Production Process

Pelletizing Process
at Maad Koush Pelletizing Plant

At Maad Koush Pelletizing Plant, we employ advanced Grate-Kiln technology, renowned for its energy efficiency and ability to produce high-quality iron ore pellets. The process begins with raw material handling, where concentrate is fed into a Ground hopper and transferred to the Raw material stockyard. From there, it moves through a Pre-proportioning bin for initial preparation before undergoing grinding in a Wet Ball mill.

Next, the slurry is processed through a Hydrocyclone, Thickener, and Filter press for homogenization and water removal. The material is then mixed in a Proportioning bin and Mixer to ensure uniformity before pellet formation in the Balling Disc. The green pellets are preheated on the Travelling grate, fired in the Rotary kiln for hardening, and cooled in the Annular cooler, where heat is recycled to enhance energy efficiency.

Following the induration process, the pellets are screened for size consistency and stored in the Pellet bin before being transported to the Product stockyard. The system is highly energy-efficient, recycling gases from the Annular cooler back to the Rotary kiln and Travelling grate. This process produces iron ore pellets with superior compressive strength, ideal for Direct Reduction (DR) or Blast Furnace (BF) applications, while maintaining low power consumption and high sustainability.

The combination of lower bed depth, uniform temperature profile, and reduced pressure drop contributes to lower power consumption, making the Grate-Kiln technology at Maad Koush one of the most effective systems for producing high-quality iron ore pellets.

Raw Material Handling

Concentrate is fed into a Ground hopper, then transferred by a Stacker to the Raw material stockyard. The material is reclaimed and passed through a Pre-proportioning bin for initial preparation.

Wet Ball Milling

The raw materials are then directed to the Wet Ball mill for grinding, ensuring the materials reach the desired size before moving to the next stage.

Homogenization and Filtration

The slurry is processed through a Hydrocyclone and Thickener, homogenized, then dewatered with a Filter press for further processing.

Mixing and Proportioning

After filtration, the material is mixed in a Proportioning bin and Mixer for uniformity, then goes to the Balling Disc for pellet formation.

Energy Efficiency and Sustainability

Gases from the Annular cooler are recycled to the Rotary kiln and Travelling grate, boosting energy efficiency. This process produces iron ore pellets with high compressive strength, reducing transport losses and making them ideal for Direct Reduction or Blast Furnace use.

Screening and Storage

The indurated pellets are screened for size consistency, stored in the Pellet bin, and then transported by a Wide belt conveyor to the Product stockyard for final storage and distribution.

Induration Process

Green pellets are preheated on the Travelling grate, fired in the Rotary kiln to harden, and then cooled in the Annular cooler, where heat is recycled for energy efficiency.

Balling Disc and Green Pellet Formation

In this process, gases from the Annular cooler are recycled to the Rotary kiln and Travelling grate, enhancing energy efficiency. It also produces iron ore pellets with high compressive strength, ideal for Direct Reduction or Blast Furnace use.

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