IRON ORE & STEEL
Rotary Scrubbers are used to clean clayey/siliceous coatings from iron ore lumps as the first stage of Iron Ore Beneficiation.
Circular Motion Screens are used to segregate various size fractions in ore streams. Sometimes Circular Motion Screens are used to reduce load on crushers by removing fraction which is already smaller than required product size and at other times Circular Motion Screens are used to recirculate oversize fractions from crushed product stream back to crushers. Possible application is in Mines before despatch to beneficiation plants and also in beneficiation plants. Circular Motion Screens Screens are available in 1, 2 and 3 decks to get 2, 3 and 4 size fractions respectively. Each size fraction may be requiring different post processing.
Linear Motion Screens are used for similar applications but in more demanding situations, e.g.-
- Where the height is limited by surrounding facilities,
- For the screening of small and short fractions
- Where required throughput is high.
High Particle Acceleration Screens
Also known as Flip Flo Screen, High Particle Acceleration Screens are ideally suited for screening applications for higher level of moisture and fine grain size materials (1 mm to 10 mm) with screening capacities up to 250 metric TPH. In Iron Ore & Steel industry High Particle Acceleration Screens are used for fine screening in Flux Crushing & Screening circuits. The Inner frame is agitated by means of eccentric shaft drive. The vibration is passed on to the Outer frame via flexible thrust plates.
Screening mats between the inner and outer frame are clamped and flexed by the two vibrating frames. The relative movement of both screening frames creates a “trampoline effect” in the screen mats to create-
- High acceleration up to 50g in screen mats.
- Loosening-up and de-agglomeration of the product.
As opposed to above three types of screens which are based on bed stratification principle, Roller Screens are based on free fall principle. Roller Screens are used in Iron Ore Pellet Plants when it is essential to prevent breakage and degradation of pellets and efficient separation of fines for recycling back to pelletisers. Trolley Mounted Roller Screens are used in Coke Sorting Plants. It is also good for handling Feed material containing larger boulders along with smaller particle size.
Grizzly Screens are used in primary crushing operation in Iron Ore Mining as scalping screen in downstream of the Primary Ore Crusher to separate undersized and oversized ore. Typical separation is at 80 mm. However other sizes are also used depending upon feed analysis, product size etc. Grizzly Screens are also used as Feeders to reclaim ore from Hoppers/Bins.
Grizzly Feeders /Vibrating Feeders
Grizzly Feeders /Vibrating Feeders are used to reclaim feed stream from storage bins/ hoppers or as a feeding equipment to crusher & screen where the materials are not easy to handle (wet, clayey or lot of ash content), having size fractions ranging from big lumps to significantly high percentage of wet/moist fines and where scalping is also needed.
Jaw Crushers are used as alternatives to Gyratory Crushers as primary crushers in Iron Ore Mining when the throughput needed is less than 500-600 metric TPH. For hard ores Double Toggle Jaw Crushers and for softer ores Single Toggle Jaw Crushers are customary, but based on cost and life expectations (lower costs but with lower wear life in ST variety for hard ores) this distinction is mostly blurred.
Hammer Mills (Reversible Hammer Mill)
Hammer Mills (Reversible Hammer Mill) are used in crushing the coal in Coke Oven Plants before charging to ovens. Hammer Mills (Reversible Hammer Mill) are used in recycling of iron & steel scraps by shredding to smaller size for re-melting. Reversible Hammer Mills are also used for flux crushing in preparation of Sinter Mix.
(-) 300 mm Lumps of Hot/ Cold primary crushed sinter in sintering plants is reduced to (-) 50 mm size by Toothed Double Roll Crushers. Capacity is in the range of up to 400 metric TPH. Toothed Double Roll Crushers are also used as Coke Cutter in Coke Sorting Plants.
In Iron Ore & Steel industry Smooth Double Roll Crushers for tertiary crushing of Iron Ore with feed size being limited to 45/50 mm and product in the order of 5-10 mm. Smooth Double Roll Crushers are also used crushing coke in preparation of Sinter Mix.
Rod Mills (Grinding Mill)
Rod Mills (Grinding Mill) are used to reduce crushed Iron Ore from 12 mm to 1 mm. The ore product may be used directly for sale or for further grinding to micron sizes by Ball Mills (Grinding Mill). Basically Rod Mills (Grinding Mill)are used in Iron Ore beneficiation and in Pelletisation and Coke Crushing for preparation of Sinter Mix in Sintering Plants.
Ball Mills (Grinding Mill)
Ball Mills (Grinding Mill) are used for size reduction to microns and form part of grinding circuit in an Iron Ore Beneficiation/ Pelletisation Plant. Another application is for coal/coke grinding in Coal Dust Injection system for the Blast Furnace and for Calcium Carbonate grinding in Desulphurisation circuit in Steel Making.
Bucket Elevators are used for vertical transport of powdery, small grained bulk materials e.g. dolomite, feldspar, limestone, clinker etc. particularly in flux preparation units in Steel making.
Rotary Disc Feeders
Rotary Disc Feeders are continuous volumetric device reclaiming dry small lumps, coarse, fine grained and powdery material from surge bins and hoppers to feed subsequent equipment. In Iron & Steel making Rotary Disc Feeders can be used for dosing alloying elements in mechanised casting shops.
In Iron Ore Beneficiation plants usually the process involves transporting of Ore Slurry (suspension of Crushed/ Ground Ore in Water) between various stages. This is done by use of Slurry Pumps. MSEL has a vast range of Horizontal and Vertical Centrifugal Pumps catering to Slurry Pumps requirements. Slurry Pumps are also used in Slag Granulation and ETP Plants.
Thickeners are used to dewater Ore Slurry to about 60- 70 % Solids. Overflow product is mostly water and is recycled into circuit whereas the underflow is taken for filtration (in case of Concentrate Thickeners) or to tailings as reject disposal. Thickeners are required for thickening the slurry to desired pulp density for processing, dewatering or for water recovery at the end of the process.
We have the filter press in collaboration with Choquenet France for the concentrate and tailing applications.
We can offer complete Beneficiation plant with the design and supply in our scope for Iron ore. We can also offer complete Grinding plant package for the pellet feed application.
Waste water treatment plant
The dust scrubbers of Blast furnace, SMS, BOF etc. generate lot of slurry. We can offer total water recovery system package with design and engineering where in waste solid will be converted in the form of cake for the useful purposes with least moisture.
Column Flotation Cells
Column Flotation Cells are used in beneficiation of Iron Ore fines (< 100 microns) where gravity and magnetic separations are not effective. Column Flotation Cells are also used to reduce silica by flotation process as required in Pelletisation circuits.
U Flotation Cells are used for removal of specific impurities e.g. Alumina, Phosphorous, Quartz and Silica. Tests determine the suitability of U Flotation Cells or Column Cells described above.
Basically Motorised Trippers are rail mounted conveyor discharging equipment to uniformly distribute the conveyed Ore over a large Bin or Ground Storage stockpile.
MSEL product range includes all types of drive and non-drive pulleys, and idlers.
Apron Feeders are extensively used to reclaim ROM/ Large Size ores from Dump Hoppers for primary crushing at mine end Ore Handling.
In integrated steel plants which are distant from Mines the various raw material including iron ore are brought by rail and unloaded into Hoppers by Wagon Tipplers for further conveying to various locations inside the Plant.
Paddle Feeders are used for continuous reclaiming of raw material from track hoppers (stocked by Railway Rakes) on to reclaim conveyors for further processing in Plants.
Bucket Wheel Stacker cum Reclaimers
Bucket Wheel Stacker cum Reclaimers are used in Integrated Steel Plants or at ports to create large ground stockpiles of raw materials and also to reclaim from the stockpile on to conveyors.
MSEL has agency agreements with reputed manufacturers to sell Cone Crushers equipment, which are required in Iron Ore Crushing to 30 mm/ 10 mm sizes in Beneficiation and Pelletisation circuits. Other applications are in Steel Desulphurisation circuits for crushing limestone. It is also used for crushing slag in metal recovery plants.