Jai Balaji Jyoti Steels upgrades low-grade iron ore to Fe 60+ with Oremax Multi
Jai Balaji Jyoti Steels, a unit of leading Eastern India steel manufacturer Jai Balaji Group and a CFlo client since 2012, installed a 100 TPH Oremax Multi iron ore washing and beneficiation plant in Rourkela, Odisha. The plant transforms low-grade market ore of Fe 54-55 into high-grade material of Fe 60+, cutting coal consumption and delivering substantial cost savings.
A major challenge for the steel industry is the declining quality of raw iron ore. Before the beneficiation plant, the client acquired 58 to 60-grade iron ore at high expense from various mines in the Barbil region. Without its own beneficiation plant, the company struggled to use stocked ore and to buy varied raw materials from the market: quality was inconsistent and prices fluctuated with availability.
After comprehensive testing to establish the cost-benefit case, CFlo recommended a 100 TPH Oremax Multi system covering feeding, intense washing, efficient screening, double-stage de-sliming, product dewatering, product stockpiling, water management and sludge management. The plant removes impurities such as silica and alumina from the ore.
A Jet Attrition System (JAS) on the feed conveyor dislodges surface contaminants, and the Screenmax circular motion rinsing screen with three discharge outlets separates washed +10mm and 3-10mm fractions. Fines below 3mm are pumped to a Turbo Dual Wash system of Centriscreen and Xtrill-lined modular Hydrocyclones. The skid-mounted, fully automatic plant needs limited space, recirculates 95% of process water and achieves zero effluent discharge.
With the plant, the client accesses raw materials at more cost-effective rates and processes lower-grade ore into higher-grade material, resulting in a significant reduction in coal consumption.
The decision to choose the Oremax Multi system was based on several factors. Firstly, it operates smoothly with minimal dust and noise pollution, ensuring a safe working environment. Secondly, its compact design requires minimal supervision, reducing risks and maximizing resource efficiency. Thirdly, it produces a superior quality product used in DRI. Lastly, after seeing the successful operation of the plant, we are confident with our decision and would definitely recommend this system to others.
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