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    9-Agglomeration of Ores

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    GRAHAM KUNDAI DENGEZA
    Agglomeration involves forming fine particles into larger compacted forms through processes like pelletizing and sintering. This is done to address issues with transporting and processing fine materials. Pelletizing forms particles into balls using a tumbling action and binders while sintering ignites a mixture on a moving grate to fuse materials through melting and formation of a binding phase. Testing evaluates properties like strength, swelling and reducibility.

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    9-Agglomeration of Ores

    Uploaded by

    GRAHAM KUNDAI DENGEZA
    88 views29 pages
    Agglomeration involves forming fine particles into larger compacted forms through processes like pelletizing and sintering. This is done to address issues with transporting and processing fine materials. Pelletizing forms particles into balls using a tumbling action and binders while sintering ignites a mixture on a moving grate to fuse materials through melting and formation of a binding phase. Testing evaluates properties like strength, swelling and reducibility.

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    Agglomeration involves forming fine particles into larger compacted forms through processes like pelletizing and sintering. This is done to address issues with transporting and processing fine materials. Pelletizing forms particles into balls using a tumbling action and binders while sintering ignites a mixture on a moving grate to fuse materials through melting and formation of a binding phase. Testing evaluates properties like strength, swelling and reducibility.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    88 views29 pages

    9-Agglomeration of Ores

    Uploaded by

    GRAHAM KUNDAI DENGEZA
    Agglomeration involves forming fine particles into larger compacted forms through processes like pelletizing and sintering. This is done to address issues with transporting and processing fine materials. Pelletizing forms particles into balls using a tumbling action and binders while sintering ignites a mixture on a moving grate to fuse materials through melting and formation of a binding phase. Testing evaluates properties like strength, swelling and reducibility.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 29

    AGGLOMERATION

    PELLETISING AND SINTERING


    WHY AGGLOMERATE?
    • Many processes produce fines:
    • Flotation concentrate
    • Gravity concentrate (e.g. spirals)
    • Furnace dust
    • Bag house, ESP
    • Sludge from wet gas cleaning
    • Venturi, educator, spray tower etc
    • Fine material problems:
    • Fluidization
    • Pneumatic conveying 1
     2

    • Channelling
    3
    f
    V* V 
      g (    ) 
     s f 

    • Pressure drop in furnace


    • Gas flow restriction 1
      g ( s   f )  3
    D*  D  f 
     2  2
    IMPACT OF SIZE DISTRIBUTION
    • Uniform size give highest void fraction
    • Ergun equation:
    P  (1   ) 2  (1   ) 2
     150 2 2 3
    Vs  1.75 3
    Vs
    L  p Dp   Dp 

    • ΔP = f(Void fraction)
    • Increased ε → decreased ΔP
    • Low ΔP :
    • Large particles
    • Uniform size
    3
    METALLURGICAL CONSIDERATIONS
    • Agglomerated ore may have beneficial properties
    compared to lump ore
    • Reducibility
    • Higher porosity
    • Higher gas permeability → faster reduction
    • Finer particle size
    • Greater surface area for gas reduction
    • Thermal cycle (pellets and sinter)
    • Altered mineralogy may improve reducibility

    4
    AGGLOMERATION
    • Eliminate problems by agglomeration
    • Form larger lumps
    • Compaction
    • Briquetting
    • Extrusion
    • Agglomeration
    • Sintering
    • Pelletizing
    • Nodules

    5
    BRIQUETTING
    • Pressing of powders into large composites
    • Powder preparation
    • Millings, screening, blending with binder
    • Mixture pressed between rotating rolls
    • Briquette shaped indentation in rolls
    • High pressure applied
    • Briquettes may need aging
    • Time for chemical reactions
    • Strength improves

    6
    BRIQUETTING
    • Cold process:
    • Curing temperature: ± 200 – 400  °C
    • Cost saving on capital and energy
    • Some powders can be briquetted without binder
    • Direct reduced iron (DRI) – Hot pressed
    • Low rank coal, Peat, Wood
    • Selection of binder important
    • Briquette strength: cold, hot
    • Binder cost
    • Additional slag from inorganic binders
    7
    HBI - HOT BRIQUETTED IRON
    • Direct reduced iron (Sponge iron)
    • High porosity
    • Large surface area
    • Low thermal conductivity
    • Unstable – several oxidation reaction
    4 Fe  3O2  2 Fe2O3 Spontaneous, Exothermic
    2 Fe  3H 2O  Fe2O3  3H 2 Requires high temperature
    • Unsuitable for transportation
    • Briquette while hot
    • Reduces surface area
    • Increases conductivity
    8
    PELLETIZING
    • Fine particles formed into balls
    • No pressure applied
    • Normally requires a binder
    • Suitable for fine particles
    • Typically < 150 µm
    • Recommended: 80% < 43µm
    • Typical pellet size:
    • Pellets: 6.5 – 16 mm
    • Micropellets: < 6 mm
    9
    PELLETIZING
    • Iron ore
    • Taconite ore (magnetite)
    • Concentrates: magnetic separation, floatation
    • Furnace dust and sludge
    • Fluxed pellets:
    • Acid
    • Basic: limestone added
    • Olivine: Olivine (Mg, Fe)2SiO4 or calcined serpentine
    ((Mg, Fe)3Si2O5(OH)4) added – source of Mg for improved RDI
    • Chromite
    • UG2 concentrate from platinum mining
    10
    PELLETIZING MECHANISM
    • Adhesion between fine particles
    • Water, liquid binder phase
    • Capillary force dominant binding mechanism
    • Tumbling action adds particles to growing ball

    http://www.glatt.com/

    11
    PELLETIZING EQUIPMENT: DRUM
    • Drum
    • Disc

    12
    PELLETIZING EQUIPMENT: DISC
    •

    http://feeco.com/disc-pelletizers/

    13
    GRATE KILN INDURATION
    • Combination of:
    • Grate – drying
    • Rotary kiln – firing
    • Rotary cooler

    http://www.metso.com/

    14
    STRAIGHT GRATE
    • Pellets loaded onto moving grate for:
    • Drying
    • Indurating
    • Cooling
    • Grate layer used

    15
    STEEL BELT SINTER PROCESS
    • Pellets contain fuel
    • Some extra fuel may be required
    • Sinter strand is a continuous steel belt
    • Zones for:
    • Drying
    • Heating
    • Sintering
    • Cooling
    • Efficient heat flow
    16
    BRIQUETTING AND PELLETIZING BINDERS
    • Mechanism
    • Matrix: particles embedded in binder matrix
    • Film: particles surrounded by a layer of binder
    • Chemical – matrix or film: reactions take place to bind particles
    • Water
    • Optimal water levels required
    • Types
    • Organic
    • Starch, dextrin, flour, lignosulphonates, molasses, polymer, resin
    • Bitumen, coal tar
    • Inorganic
    • Sodium silicate, lime, cement, bentonite, salts
    17
    PELLET MECHANICAL TESTING
    • Green pellets
    • Drop number: number of 18” drops before fracture
    • Wet green compressive strength
    • Dry green compressive strength
    • Fired pellets
    • Size: (ISO4701) 6.3 – 16 mm
    • Compressive strength: 200 – 350 kg for +9, -13 mm
    • Tumble test (ISO 3271)
    • 11.4 kg, + 6mm sample
    • 8 min at 25 rpm
    • Screen: < 5 % -0.5 mm, > 90 % + 6.3 mm
    18
    PELLETS METALLURGICAL PROPERTIES
    • Iron ore pellet swelling
    • Formation of iron whiskers
    • Cause the pellets to swell and break
    down
    • Controlled by composition
    • Swelling index (ISO 4698) V  100  V1  V0
    FS
    • 900 °C, 30 % CO, 70 % N2 V0
    • VFS = Free swelling index,
    • V0, V1 = Volume before and after test
    • VFS < 20 %
    19
    PELLETS METALLURGICAL PROPERTIES
    • Reduction disintegration (RDI) (ISO 11257)
    • Rotating horizontal tube furnace m0  (m1  m2 )
    • 750 °C, CO, CO2, CH4, H2 RDI DR   100
    • Sample screened m0
    • RDIDR: Direct reduction disintegration index,
    m0: reduced sample mass, m1: mass + 10 mm, m2: mass -10 mm + 3.5 mm

    • Metallization: Mass % metallic

     0.111w1 mt 
    • Reducibility index (RI) (ISO 4695) Rt    100  100
    • 950 °C, 40 % CO, 60 % N2  0.430w2 m0  0.430w2 
    • m0 : Sample mass, Δmt: Mass loss at time t
    w1: mass% iron (II) oxide , w2: mass % iron

    20
    SINTERING
    • Mixture of ore, flux, fuel ignited on moving grate
    • High temperature causes fusion of ore and flux
    • Binding phase forms from melt
    • Used for:
    • Iron ore
    • Manganese ore
    • Lead ore (combustion of PbS provide energy)
    • Lead/Zinc ore

    21
    SINTERING PROCESS
    • Blending of ore, fuel and flux
    • Granulation in mixing drum
    • Loaded onto moving grate
    • Bed ignited in ignition hood
    • Flame front pulled through bed
    • Down draught: requires grate layer
    • Up draught
    • Sinter broken and screened
    • Fines returned:
    • Grate layer
    • Blending with concentrates to improve permeability
    22
    REACTION ZONE: DOWN DRAUGHT
    • Zones in the sinter bed:
    • Charge drying, gas cooling
    • Heating to ignition temperature
    • Combustion
    • Sinter cooling, air heating

    23
    SINTER STRAND: DOWN DRAUGHT

    24
    SINTER STRAND: UP DRAUGHT
    • Initial down draught section
    • Ignition zone
    • Ore loaded onto burning layer
    • Up draught through thick bed
    • Up draught protects grate
    • Cooling
    • Liquid lead (PbS sintering)
    • Velocity limited by fluidization
    • Opening of bed reduces
    pressure drop for fine materials
    25
    DOWN DRAUGHT STRAND
    •

    26
    IRON SINTER
    • Energy supplied by fuel (coke)
    • Temperatures ± 1300 °C
    • Melt forms at high temperature http://ispatguru.com/sinter-quality-and-process-of-sintering-iron-ores/

    • Flux, ash, gangue, iron oxide form


    binding phases
    • Binding phases:
    • SFCA
    • Silicoferrite of calcium and aluminium
    • Calcium ferrite
    • Glass
    27
    •

    Modern blast furnace ironmaking – An introduction Sinter phase transformation during descent in an experimental blast furnace

    28
    LEAD ORE SINTER
    •

    29

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