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2. Iron Ore and Coal Consulting www.tatasteelconsulting.com Excellence with a global reach www.tatasteelconsulting.com 3. Foreword UK-based multi-disciplinary consultancy company providing specialised services for the development of iron ore, coal and steel industry projects. www.tatasteelconsulting.com TS Consulting Excellence with a global reach More than 40 years of proven track record in feasibility studies, market studies, benchmarking exercises for both iron ore and steel products Mining and Raw Materials Ironmaking Steelmaking and Casting Rolling Mills and Finishing Project Management Business Planning 4. Foreword www.tatasteelconsulting.com TS Consulting Excellence with a global reach TS Consulting has in-depth understanding of the global markets for steel and iron ore. Tata Steel Consulting is part of one of the Worlds largest steel companies which purchases around 25Mt/y of iron ore for its integrated steel plants in Europe and produces 10Mt/y at its wholly owned mines in India Expertise to assess the quality of a particular iron ore in respect to downstream processing (sintering, pelletising, ironmaking etc.) Knowledge of geological, mineralogical and metallurgical aspects of a wide variety of iron ore deposit styles across the globe 5. Foreword The Mining and Raw Materials Team has assisted a broad range of clients in public and private sectors all over the world. Clients sectors include: www.tatasteelconsulting.com TS Consulting Excellence with a global reach Junior Miners European Union (PHARE) Investment Banks Development Banks Metals Producers World Bank Management Consultancies Private Investors 6. Iron Ore and Coal Consulting www.tatasteelconsulting.com Excellence with a global reach www.tatasteelconsulting.com 7. Motivation www.tatasteelconsulting.com TS Consulting Excellence with a global reach Product Quality is a Key Area in Project Studies Is it Really? Product quality is increasingly often inadequately addressed in Technical Studies (Conceptual, Pre-Feasibility, Definitive Feasibility) Growing technical inaccuracy and Worrying technical corner cutting (The Mineral Corporation, 2014) Vulnerability of projects to severe criticism by independent technical reviewers (acting on behalf of lenders) Due Diligence 8. Product Quality in Technical Studies (1) www.tatasteelconsulting.com TS Consulting Excellence with a global reach 9. Product Quality in Technical Studies (2) www.tatasteelconsulting.com TS Consulting Excellence with a global reach Why is it important to know Quality Requirements? Determination of processing requirements Optimisation of product mix Identification of target customers Estimation of accurate selling price (premiums/penalties) Avoid project delays and cost increases Improvement of project robustness 10. Iron Ore and Coal Consulting www.tatasteelconsulting.com Excellence with a global reach www.tatasteelconsulting.com 11. Definition of Iron Ore www.tatasteelconsulting.com TS Consulting Excellence with a global reach What is Iron Ore? Iron ore is any rock or mineral from which iron can be extracted economically Iron ores are a mixture of iron oxides, iron (oxy)hydroxides, iron carbonates and other compounds collectively referred to as gangue The principal ore minerals are hematite (Fe2O3), magnetite (FeO.Fe2O3), goethite (FeO.OH) and siderite (FeCO3, to a lesser extent) 12. Definition of Iron Ore www.tatasteelconsulting.com TS Consulting Excellence with a global reach The most important Gangue Minerals that may occur are Silica SiO2 (or quartz) and silicates of calcium, magnesium, sodium etc. Phosphates such as apatite (Ca5(PO4)3(F,Cl,OH)) and monazite ((Ce,La,Nd,Pr)PO4) Sulphides such as pyrite (FeS2) and pyrrhotite (Fe1-xS) Oxides of metals such as titanium, manganese and vanadium Carbonates of calcium (calcite) and magnesium (dolomite) Iron oxides may contain deleterious elements in mineral lattice! 13. Production Routes to Steel (1) www.tatasteelconsulting.com TS Consulting Excellence with a global reach Source: worldsteel.org 14. Production Routes to Steel (2) www.tatasteelconsulting.com TS Consulting Excellence with a global reach There is no melting and no elimination of gangue as slag Oxygen is removed other constituents remain in direct reduced iron (DRI ) and increase in concentration ! The charge must be very permeable to the up-flow of reducing gas The charge must be strong and not disintegrate Sulphur in the iron ore feed is undesirable (