Influence of Coating Granulation Process on Iron Ore Sinter Quality and Productivity

Umadevi, T.; Deodhar, A.V.; Mahapatra, P. C.; Prabhu, M.; Ranjan, Madhu

doi:10.1002/srin.201000030

Cited by 18 publications

(18 citation statements)

References 7 publications

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“…7) The granulation behavior of a sinter mixture is largely determined by its mineral composition, initial particle size distribution, the amount of water inside the granules, and so forth. In selective granulation 8) or separated granulation, [9][10][11] the granule properties can be improved more than that in the conventional two-stage granulation, 8,12) with respect to the distributions of mineral phases, chemical components and particle sizes of the quasi-particles. Not like the process in selective granulation, pre-wetting granulation proposed here is a granulation, by which the granulation performance of a sinter mixture can be improved a lot without too much additional investment on equipment.…”

Section: Introductionmentioning

confidence: 99%

Effect of Pre‑wetting Treatment on the Granulation Behavior of Iron Ore Fines

Huang

Bai

et al. 2014

ISIJ International

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Together with the conventional granulation, a proposed pre-wetting granulation for two commercial sinter mixtures consisted of six different iron ores and other auxiliary materials has been investigated under controlled laboratory conditions. A method to describe the size variation of the granules between different granulation trials was proposed and studied in the granulation of this study. It is a method by drawing a cumulative undersized curve (CUS curve) and a differential cumulative undersized curve (Δ-CUS curve) into one figure. The results indicated that (1) with more water available for granulation, more particles in a sinter raw mixture would behave as the layering fines in granules and the upper size for these layering fines would increase from 1 mm to 4.5 mm in conventional granulation; (2) compared to the results from conventional granulation, the granulation with pre-wetting treatment on iron ore fines resulted in a tighter particle size distribution and a higher permeability before ignition. At similar moisture content, more particles can be shifted into the layering fines in pre-wetting granulation than in conventional granulation; (3) Due to the preferential granule growth and the deformation of the granules, a further increase in pre-wetting degree (PWD) from 65% to 80% had little influence on the optimal permeability before ignition. Furthermore, a sinter mixture with more materials that are high in moisture absorption capacity would lead to higher optimum moisture content in granulation.

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Section: Introductionmentioning

confidence: 99%

Effect of Pre‑wetting Treatment on the Granulation Behavior of Iron Ore Fines

Huang

Bai

et al. 2014

ISIJ International

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“…23) In work carried out in a sinter pot loaded with 65 kg of ore mixtures with different alumina contents, it was seen that an increase in the alumina content from 2 to 5.5 % raised the sinter's RI from 58 to 64 %. 24) Table 1 shows that Hamersley ore is that with the highest alumina content (2.73 %). This ore has not been included in ore mixture 3, whose alumina content therefore decreases (0.90 %) and is the lowest of the four studied ore mixtures (Table 4), and this low alumina content is expected to improve the RDI.…”

Section: Fig 12mentioning

confidence: 99%

The Influence of Different Iron Ores Mixtures Composition on the Quality of Sinter

et al. 2010

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Sinters were produced in the pilot plant using four different ore mixtures with varying proportions of iron ores, fluxes and coke. All the resulting sinters were characterised by chemical and granulometric analysis, degradation testing during reduction in the blast furnace (RDI test), cold resistance testing (Tumbler test), reducibility testing, determination of softening and melting temperatures, and determination of the sinter structure by electron microscopy. The obtained result allow for the establishment of better operation conditions to manufacture sinters.KEY WORDS: sintering; quality of sinter; ore mixtures; iron ores; blast furnace. 1089© 2010 ISIJ line with the ores present, but is three percentage points lower in mixtures 3 and 4 due to the inclusion of 'Goa Silicioso' ore with its lower total iron content. The ferrous content between 3.1 and 4.8 % can be considered as low as correspond to the hematitic nature of the iron ores that make up part of the mixtures. The alkalis content is low. Granulometric AnalysisGranulometric analysis has been performed using a ROT-TAP unit, which combines reciprocating eccentric rotary screening with a percussion system on the screen column. Figure 1 displays the granulometric curve for ore mixture 1, with an average particle size of 1.69 mm. Table 5 lists these values for the four different mixes. Granulation FitnessThe ore mixtures are subjected to granulation treatment prior to sintering in order to increase the average size of the very fine grained ores, with the aim of improving their dynamic behaviour during sintering.The granulation treatment is of basic importance in iron ore sintering, because good sinter bed permeability to a large extent determines the sintering rate and thus the plant's productivity.Granulation fitness testing of each iron ore and each ore mixture has been carried out following the SAFE (Size Analysis on Frozen Elements) standard procedure established by Centro Sviluppo Materiali (CSM) of Italy. Figure 2 shows the granulometry curve of ore mixture 1 before and after the SAFE test. Table 5 indicates the average particle size of the ore mix- ISIJ International, Vol. 50 (2010), No. 8 4) 1090© 2010 ISIJ Table 1. Chemical analysis of iron ores (wt%). Table 2. Chemical analysis of fluxes (wt%). Table 3. Composition of ore mixtures (wt%). Table 4. Chemical analysis of ore mixtures (wt%). tures after undergoing the SAFE test. All the mixtures present good granulation fitness. ReducibilityA reducibility test has been performed at 900°C following the ISO standard for sinters, adapted for ore mixtures of the 3.3-2.0 mm fraction.5) The results are displayed in Table 5. The R 60 value ranges between 50-56 % and may be considered good. Softening and Melting TemperaturesThe test to determine softening and melting temperatures of the ore mixtures has been carried out using a LECO AF-600 unit, with an oven that reaches a maximum temperature of 1 650°C, in which the following parameters have been fixed with the help of a computer: ASTM standard with inert ...

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“…Moreover, it is abundantly found in China, Australian, India and Indonesia [3]. Typically, it contains 5-20% Al 2 O 3 and 30-60% Fe, indicating that it is difficult to be used as a raw material for ironmaking [4,5]. Thus, it is important to remove alumina from HAIO.…”

Section: Introductionmentioning

confidence: 99%

An Innovative Technique for Comprehensive Utilization of High Aluminum Iron Ore via Pre-Reduced-Smelting Separation-Alkaline Leaching Process: Part I: Pre-Reduced-Smelting Separation to Recover Iron

Pan

Zhu

et al. 2019

Metals

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In this study, a novel process was established for extraction of Fe and Al from a complex high aluminum iron ore (33.43% Fe total and 19.09% Al 2 O 3 ). The main steps in the proposed process included pre-reducing high alumina iron ore and subsequent smelting to produce pig iron and rich-alumina slag, followed by alkaline leaching of the slag to obtain sodium aluminate solution and a clean slag. When smelting the pre-reduced high alumina iron ore pellets at 1625 • C for 30 min with a slag basicity of 0.40, the pig iron yielded 97.08% Fe and extracted 0.13% Al 2 O 3, together with an iron recovery of 94.54%. In addition, more than 68.93% Al 2 O 3 was recovered by leaching the slag, which was achieved by firstly roasted the slag at 900 • C for 2 h and then alkaline leaching at 95 • C for 2 h with a liquid-to-solid ratio of 10 mL/g. In addition, the alkaline leaching slag could potentially be used as raw material for construction purpose, which mainly consisted of SiO 2 and CaO.Metals 2020, 10, 57 2 of 17 remove aluminum from iron ore containing Fe total 52.94%, 9.95% Al 2 O 3 and 6.1% SiO 2 , and only 40% alumina was removed after 6 or 15 days of in situ leaching at 10% pulp density. Biological method could play a certain role in the separation of iron from alumina, but its effect may be poorer, especially the period is too lengthy compared to smelting processes.Smelting processes consist of coal-based direct reduction-magnetic separation, roasting-magnetic separation, and smelting separation [11][12][13]. It is effective to recover iron from low-grade refractory iron ore through coal-based direct reduction-magnetic separation. However, there is a problem that exists in this process, low reduction rate [14,15]. Zhou et al. [13] proposed a high temperature reduction followed by magnetic separation for high aluminum hematite-limonite ore treatment. Their findings indicated that approximately 90.25% of iron recovery was obtained, but the recovery of Al 2 O 3 was not considered. Sellaeg et al.[16] adopted a direct smelting reduction process to recover iron from red mud, and the result showed that only 70% of iron was recovered and an Al 2 O 3 -containing slag was obtained. He et al. [17] proposed a slag-iron bath smelting reduction process for the treatment of alumina-rich iron ore, and more than 90% iron was recovered using this method. It is worth noting that the smelting separation process can achieve the separation of iron and alumina. However, the slag could not be effectively used, resulting in a difficulty of extracting aluminum.Considering that the existing processes for HAIO treatment have highly energy consumption and are economically impractical, it is urgent to develop a more economical and valid process. In this work, a new process was developed through the pre-reduction of high alumina iron ore and subsequent smelting to produce pig iron and rich-alumina slag, followed by alkali leaching to extract aluminum and generate a clean slag for cement industry.

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Influence of Coating Granulation Process on Iron Ore Sinter Quality and Productivity

Cited by 18 publications

References 7 publications

Effect of Pre‑wetting Treatment on the Granulation Behavior of Iron Ore Fines

Effect of Pre‑wetting Treatment on the Granulation Behavior of Iron Ore Fines

The Influence of Different Iron Ores Mixtures Composition on the Quality of Sinter

An Innovative Technique for Comprehensive Utilization of High Aluminum Iron Ore via Pre-Reduced-Smelting Separation-Alkaline Leaching Process: Part I: Pre-Reduced-Smelting Separation to Recover Iron

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