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Bhushan Steel, India

Case study

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Introduction of the M2500 washing plant to the Bhushan Power & Steel facility in Orissa, India has resulted in an increase in Fe from 58.24% to 63.2%

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The increase in Fe has been achieved as a result of a 37% reduction in alumina from 4.3% to 2.7% and a 32% reduction in silica from 6.6% to 4.5%.

Commenting on these results Dr Arabinda Bandyopadhay of CDE Asia said “The reduction in alumina and silica levels and the resulting increase in Fe will lead to a reduction in coal consumption of around 5% during the various steel production processes which represents a very significant efficiency gain for Bhushan Power & Steel.”

This project represents the completion of a major product development initiative by CDE to produce a mobile washing plant suitable for application in the iron ore processing sector. “Following the initial success of the M2500 in sand and aggregate washing applications we embarked on a project to develop the M2500 to cope with the specific challenges of iron ore processing” explains Manish Bhartia, Managing Director at CDE Asia. “The success of the M2500 on this iron ore washing project is evidence that the major product developments we have introduced over the last 12 months will lead to further opportunities in iron ore applications not only in India but throughout the world” says Chris McKeown of CDE Global.

The M2500 has now been applied on a wide variety of projects in Europe, Asia, Australasia and Latin America on materials including sand & gravel, crushed rock, scalpings, construction & demolition waste recycling and iron ore washing. The new iron ore washing plant is located in Sambalpur in the state of Orissa and in addition to the M2500 mobile washing plant there is an Aquacycle A600 thickener allowing for recycling of 90% of the water used as well as significantly reducing the space required for settling ponds.

The processing capacity of the plant in this instance is 200tph of minus 40mm material and the washed products are -5mm washed fines in addition to 5-16mm and +16mm washed ore. The washed ore is subsequently used as input to the blast furnace. 

Bhushan Power & Steel Case Studies