This document summarizes the process developed by B.D. Nanda and team to recover saleable slag from jigging tailings at the Ferro Alloys Plant in Joda, India. The team developed a process to crush the mixed metal and slag waste to under 15mm, then screen it to separate slag with manganese content over 30%, addressing a growing demand-supply gap. This process eliminated waste dumping, reduced environmental impacts, and generated an annual net benefit of over 322 lakhs for the plant and 412 lakhs for downstream industries by providing higher quality slag. The innovative solution converted waste into a usable input that improved operations while achieving environmental and economic benefits.

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RECOVERY OF SALEABLE SLAG FROM JIGGING TAILINGS
WEALTH OUT OF WASTE…

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 Leader : B.D.NANDA (HEAD, FAP JODA)
 Unit : FAP JODA
 Division : FAMD, TATA STEEL Ltd.
 Members :
 D.D.Parida
 B.Srinivas
 Kaushik Shubhank
 B.N.Rout
INNOVATORS

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PROCESS FLOW OF FERRO ALLOYS PLANT, JODA
ARC FURNACE TAPPING METAL & SLAG CAKES
H C FERRO MANGANESE
HIGH MnO SLAG
STEEL MELTING SHOP
SILICO MANGANESE INDUSTRY
CUSTOMER

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PROCESS FLOW OF METAL & SLAG RECOVERY
WASTE
MIXED METAL WITH SLAG INCLUSIONS MIXED METAL CRUSHING [0-20mm]METAL & SLAG BREAKING
JIGGED METAL
JIGGING MACHINE

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BACKGROUND [THE TRIGGERS…]
 FAP, Joda produces 50400 MT of High Carbon FeMn /annum and generates about 36000 MT of High
MnO slag as a byproduct.
 High MnO slag is one of the input raw materials for SiMn industry [FY 11 requirement ~ 55000 MT ].
 As per the TS expansion plans for FY15, 78000 MT of High MnO FeMn slag will be required.
 Current demand-supply gap [19000 MT] will shoot up.
 200 Kg of waste is generated per ton of FeMn produced at FAP,Joda [ ~ 800MT/month].
 Storage of waste creates space constraint and dumping is not an environment friendly methodology.
Idea
generation
Trial
implementation
Triggers Results Benefits
Waste dump

6. GENERATION OF IDEAS
 IDEA # 1: Entire waste can be sent for re-jigging with an attempt for slag separation.
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Execution
• Job: Re-jigging of waste by jigging machine
• Purpose: Slag removal by gravity separation
Result
• No separation of saleable slag
• Unfruitful running of machine with no desired
output
Problems
• Density of slag and other waste was same.
Idea
generation
Trial
implementation
Triggers Results Benefits

7. IDEAS
 IDEA # 2: Entire waste can be sent for dressing of slag pans used for tapping.
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Execution
• Job: Dressing of slag pans for tapping
• Purpose: To increase the life of slag pans.
Result
• Unsafe tapping conditions.
Problems
• Burnt coke particles lead to boiling of metal due
to burning.
• Waste not facilitating in cooling of cakes.
Idea
generation
Trial
implementation
Triggers Results Benefits

8. IDEAS
 IDEA # 3: Entire waste can be sent for filling of low lying areas (inside plant)
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Execution
• Job: Filling of nearby low lying areas
• Purpose: Discard the tailings to tackle space
constraint inside the plant.
Result
• Waste disposal to low lying areas inside plant
since 10 years.
Problems
• Space constraint building up.
• Non-environment friendly approach.
• High Disposal cost [Rs 8.64 lakhs/yr]
Idea
generation
Trial
implementation
Triggers Results Benefits

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NEED FOR AN INNOVATIVE APPROACH:
 It was observed that the waste material had 60% of slag pieces in it.
 Customer requirement of High MnO slag was for MnO ~30%, Silica ~22%.
 Composition of tailings: MnO ~ 22%, Silica ~ 38%.
 A challenge came up to convert the waste into usable material.
 The major challenge was to enhance the quality from 22 – 30 % MnO.
 An innovative thought of recovering slag from the waste and reducing the
waste dumping simultaneously.
Idea
generation
Trial
implementation
Triggers Results Benefits

10. IDEAS
 IDEA # 4: Entire waste can be sent for manual screening to recover saleable slag.
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Execution
• Job: Screening of jigging waste by 6 /8 /10 mm
screen.
• Purpose: Recover saleable slag by removing
impurities.
Result
• MnO = 22 -24% and Silica ~ 38%
Problems
• Specification not up to customer’s requirement
of MnO > 30%
Idea
generation
Trial
implementation
Triggers Results Benefits

11. PROCESS IMPROVEMENT
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Process designed for Secondary crusher to reduce jig
feed to – 15 mm.
Fused sand got crushed to undersize and
separated as hutch with water
CHEMICAL ANALYSIS OF SLAG:
MnO = 34 % , Silica = 25%
38% Silica in recovered slag was analyzed wherein
fused sand particles were found .
Fused sand inclusions coming out after
screening (14%) [Jig feed size : 0-20mm]
CHEMICAL ANALYSIS OF SLAG:
MnO = 22-24%, Silica = 38%
FUSED SAND
FINAL PRODUCT
Idea
generation
Trial
implementation
Triggers Results Benefits

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ACHIEVEMENTS:
THE ASPECT OF DEMAND–SUPPLY GAP
 +10 mm screen recovered slag having MnO
~ 34 % and Silica ~ 25%.
 The recovery of slag is 500 MT/month.
 Supply-demand gap of slag was reduced
by 6000 MT/annum.
 Recovered slag was used @ 400Kg/MT of
SiMn as input material.
QUALITY TRAILS & RESULTS
6/8/10 mm MANUAL
SCREEN [Jig feed: -20mm]
10 mm MANUAL SCREEN
[Jig Feed: -15mm]
Chemical Analysis
MnO – 22% MnO – 34%
SiO2 – 38% SiO2 – 25%
Idea
generation
Trial
implementation
Triggers Results Benefits

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 Dumping of waste was reduced by 100%.
 Environment friendly approach adopted.
 Elimination of diesel consumption by vehicles used for
dumping from 160 L/month to 0L.
ACHIEVEMENTS:
ENVIRONMENTAL ASPECT
Total captive reserve of Mn Ore in Joda contains only 20% of High grade Ore,
rest being medium and low grade ore.
 Recovered slag substitutes High Grade Mn ore by 400Kg/MT of SiMn produced, thus
saving the precious natural reserves.
 High Mn:Fe ratio helps in consuming more of low/medium grade Mn ore for SiMn.
Idea
generation
Trial
implementation
Triggers Results Benefits

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 The undersize waste from screening is
being used for dressing of slag pans.
 Recovered slag substitutes fresh river
sand consumption by 30%.
ACHIEVEMENTS:
ENVIRONMENTAL ASPECT
Using High MnO slag instead of high grade ore reduces the need for carbothermic
reduction of the substituted amount.
Coke consumption required for reduction reduces by 320 MT/annum.
Power consumption accordingly drops by 50 KWH/MT of SiMn when slag is used.
Idea
generation
Trial
implementation
Triggers Results Benefits

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DIRECT TANGIBLE BENEFIT:
 Total recovery of slag from waste till Feb’11
= 6200 MT.
 Realization of slag = Rs. 6000/MT
 Processing cost for screening = Rs. 90/MT
 Net benefit = Rs 322 Lakhs/annum.
ACHIEVEMENTS:
FINANCIAL ASPECT
Idea
generation
Trial
implementation
Triggers Results Benefits
RIVERSAND :
 Reduction in fresh river sand consumption
= 1235 Cu.m/annum.
 Cost of sand = Rs 435/Cu.m
 Net benefit = Rs 5.3 Lakhs/annum.
DISPOSAL:
Reduction in waste = 9600 MT/annum.
Cost of handling = Rs 90/MT
Net saving = Rs. 8.64 Lakhs/annum.

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ACHIEVEMENTS:
FINANCIAL ASPECT
Idea
generation
Trial
implementation
Triggers Results Benefits
BENEFITS to SiMn INDUSTRY:
[A] High Grade Mn Ore:
Substitution of high grade ore = 400 Kg/ MT of SiMn
Total substitution = 4000 MT/annum
 Differential cost = Rs 9000 / MT
Net benefit = Rs 360 Lakhs/annum

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ACHIEVEMENTS:
FINANCIAL ASPECT
Idea
generation
Trial
implementation
Triggers Results Benefits
Total saving for FAP Joda = Rs. 336 Lakhs/annum
Total saving for SiMn industry = Rs. 412 Lakhs/annum
BENEFITS to SiMn INDUSTRY:
[B] COKE:
Reduction in coke consumption = 320 MT/annum.
Cost of coke = Rs 10000/MT
Net benefit to SiMn industry = Rs 32 Lakhs/yr.
BENEFITS to SiMn INDUSTRY:
[C] POWER:
 Reduction in power = 50 KWH/MT of SiMn
 Cost of power = Rs 4 /KWH
 Cost saving = Rs 20 Lakhs/yr
[D] QUALITY:
 Slag substitution helps to reduce detrimental
Phosphorus contribution to Steel.

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ACHIEVEMENTS:
CUSTOMER APPRECIATION

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FLOW DIAGRAM OF SALEABLE SLAG RECOVERY PROCESS