PROFESSIONAL QUALIFICATIONS & EXPERIENCE:
THEODORE E. SEPPANEN, SR.
Senior Metallurgist, Pelletizing Systems

GRATE-KILN PROCESSING OF IRON ORE

• Trained and worked on all aspects of the grate-kiln operation at the Empire Mine operated by Cleveland-Cliffs including: Balling and Screening (Vibrating and Roller Screens), Bentonite and Organic Binder Addition and Mixing, Conveying and Distribution of Green Balls on the Grate Bed, Induration of Green Balls, Grate-Kiln-Cooler Airflow, Process Control, Pellet Discharging and Sampling, Pellet Conveying and Stockpiling and Pellet Quality Analysis.
• Ran the test program that proved the efficiency of roller screens compared to vibrating screens, which resulted in the replacement of vibrating screens with roller screens.
• Participated in the installation of the heat recuperation systems that were retrofitted onto the three oldest grate-kiln systems.
• Ran the test program the proved the cost efficiency of using industrial diamond inserts on cutter bar teeth in balling drums.
• Participated in the retrofitting of roller conveyors that conveyed and screened green balls prior to addition to the grate.
• Conducted the shake down and startup of the coal conveying and firing system for the grate-kilns at Empire.
• Conducted the testing of an alternative coal fining system on Unit 1 grate-kiln that is now installed on Empire Unit 2.
• Participated in the modification of the Unit 4 heat recuperation system at Empire.
• Assisted in the development of fluxed pellet production at Empire with Ispat-Inland and Kobe Steel.
• Installed the Statistical Process Control system used at Empire to control production and quality of fluxed and standard pellets.
• Assisted in the compilation of production and quality data using computers for reporting and control purposes.
• Participated in the development of the chemical control system used to minimize the buildup of calcium and magnesium compounds caused by the reuse of process water during fluxed pellet production.
• Developed the systems that were used to control fluxed buildup in the grate-kilns.
• Participated in the use of internal fuel with hematite processed in the grate-kiln.
• Ran bench scale Pot-Grate-Kiln test programs for Empire and Tilden.

STRAIGHT GRATE PROCESSING OF IRON ORE

• Trained and worked on aspects of the traveling grate operation at the Northshore Mining Co., Hibbing Taconite Co. and Wabush Mines operated by Cleveland-Cliffs including: Balling and Screening (Trommels and Roller Screens), Bentonite and Organic Binder Addition and Mixing, Conveying and Distribution of Green Balls on the Grate Bed, Induration of Green Balls, Airflow, Process Control, Pellet Discharging and Sampling, Pellet Conveying and Stockpiling and Pellet Quality Analysis.
• Oversaw the bench scale test program using limestone addition to enhance the quality of Hibbing Taconite pellets.
• Ran the bench scale test program to produce superior quality pellets from concentrates that included tolled concentrates with the Wabush ore.
• Participated in Traveling Grate Airflow studies.

SHAFT FURNACE PROCESSING OF MAGNETITE

• Trained and worked on all aspects of shaft furnace operation at Erie Mining Co, Pickands Mather Co. (LTV Steel Mining managed by Cleveland-Cliffs) including: Thickening, Filtering, Balling and Screening (Trommels), Bentonite and Organic Binder Addition and Mixing, Conveying and Distribution of Green Balls on Shaft Furnace Bed, Induration of Green Balls, Shaft Furnace Airflow, Process Control, Pellet Discharging and Sampling, Pellet Conveying and Stockpiling and Pellet Quality Analysis.
• Designed and ran the testing of limestone addition to enhance pellet quality on plant scale.
• Developed heat and oxygen profile within the shaft furnace.
• Participated in the production of specifically sized pellets for Blast Furnace scale testing.
• Participated in the installation of pug-mill mixing of concentrate and binder that led to the installation of Litterford/Lodige mixers at Hibbing Taconite.
• Functioned as Quality Control Engineer on shift.

QUALITY CONTROL AND ANALYSIS

• Trained in Statistical Experimental Design, Statistical Process Control, Measurement Systems Assessment, Hazardous Chemical Safety and EPA Qualified Observer of Visible Emissions.
• Member of the ISS and was TAG Chairman for the ASTM and ISO for Iron Ore Analysis and Quality.
• Conducted training programs in Interpersonal Skills at Work, Statistical Process Control and Hazardous Chemical Use.
• Qualified to run and evaluate quality tests such as wet and dry green ball compression; moisture content of concentrate, green balls, pellets, coal and other solid fuels and bentonite; bentonite grit, -200 mesh, PWAT and other bentonite evaluation tests; wet green ball drop test; concentrate, bentonite, green ball and pellet size analysis; chemical analysis of concentrates, bentonite, solid fuels, green balls and pellets; pellet compression; pellet porosity; pellet reducibility (R40, Relative Reducibility and Reduction Under Load); pellet low temperature disintegration (breakdown) with and without hydrogen; Kobe Contraction and Reduction Under Load; and High Temperature Softening and Melting (British Steel and DOFASCO test method).
• Ran Cleveland-Cliffs pellet quality program evaluating pellets on a daily, weekly, monthly, quarterly, semi-annual and annual basis to satisfy customer/supplier contractual requirements. Reported quality results for Empire, Hibbing Taconite, Northshore Mining, Tilden and Wabush Mines as required. Prepared formal quarterly, semi-annual and annual pellet quality reports.
• Evaluated the results of fuel analysis of natural gas, oil, petroleum coke, coke and coal for heat content, emissions and slagging potential.
• Conducted the test program and prepared the report on the Effect of Particle Size on Standard Pellet Quality for the Iron Ore Cooperative Research Program of the Minnesota DNR.

PELLETIZING BINDERS FOR IRON ORE

• Worked at Jones and Laughlin Co., Ores Research Laboratory (LTV Steel Co.) analyzing and testing Bentonite and Organic Binders on bench scale.
• Worked at Erie Mining Co., Process Development Department analyzing and testing Bentonite and Organic Binders on plant scale.
• Conducted numerous plant tests at the Empire Mine of Cleveland-Cliffs on various commercial Bentonites.
• Conducted numerous plant tests at the Empire Mine on various Organic Binders from sources as: AKZO, Allied Colloids Inc., Aqualon, SNF (Floerger), Glenn Corp., Grain Processing Corp., Hercules Inc., NALCO, and Union Carbide.
• Continued bench scale analyzing and testing of US, European and Asian Bentonites and Organic Binders at Cleveland-Cliffs Technology Center.

GENERAL

• Bachelor’s degree in Chemical Engineering (Michigan Technological University, 1964).
• Coauthored technical papers on fluxed pellet production at Empire and Tilden Mines, chemical reduction of buildup in grate-kiln systems and the use of internal fuel while producing hematite pellets in the grate-kiln system.
• Conducted bench scale iron ore sinter tests.