The iron-ore products are characterized in order to investigate the effect of the mineralogical features on the grinding results into pelletizing plant. The studied materials are from four mines of the different regions of Iron Quadrangle, processed by flotation, magnetic separator and produced from screening with P 80 in 8 mm. In this study, we apply for the first time the novelty of electron backscatter diffraction technique for the iron ore phase identification and quantification of the microstructural parameters. The mineralogical and microstructural parameters were introduced as a base in the specific grinding test applied in the industrial routine. Each sample was characterized based on the mineral shape, pores, fractures, polycrystalline hematite, and aggregate of hematite with goethite. The test results demonstrate that there is a strong relationship between the gain of the specific surface area, represented by the K-factor, and the morphological types.
there were a redesign and simplification of the flow of decision making, increased productivity, clarity of roles and increased synergy between sites. All of the development and deployment of the solution were conducted based on the company's Change Management tools. The study showed that processes should be constantly evaluated and that opportunities for improvement and productivity increase are always present. Using appropriate methods and tools can implement a complex change process with risks involved under control.
ResumoEste trabalho tem como objetivo principal a redução do custode produçãonuma planta de pelotização de minério de ferro, com aplicação da metodologia LeanSix Sigma na fase de maior custo, o processamento térmico. O desenvolvimento do trabalho se deu em três usinas de pelotização.Para que não houvessem prejuízos do atendimento à qualidade do produto final, foram realizadas adequações no processo de pelotamento levando em consideração a teoria de ajuste do diâmetro médio das pelotas e sua influência na máquina de endurecimento de pelotas [4]. Para alcance dos resultados, a atuação foi direta no desenvolvimento de novos perfis de queima por nível de produção, ajuste no percentual de aplicação do combustível sólido e balanceamento termodinâmico. O resultado do trabalho representou uma redução no consumo específico do gás natural de 12,93%, 12,15% e 5,66% nas usinas A, B e C, respectivamente. Estes ganhos foram garantidos pela manutenção dos resultados de resistência à compressão e abrasão da pelota processada termicamente. Palavras-chave:Forno de pelotização; Eficiência energética; LeanSix Sigma; Consumo específico de gás natural. ENERGY EFFICIENCY IMPROVEMENTS ON THE INDURATING MACHINE OF PELLETIZING PLANTS AbstractThe main target of this work is to reducethe productioncosts of a pelletizing plant using the Lean Six Sigma approach in the most expensive process, the indurating.The development of this work was in 3 plants. To avoid quality loss of the indurated pellets, have been done adjustmentson the balling process based on the diameter average theory and their influence on the indurating machine. To achieve the results, new thermal profiles were developed by level production, adjustments on the balance of solid/gas combustibleratio and thermodynamic balance of the machine. It was reduced 12,93%, 12,15% and 5,66% of the plants A, B and C, respectively, assuring the abrasion index and cold compression strengthof the indurated pellets.
ResumoA determinação de características microestruturais como base de controle de qualidade tem demonstrado cada vez mais a sua importância nos processos de aglomeração de minério de ferro. A linha de pesquisa do presente trabalho envolveu o desenvolvimento de técnicas de embutimento de pelotas seccionadas em resina condutora, de desbaste e polimento da superfície das amostras e emprego do microscópio eletrônico de varredura em conjunto com a técnica de Electron Backscattering Difraction. Por meio das técnicas empregadas de microscopia baseadas em parâmetros cristalográficos específicos, foram obtidas ilustrações forescatter e mapas de fases minerais ferríticas, silicatos e óxido de ferro que caracterizam a microestrutura de pelotas tratadas termicamente em forno piloto. O desenvolvimento desta metodologia promove subsídios para estabelecer futuramente uma relação das estruturas observadas em escala microscópica com as propriedades reconhecidas e mapeadas no produto final. Palavras-chave: Pelotas; Fases minerais; EBSD MINERAL PHASES IDENTIFICATION ON MICROSTROCTURE OF IRON OXIDE PELLET BY ELECTRON BACKSCATTERING DIFRACTION TECHNIQUE AbstractThe determination of microstructural characteristics as quality control has been increasingly employed in iron ore agglomeration processes. This research involved the techniques development of inlay in conductive resin, buffing and polishing samples surfaces and the Electron Backscattering Diffraction technique application. Through the combined techniques of microscopy, maps and images forescatter were obtained containing iron oxide, ferrites and silicates phases illustrating the microstructure of iron oxide pellets based on their different crystallographic parameters.
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