Sustainability Driving Efficient High-grade Pellet Process

#Automation #Metal #EssarMinmet

A. S. Prasad

India has been strengthening its Industrial development and investment activities at a rapid speed. Mr. A. S. Prasad, Director, Essar Minmet, shares with Pro MFG Media, the journey of Indian manufacturers in the metal sector.

Metal Industry is growing at an enormous rate, and India is not far behind in the race. With mega-projects announced in the metal sector, the manufacturing sector is adapting many new technologies and innovations for better efficiency.

Currently, the China market has opened for pellets, and the Indian market has to compete against Brazilian pellets, which are known for their quality & commitment in the market. The Brazilian pellet has the best chemistry, physical properties and provides excellent performance for the end-users. Indian manufacturers face a challenge in controlling the chemistry and physical properties. Even though the Indian manufacturers use similar advanced technologies, the tailor-made process parameters create a massive difference. The customization takes time to meet the requirement of end-users leading to errors in the process, which is another challenge. Presently, the organization opts for standard equipment infused with customization to meet the customer’s requirements. Although they have to compromise on the physical properties, the end product is highly similar to the Brazilian product. The China market is highly interested in the Indian pellets and is content with the half chemistry pellets available. Indian metal manufacturing industries have addressed the challenges and have adopted the changes in the processes.

The iron ore processing part - enrichment of low grades ores, is performed with new automated equipment and instruments. In the initial days, they had to measure and analyze hourly to perform corrective actions, whereas nowadays, there are online instruments available to control the process. Apart from that, the equipment reliability on online condition monitoring has improved immensely, which helps to maintain the productivity levels. The mineral industry is witnessing many positive changes in the past few years.

The introduction of the new technology for Slurry transportation is one of the critical elements in the industry, and recently Essar Minmet shared its expertise on an esteemed platform. In the Indian context, the transportation of minerals by a long-distance pipeline is the future of the logistics sector. This approach will help to produce the required volume of steel. Such technologies have been well received in the Indian territory, and have been operating at three different pipelines with the highest automation levels. Similar technologies will be used by new players who are planning to install the beneficiation & palletization plants to manufacture the raw materials.

Since the metal industry emits various gases, which leads to pollution, many new clean technologies such as electrostatic precipitators, plant process fans, variable drives, and automation on the burner management systems help reduce the emissions. The new technologies support Indian operation with respect to the carbon footprint and emissions and environmental friendly technologies in all the three aspects of iron ore processing.