Research and innovation for the iron
ore to carbon steel value chain
CSIRO Minerals Down Under Flagship
Jonathan Law | Dir...
A view of the fundamental drivers…
1. Australia’s positioning
2. Our evolving industry
3. Our work across the value chain
...
Australia’s
positioning

Innovation for Carbon Steel | Law and Holmes | Page 3
Iron ore production – top 5 : 2,400Mt globally (2010)

100Mt
900Mt

260Mt
370Mt

420Mt

Data from USGS
Innovation for Carb...
Source: World Steel Association, 2012
Innovation for Carbon Steel | Law and Holmes | Page 5
New iron ore production capacity: 2011 to 2016

3%
3%

5%
34%

34%

Total 880Mt globally

Data from MEG, 2012
Innovation f...
Australian mines and developments

Innovation for Carbon Steel | Law and Holmes | Page 7
Australian production by State

Innovation for Carbon Steel | Law and Holmes | Page 8
Australian production by ore type

28% of resource base

Innovation for Carbon Steel | Law and Holmes | Page 9
Declining ore grades

Innovation for Carbon Steel | Law and Holmes | Page 10
WA water and energy resource consumption

Innovation for Carbon Steel | Law and Holmes | Page 11
Our evolving industry
‘not business as usual’

Innovation for Carbon Steel | Law and Holmes | Page 12
Source: McKinsey Sustainability & Resource Productivity Practice, 2011
Innovation for Carbon Steel | Law and Holmes | Page...
Low costs (quality and scale)
New discoveries

Source: McKinsey Sustainability & Resource Productivity Practice, 2011
In...
Source: McKinsey Sustainability & Resource Productivity Practice, 2011
Innovation for Carbon Steel | Law and Holmes | Page...
Source: PWC, Mine, the growing discontent, 2012
Innovation for Carbon Steel | Law and Holmes | Page 16
Source: MCA and Port Jackson Partners, 2012
Innovation for Carbon Steel | Law and Holmes | Page 17
Source: MCA and Port Jackson Partners, 2012
Innovation for Carbon Steel | Law and Holmes | Page 18
Source: MCA and Port Jackson Partners, 2012
Innovation for Carbon Steel | Law and Holmes | Page 19
Source: MCA and Port Jackson Partners, 2012
Innovation for Carbon Steel | Law and Holmes | Page 20
Our work across the value chain
1. Sensing
2. Impurity removal
3. Eco-friendly steel making

Innovation for Carbon Steel |...
Global first – seamless national ASTER map

Innovation for Carbon Steel | Law and Holmes | Page 22
17 ASTER Geoscience maps of Australia

AlOH Group content
composition
Ferric index composition
Silica oxide content
Ferric...
Iron oxide zoom for iron ore exploration

channel iron ore

10 km

Innovation for Carbon Steel | Law and Holmes | Page 24
Delivered free via the web…
http://portal.auscope.org/portal/gmap.html

SBDD079 Tray 9, 36.7 to 41.6 m
37.2 m

37.6 m

36....
Ore Characterisation

VG

QEMSCAN

K

Recognition
OG
H

30 microns
Real time exploration data: downhole NAA

Innovation for Carbon Steel | Law and Holmes | Page 27
Real time blast hole analysis
 Laser Induced Breakdown

Spectroscopy
 Integrated with a 4WD platform

 Provides on-the-...
Our work across the value chain
1. Sensing
2. Impurity removal
3. Eco-friendly steel making

Innovation for Carbon Steel |...
Bioflotation
 Microorganisms or their
metabolites act as either
flotation reagents, collectors
or modifiers, making possi...
Phosphorus Removal
 Phosphorus tends to be associated largely with the goethite in Australian
iron ores
 Desliming can r...
Our work across the value chain
1. Sensing
2. Impurity removal
3. Eco-friendly steel making

Innovation for Carbon Steel |...
Designer Biochar in steel making
 Ironmaking uses large amounts of coal and
coke
 Convert biomass into ‘designer’ charco...
Dry slag granulation
 Uses a patented technology to air quench
melts such as slag and capture a large
quantity of heat
 ...
Towards integrated solutions…
• Integrated steel making process has the potential to deliver positive impact
from agricult...
Thank you
Minerals Down Under Flagship
Jonathan Law
Director
t +61 3 9545 8316
e Jonathan.Law@csiro.au
w www.csiro.au/MDU
...
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Jonathan Law, CSIRO Minerals Down Under National Research Flagship: Research and innovation for the iron ore to carbon steel value chain

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Jonathan Law, Director, CSIRO Minerals Down Under National Research Flagship delivered this presentation at the 2012 FeTECH conference, the leading forum for technical developments evolving around the exploration, mining and beneficiation of iron ore.
FeTECH 2013 will focus on the economics of processing and the beneficiation of iron ore. In light of the slowdown in demand for iron ore and pricing decreases, the need to process more efficiently and cost effectively is a challenge. The conference will take a closer look on how we can achieve greater value from the iron ore supply chain, with topics addressing optimisation and streamlining processes, applying improved technologies, understanding the ore body and how to properly characterise it, knowing the steelmakers needs. For more information and to register, please visit the conference website: http://www.informa.com.au/fetechconference.

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Jonathan Law, CSIRO Minerals Down Under National Research Flagship: Research and innovation for the iron ore to carbon steel value chain

  1. 1. Research and innovation for the iron ore to carbon steel value chain CSIRO Minerals Down Under Flagship Jonathan Law | Director Ralph Holmes | Industry Manager – Carbon Steel Materials MINERALS DOWN UNDER FLAGSHIP
  2. 2. A view of the fundamental drivers… 1. Australia’s positioning 2. Our evolving industry 3. Our work across the value chain  Sensing  Impurity removal  Eco-friendly steel making Innovation for Carbon Steel | Law and Holmes | Page 2
  3. 3. Australia’s positioning Innovation for Carbon Steel | Law and Holmes | Page 3
  4. 4. Iron ore production – top 5 : 2,400Mt globally (2010) 100Mt 900Mt 260Mt 370Mt 420Mt Data from USGS Innovation for Carbon Steel | Law and Holmes | Page 4
  5. 5. Source: World Steel Association, 2012 Innovation for Carbon Steel | Law and Holmes | Page 5
  6. 6. New iron ore production capacity: 2011 to 2016 3% 3% 5% 34% 34% Total 880Mt globally Data from MEG, 2012 Innovation for Carbon Steel | Law and Holmes | Page 6
  7. 7. Australian mines and developments Innovation for Carbon Steel | Law and Holmes | Page 7
  8. 8. Australian production by State Innovation for Carbon Steel | Law and Holmes | Page 8
  9. 9. Australian production by ore type 28% of resource base Innovation for Carbon Steel | Law and Holmes | Page 9
  10. 10. Declining ore grades Innovation for Carbon Steel | Law and Holmes | Page 10
  11. 11. WA water and energy resource consumption Innovation for Carbon Steel | Law and Holmes | Page 11
  12. 12. Our evolving industry ‘not business as usual’ Innovation for Carbon Steel | Law and Holmes | Page 12
  13. 13. Source: McKinsey Sustainability & Resource Productivity Practice, 2011 Innovation for Carbon Steel | Law and Holmes | Page 13
  14. 14. Low costs (quality and scale) New discoveries Source: McKinsey Sustainability & Resource Productivity Practice, 2011 Innovation for Carbon Steel | Law and Holmes | Page 14
  15. 15. Source: McKinsey Sustainability & Resource Productivity Practice, 2011 Innovation for Carbon Steel | Law and Holmes | Page 15
  16. 16. Source: PWC, Mine, the growing discontent, 2012 Innovation for Carbon Steel | Law and Holmes | Page 16
  17. 17. Source: MCA and Port Jackson Partners, 2012 Innovation for Carbon Steel | Law and Holmes | Page 17
  18. 18. Source: MCA and Port Jackson Partners, 2012 Innovation for Carbon Steel | Law and Holmes | Page 18
  19. 19. Source: MCA and Port Jackson Partners, 2012 Innovation for Carbon Steel | Law and Holmes | Page 19
  20. 20. Source: MCA and Port Jackson Partners, 2012 Innovation for Carbon Steel | Law and Holmes | Page 20
  21. 21. Our work across the value chain 1. Sensing 2. Impurity removal 3. Eco-friendly steel making Innovation for Carbon Steel | Law and Holmes | Page 21
  22. 22. Global first – seamless national ASTER map Innovation for Carbon Steel | Law and Holmes | Page 22
  23. 23. 17 ASTER Geoscience maps of Australia AlOH Group content composition Ferric index composition Silica oxide content Ferric oxide Innovation for Carbon Steel | Law and Holmes | Page 23
  24. 24. Iron oxide zoom for iron ore exploration channel iron ore 10 km Innovation for Carbon Steel | Law and Holmes | Page 24
  25. 25. Delivered free via the web… http://portal.auscope.org/portal/gmap.html SBDD079 Tray 9, 36.7 to 41.6 m 37.2 m 37.6 m 36.705 m Aspectral 36.8 m P1: P2: P3: 38.4 m 37.676 m Aspectral 38 m P1: P2: P3: 39.2 m 39.6 m 38.713 m Aspectral 38.8 m P1: P2: P3: 40.4 m 39.641 m Aspectral 40 m P1: P2: P3: 41.2 m 40.58 m Aspectral 40.8 m P1: P2: P3: 0 200 400 600 Distance along section (mm) Innovation for Carbon Steel | Law and Holmes | Page 25 800 1000
  26. 26. Ore Characterisation VG QEMSCAN K Recognition OG H 30 microns
  27. 27. Real time exploration data: downhole NAA Innovation for Carbon Steel | Law and Holmes | Page 27
  28. 28. Real time blast hole analysis  Laser Induced Breakdown Spectroscopy  Integrated with a 4WD platform  Provides on-the-spot elemental analysis prior to blasting  Developed as a collaborative partnership with BHP Billiton IO Innovation for Carbon Steel | Law and Holmes | Page 28
  29. 29. Our work across the value chain 1. Sensing 2. Impurity removal 3. Eco-friendly steel making Innovation for Carbon Steel | Law and Holmes | Page 29
  30. 30. Bioflotation  Microorganisms or their metabolites act as either flotation reagents, collectors or modifiers, making possible the selective separation of minerals  Potential advantages – Enhanced mineral selectivity – Environmentally benign reagents  Specifically targeting removal of impurities such as silicates, aluminosilicates, phosphorous Innovation for Carbon Steel | Law and Holmes | Page 30
  31. 31. Phosphorus Removal  Phosphorus tends to be associated largely with the goethite in Australian iron ores  Desliming can remove some phosphorus, provided it is concentrated in the ultrafine size fractions  Currently evaluating leaching options – Heat treatment – Acid or caustic leaching – Reduction from 0.15 %P (too high) to say 0.06% P (quite acceptable) 0.16 0.14 Phosphorous Assay (%) 0.12 0.1 0.08 0.06 Heat and Water Leach 0.04 Heat and NaOH Leach 0.02 Heat with 10% NaOH and Water Leach 0 0 200 400 600 Temperature (°C) Innovation for Carbon Steel | Law and Holmes | Page 31 800 1000 1200
  32. 32. Our work across the value chain 1. Sensing 2. Impurity removal 3. Eco-friendly steel making Innovation for Carbon Steel | Law and Holmes | Page 32
  33. 33. Designer Biochar in steel making  Ironmaking uses large amounts of coal and coke  Convert biomass into ‘designer’ charcoal for specific applications in iron and steel  Up to 50 per cent less carbon dioxide for every tonne produced.  With OneSteel (Arrium) and BlueScope Steel Innovation for Carbon Steel | Law and Holmes | Page 33
  34. 34. Dry slag granulation  Uses a patented technology to air quench melts such as slag and capture a large quantity of heat  Produces a highly ‘glassy’ product as a feed for Portland cement.  Reduces fresh water usage and sulphur emissions to the atmosphere  With OneSteel (Arrium) and BlueScope Steel Innovation for Carbon Steel | Law and Holmes | Page 34
  35. 35. Towards integrated solutions… • Integrated steel making process has the potential to deliver positive impact from agriculture through to cement making • Reducing greenhouse gas emissions, water usage and waste in steel making • Creating value added by products Salinity control Biomass Energy Iron & steel Energy TREE PLANTING BIOMASS BIOCHAR HOT SLAG SLAG Agriculture Bio-fuel processing Innovation for Carbon Steel | Law and Holmes | Page 35 Smelting Dry granulation Cement Cement making
  36. 36. Thank you Minerals Down Under Flagship Jonathan Law Director t +61 3 9545 8316 e Jonathan.Law@csiro.au w www.csiro.au/MDU Innovation for Carbon Steel | Law and Holmes | Page 36

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