Agglomeration in Metallurgy

Introduction ..............................................................................................................

References .................................................................................................................

1Sinter Production .........................................................................................................

1.1General Information about the Sintering Process .................................................................

References .................................................................................................................

1.2Raw Materials of the Sintering Process ............................................................................

References .................................................................................................................

1.3 Preparation of Charge Components for Sintering .................................................................

1.3.1 Dosing of the Components of the Sinter Charge .......................................................

1.3.2 Pelletizing of the Sinter Charge ...........................................................................

References .................................................................................................................

1.4 Mass Exchange Processes in the Sintering Layer .................................................................

1.4.1 Chemical Reactions with Participation of Solid Phases ...............................................

1.4.2 Processes in the Formation of the Liquid Phase during Melting .....................................

1.4.3 Processes during Solidification (crystallization) of the Melt .........................................

References .................................................................................................................

1.5 Heat Transfer in the Sintering Layer ..............................................................................................

1.5.1 General Information on the Sintering Heat Exchange .................................................

1.5.2 Zonal Heat Balances of Sintered Layer ..................................................................

1.5.3 Mathematical Model of Heat Exchange during Sintering .............................................

1.5.4 Three-Dimensional Mathematical Model of the Sintering Process ..................................

1.5.5 Calculation of the Specific Yield of the Sintering Gas ................................................

1.5.6 Vertical Sintering Speed ..................................................................................

References .................................................................................................................

1.6 The Gas Dynamics of the Sintering Process ........................................................................

1.6.1 The Basic Equation of Dynamics of the Porous Layer .................................................

1.6.2 Gas-dynamic Resistance Coefficients ....................................................................

1.6.3 Porosity of the Sintering Layer ............................................................................

1.6.4 Gas Dynamics of Sintering Technology ..................................................................

1.6.5 Sintering Machine Performance ...........................................................................

1.6.6 Ways to Improve the Performance of Sintering Machines .............................................

1.6.6.1 Modernization to Increase Sintering Capacities ..............................................

1.6.6.2 Increasing Sinter Yield ...........................................................................

1.6.6.3 Intensification of the Sintering Process ........................................................

References ....................................................................................................................

1.7 Quality of the Sinter in Terms of Influence on the Performance of Blast Furnace Smelting .................

1.7.1 Sinter Quality Indicators ....................................................................................

1.7.2 Influence of Sinter Quality on Gas-dynamic Parameters of Blast Furnace Smelting ...............

1.7.3 Requirements for Sinter Quality ............................................................................

1.7.4 Basic Solutions to Improve Quality of Sinter ............................................................

1.7.4.1 Production of Low-silicon Sinter ...............................................................

1.7.4.2 Control of the Porous Structure of the Sinter .................................................

1.7.4.3 Introduction of Low-melting Additives .......................................................

1.7.4.4 Return Mode .......................................................................................

1.7.4.5 Regulation of the Thermal Level of the Sintering Process ..................................

1.7.5 Technology of Sintering under Pressure ..................................................................

References .....................................................................................................................

1.8 Energy Efficiency of the Sintering Technology .....................................................................

References .....................................................................................................................

1.9 Environmental Aspects of Sinter Production (Best Available Technologies) ...................................

1.9.1 Thermodynamic Modeling of Emissions in the Sintering Process .....................................

1.9.2 Characteristics of Emissions from Sinter Production ....................................................

1.9.3 Influence of Technological Factors on the Emission of Pollutants during Sintering................

1.9.4 Environmental Requirements as the Main Priority of Production Modernization ...................

1.9.5 Waste Gas Recirculation Concept ..........................................................................

1.9.6 Recommendations on the Best Available Technologies (BAT) in Sintering .........................

1.9.7 Sinter Plant without Chimney................................................................................

References ......................................................................................................................

2Pellets Production .........................................................................................................

2.1General Information about Pellets Production ......................................................................

2.1.1Technological Scheme of the Production of Pellets .......................................................

2.1.2Formation of Raw Pellets .....................................................................................

2.1.3Strengthening of Raw Pellets .................................................................................

2.1.3.1Pellet Drying ...............................................................................................

2.1.3.2Roasting of Pellets .........................................................................................

References ....................................................................................................................

2.2Charge Components for the Production of Pellets ....................................................................... 

References ......................................................................................................................

2.3Formation of Raw Pellets................................................................................................

2.3.1 Interaction between Wetted Particles during the Formation of a Raw Pellet ..........................

2.3.2The Nature of the Action of Binding Additives in the Strengthening of Raw Pellets .................

2.3.3The Effectiveness of Various Strengthening Additives in Pelletizing ...................................

References .....................................................................................................................

2.4Cold Bonded Pellets Production ................................................................................... ...

2.4.1General Information about Cold Agglomeration ..........................................................

2.4.2Strengthening Mechanism of Portland cement Binders ..................................................

2.4.3Cold Strengthening under Normal Conditions ............................................................

2.4.4Cold Agglomeration at Moderate Temperatures .........................................................

2.4.5Cold Agglomeration with Accelerated Strengthening ....................................................

2.4.6Advantages of Cold Agglomeration Method ...............................................................

References .....................................................................................................................

2.5Strengthening Pellets with Thermal Methods................................................................................................

2.5.1Phenomenology of Mass Transfer Processes during Heat Treatment of Pellets .......................

2.5.2Simulation of Mass Transfer Processes during Heat Treatment of Pellets .............................

2.5.3Pellet Roasting as a Complicated Case of Sintering .......................................................

2.5.3.1 The Main Laws of Sintering Kinetics............................................................

2.5.3.2 Sintering Mechanism of Iron Oxides ...............................................................

2.5.3.3 Characteristics of Iron Oxide Structure Defects ...................................................

2.5.3.4 Dependence of the Defectiveness of the Hematite Structure on the Genesis of Oxide ......

2.5.3.5 Defects in the Crystal Structure of Iron Oxides and Sintering Processes ......................

2.5.4The Pellet Macrostructure and Strength .....................................................................

References .....................................................................................................................

2.6Metallurgical Properties of Iron Ore Pellets ........................................................................

2.6.1Pellet Quality Test Methods .....................................................................................

2.6.2Quality Requirements for Pellets ...............................................................................

2.6.3Basic Solutions for Improving the Quality of Pellets ........................................................

2.6.3.1Optimization of the Ratio of Fine and Coarse Fractions of the Concentrate .........................

2.6.3.2Minimization of the Zonal Structure of the Pellet .......................................................

2.6.3.3Introduction of Modifying Additives ......................................................................

2.6.3.4Oxide Structure Defect Management ......................................................................

2.6.3.5Regulation of Liquid-phase Sintering ........................................................................

References .................................................................................................................

2.7Resource Saving in the Production of Pellets ..........................................................................

2.7.1Resource Consumption in the Production of Pellets ...........................................................

2.7.2Energy Efficiency of Conveyor Machines as Units for Pellets Roasting ..............................................

2.7.3Best Available Technologies (BAT) in the Production of Pellets aimed at Improving Energy Efficiency..

2.7.3.1General BAT Solutions .......................................................................................

2.7.3.2Improving Thermal Schemes of Roasting Conveyor Machines .............................................

References ...............................................................................................................................

2.8Environmental Aspectss of Pellets Production .................................................................................

2.8.1General Characteristics of Emissions to the Environment in the Production of Pellets .........................

2.8.2Sources of Emissions from Technological Operations in the Production of Pellets ............................

2.8.3The Best Available Technology in the Production of Pellets .......................................................

References ...............................................................................................................................

3Briquetting ...........................................................................................................................

3.1General Information on Briquetting of Natural and Anthropogenic Raw Materials ....................................

References .............................................................................................................................

3.2History of the Industrial Briquetting in Ferrous Metallurgy ...............................................................

3.2.1Beginning of the 20th Century - the 20s of the 20th Century .....................................................

3.2.230-50s of the 20th Century .............................................................................................

3.2.360-70s of the 20th Century .............................................................................................

3.2.4The 80s - the end of the 20th Century ...............................................................................

3.2.521st Century .............................................................................................................

References .............................................................................................................................

3.3Basic Materials for Briquetting ................................................................................................

References .............................................................................................................................

3.4Basic Industrial Technologies of Briquetting in Ferrous Metallurgy ......................................................

3.4.1Briquetting Using Roller-presses .....................................................................................

3.4.2Vibropressing for Briquetting ........................................................................................

3.4.2.1The Physical Essence of Vibropressing and the Structure of the Briquette ...............................

3.4.2.2Technology of Vibropressing, Transportation, Heat Treatment and Storage of Briquettes ............

3.4.3Stiff Vacuum Extrusion Briquetting Technology ..................................................................

3.4.3.1Preparation of Burden Materials for SVE Briquetting ........................................................

3.4.3.2Technological Process of Briquetting by Method of Stiff Vacuum Extrusion ............................

3.4.3.3The Movement of the Briquetted Mass in the Extruder ......................................................

References ..............................................................................................................................

3.5Requirements to metallurgical properties of briquettes .................................................................

3.5.1Briquetting of natural and anthropogenic materials in blast furnace (BF) production .....................

3.5.1.1Metallurgical Properties of Vibropressed Blast Furnace Briquettes ..................................

3.5.1.2Metallurgical Properties and Optimization of Extrusion Briquette (brex) Compositions 

for Blast-furnace Production (Experimental Work) ........................................................

3.5.1.3Metallurgical Properties of Industrial Brex used as the Main Component of a Blast Furnace Charge ...

3.5.1.4Blast Furnace Operation with 100% Brex in Charge ........................................................

3.5.1.5Assessment of Prospects for the Use of Carbon-containing Briquettes from Iron Ore Concentrate 

3.5.2Briquetting of Natural and Anthropogenic Raw Materials for Ferroalloys Production ........................

3.5.2.1Metallurgical Properties of Brex on the Basis of Manganese Ore Concentrate ............................

3.5.2.2Metallurgical Properties of Brex on the basis of Manganese Ore Concentrate and Baghouse 

Dusts of Silicomanganese Production ...........................................................................

3.5.2.3Full-scale Testing of Silicomanganese Smelting with Brex in the Charge of Submerged EAF .........

3.5.2.4Metallurgical Properties of Briquettes on the Basis of Chromium-containing Materials ................

3.5.3Briquetting in Direct Reduced Iron (DRI) Production ............................................................

References .........................................................................................................................

4Best Available Technologies for Agglomeration of the Raw Materials for Blast Furnaces ...........................

4.1Production of sinter as a BAT ....................................................................................................

4.2Production of pellets as a BAT ...................................................................................................

4.3Stiff Extrusion Briquetting as a BAT ............................................................................................

References ................................................................................................................................

 

Chapter 1 Sinter Production

1.1   General information on the agglomeration process

1.2   Raw components of agglomeration process (ore, flux, fuel)

1.3   Preparation of the components of the charge for sintering (crushing, batching, mixing, pelletizing)

1.4   Mass transfer processes in the sintered layer (types and kinetic characteristics of processes, models)

1.5   Heat transfer in sintered layer

1.6   Gas dynamics of the sintering process

1.7   Quality of sinter and its relationship with indicators of blast furnace smelting (main solutions to improve the quality of sinter)

1.8  Brief description of sinter plant equipment

1.9   Energy efficiency of sintering technology

1.10         Environmental aspects of sinter production (best available technologies)

 

Chapter 2 Pellet production

               2.1 General information on pellets production

2.2 Charge components for the production of pellets

2.3 Production of raw pellets (technologies, methods for improving strength characteristics)             

2.4 Production of cold-bonded pellets (technology, resource conservation, quality indicators of fire-free pellets)

2.5 Mass transfer processes in the thermal strengthening of the pellets

             2.6 The metallurgical properties of the burnt pellets

                 2.7 Equipment of workshops for the production of pellets

               2.8 Resource saving in the production of burnt pellets

                  2.9 Environmental aspects of the production of pellets (best available technology)

 

Chapter 3 Briquetting

3.1 General information on briquetting of natural and anthropogenic raw materials

3.2 Basic Materials for Briquetting

 3.3 Main industrial technologies of briquetting

                                                3.3.1. Briquetting using roller presses

                                                3.3.2. Vibropressing for briquetting

                                                3.3.3. Stiff vacuum extrusion briquetting technology

               3.4 Requirements to metallurgical properties of briquettes

3.4.1 Briquetting of natural and anthropogenic raw materials in blast furnace production

                               3.4.2 Briquetting of natural and anthropogenic raw materials for ferroalloys production

                            3.4.3 Briquetting is the process of direct reduced iron production      

                            3.6

 

Chapter 4 Environmental aspects of briquetting by stiff extrusion (best available technologies)