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Haver & Boecker Niagara and Metinvest have met: Together for a future with more CO2-efficient ironmaking processing

The iron and steel industries are indispensable components of economy. Our world is built by using steel. We need even more steel for the improvement of infrastructure of our cities. Owing to this increasing steel demands we consider significantly growth of the iron ore production in recent years.

On the other hand, there are many environmental effects from the iron industry. Iron ore and steelmaking are the largest energy consumer of electricity and fossil fuels, being responsible for over 25% of hazardous atmospheric emissions and over 30% of carbon dioxide emissions. That’s why we need to think about sustainable solutions that minimize the CO2 emissions and energy use by iron ore production; solutions that deliver higher performance in terms of energy efficiency, resource efficiency and better process and product performance. We need CO2-efficient ironmaking processes.

One of the possible solutions could be direct reduction process like Midrex- or HYL, Corex process. 1

In this light, the transformation of iron ore into steel requires several process stages. First at all, we need to become H2 and iron ore pellets. Iron ore pellets produced from the iron ore concentrate by pelletizing and sintering. At the same time, the quality requirements of pellets, such as size distribution, physical, chemical and metallurgical specifications are higher and should be guaranteed by very innovative pelletizing technology that is able to ensure the perfect flow for our blue planet.

As a world’s leading supplier for customized screening, washing, pelletizing machines and plants solutions, we are feeling responsible to take actions into the protection of our environment by developing systems, which use fewer resources, fulfill the needed higher quality of the pellets and care for the health of the mother Earth.

Тhe result of our efforts we developed the SCARABAEUS pelletizing disc. The pelletizing disc fulfills the specification deeds for the processes of direct reduction and saves up to 5% energy by reduced recycling rate. The production capacity can be up to 150 t/h.

Those characteristics convinced experts from Eastern Europe in the potential of our innovative pelletizing technology for the production of iron ore pellets with a very narrow particle size distribution (10 to 12,5 mm) and high product rate (up to 70 %). Subsequently we got the great opportunity to work with one of the international steal and mining groups in east Europe: Metinvest. Аfter conducting iron ore tests in Haver Engineering in Freiburg and proving the possibility of achieving the desired parameters, a contract for the supply of the necessary equipment was signed. The pelletizing disc SCARABAEUS 7500 was delivered in combination with completely automatic control system.

In order to satisfy the higher needs of the pellets, an automatic pelletizing disc control system was introduced for the first time, incorporating three machine parameters: rotation speed, tilt angle, and board height.

In the end of July the CEOs of Haver Niagara GmbH (Peter Grotjohann) and Metinvest (Yuriy Ryzhenkov) have met in the manufactory of Metinvest in Ukraine. They inspected our powerful and reliable pelletizing technology and discussed the future course of our business relationship. The managers have dealt with all the advantages that our technology ensures to Metinvest and put heads together into developing the best strategy that is able to become fully aware of their common vision for the future: to live in a stronger, lighter and more sustainable world, where technology guarantees the care for the health of the mother Earth using highest environmental protection standards.

We are very happy that starting working together with Metinvest opened new doors to more CO2-efficient ironmaking processes and we have the unique opportunity to lay the first foundation stone of the future to green iron ore processing.

Metinvest, we would like to express our huge thanks for the trust, which you have placed in us. It is such a pleasure working together!

 

 

1 https://www.tec-science.com/de/werkstofftechnik/stahl-erzeugung-herstellung/direktreduktionsverfahren/

https://de.wikipedia.org/wiki/Stahlerzeugung

Geheimrezept hoher Druck und wenig Wasser: Der Hydro-Clean reinigt Körnungen von Schad- und Störstoffen bei geringem Ressourceneinsatz.

Die Hydro-Clean Waschanlage HC aus dem Programm von Haver & Boecker Niagara befreit in effektiver Weise Nutzkorn von Schad- und Störstoffen. Dabei soll der Wasserbedarf im Vergleich zu traditionellen Waschsystemen um bis zu 75 % niedriger liegen bei ebenfalls um bis zu 15 % geringeren Energiekosten. Dieser Spareffekt ist der kompakten Baugröße und dem geringeren Gewicht gegenüber traditionellen Waschsystemen, die zudem eine größere Aufstellfläche haben und mehr Ausrüstung benötigen, zu verdanken. Das wartungsfreundliche Design ermöglicht im Bedarfsfall den einfachen Austausch der wenigen Standardkomponenten, wobei der HC laut Hersteller wenig verschleißanfällig sein soll.

Zur Reinigung von Aufgabematerialien bis zu einer Größe von 150 mm in einer vertikalen Trommel sprühen Hydro-Clean-Hochdruckdüsen Wasser mit Drücken bis zu 140 bar bei einer Drehzahl von 90 UpM auf das Material. Das Waschsystem entfernt auf diese Weise Schlamm- und Lehmpartikel bis zu 63 Mikron aus Mineralgemischen.

Die Waschanlage ist in vier Modellgrößen erhältlich, die 18 bis 400 t Material pro Stunde aufbereiten, je nach Typ und Anwendung. Der Wasserverbrauch reicht dabei je nach Anwendung und Modellgröße von 102 bis 798 l/min.

Das System funktioniert folgendermaßen: Verunreinigtes Material wird über einen Trichter in die vertikale Trommel des Hydro-Clean aufgegeben, woraufhin die oben montierten Hochdruckdüsen rotieren und das Material mit Wasser besprühen. Die Turbulenzen in der Trommel erzeugen zusätzliche Scheuer- und Schleifkräfte, die den Reinigungsprozess verstärken, während das Material den Trommelzylinder passiert. Am Ende des Reinigungsprozesses wird die Aufgabe über einen Abzugsförderer ausgeleitet, der zu einem Waschsieb führt. Dieses ist für eine Nachwäsche zuständig, während es gleichzeitig das Material fraktioniert.

Lesen Sie den Beitrag in Ausgabe 4/2019 von Gesteinsperspektiven

Haver & Boecker Niagara Offers Turnkey Solutions for Primary Crushing Plant Systems

MÜNSTER, Germany (June 5, 2019) — Haver & Boecker Niagara offers rugged primary crushing plants in a wide variety of configurations for pre-crushing, secondary and tertiary crushing in the mining and aggregates industries. From design to installation, the manufacturer uses its extensive industry experience and knowledge to provide turnkey systems engineered and built to individual specifications. Haver & Boecker Niagara will work with any crusher and peripheral component manufacturers to ensure customers receive the best plant matched to their requirements.

Grotjohann2

“We’re entrenched in the mining and aggregates industries and are dedicated to each customer’s profitability and success,” said Peter Grotjohann, managing director of the German facility. “We use our industry experience and work closely with each operation to design comprehensive primary crushing plant systems with the highest level of durability, service and flexible design so each customer can find the best plant for their operation.”

Haver & Boecker Niagara offers turnkey primary crushing plant solutions through customer-oriented project support, from initial concept to the production phase. In addition to coordinating the physical plant, Haver & Boecker Niagara offers structural building engineering at the start, including verifiable statics calculation. The company features transportation management, supervision or the complete package: from assembly and electrical installation to plant start-up and optimization. Haver & Boecker Niagara also offers project management, on-site services, operating supplies, components or plant control. Operations also benefit from service and spare parts planning and service contracts.

Haver & Boecker Niagara provides crushing plant systems with a variety of components, including impact, jaw, cone or roller crushers, Haver screens or rolling screens, push feeders, apron conveyors and Haver vibrating feeders. The plant systems work with all peripheral components such as maintenance cranes, de-dusting systems, compressed air systems, hydraulics and hammers.

Customers choose from two types of systems, basic or master. Basic is the classic pre-crushing plant that uses a Haver & Boecker Niagara N-Class eccentric screening machine to relieve the primary crusher. It includes a feeder, vibrating screen, crusher and several conveyors. If needed, an additional screen deck screens stony earth either to be screened away or to be fed to production.

PM-261-s14-oben

The master system allows customers to get the most production and profitability out of their natural mineral deposit. The system provides increased flexibility for primary crushing stages, especially with non-homogeneous natural deposits. For high quality natural deposits, the operations can use the master system to feed extracted material completely to the production. The system can screen stony soil off to a second vibrating screen for moderate natural material deposits. The system can be configured to completely remove stony soil from difficult natural material deposits.

Both systems work with the Haver & Boecker Niagara N-Class vibrating screen. The screen is perfect for scalping thanks to its smooth operation and heavy-duty design making it capable of screening as much as 5,000 tons per hour. Haver & Boecker Niagara builds the equipment with an advanced four-bearing design that minimizes structural vibration and maintains constant g-force even through fluctuating material feed rates.

Haver & Boecker Niagara primary crushing plant systems feature rugged steel construction and a robust design incorporating a durable, optimum flow, low wear and maintenance friendly chute system and integrated custom conveyor technology. Accessibility is easy thanks to engineered work platforms, walkways and stairway systems. Integrated plant control systems and data management ensure intuitive operation.

Also included is comprehensive plant documentation on CE requirements and beyond and declaration of conforming with EC directives for machines 2006/42/EG (CE). Haver & Boecker Niagara gives extensive consideration of requirements for personal safety and the environment.

About Haver & Boecker Niagara

Haver & Boecker Niagara is a leading provider in screening, washing, pelletizing and primary crushing systems. The company’s mission is to deliver the best of these technologies to customers in the aggregates, mining, mineral processing, chemical and food industries. With deep roots and years of experience in these industries, Haver & Boecker Niagara uses its innovative and shared technologies to effectively meet the needs of customers around the world.

Underground processing plant for fluorspar

The opening up of a new mine in Germany’s Erzgebirge (Ore Mountains) in late 2013 marked a milestone for German mining, continuing the tradition in this region, following decades of stasis. The reasons for the extraction of fluorspar and baryte are closely tied to steadily rising raw material prices on the world market. The operator, the Erzgebirgische Fluss- und Schwerspatwerke, chose HAVER NIAGARA GmbH when it came to designing and installing an underground processing plant for the mine in the Erzgebirge. HAVER NIAGARA GmbH took on the challenge to set up a flexible and economically viable processing plant (Fig. 1). Despite the limited space and the high requirements to be met by the processing plant, a tailored plant was designed (Fig. 2) that fulfils the high expectations of the operator to full satisfaction.

Fig. 1: Production line installed by HAVER NIAGARA GmbH

Fig.2: The space restrictions made it necessary to speciallytailor the plant to the conditionsin one of the two underground chambers

 

 

 

 

 

 

 

 

 

 

 

 

The processing plant roughly consists of two independent production lines, which were installed in two parallel underground caverns. In the first process stage, the blasted raw material is removed from the feed bin by means of reciprocating feeders and fed to a NIAGARA scalper (Fig. 3). This reduces the load to be processed in the downstream jaw crusher. The material from the primary crusher is conveyed on a troughed belt conveyor to a NIAGARA screen, which as well as screening off the ultrafine material, splits the material into two sub-streams to feed an X-ray sorting plant. This sorter separates the raw spar from the “dead rock” on the basis of the atomic density. The raw spar obtained in this way is crushed in a cone crusher to the necessary finished grain. The crusher discharge is sent via a downstream NIAGARA screen to a loading silo, there the raw spar is loaded onto road trucks.

Fig. 3: NIAGARA scalper in the first stage of the process

From there, the material is conveyed to the processing plant above ground, where it is ground and enriched in a flotation plant and then separated into the main components baryte and fluorite. After drying, two high-grade raw materials are produced, which are then sold.

Over the next years, HAVER NIAGARA GmbH will be on hand providing services for our german customer to keep the complete plant at its best both economically and ecologically.

More profit with the innovative washing technology Hydro-Clean®

Reduced water and energy use

Haver & Boecker Niagara advanced Hydro-Clean® washing technology is helping a gold producer looking to expand its operation in eastern Russia increase production, reduce water consumption and minimize wear. The producer currently uses a test washing drum and two bearing screen to separate the sand and clay from its mined gold ore. This method provides inadequate washing results, causes excessive equipment wear and consumes high volumes of water and energy. Working closely with the customer, the HSG set up the Hydro-Clean 700 unit (Fig. 1) and rinse screen as a separate test operation to prove it could successfully wash the operation’s three distinct products better than the current test equipment. Each product has varying degrees of impurities, ranging from easy-to-wash to sticky material that is nearly impossible to clean with the current washing system. Since installing this combination, the operation has increased production from 5 t/h to 25 t/h, reduced its water consumption by up to 70 % and saved up to 30 % energy for every ton of material.

In preparation for a large mine upgrade project, these positive results have led the operation to put the Hydro-Clean in its plans for all future mineral washing.
The Russian gold producer, who asked to remain unnamed due to the competitive advantage this equipment provides, first contacted the HSG about the Hydro-Clean in 2009 after seeing impressive results at a different gold operation using HSG equipment. The Hydro-Clean appealed to the producer because its current washing system, a traditional washing drum, was not removing enough sand and clay content to produce the required 2 mm to 120 mm gold product with clay content less than 2 %.

 

 

 

 

 

 

• Clay-heavy material on the conveyor

Ideal for use in clay-heavy material deposits (Figs. 2 and 3), the Hydro-Clean employs high-pressure nozzles, rotating at 90 rpm, to spray up to 90 % recycled water on the material with pressures up to 200 bars (2900 psi) to remove silt and clay particles as small as 63 μm from mineral mixtures. While the high-pressure nozzles mounted at the top rotate and spray the material with water, the turbulence in the drum creates additional scrubbing and abrasive forces that enhance the cleaning process to break up agglomerates and clean the particles of stubborn material. The Hydro-Clean also injects high-pressure streams of water into areas of the material (holes, cracks, etc.) that are difficult to reach with traditional cleaning methods. A UME 1200 x 4500 mm rinse screen follows and rinses away the loose sand and clay contaminants. The end result is a cleaner gold ore product with clay content less than 2 % (Fig. 4).

• Final product is a clean washed material

The Hydro-Clean consumes far less water and energy. The test washing drum and two bearing screen used by the Russian gold producer consumes up to 13 m3 (13 000 liters) of water to wash just one ton of material. With the Hydro- Clean and rinse screen, the producer only uses a maximum of 4 m3 (4000 liters) of water for each ton of material, reducing the operation’s water consumption by up to 70 %.

In addition to water savings, the Hydro-Clean 700 model used by the gold producer was able to save up to 1.8 kW of energy for every ton of cleaned material when compared to the washing drum system. The Hydro-Clean’s compact size and reduced weight keep overall operating and structural costs considerably lower than with traditional washing systems – which also require more equipment and a greater footprint. In addition, it experiences little wear with a low-maintenance design that allows for simple replacement of the few standard components that are subject to wear. This allows operations to save thousands of rubbles in yearly maintenance costs. Thanks to the success of the Hydro-Clean 700 test unit, the producer plans to authorize an investment program that will allow the installation of a larger washing operation with several HSG Hydro-Clean 1000 units.

This operation would be capable of washing up to 4 million t of auriferous ore a year. To make the adaption of this new, advanced washing technology easier, the HSG has provided easy-to-understand flow sheets on how the Hydro-Clean would fit into this new operation. If made part of the producer’s every day operation, the Hydro-Clean could reduce its total water usage by up to 70 % and energy costs by up to 30 %.

 

Primary crushing plant and processing of riprap in the Sauerland region

 

HAVER NIAGARA GmbH: after one and a half year new operators came to a positive result

The quarry for greywacke “Kleinhammer” is situated among a wooded mountainous region in Sauerland, sixhundred meters in south-east direction to the town Werdohl-Kleinhammer. Since the change of ownership in January 2015, Holcim, a manufacturer of construction material, has operated the quarry. Ownership changes did not result in a change of personnel.

In close collaboration with the previous operator HAVER NIAGARA GmbH designed a new primary crushing plant with subsequent processing of riprap. Besides the primary crushing plant and processing of riprap the scope of supply also included the complete conveying system, the intermediate silo and the dust silo as well as the planning of concrete works and the overall assembly.

The main challenge in this project were great demands of the customer on quality specifications, emission and environmental standards as well as the tight schedule for finalization. Furthermore, the installation should secure a safe and flexible production for the next decades. By means of the designed concept HAVER NIAGARA provided an innovative solution for the fulfilment of these requirements.

An example of the flexible production is the processing plant for riprap. The weight classes 540 kg and 10-60 kg can be processed separately or simultaneously on request by means of two heavy duty screening machines. Soundproofed building facades, energy saving electrical components and the dedusting unit are the main objective with regard to emission and environmental protection.

The period for the realization from the start of project until commissioning took 12 months. Due to the onset of winter at the beginning of 2013 concrete works had to be stopped for several weeks. Therefore, the planned start of production was endangered. The specialist in  from Münster took up that challenge and modified the assembly process, so that contrary to the initial plan the building for the processing of riprap was installed at first. The concrete works on the building for the primary crushing plant have been continued at the same time. As a result of the measures taken, the scheduled start of production was at the beginning of September 2013. On the occasion of the opening celebration on 27 September the installation was formally inaugurated with a spectacular firework.

The successful realization of the project has been achieved by long-term and close cooperation between the previous operator and the experts from HAVER NIAGARA. This is the pooling result of years of experience and the technical know-how of both companies.

The precise realization on the basis of prescriptions is an impressive example for the problem-solving expertise of HAVER NIAGARA – particularly with regard to an efficient conception of primary crushing plants and its precise implementation.