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, 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 ...

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

  • 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
  • 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
  • Australia’s positioning Innovation for Carbon Steel | Law and Holmes | Page 3 View slide
  • 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 View slide
  • 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 for Carbon Steel | Law and Holmes | Page 6
  • 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 13
  • Low costs (quality and scale) New discoveries Source: McKinsey Sustainability & Resource Productivity Practice, 2011 Innovation for Carbon Steel | Law and Holmes | Page 14
  • Source: McKinsey Sustainability & Resource Productivity Practice, 2011 Innovation for Carbon Steel | Law and Holmes | Page 15
  • 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 | Law and Holmes | Page 21
  • 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 oxide Innovation for Carbon Steel | Law and Holmes | Page 23
  • 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 36.705 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
  • 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-spot elemental analysis prior to blasting  Developed as a collaborative partnership with BHP Billiton IO Innovation for Carbon Steel | Law and Holmes | Page 28
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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