Iron ore sintering process model to study local permeability control. In industrial iron ore sintering, the raw material is heated in a reducing atmosphere and cooled in an oxidizing atmosphere. The formation of liquid phase is of great significance for improving the quality of high basicity sinter which is widely used as raw materials in blast furnace ironmaking. There are four main types of iron ore deposits worked currently, depending on the mineralogy. Sinter plants process a mixture of iron ore fines, recycled ironmaking products, slagforming agents and solid fuel coke with the finality of obtaining a product with the suitable.
Pdf iron ore sintering venkata krishnaiah academia. May 10, 2016 the presentation describes sinter structures, bonding, mineralogy, quality and other details of iron ore sinter. Sintering conditions for simulating the formation of. K white, pennsylvania state univ, pennsylvania, usa. On dioxin formation in iron ore sintering environmental. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the. Mineralogy of iron ores of different alumina levels from. The reduction of iron oxides during s i n t e r i n g of fe c o m p a c t s in nh a t m o s p h e r e s w a s i n v e s t i g a t e d by m o n i t o r i n g the h2o c o n t e n t of the emergent gases. However, further improvements regarding energy efficiency, flexibility of raw materials and environmental load have continuously been demanded.
Model predictions of pcdd and pcdf emissions on the iron ore. Sinter plants agglomerate iron ore fines dust with other fine materials at high temperature, to create a product that can be used in a blast furnace. 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. Furthermore, several indices were defined to evaluate sintering properties of iron ores. From iron ore to iron sinter process control using xray diffraction xrd uwe konig1 nicholas norberg2 luciano gobbo3 abstract traditionally quality control of iron ore sinter, its raw materials and raw mixtures has relied on timeconsuming wet chemistry. 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. Thermodynamic modelling of iron ore sintering reactions. Liquid phase sintering small amounts of liquid phase are present during sintering 3. Sintering it is a agglomeration process wherein a clinker like aggregate is formed from a relatively coarser iron ore fine6. As an important component of gangue in iron ore, alumina affects the amount of liquid phase by influencing the formation of calcium ferrites. In iron ore sinter plants blast furnace dust and other finegrained residues which are rich in iron or car bon content are recycled. The process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Micro and nanostructures produced before sintering are often destroyed. Steel community and the country demand technological solutions for utilising low grade ores.
Simulation of sintering of iron ore packed 1 simulation of sintering of iron ore packed bed with variable porosity s. Fraction of 2 mm to 5 mm should be as higher as possible for better sintering process. The blast furnace demands sinter with high strength, a low rdi, high ri. Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. Iron ore fines are the main source for sinter, and the chemical composition of the iron ore fines, together with the thermal conditions that blends are subjected to, plays an important role in forming the primary melt during the sintering process and accordingly determines the sinter structure and quality.
Iron ore sintering process model to study local permeability. The reduction of iron oxides during sintering of iron. After beneficiation iron ore availability can improve by about 50%. The sintering process begins with the preparation of a sinter mixture consisting of iron ore fines, fluxes, solid fuel called bonding agents in japan such as coke breeze, and return fines from the sinter plant and blast furnace as well as recycled ferruginous materials from downstream iron and steelmaking processes. Iron ore sintering is a material preparation process employed worldwide in the production of iron and steel. Iron ore sintering is a type of powder metallurgy used to pretreat iron before using it in manufacturing applications.
It is wellknown that its lower particle size negatively affects the permeability of the sintering process, restricting its use to. 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. During the iron ore sintering process, the loose raw materials, mixtures of fine ore, limestone flux and coke breeze, are converted into a porous but physically strong cake, which is generally composed of four main phases. The invention provides a preparation method of a sintering flux for iron ore sintering, which can solve the problem of waste recycling of converter slags, also can produce a lowcost sintering flux, and reduces the damages of converter slags on the environment. 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.
High temperature reaction calorimetry has been used to measure the heat of solution of the ore in the melt formed during iron ore sintering. Sintering conditions for simulating the formation of mineral. Iron ore is the main source of primary iron required for the global iron and steel industries. In order to study the effects of gas atmosphere in industrial sintering, small tablet specimens containing powdered commercial iron ore, limestone, quartz and kaolin were heated in controlled gas atmospheres to examine the effects of gaseous atmosphere, heating. According to statistical data on pollution, sintering plants rank second in terms of toxic emissions, after the incineration of municipal solid waste. This pdf file is created by trial version of quick pdf converter suite. The iron ore sintering process consists in high temperature agglomeration method where mainly sinter feeds together with fluxes, solid fuel, other ferrous. Iron ore sintering consists of heating a layer of fines until partial melting occurs and individual ore particles fuse together.
The iron ore fines and coke breeze fines mix with moisture is fed on the sinter bed which is ignited by a gas burner to. The metallurgical properties of iron ore sinter mainly depends on sinter mineralogy and microstructure, which in. Pdf sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes. The iron ore sintering process in the integrated steelworks is a well established technology and has been responsible to provide high quality of agglomerate raw materials for the blast furnace. It is essential to produce steel, which helps to create and maintain a strong industrial base. The combustion of coke fines breeze during sintering contributes to greenhouse gases e. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. In order to obtain good sintering performance, it is important to understand sintering properties of iron ores. 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. Effect of mgo and basicity on microstructure and metallurgical. Sintering is an agglomeration process that fuses iron ore fines, fluxes, recycled products, slagforming elements and coke. Sintering properties including chemical composition, granulation and hightemperature behaviors of ores from china, brazil and australia.
Nowadays, as the demand for iron ore increases together with the depletion of high grade ore deposits, mining companies have been investing to produce iron ore concentrates, such as pellet feeds 95% lower than 0. Recycling of blast furnace dust in the iron ore sintering. The iron blast furnace is the most widely used and efficient producer of liquid iron. Normally we get iron ore fines that is having 100 mesh 0. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Bhagat, r p 2007 fundamentals of iron ore sintering.
Benchscale sintering of iron ore mixes containing new zealand ironsand to better understand the behavior of new zealand ironsand during sintering, an iron ore blend with 5 wt pct of ironsand was sintered under di. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The following relationship modelled flame front speed for a jsm style sinter mix over a fuel reactivity range of 1. Apr 02, 2020 to understand iron ore sintering, it is necessary to first understand certain aspects of raw iron ore. Development of an iron ore sinter process model to predict. Alternative to deal with high level of fine materials in iron ore.
Changing bed bulk density and other process conditions during. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace. The mineralogical composition that defines the properties is often not monitored. Mining operations pull raw ore from the earths crust, separating it into highgrade and lowgrade, based on how much raw iron is present. 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. Jul 18, 20 the iron blast furnace is the most widely used and efficient producer of liquid iron. Kumba iron ore, anglo american plc iron ore fines are agglomerated in the sintering process to produce sinter.
Pdf sintering is a process by which a mixture of iron ores, fl uxes and coke is agglomerated in a sinter plant to. Iron ore sintering is an important source of dioxins, polychlorinated dibenzopdioxins and dibenzofurans pcddfs. Alternative to deal with high level of fine materials in. Raw iron ore is found throughout the world and is, in fact, one of the most prevalent elements on earth. Sinter plants process a mixture of iron ore fines, recycled ironmaking products, slagforming agents and solid fuel coke with the finality of.
Kasai institute of multidisciplinary research for advanced materials tohoku university japan phoenics user conference melbourne,2004 2 flowchart of steel production 3 sintering process concept region of. The presentation describes sinter plant, its major equipments, its operation, sintering process and the technological developments. Ppt simulation of sintering of iron ore packed powerpoint. Reflected light photomicrograph of hightemperature completely melted iron ore sinter magnification x200. Plastic materials are formed by sintering for applications that require materials of specific porosity. Effect of alumina on liquid phase formation in sintering. Characterization of minerals, metals, and materials 2016 pp 167174 cite as. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Iron ore mining methods vary by the type of ore being mined.
The complexity of the reaction poses difficulties to optimize the process and hence the quality o f the sinter. As emphasized in chapter 3, we recommend treating the whole iron ore sector with a fallback approach see section 5 of the report on the project approach and general issues and do not consider product benchmarking an adequate approach. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard. In order to study the effects of gas atmosphere in industrial sintering, small tablet specimens containing powdered commercial iron ore, limestone, quartz and kaolin were heated in controlled gas atmospheres to examine the effects of gaseous atmosphere. Apr 15, 2014 liquid phase sintering small amounts of liquid phase are present during sintering 3. The purpose of sintering is to obtain a product with suitable. 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. Reactive sintering particles react with each other to new product phases 5.
The presentation describes sinter structures, bonding, mineralogy, quality and other details of iron ore sinter. Rom iron ore with fe less than 58 60% discarded as waste. Sintering involves heating iron powder to partially, but not completely, melt the iron particles. Cn104278146a preparation method of sintering flux for iron.
The dehydration and calcination of iron ore and flux samples was also examined using hightemperature reaction calorimetry. One of the possibilities to increase iron content in sinter is the modification of raw materials ratio. Model predictions of pcdd and pcdf emissions on the iron. Guidelines for laboratory potgrate sintering tests. Cn104278146a preparation method of sintering flux for. Expired lifetime application number us449376a inventor william m stewart. An experimental program conducted at csiro showed that flame front speed ffs and sinter productivity increased with fuel reactivity r while sinter strength and fuel utilisation fell. In this chapter, the sintering process is first described and the key steps of the sintering process, namely, granulation and thermal densification, are identified. This process allows recycling of waste products from other sections of the steel making process. Skorokhod p o w d e r bodies a r e objects which a r e in a state of t h e r m o d y n a m i c nonequilibrium and have a l a r g e e x c e s s of f r e e e n e r g y the moving f o r c e of the s i n t e r i n g p r o c e s s.
Sintering of iron ore pdf figure 1 presents schematically an iron ore sintering process. According to the invention, converter slags and air are fully reacted at a high temperature of 8001100 deg c, a main. Influence of alumina on iron ore sinter properties and. This paper reports on attempts to identify materials, conditions, and mechanisms responsible for pcddf formation i by investigating salient properties of ores viz. 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. In the sintering process, the iron ore corresponds to the mixture of hematite, goethite and other gangue. The influence of fuel reactivity on iron ore sintering. The exact process used and additional elements involved vary, with some methods using gas or electricity in addition to heat.
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. In the iron ore sintering process, air flow rate is a major factor in determining the flame front speed which in turn influences the sinter quality and productivity. Iron ore market iron ore sintering free 30day trial. Theory and practice of sintering pdf free download. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in.
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