Transcript No Slide Title

Emerging steel markets
and their impact on coking
coal and coke.
Dr. Kalyan Sen
CFRI
India Govt. thrust on infrastructure projects,
lower interest rates, booming economy:
The steel production is expected to grow at
rapid pace.
The buoyancy in Indian steel market is a
combination of demand for exports, mainly to
China and a positive outlook in certain sectors.
This will lead to increased demand of good
quality coking coal and Low ash metallurgical
(LAM) coke.
Part II
3
Estimated Demand of Met Coke
• By 2011-12 India would require 31 million tonnes (mt)
• 12.5 mt produced & consumed by main producers
• 18.5 mt will be required by secondary steel producers
out of which 14 mt need to be produced by Merchant
coke producers.
31 mt of coke is equivalent to ~ 44 mt of
washed coking coal !!
What are the supply sources ?
Fuel supply chain
Existing trend (2002-03)
· Import of coke 2.245mt
· Import of coking coal 12.947 mt
· Washery Cleans ~ 8 mt
Fuel supply chain
Future projection (2011-12)
·Import of coke 4.5mt
·Washery cleans ~ 8 mt (The output of the
existing washeries is likely to decline)
· Import of coking coal 30 mt ?
Considering steep increase in price of both coke &
coking coal and their availability, the situation is
rather gloomy
Constraints of price & availability
Coke imports in india were 2,782mt in 02-03 out
of which 89% was from China..
Coke price rise
 Explosion in coke demand in China
 Large rise in Chinese coke production costs
 Gradual erosion of coke capacity out side of China
The rise in coke price coupled with its unavailability
has become the biggest challenge confronting the
secondary sector pig iron industry
Coking coal having good coking properties, low
sulphur and ash contents has become world wide
a costly and rare commodity.
Additional global sources for long term
availability
China & USA- envisaged increased production will
mostly be consumed by the respective countries.
Indonesia - a meagre amount may be available
Russia - a lot , but requires major infrastructural
investment
Scope for utilsation of Indigenous
resources
Area for Improvement
Quality
Quantity
Optimisation
Cost
Culture
Indian Coal Scenario:
Total Coal Reserves 246 Bt
Others
3.0%
84.0%
Noncoking
Inferior
grade 68%
13.0%
6%
11%
Semi-coking
HVC
15%
MVC
50%
LVC
19%
Prime coking
Coking
GSI, Jan.2004
Imperatives for enhancing washed coal
production
• Renovation & modernisation of existing washeries to
maximise the output at desired quality; with further
deterioration of feed quality the washery output, in the
absence of drastic modernisation programme , is going to
decline.
• Installation of fine coal treatment plant to treat the
‘waste’ slurries & the freshly generated fines to produce
Cleans in the ash range 10-14%.
• Installation of new washeries to treat the Low Volatile
NLW coals (LVC coal, if prepared judiciously, has the potentiality to
offer excellent quality coke)
The challenge of minimising the import
dependency on desired fuel can be met
• by increasing the capacity of washed
coal production, adoption of innovative
coke making technology and PCI
route.
• by utilising abundantly available
non-coking coal through adoptation of
alternate routes of steel making
Characteristics of LVC(NLW)
 High raw coal ash
 High Maturity
35-45%
Ro = 1.3
 Low volatile matter content 15-20%
 High Inertinite content
(60-70%)
 Poor washability potential
Beneficiation in existing washeries
 2-product circuit
About 70-75% with 40-45% ash with no
market outlet
Beneficiation in existing washeries
 3-product circuit
LVCC requires disposal of 20% as reject
50% middling with 41% ash (outlet ?)
Coals of western Jharia
coalfields need a different
beneficiation strategy
INTEGRATED MULTI-STREAM
BENEFICIATION
4-Product Circuit
 Cleans
(25-30%), 17-18% ash
 Cleans II (18-20%), 22-28% ash
 Middlings (20-22%), 34% ash
 Rejects (28-30%), 60-65% ash
Suggested beneficiation scheme:
 Coal crushed to a nominal top size of 100/75 mm
and screened at lower size, 25/20/13 mm
 Coarser fraction ( oversize) treated in washing unit
to produce POWER COAL (~ 34% ash)
 Finer fraction (undersize) deep beneficiated for
metallurgical coal of ash 17-18%
 Combined rejects (ash 50-55%) sent to FBC boilers
For a typical SR - process,
Judicious beneficiation
of available coal is a
necessity
Beneficiation strategy
Category I:
Non-coking coal (ash 30-40%)
Jigging
Cleans
Reject (ash 60-65%)
75-80% (ash 25%)
(FBC boiler)
Beneficiation strategy …...
Category III: LVC coal (ash > 35%)
Total Cls
3-pdt Jig
4-pdt washing User
Yld% (A%)
Yld% (A%)
---
24-27 (17-18) Steel
Jig Cleans 50 (22-24)
--
Corex
Cleans II
---
18-20 (25-30)
Corex**
Middling
20-22 (34)
20-22 (33-35)
Power
Reject
28-30 (60-65)
25-30 (55-65)
FBC
Thank You
Part II
22
Scope for utilsation of Indigenous
resources
Area for Improvement
Quality
Quantity
Optimisation
Cost
Culture