Iron ore is beneficiated by crushing and then separating the iron from the gangue minerals through screening. Dry magnetic separation and wet magnetic separation. Beneficiation of indian high alumina iron ore fines a case. The iron ore concentrate is now mixed and ready for the pelletizing process.
Modeling sintering process of iron ore, sintering methods and products, volodymyr shatokha, intechopen, doi. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants. Numerical modeling of the iron ore sintering process. Iron ore fines are agglomerated in the sintering process to produce sinter. Ore assimilation and secondary phases by sintering of rich. Iron ore mining process and iron ore mining equipments sbm. High grade iron ore less than 10% of the total reserves. Iron ore sintering is a complex high temperature gassolid reaction process for bulk production of blast furnace raw material. Steven furedy product manager iron ore pelletizing. Highgrade iron ore is crushed for sizing, producing both fine ore as well as lump ore. After beneficiation iron ore availability can improve by about 50%. Process, mineral processing and extractive metallurgy.
This paper reports on attempts to identify materials, conditions, and mechanisms responsible for pcddf formation i by investigating salient properties of ores viz. A finite difference model of the iron ore sinter process. Iron ore sintering is a type of powder metallurgy used to pretreat iron before using it in manufacturing applications. In 2009, the co 2 emission from chinese iron and steel sector is nearly equal to 50% of the worlds steel industrys co 2 emission. To beneficiate lowgrade ore, it is first pulverized into finer particles called pulverized ore. Sintering involves heating iron powder to partially, but not completely, melt the iron particles.
Some sinter feed cargoes are produced by a concentration process, and are therefore a sub type of iron ore concentrate itself a group a cargo listed in the code, whereas others are unprocessed fines. Coarse ore fraction, sintering temperature, holding time and oxygen partial pressure were selected as. Consequently, this phenomenon resulted in the decrease of ca to combine with. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical. 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. Automated measurement of sintering degree in optical. Magnetite, as the name implies is the most magnetic of all the naturally occurring minerals and has a black color with a brownish tint. Mineralogically iron sinter comprises, essentially, relict original surviving particles of iron ore, silicate and former carbonate, bound within a matrix of secondary phases formed only during sintering. Iron ore sintering is an important source of dioxins, polychlorinated dibenzopdioxins and dibenzofurans pcddfs. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in. Simulation of particle bed in sintering process is one of the most interesting research topics. Sinter is a material charged to the blast furnace in the ironmaking process. This paper analyses the effect of the chemical composition on mineralization characteristics of liquid production.
It was seen that raising the mgo content in the sinter, from 1. The iron ore fines sample was collected from the spiral classifier overflow of a typical iron ore beneficiation plant of noamundi, india. Microstructure and minerals evolution of iron ore sinter mdpi. Us786814 invented a sintering process for copper sulphide ores. Iron ore sintering is a hightemperature, nonequilibrium reaction process that involves. This is usually so efficient that lower grade ore can be treated especially when the magnetite is quite coarse.
Sintering process is developed mainly to utilize under size of lump ore called iron ore fines. The proposed model confers a phase on each solid material. The results show that the carbon content and the melting temperature affect the. Sintering takes place in a sinter plant, sinter plants are also used to recycle waste material generated elsewhere in the. Steel community and the country demand technological solutions for utilising low grade ores. Normally we get iron ore fines that is having 100 mesh 0. The results show that, the ores of different types have apparently differences in bonding intensity, ores from brazil and south africa have high bonding intensity, while ores from australia have low bonding intensity. Beneficiation, sintering, and processing of raw materials for the iron and steel industry p. Thermal cycle of the materials in the sinter strand. Sintering of iron ore pdf figure 1 presents schematically an iron ore sintering process.
In this chapter, the sintering process is first described and the key steps of the sintering process, namely, granulation and thermal densification, are identified. The complexity of the reaction poses difficulties to optimize the process and hence the quality o f the sinter. Fraction of 2 mm to 5 mm should be as higher as possible for better sintering process. At low oxygen partial pressure, the two melt regions combine into one large melt.
Sintering is a thermal process carried out at 0 deg c to 1400 deg c by which a mixture of iron ore, return fines, recycled products of the steel plant industry such as mill scale, blast furnace dusts, etc. In order to conserve these, otherwise waste material, they are compacted together and made into lumps by a process known as sintering. Development of an iron ore sinter process model to predict. 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.
Three dimensional mathematical model of the iron ore sintering process based on multiphase theory. The present model was established with a series of conservation equations in the form of a partial differential equation for each solid phase and gas phase. Pelletization is an agglomeration process of iron ore concentrates with a granulometry lower. Samples were taken from the six hills of muko ore deposits and tests carried out to establish their composition and properties. Simulation of sintering process effects of contraction. Differential scanning and high temperature reaction calorimetry have been used to characterize a series of natural iron ore and flux samples commonly used during iron ore sintering. This secondary matrix between relict particles comprises a mixture of iron oxides, diverse. The quality of sinter is very important for smooth operation and high productivity of blast furnace since it improves the permeability and reducibility of the burden material. Vanadiumtitanium magnetite ore blend optimization for sinter strength based on iron ore basic sintering characteristics. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals.
Alumina increases the viscosity of the primary melt that forms during the sintering process, leading to a weaker sinter structure with more interconnected irregular pores 7. During the iron ore sintering process, two types of particles are present. It is aimed at converting iron ore fines to suitable feed for efficient ironmaking in the blast. In the case where the ore consist of magnetite ironoxide, the nature of the sintering is dependent on the initial process of oxidizing. Viscous and diffusion mechanisms of mass transport 3. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed mixtures is evaluated. Experimental research on bonding intensity of iron ores in. In the literature simple and more sophisticated iron ore sintering models have been reported. 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. There are three main types of aluminacontaining iron ores and due to their unique properties they perform differently during the sintering process. Three dimensional mathematical model of the iron ore.
Common iron ore crushers are jaw crusher, cone crusher and fine jaw crusher. The iron ore may be natural ore, which usually has a particle size up to 10mm, or concentrate which is very fine with a. Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. 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. As such it is a cargo which effectively has the same characteristics as iron ore fines and is subject to the same risksof liquefaction. 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. Simulation of sintering of iron ore packed 1 simulation of sintering of iron ore packed bed with variable porosity s. School of minerals processing and bioengineering, central south. On dioxin formation in iron ore sintering environmental. 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 main effect on iron ore mineralization performance in the sintering process is the grain size of raw material and chemical composition. Study on the effect on sintering mineralization of iron ore. The sample was dried, thoroughly mixed and analysis indicated that the dried sample contained 59. Rom iron ore with fe less than 58 60% discarded as waste.
The integrated iron and steel industry is the most energyintensive sector, accounting for 1015% of the total energy consumption in the world. How to measure phase distribution and degree of sintering. The role of coke size in the sintering of a hematite ore blend. It is an abundant element and occurs as a major or minor constituent of all the mineral classes. Influence of iron ore characteristics on feo formation during. Lx yang, d witchard, zn yuintroduction of pisolitic goethite ore into a chinese ore blend j. Pellets are comprised of ore that has been agglomerated into balls. Several attempts have been done to predict the final properties of the sinter product water et al. The quality of this iron ore was evaluated to establish its suitability to serve as a raw material for iron production. Iron ore fines are agglomerated to produce sinter, which is an important feed material for blast furnaces worldwide. Coke combustion, limestone decomposition, gaseous reaction, heat. 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. Sinter strength evaluation using process parameters under. 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.
A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed. Mathematical model of thermal processes in an iron ore. Quite different behaviors of different iron ore fines are observed at higher temperatures. Like other sintering processes, iron ore sintering converts iron ore fines of often. Pelletizing of iron ores kurt meyer free ebook download as pdf file. Pdf modeling sintering process of iron ore researchgate. Oxidized iron ores with a granulometry within 10 and 120 mm were loaded. Agglomeration is the size incensement process of the fines ore. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. 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.
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. Influencing factors and effects of assimilation characteristic of iron. Beneficiation, sintering, and processing of raw materials. Introduction the iron ore extracted from lkabs underground mines consists mainly of the mineral magnetite. Since design and fabrication of iron ore sintering process involves proper understanding and to have desired strength and quality of sinter,keeping this in mind suitable process and materials are selected for the laboratory scale sintering machine. Design and fabrication of iron ore sintering machine. The study aimed at investigating the chemical composition and microstructure of raw iron ore from the deposits in muko area southwestern uganda.
The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The bonding intensity of four kinds of ores from brazil, australia and south africa is researched in this study, and the influence factors are analyzed. In the sintering process, the iron ore corresponds to the mixture of hematite, goethite and other gangue. Mining industry agglomerated the development of techniques of mining and concentrating taconite led to the introduction of the ironore pellet. An unsteady onedimensional model of an iron ore sintering bed with multiple solid phases was proposed. Extrapolation of sintering concepts towards constitutive modeling of sps 6. Optimising iron ore sinter leads to cost savings csiro. Pdf sintering is a thermal agglomeration process that is applied to a. Aluminacontaining iron ores are major feed materials used in iron ore sintering in the asia pacific region. The pellet is the major form of introducing iron into the steelmaking blast furnace. One of the possibilities to increase iron content in sinter is the modification of raw materials ratio.
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