Aluminacontaining iron ores are major feed materials used in iron ore sintering in the asia pacific region. Oreblending optimization model for sintering process. Numerical modeling of the iron ore sintering process. Samples were taken from the six hills of muko ore deposits and tests carried out to establish their composition and properties. Design and fabrication of iron ore sintering machine. Iron ore sintering process optimization optymalizacja procesu aglomeracji rudy zelaza the work deals with examination of the influence of the ratio between iron ore concentrate and iron ore on quality of produced iron ore sinter. A finite difference model of the iron ore sinter process by j. How to measure phase distribution and degree of sintering in.
Sintering ofiron ore fines, and raw materials for bhilai steel plant g. Iron sinter is the thermally agglomerated substance formed by heating a variable mixture of iron. The purpose of the sintering process is manufacturing a product with the suitable characteristics thermal, mechanical, physical and chemical to be fed to the blast furnace. Owing to the depleting reserves of traditional high grade iron ore, there have. A novel approach for utilization of ultrafines iron ore in. Theory and practice of sintering of iron ore ispatguru. Influence of high grade iron ore usage on the performance. Currently, coke was used as main fuel in sintering of iron ore. Pellets are small and hardened iron balls with a diameter of 1020 mm and are used as raw material for iron steel manufacturing. Automation and control systems are vital tools to assist plant operators in the monitoring of each stage of the sinter production process.
This pdf file is created by trial version of quick pdf converter suite. The chemical analysis of the olivine from greenland shows an. An ore blending optimization model for the sintering process is an intelligent system that includes iron ore characteristics, expert knowledge and material balance. How to measure phase distribution and degree of sintering in iron ore pellets martin simonsson department of computer science, electrical and space engineering, lulea university of technology, lule. Control of the grain size distribution of t the raw. Ironore sintering process optimization optymalizacja procesu aglomeracji rudy zelaza the work deals with examination of the influence of the ratio between iron ore concentrate and iron ore on quality of produced iron ore sinter. The sintering fundamental characteristics of black iron. Iron ore sintering is a material preparation process employed worldwide in the. The current study presents a novel approach for the utilization of ultrafines iron ore. The usage of low grade iron for sintering process has been continuing due to abundance of low grade iron ore 2. The raw materials used in the sintering experiments were thabazimbi iron ore, sishen iron ore, return fines, coke, lime, quartz, water and ferric chloride fecl3. This paper reports on attempts to identify materials, conditions, and mechanisms responsible for pcddf formation i by investigating salient properties of ores viz. In the sintering process, the iron ore corresponds to the mixture of hematite, goethite and other gangue mineral typologies. Investigation on reaction schemes of iron ore sintering process by.
Apr 02, 2020 to understand iron ore sintering, it is necessary to first understand certain aspects of raw iron ore. Pdf modeling sintering process of iron ore researchgate. The assimilation temperature of some fines ore is low at about 1260. Optimization of sinter plant operating conditions using advanced. The production of most pig iron in the world is based on the use of iron ore sinter which consists of various mineral phases produced by sintering iron ores with fluxes and coke breeze.
Sintering process is developed mainly to utilize under size of lump ore called iron ore fines. After beneficiation iron ore availability can improve by about 50%. Several attempts have been done to predict the final properties of the sinter product water et al. Iron ore sintering is a hightemperature, nonequilibrium reaction process that involves. Development of a method for evaluating raw materials for.
In the literature simple and more sophisticated iron ore sintering models have been reported. The exact process used and additional elements involved vary. Furthermore, using coke breeze without sieving in sintering of an iron ore decreases the vertical velocity of sinter machine and increases the reduction time. Pdf iron ore sintering venkata krishnaiah academia. Sintering theory was traditionally developed either as the application of complex diffusion. A model of the iron ore sintering process has been developed with the objective of being. Influence of binder dosage on granule structure and packed. Included in this article also is a discussion of the mining of iron and of. The sintering technology was developed for the treatment of the waste fines of iron ore, coke, limestone, dolomite and metallurgical wastes. Vreugdenburg synopsis iron ore fines are agglomerated to produce sinter, which is an important feed material for blast furnaces worldwide. Carriage of iron ore fines and associated cargoes circular to assureds no 006 2011 this is the third circular issued by the club dealing with the carriage of iron ore fines and follows on from our october 2009 number 005 2009 and july 2010 number 008 2010 circulars both of which are attached. High grade iron ore less than 10% of the total reserves. Sintering involves heating iron powder to partially, but not completely, melt the iron particles. Sintering is a process by which a mixture of iron ores, fl uxes and coke is agglomerated in a sinter plant to manufacture a sinter product of a suitable composition, quality and granulometry to be used as burden material in the blast furnace.
Oreblending optimization model for sintering process based. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. The quality of this iron ore was evaluated to establish its suitability to serve as a raw material for iron production. The process of pelletization helps converting iron ore fines into uniform size iron ore pellets that can be fed in the blast furnaces or in the dri kiln dri. Vreugdenburg kumba iron ore, anglo american plc iron ore fines are agglomerated in the sintering process to produce sinter. Optimising iron ore sinter leads to cost savings csiro. However, high quality iron ore resources are being depleted due to the heavy demand, and thus it is necessary to continue improving sintering technology in order to use lower quality iron ores in the raw mix.
Development of secondaryfuel injection technology for. The granulability and permeability of the ore blend improved. This pdf file is created by trial version of quick pdf. Sintering properties and optimal blending schemes of iron. Rom iron ore with fe less than 58 60% discarded as waste. Sintering is a process by which a mixture of iron ores, fl uxes and coke is agglomerated in a sinter plant to manufacture a sinter product of a suitable composition, quality and granulometry to be. A finite difference model of the iron ore sinter process. This process sits at the interface of mineral processing and extractive metallurgy.
Sintering of iron ore pdf figure 1 presents schematically an iron ore sintering process. Iron ore is widely distributed around the world with large and numerous resources. The study aimed at investigating the chemical composition and microstructure of raw iron ore from the deposits in muko area southwestern uganda. Return sinter fines having lower fusion temperature than the raw mix serve as seeds for initiation of the sintering process. Twolayer sintering, iron ore, coke rate, sinter quality for melting, multiobjective optimization, pareto set, genetic algorithm. Mn ore sinters are almost as strong as iron ore sinters. As mentioned before it is a high grade iron ore with low gangue content, which make it a very good ore to be used in sintering process. Moreover, sinter pot test using blending mix was performed, and the results indicated that the ore blending scheme led to good sintering performance and sinter quality. The blast furnace demands sinter with high strength, a low rdi, high ri. Study of sinter reactions when fine iron ore is replaced. Steel community and the country demand technological solutions for utilising low grade ores. The fundamental sintering characteristic of black iron concentrate improved rapidly and fully completed at 70 the assimilation temperature of iron concentrate is much higher than that of fines ores. The results show that the carbon content and the melting temperature affect the final structure of the bed.
The dehydration and calcination of iron ore and flux samples was also examined using hightemperature reaction calorimetry. Basic characteristics of australian iron ore concentrate and its effects. Iron ore sintering can be described as the controlled burning of a fuel mixed with iron ore barker et al, 2006, p. How to measure phase distribution and degree of sintering. In this investigation the usefulness of the olivine mined at greenland for sinter and pellet production was studied. Paper open access effect of temperature on porosity of. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in. In order to obtain good sintering performance, it is important to understand sintering properties of iron ores. The main effect on iron ore mineralization performance in the sintering process is the grain size of raw material and chemical composition. Iron sintering plants rationale for standard unique to ontario, the sintering of iron bearing steel mill secondary materials and ore results in an estimated annual release of 6. Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue.
Pdf sintering is a process by which a mixture of iron ores, fl uxes and coke is. Seqiolivine improves the sintering and pelletizing. Sinter is the main iron bearing burden for the blast furnace and its production is based on coke breeze as a source of fuel. In order to conserve these, otherwise waste material, they are compacted together and made into lumps by a process known as sintering. Granulation of coke breeze fine for using in the sintering. Pdf study of softening and melting behaviour of iron ore. Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming agents and solid fuel coke. Sintering ofiron ore fines, and raw materials for bhilai. This presentation has been prepared by anglo american plc anglo american and comprises the written materialsslides fora presentation concerning anglo american. Thermal cycle of the materials in the sinter strand.
The book begins with a discussion of raw materials preparation and the beneficiation process. Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming agents, and solid fuel coke. The following abbreviations are used to describe the examined samples. The iron ore may be natural ore, which usually has a particle size up to 10mm, or concentrate which is very fine with a. In the sintering process, the iron ore corresponds to the mixture of hematite, goethite and other gangue. Iron ore sintering involves the movement of a flame front down a particulate bed, and a series of physicochemical reactions over a large temperature range. The steel making needs very little share 4% as the process is exothermic in nature. In the present work, 14 indices are proposed to represent chemical composition, granulating properties and high temperature properties of iron. The process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Study on the effect on sintering mineralization of iron ore. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. In the present work, 14 indices are proposed to represent chemical composition, granulating properties and high temperature properties of iron ores.
Simulation of sintering process effects of contraction. All topics have been written and formatted based on the practical observations. In 1902, a sintering method for pyrite cinder and dusty iron ores with. The minipellets were composed of ultrafine iron ore and calcium hydrate while coke fines were used as a coating layer.
After the relationships between iron ore characteristics and sintering performance. The distribution of this document in certain jurisdictions may be restricted by. Ore assimilation and secondary phases by sintering of rich. Development of an iron ore sinter process model to predict. The pelletizing process was commercially introduced in the world market in 1955, following the world war ii scarcity of highgrade natural iron ore. The main scope of this paper is to obtain the least expensive iron ore blend for the sintering process, which will provide suitable chemical and. The sinter mix, besides the ore fines, usually contains other materials like flue dust, return fines, limestone andor dolomite etc. The thermal energy used in power generation and hot rolling account for 8% and 11%, respectively. Jun 24, 2015 design and fabrication of iron ore sintering machine 1.
Development of an iron ore sinter process model to predict sinter strand operating parameters using the finite difference method j. Sintering takes place in a sinter plant, sinter plants are also used to recycle waste material generated elsewhere in the steelmaking process. Sintering of iron ore is a generic term which is used to describe the process whereby a sinter mix raw mix or green mix of iron ore fines, fluxes, fuel coke breeze and plant return fines e. Study of softening and melting behaviour of iron ore sinter and pellets. Melting tendencies at the grain boundaries lead to a caking of the material. This topic features are related and suitable for 25 m2 annular sinter machine. Sinter plants 73 030301 sinter plants process description by sintering, the pelletisation of finegrained, smeltable ores, iron ore in particular, to compact lumps by heating nearly to the melting or softening point is understood.
During the iron ore sintering process, two types of particles are present. It can be noted that the major share 72% of energy is required during iron making which includes coke making 12%, iron ore sintering 6%, and blast furnaces 54%. Waste gases from iron ore fine preparations for blast furnace ironmaking, or sintering, contain minute quantities of acidic species, dust, and dioxin pollutants, but because of the very large quantities of iron ore processed and the large volume throughput of air involved, sintering is a major source of these emissions and also co 2 into the atmosphere. In this chapter, the sintering process is first described and the key steps of the sintering process, namely, granulation and thermal densification, are identified. A millipot setup for sintering investigation of iron ores. There are three main types of aluminacontaining iron ores and due to their unique properties they perform differently during the sintering process. Main feed into a sinter plant is base mix, which consists of iron ore fines, coke fines and flux limestone fines. Andrey panov, gennadiy podgorodetskiy, vladislav gorbunov. This book focuses on agglomeration, or the size enlargement process, of iron ores.
In this respect, specific issues, which now require further investigation and understanding, include the sintering of ore types with. Characterization of chemical composition and microstructure. Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. The process converts natural fine iron ore material, screened iron ore fines, coke, and lime into a fused clinkerlike aggregate that can be effectively used in the bf.
The complexity of the reaction poses difficulties to optimize the process and hence the quality o f the sinter. Mining operations pull raw ore from the earths crust, separating it into highgrade and lowgrade, based on how much raw iron is present. One of the possibilities to increase iron content in sinter is the modification of raw materials ratio. Changing dynamics of iron ore pellets industry blogs. It is an abundant element and occurs as a major or minor constituent of all the mineral classes. This corresponds to 4 percent of the national total of dioxins and furans emissions documented in the. However, the ore deposits are quite different and during wet processing there is a wide range of particle sizes that need to be treated. In research carried out in a sinter pot with 65 kg of raw mix, the mgo content of four manufactured sinters was increased from 1. The iron ore sinter which was produced by using coke breeze without sieving yielded low productivity for both sinter machine and blast furnace. Pdf sintering is a thermal agglomeration process that is applied to a. Sintering is defined as the agglomeration of the iron ore fines generally sintering process.
Iron ore sintering is a type of powder metallurgy used to pretreat iron before using it in manufacturing applications. On dioxin formation in iron ore sintering environmental. Jan 12, 2009 high temperature reaction calorimetry has been used to measure the heat of solution of the ore in the melt formed during iron ore sintering. The mineralogical composition that defines the properties is often not monitored. It is conventional to represent the bulk composition of complex oxide materials, such as iron sinter, iron ore pellets, minerals, ores and refractory products, in terms. Steelmakers are increasingly motivated to use iron ore resources with a wider range of grades and mineral types that were previously considered unsuitable or uneconomical for sintering. Pelletizing of iron ores kurt meyer free ebook download as pdf file. The limestone, silica sand, return fine, and coke breeze were obtained by sampling at the commercial plant.
Sintering emissions and their mitigation technologies. Sintering is the most economic and widely used agglomeration. How a blast furnace works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in productivity and saving in coke rate to the blast furnace. Steven furedy product manager iron ore pelletizing. The blending ratio of the limestone and silica sand were adjusted to obtain a sio2 content of 4. Simulation of particle bed in sintering process is one of the most interesting research topics. The role of coke size in the sintering of a hematite ore blend. Process, mineral processing and extractive metallurgy. This paper analyses the effect of the chemical composition on mineralization characteristics of liquid production. Mineralogy of iron ores of different alumina levels from. Introduction iron ore sintering is a complex high temperature gassolid reaction process for bulk production of blast furnace raw material. Quite different behaviors of different iron ore fines are observed at higher temperatures.
Narayanan a detailed study has been made at the national metallurgical laboratory on the sintering characteristics of the iron ores of rajharapahar, madhya pradesh, and other raw materials likely to be used. During the sintering process, the chemical reactions are taking place at high temperature and iron ores and fluxes are combined together and form a. Sintering and pelletization are the most important agglomeration technologies, in this way, in the eu27, 14 countries operate 34 iron ore sinter plants with 63 iron. At low oxygen partial pressure, the two melt regions combine into one large melt region, resulting in an. It consists of fine iron ore fused at high temperature with fluxes to form a porus clinker, which is later charged to the blast furnace.