Pelletization of magnetite ore with colemanite added organic binders

A new generation binder consisting of an organic binder and a borate salt was tested as an alternative to bentonite in magnetite ore pelletization. Carboxyl methyl cellulose (CMC), Ciba DPEP06-0007 and corn starch, and calcined colemanite were used as organic binders and the borate salt, respectively. They were added to the pellet feed separately and in different combinations at several addition levels. It was found that the use of organic binders is sufficient in terms of wet pellet quality; however, they fail to render the required compressive strength to pre-heated and fired pellets. Therefore, organic binders and calcined colemanite were used together so that wet pellets, pre-heated and fired pellets would be of the required quality. The results showed that the use of an organic binder together with calcined colemanite indeed yielded pellets with equal or better wet and indurated pellet qualities compared to the pellets produced with bentonite binder alone.     

A study on plasticity and compression strength in wet iron ore green pellets related to real process variations in raw material fineness

The main binding force in wet iron ore green pellets has been found to be the cohesive force of the viscous binder. The wet compression strength (wet-CS) in green pellets is, however, also influenced by the green pellet plasticity. A certain degree of plasticity is needed to sustain the green pellet growth rate. Too much plasticity results in decreased bed permeability and production problems. As the plasticity increases, wet-CS decreases. The amount of moisture needed to create a given degree of plasticity depends on particle properties and on the particle size distribution. Therefore, it was of interest to study how wet-CS would be influenced by variations in raw material fineness, if the green pellet plasticity was kept constant, i.e. the green pellet properties would be compared under relevant industrial balling conditions. For this purpose, magnetite concentrates of different particle size distributions were balled in a laboratory drum and the moisture content for constant plasticity was determined for each of the materials.No difference in green pellet wet-CS as a function of the raw material fineness was found when the bentonite binder was used and the plasticity was adjusted to a constant level. Green pellets prepared of raw materials with narrow size distributions were just as strong as those with broader ones. This is because the main binding force is the cohesive force of the viscous binder. In green pellets balled without the bentonite binder, wet-CS increased with increasing specific surface area in the raw material, in a similar manner as has been shown in earlier agglomeration literature. In this case, the capillary forces prevail. Comparison of wet-CS at constant moisture, instead of constant plasticity, would lead to erroneous conclusions. Fineness, or rather the slope of the particle size distribution curve, had a major impact on the moisture content needed for constant plasticity. If the slope increases, more water is needed to keep the plasticity on a constant level. Implications of these results in control of industrial iron ore balling circuits are discussed.     

磷矿-碳复合球团冷固结成型试验研究

为了促进磷矿-碳复合球团在黄磷生产中的应用,进行了磷矿粉-碳质还原剂冷压造球试验研究,考查了黏结剂种类及配比、原料粒度、配碳量等因素对生球性能的影响以及生球烘干过程的脱水行为和强度变化.试验结果表明:随着腐植酸钠配比从0.5％增至2.0％,落下强度和抗压强度均先升高后降低;随着膨润土配比从0.5％增至2.0％,抗压强度...     

Binding mechanisms in wet iron ore green pellets with a bentonite binder

Fundamental research during the past decade has been focussed on understanding the role of viscous forces on agglomerate deformability and strength. Much of this work has been done on glass spheres using Newtonian liquids as a binder. In this work, we show the variations in plasticity and strength of magnetite iron ore green pellets with varying liquid saturations and binder dosages (viscosities). For this purpose, a new measuring instrument was built to analyze the green pellet wet compression strength, plastic deformation and breakage pattern.Industrial iron ore green pellets are over-saturated and a supporting “network” of viscous liquid is formed on the green pellet surface. At least half, probably more, of the total binding force appeared to be due to the cohesive force of the network. The other half (or less) of the total compression strength can be explained by the capillary force. Due to irregularities on green pellet surfaces, both fully developed concave pore openings and saturated areas are expected to be found at the same time.Wet green pellets started showing plastic behaviour as they became over-saturated. In over-saturated green pellets, an explosive increase in plasticity with increasing moisture content was seen, due to the contemporary increase in porosity. Plasticity is an important green pellet property in balling and should gain the status of a standard method in green pellet characterization. It is suggested that the control strategy for the balling circuits be based on plastic deformation and compression strength of green pellets instead of the rather inaccurate drop number. The results also point out the importance of knowing whether the balling process should be controlled by adjusting the moisture content (plasticity) or by adjusting the bentonite dosage (viscosity). These two operations are not interchangeable—even if they would compensate in growth rate, the green pellet properties would differ.A new green pellet growth mechanism is suggested, based on the measured over-saturation. Firstly, green pellet plasticity needs to exceed a minimum level to enable growth. This limiting plasticity defines the material-specific moisture content needed in balling. Secondly, it is suggested that the growth rate be controlled by the viscosity of the superficial water layer rather than by the mobility of the pore water.     

钙基膨润土提纯制备球团黏结剂试验

以朝阳钙基膨润土为原料,采用擦洗-分散-分选的流程对其进行提纯,并对提纯膨润土进行挤压钠化改型试验.试验结果表明,当选用朝阳钠化提纯膨润土做球团黏结剂,粘结剂添加量为1.1％时,生球的落下强度为4.0次,爆裂温度为525℃,干球抗压强度为306 N/个,可以满足冶金球团性能需要.采用钠化提纯膨润土制备球团黏结剂可以有效降低球团中黏结剂的添加量.     

Natural gas storage in activated carbon pellets without a binder

Activated carbon pellets without a binder from cellulose microcrystals as a raw material were investigated. After compression of the raw materials, the thus obtained raw material pellets were slowly carbonized to 1073 K under nitrogen. To activate them, the carbon pellets were heated to 1173 K under carbon dioxide. The activated carbon pellet shape, after heat treatment, was columnar by using the previous employed compression of the raw material. The total surface area, pore volume, and average pore diameter for all the samples were evaluated from the analysis of N₂ adsorption isotherm data. The total surface area and the pore volume were decreased with an increase in compression pressure under the same heat treatment conditions. On the contrary, the bulk densities of the activated carbon pellets were increased. However, these properties can be easily controlled by changing the sintering temperature and time. The bulk density of sample pellet was 0.56 g/cm³. It is 2.3 times higher than activated carbon powder, which was made without the compression process. The total methane storage capacity at 298 K reached 164 cm³ in 1 cm³ volume of activated carbon pellets at 3.5 MPa.     

Mechanisms in oxidation and sintering of magnetite iron ore green pellets

Thermal volume changes and oxidation mechanisms in magnetite iron ore green pellets balled with 0.5% bentonite binder, as a function of raw material fineness and pellet porosity, are shown. When a pellet starts to oxidize, a shell of hematite is formed around the pellet while the core still is magnetite. Dilatation curves were measured under non-oxidizing and oxidizing atmospheres to separately describe thermal volume changes in these two phases. Dilatation measurements showed contraction during oxidation between 330 and 900 °C by 0.5%. The extent of contraction was not influenced by the raw material fineness or the original porosity in pellets. Sintering started earlier in the magnetite phase (950 °C) compared to the hematite phase (1100 °C). The sintering rate increased with increasing fineness in the magnetite concentrate. A finer grind in the raw material would, therefore, promote the formation of duplex structures with a more heavily sintered core pulling away from the less sintered outer shell.At constant porosity in green pellets, the oxidation time became longer as the magnetite concentrate became finer, because of the enhanced sintering. In practical balling, however, the increase in fineness would necessitate the use of more water in balling, which results in an increase in green pellet porosity. These two opposite effects levelled out and the oxidation time became constant when green pellets were balled at constant plasticity. Combining the results from the oxidation and dilatation studies revealed new information on the rate limiting factors in oxidation of iron ore pellets. At 1100 °C, the diffusion rate of oxygen was limited by sintering in the magnetite core, taking place before oxidation rather than by the diffusion rate of oxygen through the oxidized hematite shell, as has been claimed in earlier literature. The oxidation rate was at maximum at around 1100 °C. At 1200 °C, the rate of oxidation substantially decreased because both the hematite shell and the magnetite core show heavy sintering at this temperature.Dilatometer measurements showed large thermal volume changes in the presence of olivine, at temperatures above 1200 °C. This is explained by the dissociation of hematite back to magnetite. Dissociation leads to an increase in the volume of the oxidized shell, while sintering of the magnetite core is further enhanced by the olivine additive.     

Studies on the influence of a flotation collector reagent on iron ore green pellet properties

The properties of iron ore green pellets with varying additions of a surface-active flotation collector reagent (Atrac) were studied by small-scale balling. The compression strength and plasticity were measured with a semi-automatic measuring device and the pressure curves were saved and subjected to further mathematical treatment. The green pellet breakage was also filmed with a high-speed camera. Adding Atrac to the pellet feed seriously damaged the quality of green pellets, even in small dosages. This is because an increasing amount of air bubbles became so strongly attached on the particle surfaces that they could not be removed during compaction by balling. The adsorption of air in green pellets was seen as an increase in porosity and a decrease in the filling degree (proportion of pores filled with water). Both the wet and dry compression strength decreased. The air bubbles behaved in wet green pellets like large, plastic particles and the plasticity increased beyond an acceptable level. Breakage started inside the green pellets, along the air bubbles, and generated multi-breakage patterns in wet as well as dry green pellets. Green pellet breakage to crumbs instead of a few distinct segments, promotes the generation of dust and fines and leads to lower bed permeability in the pelletizing machine.The results show that the decrease in iron ore green pellet wet strength in the presence of surface-active agents is not fully described by the so called Rumpf equation, where surface tension and contact angle are used as variables to describe the capillary forces. The green pellet breakage in the presence of air bubbles took place by crack propagation along pore structures rather than through the loss of the capillary forces.     

水热氧化预处理对棉秆成型颗粒理化性质的影响

以棉秆为研究对象,经180～280℃水热氧化预处理后热压制备成型颗粒。利用热重分析、X射线衍射(XRD)及傅里叶变换红外光谱(FTIR)等分析手段,考察了水热氧化预处理温度对棉秆成型颗粒理化性能及燃烧性能的影响。结果表明:随着水热氧化温度的升高,棉秆的固相产物产率降低,半纤维素于180℃之前完全分解,无定形纤维素于200℃完全分解,结晶纤维素于260℃完全分解,水热氧化固相产物的纤维素结晶度呈现逐渐减小的趋势,而木质素相对含量增加;棉秆成型颗粒的固定碳含量、热值和能量密度增加,但燃烧性能变差。水热氧化预处理后棉秆成型颗粒的表观密度保持在1300kg/m³左右,抗压强度则随着水热氧化温度的增加而下降,其中180℃水热氧化预处理后棉秆成型颗粒的抗压强度相比原料成型燃料增加了183.33%。本研究范围内,经180℃水热氧化预处理后获得的棉杆成型颗粒的燃烧性能和物理性能最佳,其热值为17.76MJ/kg,能量密度为23.44GJ/m³,抗压强度达11.90MPa,可作为优质生物质成型燃料使用。     

THE REACTIVITY AND DURABILITY OF ZINC FERRITE HIGH TEMPERATURE DESULFURIZATION SORBENTS

Cylindrical pellets of zinc ferrite high temperature desulfurization sorbent have been prepared using a number of formulation recipes and induration conditions. Physical and structural properties of the resultant sorbents were measured, and reactivity and durability screening tests were carried out using a single pellet electrobalance reactor. The formulation variables studied were ZnO to Fe₂O₃ ratio, Fe₂O₃ source, and the addition of inorganic (bentonite) and organic (methocel) binders to the sorbents. Pellet induration conditions ranged from 0.25 hours at 815^°C to 4.0 hours at 1038°C. Stronger pellets having greater attrition resistance resulted when 5% bentonite was added to the formulation recipe and when the pellets were indurated at high temperature for extended times. In contrast, bentonite content was not a significant factor in determining sorbent reactivity and durability, both of which were improved by mild induration conditions. Sorbent regeneration temperature was found to be an important factor in improving reaction durability, as was the addition of 0.5% methocel to the formulation recipe. Pellets containing catalyst-grade Fe₂O₃ were more reactive than those containing pigment-grade Fe₂O₃. This effect, however, was less important than the effect of induration conditions.     

The measurement of porosity for an individual taconite pellet

The knowledge of the variability in the properties of individual taconite pellets as a function of processing conditions may lead to the improvement of the production of iron. An important property is porosity. Pellets with high porosity are desirable for the reduction to iron in the blast furnace. There is a published work describing the measurement of porosity on collections of pellets. Here I describe a method for the determination of the porosity of an individual pellet.Recent determinations of porosity have used the measurements of the skeletal volume and the envelope volume. Helium pycnometry is the method of choice for the measurement of the skeletal volume, whereas volumetric displacement of dry material is now the preferred method for the envelope volume, requiring collections of pellets. I have adapted a method of silhouettes, developed for single items of fruit, to measure the envelope volume of a single pellet. The porosities of six individual sintered pellets from a facility in North-Eastern Minnesota, USA, range from 33 to 38% with a relative uncertainty of about 1%. Certain pellets have significantly different porosities from each other. The magnitudes are comparable to published porosities on green pellets, ranging from 30 to 36%, and to fired pellets, ranging from 28-38%.     

Mixed solvent system as binder for the production of silicified microcrystalline cellulose-based pellets

Silicified microcrystalline cellulose pellets with hydroxypropyl methylcellullose (HPMC) as modifier were prepared using a mixed solvent as liquid binder. Pellets were produced using extrusion-spheronization with a mixed solvent consisting of water and isopropanol as liquid binder. The key spheronization aid was Prosolv® SMCC 90. Low viscosity grade HPMC was incorporated aiming to modify release of indometacin. Physical characteristics including breaking load, apparent density and flow properties, particle size distribution and shape were determined. Drug loaded pellets were also tested for dissolution profiles. By adjusting liquid binder property, at isopropanol to water ratio of 3.5 to 6.5, pellets of desirable size and shape with reasonable yields were obtained. Pellets exhibited good flow property and they were mechanically strong. Pellet with higher HPMC content displayed a faster drug dissolution profile. This was because low viscosity grade HPMC was not enough to create strong gel. Instead hydration of HPMC molecules increased matrix's hydrophilicity and weakened the structure of pellet faster. The release of indometacin was partly based on the erosion of hydrated matrix. The presence of HPMC in the pellets would require a mixed solvent to produce desirable shape. Incorporation of HPMC had modified drug release from the pellets without further coating. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47924.     

钒钛磁铁矿含碳球团转底炉直接还原实验研究

对转底炉直接还原钒钛磁铁矿新工艺进行了实验研究,将钒钛磁铁矿精矿粉与煤粉等混合,采用压球机压球,并用石油液化气同空气混合燃烧牛成的热烟气干燥生球,通过正交实验考察C/O、焙烧时间和焙烧温度3个因素对金属化率与抗压强度的影响,得出最优的实验方案是:C/O为1.3,焙烧温度为1330℃,焙烧时间为25-min.通过XRD分析发现在金属化率较高的球团中存在假板钛矿.     

有机物/膨润土复合球团粘结剂的研究

本文利用X射线、红外光谱、TG等分析方法,研究了某膨润土及有机物的特性,通过试验分析研究,确定了用于工业生产的有机物/膨润土复合球团粘结剂的制备工艺,分析了球团粘结剂的作用原理,该粘结剂应用于工业生产使其添加量降低为1.3％,各项指标满足生产要求.     

Extrusion of α-Al2O3–Boehmite Mixtures

A water-based binder system consisting of colloidal boehmite (AlO(OH)) and 0.3 wt% poly(vinyl alcohol) was developed for low-pressure piston-type extrusion of alumina. Batches using this binder system and two different types of commerical alumina powder were characterized with regard to extrusion pressure, densification, and physical properties in the green and fired states.     

Effect of CaSO4 Pelletization Conditions on a Novel Process for Converting SO2 to Elemental Sulfur by Reaction Cycles involving CaSO4/CaS – Part I. CaSO4 Pellet Strength and Reducibility by Hydrogen

A new process for converting sulfur dioxide to elemental sulfur by reaction cycles involving calcium sulfide and calcium sulfate without generating secondary pollutants was developed at the University of Utah. In this process, sulfur dioxide is reacted with calcium sulfide to produce elemental sulfur and calcium sulfate. The latter is reduced by hydrogen to regenerate calcium sulfide. In the present work, the effects of different pelletization conditions for the initial reactant calcium sulfate on the strength and reactivity of the pellets were determined. These pelletization conditions included the type, amount, and impregnation method of catalyst, the binder amount, and sintering. The pellets with the best properties were then reduced with hydrogen in the temperature range 973 to 1173 K, while measuring the kinetics, over several cycles of the two‐step process. Nickel‐catalyzed and fired pellets produced by the use of molasses or cement as a binder showed the highest compressive strength as well as good reactivity during the cyclic tests. The binder amount did not significantly affect the reaction rate.     

Effect of bentonite addition on fabrication of reticulated porous SiC ceramics for liquid metal infiltration

SiC with different particles and a clay mineral bentonite (montmorillonite) were mixed in water to prepare ceramic slurry. The slurry was then infiltrated high porous polyurethane sponge. Excess slurry was squeezed out to adjust ceramic rate in the infiltrated body. The pore walls were coated with ceramic mix after the infiltrated body was dried. The polyurethane containing SiC particles and bentonite was fired in a box furnace to burn out the polyurethane from the body at 500 °C for 30 min. The remaining porous ceramic bodies were sintered at elevated temperatures to give strength. SiC particles with bentonite surface coating took polyurethane pore forms after firing the sponge. Bentonite was both used as binder for ceramic slurry at room temperatures and the sintering additives at elevated temperatures. Therefore, increasing bentonite addition gives higher strength to the resulting ceramic performs.     

高炉瓦斯灰含碳球团粘结剂研究

在掌握高炉瓦斯灰和粘结剂特性的基础上,通过测试生球、干球和焙烧后球团的抗压强度和落下强度,实验考察单一粘结剂和复合粘结剂对高炉瓦斯灰含碳球团强度的影响. 结果表明,加入淀粉类粘结剂能改善球团的低温强度,生球的抗压和落下强度分别达到72 N/个和5.9次/0.5 m;干球的抗压和落下强度分别达到58 N/个和4.3次/0.5 m;但焙烧后球团的抗压强度相对较低. 加入水玻璃含硅类粘结剂能改善其高温强度,焙烧后球团抗压强度最高达到1764 N/个,但生球和干球的强度较低,达不到生产要求. 加入玉米淀粉和水玻璃组成的复合粘结剂后球团强度的改善效果更明显,生球的抗压和落下强度最高达到60 N/个和5.5次/0.5 m;干球的抗压和落下强度达到55 N/个和3.4次/0.5 m;焙烧后球团的抗压强度最高达到1958 N/个.     

磷矿含碳球团技术的开发与应用

介绍磷矿含碳球团的生产工艺、操作控制指标、性能特征及应用情况。利用磷矿粉、焦炭、黏结剂等制成球团,在烧结立窑中950℃下烧制成球团熟料,并按一定的比例掺入磷矿中进行了钙镁磷肥工业生产试验,改善了炉况,降低了焦炭的消耗,开发利用了低品位磷矿资源。     

Interfacial characterizations of iron ore concentrates affected by binders

Binders are widely used to modify the interfacial characteristics and improve the ballability of iron ore particles. Funa is a natural polymer binder. It was developed and used in the production of iron ore pellets in China. In this paper, the interfacial interactions between Funa and a magnetite concentrate were investigated by measurements of surface tension, contact angle, wetting heat, zeta potential as well as by Infrared Spectroscopy (IRS) analysis as compared to bentonite binder. Results show that Funa behaves like surfactants and possesses the characteristics of colloid particles. It decreases the surface tension of water from 73 to 65 dyn cm⁻¹. The binder reduces the contact angle of the concentrate sharply from 46° to 0° at a dosage of 0.6% and hence greatly improves the hydrophilic character of the concentrate. Zeta potential measurements show that the surface of the magnetite concentrate is negatively charged and the addition of Funa causes more negative surface charges. IRS analysis shows that the binder adheres to the concentrate surface by chemical adsorption. It was also shown that bentonite has little effects on the surface tension, contact angle, wettability and Zeta potential. No chemical adsorption of bentonite on the concentrate was observed.