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Siemens VAI to Install Intensive Mixing, Granulation Systems for Usiminas Sinter Plants

01/21/2011 - Siemens VAI Metals Technologies will install two intensive mixing and granulation systems in Usinas Siderurgicas de Minas Gerais SA’s sinter plants located in Cubatão and Ipatinga steelworks in southern Brazil.

Brazilian steel producer Usinas Siderurgicas de Minas Gerais SA (Usiminas) has placed an order with Siemens VAI Metals Technologies to install two intensive mixing and granulation systems in sinter plants located at the company's Cubatão and Ipatinga steelworks in southern Brazil.
 
The project will be jointly implemented on a full turn-key basis by the Metals Division of Siemens Ltda in Belo Horizonte, Brazil, and Siemens VAI headquarters in Linz, Austria. Once it is implemented, the solution will enable the use of a high portion of pellet feed, which is normally not suitable for the sintering process, in the company's sinter plants.
 
Although the portion of fine and ultra-fine ores continues to increase in iron ores worldwide, existing sinter plants are not designed to efficiently process larger quantities of undersized ore fractions. Siemens VAI’s intensive mixing and granulation system was designed to enable a much higher portion of pellet feed to be included in the sinter raw mix without adversely impacting operations. This solution, which can be installed in both new and existing plants, allows a thoroughly homogeneous sinter raw mix to be achieved, which is the basis for high sinter quality and a stable sintering process.
 
The Siemens project scope includes complete engineering, civil works, steel construction, and the supply of mechanical equipment, electrics, automation and utilities. The mechanical equipment will comprise two intensive mixers outfitted with vapor removal, the belt-conveyor and pneumatic-transport systems, and secondary dedusting facilities. The existing granulation drums will be modified to ensure optimum granulation of the sinter raw mix. Siemens VAI will also provide advisory services for erection and commissioning, and assisted operation, as well as personnel training.
 
The Usiminas Group, the largest flat-steel producer in Brazil, is currently in the process of partially substituting purchased iron ore with its own ores sourced from its mining complex in southern Brazil. The Usiminas mines will generate a large percentage of ultra-fine ores, which normally would have to be pelletized prior to charging in a blast furnace. In order to enable up to 25% of the ultra-fine ores to be used in the company's existing sinter plants, special treatment of the entire sinter raw mix is required.
 
The extra processing necessary for working with internal ultra-fine ores helped the company to justify installing two intensive mixing and granulation systems. The new equipment will process the sinter raw mix for the Sinter Plant No. 3 at the Cubatão (Sao Paulo) steelworks, and the Sinter Plants Nos. 1 and 2 at the Ipatinga (Minas Gerais) site. The total output from all three sinter plants is nearly seven million tons of sinter per year.
 
Intensive mixing and granulation systems from Siemens VAI are successfully operating in the sinter plants of voestalpine Donawitz GmbH, Austria, and at Dragon Steel Corporation, Taiwan. The value of the newest order is a low two-digit million euro figure. Start-up of both Usiminas systems is scheduled for late 2011.
 
The Siemens Industry Sector, Erlangen, Germany, is a leading international supplier of environmentally friendly production, transportation, building and lighting technologies. The Sector comprises six divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 204,000 employees worldwide (September 30), Siemens Industry achieved in fiscal year 2010 total sales of approximately €34.9 billion.
 
The Siemens Industry Solutions Division, Erlangen, Germany, is one of the world's leading solution and service providers for industrial and infrastructure facilities comprising the business activities of Siemens VAI Metals Technologies, Water Technologies and Industrial Technologies. Activities include engineering and installation, operation and service for the entire life cycle. A wide-ranging portfolio of environmental solutions helps industrial companies to use energy, water and equipment efficiently, reduce emissions and comply with environmental guidelines. With around 29,000 employees worldwide (September 30), Siemens Industry Solutions posted sales of €6.0 billion in fiscal year 2010.