DR GRADE IRON ORE
When operational in 2026, Mesabi Metallics’ pellet plant will produce 7 million metric tons of Direct Reduction grade iron ore pellets every year.
Mesabi Metallics’ product will be world-class, because the Mesabi Range is world-class. Our pellets will have very high iron content combined with some of the lowest levels of impurities compared to other mines, which will materially reduce carbon emissions in the production of steel, a necessary step in creating a stronger, greener future for generations to come.
OUR PROCESS
Transforming Iron Ore to DR Pellets: A Journey from Earth to Innovation. At Mesabi Metallics, we take pride in our efficient and environmentally friendly process of converting iron ore into Direct Reduction (DR) grade iron ore pellets. Here’s an overview of our 9-step journey:
Step 1. Responsible Mining: We begin by extracting our taconite iron ore using the most advanced open-pit mining methods. The taconite ore will be drilled, blasted and mined with environmentally friendly electric shovels and hauled to our primary crusher with the most advanced haulage fleet available with reduced emissions.
Step 2. Crushing: In this step, we break down the mined taconite ore into smaller pieces, separating larger fragments from finer materials for further processing. This separation of larger fragments from smaller ones ensures efficient feeding of the autogenous mills in the concentrator.
Step 3. Grinding: Our unique grinding process blends crushed ore from two storage facilities to feed the autogenous mills. Here, large fragments grind the smaller ones to fine powder.
Step 4. Concentration: We use advanced magnetic separators and cutting-edge flotation technology (like a giant, high-tech washing machine) to separate valuable iron minerals from unwanted impurities. This way, we produce some of the purest iron ore globally, with SiO2 levels expected at 1.8% and AI2O3 at 0.1%.
Step 5. Pelletizing: Next, we take our concentrated iron ore and mix it with limestone and carefully selected binders – think of these as glue that helps hold everything together. Using advanced rolling and screening process, we turn this mixture into round pellets, similar to a bouncy ball from a vending machine. Our pelletizing technique ensures uniform size and composition for optimal processing.
Step 6. Induration: The induration process is where science truly comes alive. The round pellets are conveyed to our state-of-art furnace where they are dried and then fired at high temperatures. This crucial step hardens the pellets and gives them the strength and quality needed for direct reduction iron making process.
Step 7. Cooling: After induration, the pellets are cooled down gradually to avoid cracking and to prepare them for handling and loading into rail cars. Additionally, the heat from the cooling zone is recovered to reused, promoting energy efficiency.
Step 8. Quality Control: Each batch of pellets undergoes rigorous testing for size, chemical composition and metallurgical properties. This guarantees our pellets are suitable for direct reduction and meet our strict quality benchmarks.
Step 9. Storage and Transportation: Finally, the finished DR grade iron ore pellets are stored and prepared for transport. By producing premium DR-grade iron ore pellets, we’re not just manufacturing a product –we’re engineering a sustainable future for global steel production. At every step, our process remains rooted in innovation, quality and sustainability, aligning efforts with creating a greener future.
Why it matters:
- Our process helps reduce emissions and minimize environmental impact.
- Our iron ore pellets enable the production of eco-friendly Green Steel.
- We’re committed to delivering high-quality pellets with ultra-low impurities while promoting environmental responsibility.
THE VALUE OF IRON
Iron and steel are the backbone of modern civilization, pivotal in shaping our infrastructure, technology and everyday life. From towering skyscrapers to intricate machinery, Mesabi Metallics’ metals provide strength, durability and versatility.
Applications Across Daily Life:
Construction: Steel beams and reinforcements ensure that our buildings stand tall and strong, providing safety and stability in both residential and commercial projects.
Automotive: The automotive industry relies on high-strength steel to create vehicles that are not only safe but also fuel-efficient, making cars lighter without sacrificing performance.
Manufacturing: Iron and steel components are essential in machinery and equipment, driving productivity in sectors ranging from aerospace to agriculture.
Energy: Iron and steel are vital in energy production, supporting renewable resources and traditional energy sectors alike.
Home Goods: Everyday items such as cookware, appliances and furniture often feature iron and steel, combining functionality with modern design.
Why Choose Iron and Steel?
- Strength and Durability: Iron and steel are known for their incredible strength-to-weight ratio, making them ideal for heavy-duty applications.
- Sustainability: Steel is one of the most recycled materials in the world, contributing to a circular economy and reducing environmental impact.
- Cost-Effectiveness: The longevity and strength of iron and steel lead to reduced maintenance costs and a lower total cost of ownership over time.
THE FUTURE OF IRON & STEEL
Innovative Solutions for a Changing World
As technology evolves, so does the manufacturing and applications of iron and steel. Advancements in metallurgy and manufacturing processes allow for even more efficient, resilient and eco-friendly products.
Mesabi Metallics’ DR grade pellets power the decarbonization of global steel production, creating a stronger, greener future.
