Pellet Plant

Located in Reynolds, Indiana, the Pellet Plant commenced operations in September 2014.  This 3.0 million mt per year facility processes iron ore concentrate from Magnetation’s northern Minnesota operations to produce high quality fluxed iron ore pellets.  These pellets serve as feedstock for Magnetation partner AK Steel’s blast furnace operations in Middletown, Ohio and Ashland, Kentucky.  The Pellet Plant employs the latest pelletizing technology and engineering used in global pellet production today, and employs over 100 people in the state of Indiana.

Pellet Plant
64 E 100 N
Reynolds, Indiana 47980


Pellet Plant Construction Progress

August 2014

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.

July 2014

Refractory and conveyor system installations are completed.

Started siding and roofing the concentrate grinding, balling, and indurating buildings.

Received first shipment of hearth layer pellets to charge the furnace in anticipation of start-up and first pellet production.

June 2014

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.

May 2014

The furnace burners are set. These burners will heat the furnace to 2400 degrees Fahrenheit.

Erection of the balling discs is started. These discs will roll the fluxed concentrate mix into ½” diameter pellets.

Car dumper installation is nearly complete and ready for commissioning.

April 2014

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.

March 2014

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.

February 2014

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.

January 2014

Car dumper assembly is put in place. This assembly will physically turn 286,000 pound rail cars full of iron ore concentrate on their side for unloading.

Major mechanical installations begin with vacuum pumps and the massive gear box that will operate the car dumper.

December 2013

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

November 2013

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.

October 2013

Conveyor trusses are hung to carry iron ore concentrate from the car dumper area into the ore barn

Pellet load-out area work begins with foundation work. This area will stockpile and load finished pellets into rail cars and before being shipped to AK Steel blast furnaces.

September 2013

First steel erection occurs at the pellet plant on the induration building.

Grinding area progresses as slurry and thickener tank bases are formed. These massive tanks will handle the iron ore concentrate and water mix, also called slurry, before it is turned into pellets.

August 2013

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.

July 2013

Major concrete work started with 7,000+ yards poured between the car dumper and concentrate storages areas.

Foundation work substantially completed on indurating, balling, and mixing buildings

June 2013

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.

May 2013

Electrical substation work is started

Pilings installed for indurating, balling, and concentrate storage barn to support the heavy loads they will bear once construction is complete

Majority of earthwork and site grading completed in preparation for installation of buildings and equipment

April 2013

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.