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To be launched under the brandname of `Electro CRS-Gold', initially in Gujarat and Mumbai where coastal climate corrodes steel frames of buildings rapidly. The company expects to market 25 per cent of its 1.20 lakh tonne manufacturing capacity of thermo-mechanically treated (TMT) bars in the first year of the launch. Its Kutch-based plant has a total billet and TMT production capacity of 3.50 lakh tonnes annually, Mr Avinash Bhandari, Director (Operations), said here.

Electrotherm has invested nearly Rs 514 crore so far in its fully integrated steel plant at Samkhyali in Kutch that came up in 280 acres after the Centre and the Gujarat Government gave tax incentives in the district ravaged by the 2001 earthquake.

The current price of normal TMT bars is Rs 43,000 per tonne, whereas the CRS bars would cost Rs 47,000 per tonne, he told Business Line on the sidelines of the launch. The CRS bars would be available in 8 mm to 32 mm in sizes in both Fe 500 and Fe 415 grades.

Ministry of Steel in association with Joint Plant Committee, had organized a one-day International Seminar on Iron Ore Beneficiation and Pelletisation on 1" October, 2007 at Hotel Le Meridien, New Delhi. The focal point of the seminar was discussion on the present status of iron ore beneficiation arid pelletisation situation in the country, its prospect for growth specially in context of the projected rapid growth of the Indian steel industry as also for gainful use of the iron ore fines, generated in huge numbers but mostly exported with the domestic market failing to make proper use of them, since pelletisation facilities are lacking significantly. The Seminar drew a significant participation from the Indian industry and also saw representation from global industry, especially China. For a meaningful discussion, the Seminar was split into three Sessions: Session 1 on Raw Material Character & Beneficiation, Session 2 on Pelletisation and Session 3 on Recent Technical Development. Each of the Sessions saw presentation of technical papers in line with the theme of the Session, by the participants. In Session 1, experts of RDCIS, SAIL expressed in their paper, 'Beneficiation of low grade iron ore for pellet making' their concern with respect to extremely limited reserves of high grade iron ore in total ore reserves in the country. Considering the position of reserves and massive increase in steel production targeted by 2019-20, they placed great stress on utilization of low grade iron ore in the range of 50-58 per cent as well as huge quantities of dump/ slime, after beneficiation, which shall not only improve the reserves position, to the tune of about 10-15 per cent, but also provide micro-fines for pellet making for use in blast furnaces. They also pointed out the need for technological up gradation in iron ore processing circuit by introducing newer technology of iron ore beneficiation through R&D back up. Specific module for appropriate technology application needs to be developed for recovery- of micro-fines for each of the deposit with respect to ore body variation, size wise beneficiation test work, flow sheet development and feasibility assessment- In another paper in the same Session, representatives from All Mineral GmBH, Germany titled, 'Challenges and solutions for upgrading Indian iron ore to optimise mining arid steel production', emphasized the need of maximized utilization of ore resources for long term sustainability by using suitable beneficiation techniques. Among the many informative papers presented during Session 2, steel industry representatives from China detailed the present status and development of technology and pelletizing of Hematite in China. The counterpart Indian scenario was provided by the paper from MECON Limited, Pelletisation in India -Retrospect and Prospect', which revolved around the future prospect of pelletisation in India. The authors opined that in view of the changing iron ore scenario in the country, the Indian iron makers must shift focus from sinter intensive blast furnace operation to pellet oriented (15%-20%) operation. Authors also felt that due to sharp rise in Calibrated Lump Ore (CLO) price, it is imperative to switch over to pellets in some of the coal based DR installations. Among other papers, a detailed presentation, was made on iron ore beneficiation and its effect on pelletisation at JSW Steel, where representatives from JSW Steel shared their own experience in this field with ail. Keeping in tune with the other sessions, Session 3 also saw interesting presentations. Representatives from MCC, P.R. China briefed the audience in detail on the development of Hematite beneficiation and pellet technology, contrasting experience of both India and China. The authors emphasised the use of Chinese experience of beneficiation technology in India for supply of quality iron ore to the Indian steel industry since India has major reserves of hematite ore of varying quality. Essar Steel gave a succinct presentation on 'Techno economics of production of DR grade pellets' in which they described the source and beneficiation technique for preparation of iron ore concentrate and its transportation system through slurry pipeline to the Pellet plant at Vizag along with other operating aspects of the Essar pellet plant. The Seminar concluded on the note that beneficiation of low-grade ores, mostly at micro-fines level, provide concentrate, which can be used in iron making in the form of pellets. Therefore, pelletisation technology will have a. predominant role in supplying the prepared burden for iron making. Adoption of suitable pelletisation technology of varying capacity be encouraged to meet specific needs with respect to availability and type of iron ore fines/concentrate in the country. The role of Government was also stressed in the need to provide encouragement by way of policy support, incentives, so as to facilitate entrepreneurial initiative towards upgradation of low grade iron ores including slimes in tailing ponds by beneficiation and subsequent utilization of concentrate for sintering/ pellet making.

STEEL COS CUT TMT PRICE BY RS 1, 000 HRC's RS 500/T

CONCERNED over the political fallout, the government on Thursday succeeded in getting steel companies to agree to a rollback of steel prices that were increased 6-8% early this month. The integrated steel producers have announced an Rs 1,000 per tonne reduction in price of TMT bars and rounds used for construction activities and an Rs 500 cut in price of benchmark hot rolled coils (HRC) price. The price cm would be applicable with immediate effect. "Steel sector is on a path of rapid growth. At this juncture, we do not want to give a wrong signal that companies arc increasing prices frequently and profiteering, We are happy that steel companies have acceded to our request of rolling back some part of the hike, which would benefit the consumers," steel minister Ram Vilas Paswan told reporters after his meeting with representative of major steel producing companies. With the rollback, the benchmarks HRC prices are expected to come to a level of Rs 29,500-Rs 30,500 per tonne. Long products would benefit the most with the expectation that prices would fall by 3-5%. After partial increase in prices in January, public and private sector integrated steel makers increased HRC prices between Rs 2,000-2,500 per tonne early this month on account of rising prices of iron ore, coking coal and energy prices. The government stepped in because of the expectation that steel prices may increase further in coming days. "Sharp rise in input cost remains a concern for steel companies. I have written to finance minister P Chidambaram to consider reducing excise duty on steel from present 16% to 8%. I would also write to the railway minister Lalu Prasad Yadav to reduce freight charges on steel thai has increased between 50-90%," he said. As per the agreement, it is expected that steel prices would remain at current levels for at least a month. Any hike may be considered only in April, an industry source said. "Government has not restricted free movement of steel prices. The steel price may even fall down if global price of raw material softens," Jindal Steel and Power (JSPL) managing director Naveen Jindal said. While the present rollback is aimed at providing relief to the common man from a possible increase in his cost of construction materials, sources said in the current arrangement, the government has not ensured that this price cut would actually reach the consumers and not get absorbed by middlemen and intermediaries.

STEEL COMPANIES RELENT, AGREE TO ROLL BACK HIKE

Bowing to steel minister Ram Vilas Paswan's appeal, major steel producers, including Tata Steel, Steel Authority of India Ltd, and JSW. Essar and Ispat industries, on Thursday agreed to partially rollback the hike in steel price earlier this month. The domestic steel producers have decided to reduce the prices of TMT bars and rounds by Rs 1,000 and hot-rolled coils by Rs 500. In February, integrated steel producers had increased the prices of hot and cold rolled coils by Rs 1,500 to Rs 2,500 per tonne, citing high prices of input material in the international market. This was in addition to steel price hike in January when prices were hiked between Rs l, 000 and Rs 1,500. The decision to roll back prices was taken after the second meeting, which the steel ministry called. The first meeting on February 12 was inconclusive. "In the larger interest of the consumers we urged all steel producers to cut prices and they have agreed to reduce the prices of both TMT bars and hot rolled," steel minister Ram Vilas Paswan said after the meeting. The minister said the price hike, apart from hitting the common man due to its cascading effect on inflation, would also affect many of the down stream consumer industries such as small and medium manufacturers and construction sectors. Paswan also suggested the industry to maintain transparency in the price hike, besides advising them not to create havoc by predicting that steel prices may harden a sit only helps the middlemen. Paswan, however, assured the industry that he would write to the finance ministry for reduction in excise duty to 8% from l6% currently. The ministry would ask the finance minister to reduce custom duty on iron ore and coking coal from current 2% to 0% and that on scrap from 5% to 0% to help the country meet the target of steel production of' 100 Mt by 2011.

SLOW GREEN NODS MAKE POWER MIN SEE RED

Through the technology solution comparison of the hematite beneficiation and pellet between India and China in this paper, the conclusion can be summarized as below: China has rich experience in the technology of hematite beneficiation and pelletisation which can be completely applied in India hematite beneficiation and peilet industry and provide a platform for the cooperation of India and China's iron ore beneficiation and pellet technology.
Keywords: beneficiation; pellet; hematite.

CHINA'S IRON ORE RESOURCE CONDITION

With fast and stable development of China's economy, the steel industry has been developing promptly. The requirement parameters of all the local steel companies have been increasing rapidly. We can't depend on only high quality ore resources from abroad just because the local ore mine can't meet the requirement far. According to the statistics, China imported iron ore more than 10 million tonnes in the year of 1985, while in 2002 more than l00 million tonnes, in 2004 more than 200 million tons, in 2006 more than 275 million tons. In the local iron ore resource, the easily to be beneficiated magnetite has become less and less. For the purpose of making best use of the local iron ore resource, enhance the degree of self-sufficiency of the local steel companies, reduce the ore importing pressure and keep in good supply of the high quality iron ore, we must promote the high efficiency development and utilization of the poor iron ore resource based on the science and technology improvement. In China the iron mine has a lot of deposits with complex deposit condition, ore types are too many, sulfur, phosphor and silicon dioxide etc. malign materials contents are high, multi component inter growth iron mine occupies a high ratio. Further more the useful components the inlet grain size are small, so the beneficiation with big difficulty, low rate and poor product quality. Due to poor quality of China's iron ore resource, causes the development of the iron ore beneficiation of China and the overall level is very high. Especially at recent years, we researched and successfully utilised the new advanced high efficiency beneficiation equipment, flotation reagent and new beneficiation process, so caused the beneficiation process index to get the breakthrough development.

THE BENEFICIATION PRACTICE OF CHINA'S HEMATITE

The hematite iron includes magnetite-hematite mixture ore, which is the important iron resource of China. In the beginning of 1960s, the main hematite processing technology with poor production index was baking-magnetic separation and single flotation. In recent years the hematite beneficiation got breakthrough because of the new process, new equipment and reagent are adopted.

ANGANG DIAO JUNTAI BENEFICIATION PLANT
The hematite is the only iron ore in the crude ore of AnGang Diao Juntai beneficiation plant, gangue is quartz, the crystallization grain of the mine is big. The beneficiation plant design capacity is 9MT/ year, adopted two sections continuous grinding mine, weak-separation--strong separation-- reverse flotation process. On the basis of iron grade 28 per cent, the beneficiation index reaches: the concentrate iron grade 67 per cent above, the iron recovery more than 75 per cent, tailing iron grade about 10 per cent.

ANGANG QIDASHAN BENEFICIATION PLANT

The hematite is the only iron ore in the crude ore of AnGang QiDaShan beneficiation plant, gangue is quartz, the crystallization grain of the mine is small. The beneficiation plant design capability is 8MT/annum. The original design adopted baking -- magnetic separation -- flotation process technology; the concentrate only can get the grade about 63 per cent. After the improvement of the process technology, adopted the process technology of stage grinding, rough concentrate rewashing and weak magnetic separation -- strong magnetic separation
-- reverse flotation, so that on the base of crude iron ore 29 per cent can get the index of concentrate grade more than 67.5 per cent, the recovery rate higher than 70 per cent and the tailing iron grade about 13 per cent.

ANGANG HUJIAMIAO BENEFICIATION PLANT

The hematite is the only iron ore in the crude ore of AnGang HuJiaMiao beneficiation plant, gangue is quartz, the crystallization grain of the mine is asymmetry. The beneficiation plant design capability is 8MT/annum, adopted the process technology of stage grinding, rough and fine separation, weak magnetic separation -- strong magnetic separation
-- gravity separation -- reverse flotation, so that on the base of crude iron ore 28 per cent can get the index of concentrate grade more than 67 per cent, the recovery rate higher than 70 per cent and the tailing iron grade about 11 per cent.

WUYANG IRON MINE TIESHANMIAO BENEFICITION PLANT

The hematite is the only iron ore in the crude ore of WuYang iron mine TieShanMiao beneficiation plant, gangue is quartz, the crystallization grain of the mine is asymmetry. The beneficiation plant design capability is 3.5MT/annum, adopted the process technology of stage grinding, weak magnetic separation--strong magnetic separation--gravity separation and reverse flotation for the tailing of gravity separation, so that on the base of crude iron ore 29 per cent can get the beneficiation index of concentrate grade more than 65 per cent, the recovery rate higher than 70 per cent and the tailing iron grade about 12 per cent.

TANGSHAN SIJIAYING BENEFICIATION PLANT

The hematite is the only iron ore in the crude ore of Sijiaying beneficiation plant, gangue is quartz, the crystallization grain of the mine is asymmetry. The beneficiation plant design capability is 7MT/annum, adopted the process technology of stage grinding, respective separation for rough and fine ore, gravity separation--magnetic separation--reverse flotation, so that on the base of crude iron ore grade 29 per cent can get the beneficiation index of concentrate grade more than 66.55 per cent, the recovery rate higher than 75 per cent and the tailing iron grade about 10 per cent.

CHINA'S IRON ORE PELLET TECHNOLOGY

Though the starting of China's iron ore pellet technology is late, the development is fast .In the beginning of 1990s, there were only several shaft furnace pellet plant with several million tonnes output, while till 2007 develops into more than 20 production plants and the output exceeds 100 million tons, the production equipment changed from the low efficient shaft furnace into belt baking machine and traveling grate machine-rotary kiln, the single equipment capability reaches 5MT/annum. The pellet plant newly put into production almost adopt imported iron ore with the main content hematite which is more than 80 per cent of the raw material. Since the magnetite is the main part of the iron concentrate in local, almost all producers blended the local magnetite during the pellet production. At present the ongoing WISCO No.2 pellet production line, and Bao Steel ZhanJiang pellet plant both adopt the hematite as the only iron ore material, the designed capacity is 5MT/annum. Almost all pellet plants of China adopt traveling grate machine-rotary kiln except a few who adopt shaft furnace and belt type baking machine. The advantages are saving the building investment, stable product quality, strong adaptability for the fuel, natural gas, oil and coal all can be used.

PROFILE OF INDIAN IRON MINE

India is one of the countries with the most abundant mineral reserves in the world. The basic reserve of the iron ore is about 23.58 million tonnes, of which about 12.9 million tonnes of hematite and 10.68 million tonnes of magnetite ore, ranking sixth in the world and accounting for about 6.8-7 per cent of the world's total reserves. At present, the output of iron ore India ranks eighth accounting for about 8 per cent of the world's total reserves. As the demands of domestic and export boosted in recent years, the iron ore output of India increased substantially. The annual output was 86.22million tonnes in 2002, and reached 145.94 million tonnes in 2005, of which 48.15 million tonnes for domestic demand and 78.14 million tonnes for export. Currently India's total iron ore mining capacity is 154.43 million tonnes annually, of which state-owned enterprises account for 51 per cent and the rest is produced by private enterprises. The lump ore that contains over 65 per cent iron accounts for 21 per cent of India's total iron ore output, and the iron ore fines that contains over 65 per cent iron accounted for 16.2 percent. The Indian government divides the resource into three grades according to the iron level: over 65 per cent is high-grade ore, 62-65 per cent is mid-grade ore, and less than 62 percent is low-grade ore. Of the hematite resources, 10.4 per cent are high-grade ore that concentrate in Chattisgarh, Orissa, Karnataka and Jharkhand; and 34 per cent are mid-grade ore that concentrate in Orissa, Karnataka, Jharkhand and Madhya Pradesh. Since many Indian iron ore resources are located in the nature reserves or in the jungles and mountains, it's difficult to exploit, so in the 23.58 billion tons of iron ore reserves of India the basic reserves that can be exploited is only 17.27 billion tonnes. Environmental problem has become a key issue affecting the future of India's iron ore resources exploitation. Such as the mine owned by Kudremukh Iron Ore Company (KIOCL) in the forest land of West Coast in Karnataka, has ever been India's largest single mine. The output of the raw ore reached 20 million tonnes annually, and its pellet ore also reached 350,000 tonnes every year, but because of the opposition of the domestic environmental organisations, the Indian High Court adjudged to close the mine at the end of December 2005.

INDIAN IRON ORE BENEFICIATION AND PELLET

Since the Indian iron resource almost is the rich ore with high iron grade, the grade more than 60 per cent iron ore occupies more than a half of the total. The already exploited mines have few beneficiation process and only a few mine add the washing process in ore crushing screening procedure, and leave the slime as tailings impoundment. The main raw material of the pellet is the powder of the rich ore, which utilizes concentrate from beneficiated ore. Under the present scenario with the stable growing of iron ore price, the question how Lo increase the utilisation rate of the iron resource and protect the environment of the mine has been the priority by the government and enterprises. On one hand, the slime obtained from the washing are comprehensively to be used, reduce the tailing impoundment and reduce the pollution for the air; On the other hand, beneficiate the powder which obtained from the lump ore production to reduce the silicon and alumina etc, gangue volume and improve the quality. Compared to China's hematite, Indian hematite has absolute priority in the grade quality. The grade of China's hematite crude ore is only about 30 per cent, while that of Indian ore can reach 45 per cent and above. Mono mineral crystallization grain of China's hematite is relatively coarse and the gangues are mainly quartz, the ore with high hardness is difficult to be slimed, so the separation rate is high. In the low-grade hematite of India, the grain of iron ore and gangue are both small and the gangue contents a large amount of alumino-silicate except, so the beneficiation should decrease silicon as well as aluminum. The sulphur and phosphor quantity contained in Indian hematite are also relatively high, so it's difficult for beneficiation. The hardness of the India's low grade hematite is low, which gives advantage of low energy consumption when crushing and grinding, while the disadvantage is the ore easily to be slimed and after sliming the ore can be washed away with water which cause low recovery of iron. Borrowing experience from the beneficiation of China, take beneficiation into the low-grade hematite of India and further utilize the concentrate beneficiated for pellet production has already got big improvement. Utilizing the high microseism gradient magnetic separator and combine the reverse notation process, can get concentrate grade about 66 per cent, SiO2, less than 4 per cent, A12O3 less than 3 per cent, the recovery more than 65 per cent as well the sulphur and phosphor content volume can be reduced. Recently the hematite pellet test of India got success and the pellet quality reaches the requirement of blast furnace iron making. Technically it's not a problem to use the concentrate from the low-grade hematite beneficiation for the pellet production.

CONCLUSION

From the comparison of hematite resource condition, ore property, beneficiation type index and the pellet technology between China and India, though the big difference exists in the quantity, quality and beneficiation type index, the rich experience of China in hematite beneficiation and pellet technology can be completely utilized in hematite beneficiation and pellet technology of India. The successful test and research in partial mine validate this point and will provide the reference for the cooperation of China and India in the beneficiation and pellet technology area.

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In the wake of rapid growth in the expansion of steel plants, India may face acute crisis of coking coal in coming years and to face this challenge, the country should find out suitable technologies to accommodate inferior quality of coal in the blast furnace without losing the productivity and quality of steel, industry experts warned at the recent "International conference on coking coals & coke making: Challenges & Opportunities".

Rourkela Steel Plant (RSP) managing director, Sanak Mishra, inaugurating the conference said India has to continue the coke oven system in the steel plants as electronic furnaces were costly and would increase the production cost of steel.

A Bhattacharya, director (commercial) Mecon Ltd., said time has come to modernise coke ovens as this would remain the main route of steel production in India.

Other speakers highlighted areas like widening coal supplies by identification of new sources, adopting technologies which can accommodate inferior quality of coal; sea-borne trade in coking coal, developments in coal preparation and pre-carbonization technologies, enhancemennt of battery life efficiency, optimal operational practices for enhanced coal production and eco-friendly and emission free coke production.

More than 250 delegates representing various plants and units of Sail, Tata Steel, JSW Steel, Sesa Industries, Simplex and others participated in the conference.

Overseas delegates from Ukraine, Australia, China, Germany, Indonesia, etc. also joined the conference.

Professor Veena Sahajwalla of the University of New South Wales has won a prestigious Australian science award for what she calls "the hottest research in town", which she hopes will turn an environmental headache into a valuable resource.

Under the process, waste plastics are fed into electric steel-making furnaces as an alternative source of carbon and heated to super-hot temperatures of 1 600°C.

Sahajwalla said many waste plastics, from shopping bags to dishwashing liquid containers and drink bottles, contain high enough levels of carbon to be useful in steelmaking.

Carbon is used to add strength to steel. The higher the carbon content, the stronger but less ductile it is.

"What happens in a steelmaking furnace is that we are melting scrap steel, you can imagine if you've got your old cars and washing machines and so on," Sahajwalla said.

"The carbon component that's present inside plastic is what we're after and, at those high temperatures, we're able to react it in a way that we're able to use that carbon that's locked in the plastics.

Typically you would add coal and coke," she said. Clyde Henderson, of coal industry newsletter Energy Economics, said similar technology using pellets of recycled plastic had been used in firing power stations in Japan.

"I guess it's probably going to be, in terms of proportion of feed for these kinds of plants, a relatively minor kind of thing," Henderson said.

"I don't think the coal industry would see it as a threat. It's more an environmental angle, I think," he said.

Sahajwalla said her process did not replace all of the coal and coke, and used a mix of plastic and coal.

Australia is the world's top coal exporter, shipping 122 million tons of metallurgical grade coal worth $9-billion (about R43-billion) last year.

Australians use roughly a million tons of plastics a year, much of which ends up as waste destined for landfills.

"If you've got a whole lot of waste plastics that end up in landfill, not just in Australia but across the world, then it's really coming up with alternative technology for its disposal which is environmentally friendly," Sahajwalla said.

Conventionally, welding steel and aluminium together has been a rather impossible task. However, by optimising the rotating tool shape and joining characteristics, and by using galvanised steel on one side, this process has been made possible.

Galvanised steel helps prevent the galvanic corrosion that results from contact of two different types of metal. Compared to conventional joining techniques such as riveting or clinching, steel and aluminium spot friction welding makes it easier to join materials that are difficult to deform. Additionally, running costs can be reduced as riveting becomes unnecessary. The process also contributed significantly to Mazda's vehicle weight reduction efforts during the development of the Mazda MX-5 sports car.