Prospect of Titania-Magnetite Bearing Iron Sand Processing to Increase the Cost Competitiveness of Seaisi Countries

by Yakov Gordon, Michiel Freislich, Leigh Harris, Len Woods

Publisher - Hatch Associates Pty Ltd

Category - General Novel

Titania-magnetite and vanadium bearing iron sand represents a largely untapped resource for SEAISI steelmakers, particularly in the regions of Indonesia and the Philippines. Recent developments in titania–magnetite ore processing technologies have made their use economically viable. This paper explores the maturity of the titania-magnetite blast furnace, rotary hearth furnace in combination with smelter and ITmk3, their basis of operation, comparative cost position and viability. The Value-In-Use of these alternative Iron Units (Hot metal and Nuggets) are then assessed in EAF steelmaking. The technology options analysis shows that the selection of the appropriate technology depends on local cost factors. For conditions with high energy costs representative of South East Asia, the Ti BF with maximum TiO2 load of about 50-60 kg/thm should be considered as the technology of choice. Under conditions where reasonably priced gas and power might be available long term, ITmk3 is viable, providing the first commercial plant at Mesabi is successful. The RHF + Smelter route will only be a viable option in South East Asia if low cost energy is available long term and higher TiO2 bearing ores are utilized thereby requiring a smelting step. The value in use analysis using cost assumptions generally representative of South East Asian conditions shows that the Ti BF hot metal is the best replacement for DRI in the EAF. The advent of these new technologies makes titania-magnetite a viable alternative feedstock for steel plants in South East Asia.

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