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Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
Christopher Price, Green Iron Technology
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Christopher Price, Green Iron Technology

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  • 1. IRON ORE BENEFICIATION AFRICA 2014 Presentation by: Christopher Price - Green Iron Technology (Pty) Ltd.
  • 2. This presentation contains protected Intellectual Property (IP) and “Know-How” and is protected by Patent Law. Use of this information in commerial applications is strictly prohibited, unless approval is granted in writing by the IP owner, sight of this literature is acknowledgement of its protected status on the part of the recipient. PATENT NO. 2010/04810
  • 3. The future is bright
  • 4. “The cost of producing steel can be reduced by 30%”   Christopher Price - CEO Green Iron Technology
  • 5. “The carbon footprint of steel production can be reduced by 30%”   Christopher Price - CEO Green Iron Technology
  • 6. “Imagination is more important than knowledge ....Knowledge is limited to all we know and understand...... Imagination embraces the entire World and all there will ever be to know and understand” Albert Einstein
  • 7. We need to think outside of the box
  • 8. The ones who are stupid enough to think that they can change the world, are the ones that do Steve Jobs
  • 9. At the 1968 Olympics Bob Beamon made a leap in the Long jump that minutes before would have been considered impossible. He broke the previous world record by nearly two feet, previously the record had progressed by fractions of an inch. Our industry needs to take a quantum leap – Noun: An abrupt change, especially in method
  • 10. Iron Beneficiation It’s not new It is not difficult to achieve It need not be expensive
  • 11. It is not new The iron age in Africa dates back 2500 years when early forms of steel were produced. Zimbabwe Ruins – African Iron Age City
  • 12. It is not difficult Iron-age man produced iron with iron rock, wood and fire. The method is simple, the ingredients are few, cheap and readily available.
  • 13. “Everything should be as simple as it can be” Albert Einstein
  • 14. The Direct Reduction Process Iron ore is beneficiated by altering it’s chemistry so that iron oxide is converted into elemental iron, to achieve this oxygen is extracted from the ore using a reductant under high temperature conditions (700ºC – 1250ºC ). Reduction* can be achieved without melting the ore, this is termed “solid state reduction” . * Reduction means: reducing the amount of oxygen
  • 15. Common reductants are coal and natural gas – the choice of which is driven by the cost and location of the reductant source relative to the iron ore deposit. Reduction is normally a process step carried out in an industrial setting e.g. at a steel mill – it is possible given suitable equipment to carry out reduction, which provides a significant value uplift, at the mine site. This is true beneficiation
  • 16. Coal + Heat + Iron Ore = HBI
  • 17. Current solid state reduction processes Rotary Hearth Rotary Kiln Shaft Furnace
  • 18. Heavy steel construction – thick as amour Conventional iron reduction plant is constructed from very heavy steel plate Strong enough to support huge rotating masses
  • 19. Refractory linings – thick as Castle Walls Thick refractory linings are: Heavy Expensive Poor insulators Have high thermal mass
  • 20. Large expensive mechanics Expensive gearing High component wear Large rotating mass High component wear
  • 21. The solution Space age materials Light-weight Ultra high temperatures Reduced costs
  • 22. Reduction time Small particles = fast 1mm = 5 minutes Large particles = slow 12mm = 10 hours
  • 23. Rotary Kiln High velocity gas flow Not suitable for fines Fines get blown out
  • 24. High Titanium and low-grade ores These ores present processing difficulties and increased costs to the steel maker. South Africa has substantial deposits of these ores, which would be of significant commercial benefit to the country if they could be beneficiated locally.
  • 25. High percentages of titanium are deleterious to blast furnace operation. Low-grade ores need to be ground to small particle sizes to liberate and concentrate the iron content, after grinding these ores cannot be used in commercial scale production plants. The solution: Pre-reduce – Briquette - Melt in an arc furnace = pig iron
  • 26. Process time is temperature dependent Low temperature = slow High temperature = fast Rotary kilns operate at low temperatures
  • 27. CO CO CO 1600ºC 1250ºC Fe₂O₃+C CO + O₂ = CO₂ + HEAT 250ºC CO₂O₂O₂ H₂ CH₄ O₂ 1100ºC 850ºC AIR 20ºC Fe Fe HBI CO CO CO CO CO CO CO CO CO O₂ O₂ O₂ O₂ O₂ O₂ O₂ CO₂ CO₂ CO₂CO₂ CO₂ O₂ O₂ O₂ O₂ O₂ O₂ O₂ CO₂ CO₂ CO₂ O₂ O₂O₂ O₂ O₂O₂
  • 28. Static slope furnace Has a fixed slope down which fine ore feed slides under gravity Makes use of the principal of the angle of repose of granular solids Controlled residence time governed by rate of removal of DRI Thermal coal fines are used as the reducing agent
  • 29. Suitable for ore fines without further pre-treatment Furnace constructed from light-weight materials It has no moving parts within the furnace hot zone Allows heating from above and below the hearth- result is high production rates Special hearth floor has very high thermal conductivity
  • 30. Very low power requirement – can operate off a generator Lowest production cost of any process Modular - projects can commence with low capital investment Proof of concept completed – ready for commercial applications
  • 31. Key facts Steel construction is 1/6th of the weight of conventional equipment Space age insulation is 1/10th of the weight of industry standard Temperatures of 1550ºC are possible Extremely short residence time – 5-10 minutes All energy is used in the process – no CO emissions Very low maintenance costs
  • 32. Packaged concept A packaged design has been designed for use in remote locations Built off-site in a factory setting Modular Can be relocated
  • 33. Built in power supply Modules from 25kt/yr High return on investment – R.O.I. of over 50% Equipment built into standard 12m shipping containers for easy transport
  • 34. Capital $450 Inputs $150 Outputs $400 Profit $250 R.O.I + 50% HBI Production
  • 35. “It seems impossible until it’s done“ 46664 Nelson Mandela
  • 36. Thank You

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