Resource efficiency

Iron ore & pelletizing technology

I‌ron ore is the main source of iron and steel and the world is made of it. The computers we use, the chairs we are sitting on, the cars we are driving with, the buildings we are working in, the schools, we are learning in and the cell phones we are communicating with – everything contains iron ore. Iron ore is so present in everyday lives that it is practically impossible to imagine a world without this mineral resource.

All modern methods of energy generation and transmitting consist of iron and steel. Thus, we cannot renounce iron ore mineral processing, even though iron and steelmaking sector is one of the largest energy consumers in the world. It is our duty to improve the iron ore beneficiation in order to implement sustainable solutions to minimize CO2 emissions and to improve resource efficiency by better process and product performance.

SCARABAEUS pelletizing discs provided by HAVER & BOECKER NIAGARA are used for sustainable and efficient production of iron ore pellets. The unit’s design minimizes circulation, increases productivity and profitability. The pelletizing discs used for agglomerating iron ore concentrates into pellets are remarkable for their very narrow particle size distribution with a target size of 10 – 14 mm, important for DR-processes.

The powder-type feed material is formed into pellets with use of water as the liquid binding agent. The optimum operating ­parameters can be set by changing the inclination, the rotational speed, mass flow rate, and now also the rim height thanks to the innovative automatic pelletizing disc control system. The integrated camera ensures continuous monitoring of the quality of the pellets. In order to develop the best solutions for customers and to determine which process is the best for their iron ore and pellets requirements HAVER & BOECKER NIAGARA are conducting iron ore pelletizing tests in the Associated-Institute of  TU BERGAKADEMIE Freiberg – HAVER ENGINEERING GmbH.

The SCARABAEUS process generates higher tonnages by minimizing the material return rates and avoids double processing of over- and undersized pellets due to automatic machine parameter adjustments, which can also adapt to varying material property fluctuations in the feed material.  The SCARABAEUS process creates pellets so high in quality that they can be utilized for the direct reduction process. This in return can create enormous CO2 emission savings, thus minimizing the mine’s impact on the environment.

Pelletizing – why?

The undiminished demand of iron ore leads to mining of even lower-valued deposits. The reduced quality of the natural resources stands in opposition to the economic, ecological and technological restrictions, which require an intensive mineral processing of the iron ore. An enrichment of iron components is achieved by separation of undesirable components.

However, for this it is necessary to crush the ore to the decomposition grain size and to supply sorting processes such as magnetic separation and flotation. To improve the process and product properties of the fine-grained iron ore concentrates, it is necessary to agglomerate these concentrates. Pelletizing of iron ore concentrates in pelletizing discs leads to narrow grain size distributed pellets with smooth surface.

Pelletizing – how?

The process chamber of a pelletizing disc is made by an inclined, rotating, flat cylindrical pan. Due to rotation of the pan, the fine material is pulled along to the disc uppermost point and then rolling down onto a material bed. Caused by the special movement of the material itself and the addition of water onto the material, nucleation and growing occurs as a result of the settings of the pelletizing disc. Typically, final pellets with a very tight particle size distribution are discharged continuously over the board of the SCARABAEUS® 7500.


Related articles:

Innovative pelletizing technology

Sustainable and efficient production of iron ore pellets with HAVER & BOECKER NIAGARA

HAVER & BOECKER NIAGARA is launching a new landing page – – presenting an innovative pelletizing technology: The SCARABAEUS® 7500 pelletizing disc, which aims to...

Issue 12/2021 Pelletizing iron ores

SCARABAEUS© 7500 pelletizing discs: Sustainability meets efficiency

B?y winning a further major contract in pelletizing of iron ores, Haver & Boecker Niagara added another successful story to its portfolio and thus lays new tracks on the way to Green Steel. With a...

Issue 06/2015

Fertilizer production with the HAVER pelletizing disc SCARABAEUS

In view of the increasing food requirements of the world’s population and the continuing eluviation of the soil due to intensive agriculture as well as the loss of arable land following sealing of...


Intelligent agglomeration technology for recycling steel mill residues

M?ost metallurgical processes are characterized by a gas flow through the material bed. Thus fine particles are carried away and have to be filtered after the metallurgical device. Every modern...


Metso Outotec has won order for iron ore pelletizing plants in China

Metso Outotec has signed a contract with Beijing Shougang International Engineering Technology Co. Ltd (BSIET) for the delivery of two compact-sized iron ore pelletizing plants for Chengde Zhaofeng...