Conference,
20/10/2005 19
Blending and Homogenisation
Similar methods are employed
¾ Emphasis for blending is usually in product assembly
¾ Some raw coal blending is practised if yield optimisation is a goal
¾ Various stockpile types are used for both commodities
¾ Iron ore blending is essential to ensure grade targets are met
¾ Chevron stacking is most common, but some windrow stacking occurs
¾ Full-face reclaiming common in both applications
Courtesy: Pilbara Iron

20/10/2005 20
Quality Control
Moisture
Ash level
Calorific value
Sulphur content PREPARATION PLANT
Size distribution
Ash constituents
Moisture consistency
Ash value consistency
Calorific value consistency STOCKPILE BLENDING
Sulphur consistency
Free moisture
Size distribution
Fluidity and RoMax
Hardgrove grindability
Proximate analysis
MINE PLANNING/OPERATIONAL
Ash elements
Ash fusion characteristics

Proximate analysis
Ultimate analysis
Ash elements
Crucible swelling
Sulphur forms GEOLOGICAL DATABASE
Toxic elements

20/10/2005 21
Supply Chain Control
“A fundamental need ..... large mining operations ..... to
reliably measure real-time, on-line, quantitatively and
qualitatively”
Reliable “fit-for-purpose” feed / product sensors
Reliable sampling/preparation
On-line analysis
moisture - dust
size analysis
Geological
database
yield
Maintenance Sales Operations
Transportation
mass KEY Mine

Mining
Coal Export
User
ACTIVITIES Planning Preparation Terminal
Process &
plant modelling Mine Production data Customer Feedback
Intelligent Plant!! database Real time measurements

20/10/2005 22
Testing / Properties
Why test materials?
¾Impractical to use either the blast furnace or
coke ovens to evaluate alternative coal
purchasing options – too prohibitive in time and
cost.
¾Material tests are designed to characterise the
behaviour of materials
¾ Prior to charging
¾ In the lumpy zone
¾ In the cohesive zone
¾Ideal physical properties are those that allow all
zones in the BF to best perform their respective
functions as distributors of gas and liquids.
¾This will translate to optimised costs,
productivity, quality and campaign life.

20/10/2005 23
Product Quality Aspects
For iron ore
¾ Direct charge (lumpy) ore must resist breakdown into
fines during transit and inside the BF.
¾ Fines ores must comply with sinter production, to create
properties that ensure strong sinter is produced.
¾ Both cold and hot properties are assessed for lump ores
and sinter.
¾ Tumbler and Abrasion Indices are determined for cold
strength.
¾ Decrepitation (DI) reduction degradation (RDI) indices are
measures for inside the blast furnace.
¾ Reducibility is also tested.
¾ Standard tests are prescribed for these parameters.

20/10/2005 24
Iron Ore Quality
Lump Ore ISO ISO RDI % R%
Physicals TI % AI %
BHP- B Newman (Aus) 85.0 9.0 23.0 56.0
HIP-L Blend (Aus) 85.8 5.7 26.1 53.7
Carajas (Bra) 79.7 20.3 11.2 43.0
MBR (Bra) 79.0 10.0 16.0 49.0
Sesa Goa (Ind) 75.0 16.0 26.8 59.0
Kumba / Sishen (RSA) 93.0 2.0 2.0 38.0
Portman Koolyanobbing 87.7 7.7 17.1 60.6

(Aus)

20/10/2005 25
Product Quality Aspects
For coking coals
¾ Products must contribute to producing coke that resists
breakdown into breeze, whilst being handled in the works
and later on whilst inside the blast furnace.
¾ Breeze is commonly used as the fuel in sinter production.
¾ Properties relating to cokemaking are; volatiles, fluidity,
dilatation and crucible swelling.
¾ Coke is tested for both cold and hot properties in a similar
way to lump ores and sinter.
¾ Tumbler and Abrasion (Micum) Indices are determined for
cold strength, whilst coke strength (CSI) and coke strength,
after reaction (CSR) indices are measures for inside the
blast furnace.
¾ Standard tests are prescribed for these parameters.
20/10/2005 26
Coking Coal Properties
Coking Coal
CSN M40 M10 CSR CRI Stab Hard
Physicals
German Creek (QLD, 8-9 87 8 72 62 65

Aus)
Moranbah North 7-8 80 8 63 27 56 61
(QLD, Aus)
7.5 78 8 50 30 55 64
Moura (QLD, Aus)
7 87 7.4 70 20 61.5 64.2

Hail Creek (QLD, Aus)
South Blackwater 6 76 10 39 64 61
(QLD, Aus)
Oaky Creek (QLD, 8 78 9 57 58 64

Aus)
8 85 7 73 18 62
Illawarra (NSW, Aus)
6.5 75 9 72 56 70
Line Creek (Canada)

20/10/2005 27
Quality Control
Sampling systems - similar standards.
¾ increment mass & stages of sample preparation for a
representative laboratory sample.
Iron ore sampling - upstaged coal by introduction of
robotics that collect and prepare the primary sample
to the final laboratory sub-samples.
¾ In one case, stages of preparation extend to the final
laboratory sample needed to prepare for XRF analysis.
In addition to achieving absolute values for product
quality, producers strive for consistency targets.
A reference is the JSM that ranked suppliers on Ship-
to-Ship variation, e.g.
¾ Element “RANKING” is from A, B & C.
20/10/2005 28
Automated Laboratory
Sample reception and preparation at Dampier
Courtesy: Pilbara Iron

20/10/2005 29
Quality Assurance
¾ Quality assurance governed by Statistical Process Control
in both commodities.
¾ In iron ore - key parameters are Fe, Al2O3, SiO2 and P.
¾ Other parameters also important, i.e., trace metals & LOI &
TM (surface moisture).
¾ For coking coal - plastometric (including swelling index),
coke strength, proximate and ash analysis.
¾ For PCI coal - specific energy, ash content and analysis,
as well as sulphur and phosphorus contents are important.
¾ For both commodities, sizing and moisture are significant
in relation to freight and handling.
¾ Bottom line – ensuring consistency is of great importance!

20/10/2005 30
Raw Materials Consistency
Any Raw
Cycle of Change
Material
Properties Burden / Gas
Distribution
Change Altered
(Worse / Better) Smooth Internal
Operations Conditions
Altered
Overall Response Time

to stabilise after a disturbance
Can be
Several Days
to
Gas Several Weeks Furnace
Performance
Distribution
Changes
Altered
Burden
Distribution
Changed
Consistency is a key raw material property !

20/10/2005 31
Value in Use
Understanding of factors affecting VIU is continually
evolving as process knowledge advances.
Comparison of VIU with delivered price provides an
indication of the incentive for the steelmaker to use
that material.
¾ Applies to all the raw materials used.
¾ Procedure for determining VIU may differ, but methodology
will be similar.
¾ Calculation of the cost/benefit impacts/unit input relative to a
base blend, or reference material.
¾ Calculated fairly precisely for chemical characteristics.
¾ More difficult for physical / metallurgical properties.
¾ Impact of contaminants e.g. Sulphur, Phosphorus, Zinc, etc.

20/10/2005 32
Value in Use
Every supply chain is unique!
¾ Numerous factors are affected by a change in raw material
O2
Sinter (production/quality) Lump ore Coolant
Pellets (Scrap/ Ore)
Flux
O2
Fluxes Sinter BOF Slag
HM HM
Reverts Plant Blast
Fluxes (Production Hot Metal Steel
Furnace quality) Pre- Plant
Treatment
Fine ore Coke breeze Fuel (PCI)
BF Slag
Coke Liquid Steel
Coal Coke (quality)
(Production ,
Battery quality)
Coke Oven Gas (fuel

supply)

20/10/2005 33
Next Steps
For iron ore.
¾ Diminishing reserves of lower P ores may drive interest
in increasing recovery.
¾ Operators may look at methods of ultra-fine ore
recovery perhaps introducing flotation.
¾ Lucrative reserves remain in deeper zones of ore
bodies - increased efforts toward treating wet ores
mined from below water table.
¾ Perhaps by further wet beneficiation plants?
¾ Most probable short-term focus with abundant reserves
of pisolite and marra mamba - lower cost production.
¾ Some form of simple beneficiation process(es) to
remove clays that impair handling and transportation.
¾ Blending is the key to ensuring value-in-use.
20/10/2005 34
Next Steps
For coking coal
¾ Improved recovery of vitrinite-rich, fine coal to ensure
that the products have good coke strength/reactivity.
¾ Marginal coals, move towards the high-energy market -
attractive to steel companies as potential coke blend
component and/or PCI.
¾ Coal producers forced to address increasing trend of
contaminants, especially Phos & Sulphur.
¾ Deeper cleaning needed, via crushing smaller top-size.
¾ Reducing top size (lowering mean size), will lead to
higher moisture and risk of handling problems
¾ Moisture impact stretching limits of mechanical
dewatering – need innovative methods/alternatives.
¾ Possible agglomeration or thermal drying.
20/10/2005 35
Still much to be shared and learned by both sides.
Coal side.
¾ Coal preparation engineers need to be more
open to learning from all industries.
¾ Not be constrained by previous successes
– actively seeking opportunities for innovation.
¾ Work with manufacturers/suppliers to ensure they tailor
equipment to suit the application.
Iron Ore side.
¾ Producers don’t have benefits of industry funded ACARP.
¾ Depend more on equipment manufacturers and R&D
organizations, such as CSIRO/AMIRA, for innovation.
¾ Focus has been more on reduced “footprint” plants; and
larger unit capacities.
20/10/2005 36
Corporate requirement for “risk averse” plants &
solutions can potentially stifle innovation.
The two industries can learn from each other.

¾ There is much to encourage exchange of information
¾ Perhaps conference/workshop linking the ACPS with
iron-ore producers and users would be mutually
valuable?
There are more similarities than differences!

"That which has been is what will be
That which is done is what will be done
And there is nothing new under the sun“
Ecclesiastes 1:9
20/10/2005 37
Many Thanks To……
¾ All of you
¾ Anglo Coal Australia Any
Questions?
¾ AusIMM and CSIRO
¾ Rio Tinto Iron Ore

20/10/2005 38
20/10/2005 39
Iron-ore Concentrator Plant
• Mt Tom Price concentrator has an annual capacity of ~8Mt; ~ 2200 tph
• High grade ore is not treated – crushed and screened. Contaminated ore is washed.
• Product split is ~60% lump /40% fines sizing is 31.5 x 6.3mm; minus 6.3mM
PROCESS - Wemco drum, DMC, spirals

20/10/2005 40
Coal Preparation & Handling Plant
• Moranbah North washing plant has a nameplate capacity of 1300 tph
• Raw coal blending, bridge-type reclaimer; Product reclaim 3200 tph.
PROCESS
Twin 650 tph Modules; Teska bath (150x14mm),
DMC 14x0.5mm and J-Cells (minus 0.5mm)

20/10/2005 41
Iron-ore Supply Chain*
HIP-L HIP-F HIP-L HIP-F HIP-L HIP-F HIP-L HIP-F HI-Y
HIP-L HIP-F HI-Y

20/10/2005 42
Coal Supply Chain

20/10/2005 43
Preferred Coke Quality
Required coke properties vary widely.
Dependent on furnace size, levels of PCI & cost
structures – guidelines are:
¾ Mean size: 50 - 55 mm, “narrow” distribution.
¾ Cold strength: ~80% M40; ~7% M10; DI ~85%;
I10 ~18%; I20 ~78%.
¾ Hot strength: CSR 55 - 60 %; CRI 20 - 30 %.
¾ Moisture content: <3 % - higher causes more fines in BF.
¾ Gangue: ash 9 -12%, Sulf. 0.5 - 0.7% Phos ~0.05%,
Alkalis ~0.3%.

20/10/2005 44
power plant
Integrated Steelworks chemical
industry
coking plant
tar, benzene,
sulphur
coking
gas
coke
blast furnace gas
CO-gas
blast rolling
furnaces mill
steel plant
electricity
20/10/2005 45
Anglo Coal in Australia

20/10/2005 46

06coking Coal Ironore

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

06coking Coal Ironore

Uploaded by

Copyright:

Available Formats

Coking Coal and Iron Ore -

Comparisons & Contrasts

Iron Ore 2005 Conference,

 A 5-year sojourn in WA with Hamersley Iron,

Iron Ore 2005 Conference,

 Inherent within these are several notable

¾ “Black and brown”

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

¾ Two main regions have high quality deposits and supply

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

¾ Illawarra coal measures (south and west).

¾ Newcastle coal measures.

¾ Tomago coal measures (east).

¾ Singleton coal measures in the Hunter Valley.

¾ Newcastle & Tomago coal measures.

¾ Singleton coal measures & Gunnedah

sub-basin (40 seams).

100 Very Bright

Zone of Coking Coals

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

 Application of beneficiation – another contrast

 Dewatering is also a contrast

Courtesy: Pilbara Iron

Ash fusion characteristics

Iron Ore 2005 Conference,

 mass KEY Mine

 Intelligent Plant!! database Real time measurements

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

BHP- B Newman (Aus) 85.0 9.0 23.0 56.0

HIP-L Blend (Aus) 85.8 5.7 26.1 53.7

Carajas (Bra) 79.7 20.3 11.2 43.0

MBR (Bra) 79.0 10.0 16.0 49.0

Sesa Goa (Ind) 75.0 16.0 26.8 59.0

Kumba / Sishen (RSA) 93.0 2.0 2.0 38.0

Portman Koolyanobbing 87.7 7.7 17.1 60.6

Iron Ore 2005 Conference,

German Creek (QLD, 8-9 87 8 72 62 65

7 87 7.4 70 20 61.5 64.2

Oaky Creek (QLD, 8 78 9 57 58 64

Iron Ore 2005 Conference,

Courtesy: Pilbara Iron

Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

Overall Response Time

Consistency is a key raw material property !

Iron Ore 2005 Conference,

Coke Oven Gas (fuel

Iron Ore 2005 Conference,

 The two industries can learn from each other.

 There are more similarities than differences!

Iron Ore 2005 Conference,

Courtesy: Pilbara Iron Iron Ore 2005 Conference,

Iron Ore 2005 Conference,

HIP-L HIP-F HIP-L HIP-F HIP-L HIP-F HIP-L HIP-F HI-Y

HIP-L HIP-F HI-Y

A 5-year sojourn in WA with Hamersley Iron,

Inherent within these are several notable

Application of beneficiation – another contrast

Dewatering is also a contrast

mass KEY Mine

Intelligent Plant!! database Real time measurements

The two industries can learn from each other.

There are more similarities than differences!