Currently under construction in Reynolds, Indiana, the Pellet Plant will be a 3.0 million mt per year facility that processes iron ore concentrate from Magnetation’s northern Minnesota operations to produce high quality fluxed iron ore pellets. These pellets will then serve as feedstock for Magnetation partner AK Steel’s blast furnace operations in Middletown, Ohio and Ashland, Kentucky.
The Pellet Plant is scheduled to begin operations in the fourth quarter of 2014 and will employ the latest pelletizing technology and engineering used in global pellet production today. Once completed and fully operational, the Pellet Plant will employ over 100 people in the state of Indiana.
64 E 100 N
Reynolds, Indiana 47980
Pellet Plant Construction Progress
Commissioned the front end of the plant including the raw material receiving system, the concentrate grinding building, and the filter building.
Siding on the buildings is nearly complete with the final buildings (mixing and blending buildings) underway.
Started receiving shipments of raw materials including coke breeze, dolomite, and limestone. These materials will be mixed with the iron ore concentrate to produce a high quality fluxed pellet for the AK Steel blast furnaces.
Accepted and unloaded the first shipment of iron ore concentrate. The car dumper, conveyor system, and ore barn were all commissioned with this milestone.
Completed construction of the furnace ductwork. The ductwork allows the air to flow through the furnace’s heating and cooling zones.
Refractory install for the ductwork is approximately 50% complete. The refractory protects the ductwork from the extreme temperatures of the furnace.
The overhead crane in the rotary car dumper building is commissioned. This is the first major piece of equipment to be commissioned on the project.
Balling disc feed bins are set. Each of these bins will hold 100 tons of fluxed concentrate and will feed the balling discs, which roll the concentrate mixture into balls before entering the furnace.
The first electrical wire is installed in the balling building.
Assembly of the pellet load out bins is started. Each bin will hold 8,000 tons of pellets before being loaded into rail cars.
Installed grinding mill shell, cyclone tub, and induration machine (furnace) drive shaft. The drive shaft will physically move the pallet cars which carry the pellets through the furnace’s drying, pre-heating, firing, and cooling zones.
Set the roller mills in the additive grinding building which will grind the limestone, dolomite, and coke breeze to powder.
Started installation of furnace shell steel and process ductwork.
The filter and grinding areas, which will prep the iron ore concentrate before it is formed into pellets, continues to progress with equipment and electrical installation well underway. The large slurry tanks and thickeners are also nearly complete.
Mixing and blending steel erection begins. This area will house the raw materials (dolomite, bentonite, limestone) used to make iron ore pellets. This building will eventually reach a height of 160 feet.
The furnace off-gas stack reaches final elevation of 246 feet.
The concentrate ore barn frame is substantially completed.
Erection of the furnace air pollution control system is underway. This system will employ the best available pollution control technology to reduce SO2 and particulate emissions to the lowest achievable levels.
Filter building steel erection is started
The induration building where pellets will be cooked at 2,350 degree temperatures is framed to the operating floor level
The balling building, where the iron ore concentrate, limestone, and dolomite are mixed and formed into “green balls” prior to entering the furnace, starts to take shape with the first steel columns being hung.
Filter building and additive grinding building foundation work started. These buildings will grind and then filter, or dry, the iron ore concentrate before it is turned into pellets.
Backfilling of the car dumper area started. Over 300,000 yards of dirt was removed to create this hole.
Concentrate ore barn walls completed and ready to start installing the steel building shell that will protect the iron ore concentrate from the elements.
Car dumper excavation complete to bottom elevation (80’ below ground level). This depth is required to allow installation of bins and a double roll crusher that will break up frozen material for easier material handling.
Pilings for major foundation work complete on indurating, balling, and concentrate storage barn. These pilings will prevent structural failure from occurring due to the heavy weights these foundations will bear.
Earthwork underway to grade the plant site for building construction, drainage, and rail infrastructure.
Car dumper area started with initial excavation. The excavation will reach a depth of over 80 feet and will serve as the base for unloading rail cars full of iron ore concentrate.
Installation of temporary site construction power completed. This will serve as the main power source until the electrical substation is completed to provide permanent power.