Agglomeration in Metallurgy

<p>Introduction ………………………………………………………………………………………………..</p><p> References …………………………………………………………………………………………………..</p><p><br></p><p>1 Sinter Production …………………………………………………………………………………………...</p><p>1.1 General Information about the Sintering Process ………………………………………………..………</p><p>References …………………………………………………………………………………………………..</p><p>1.2 Raw Materials of the Sintering Process ………………………………………………………………….</p><p>References …………………………………………………………………………………………………..</p><p>1.3 Preparation of Charge Components for Sintering ………………………………………………………..</p><p> 1.3.1 Dosing of the Components of the Sinter Charge ……………………………………………….</p><p> 1.3.2 Pelletizing of the Sinter Charge …………………………………………………………………</p> References …………………………………………………………………………………………………..<p></p><p>1.4 Mass Exchange Processes in the Sintering Layer ………………………………………………………..</p><p> 1.4.1 Chemical Reactions with Participation of Solid Phases ………………………………………..</p><p> 1.4.2 Processes in the Formation of the Liquid Phase during Melting ……………………………….</p><p> 1.4.3 Processes during Solidification (crystallization) of the Melt …………………………………..</p><p> References …………………………………………………………………………………………………..</p><p>1.5 Heat Transfer in the Sintering Layer …………………………….............................................................</p><p> 1.5.1 General Information on the Sintering Heat Exchange ………………………………………….</p><p> 1.5.2 Zonal Heat Balances of Sintered Layer …………………………………………………………</p><p> 1.5.3 Mathematical Model of Heat Exchange during Sintering ………………………………………</p><p> 1.5.4 Three-Dimensional Mathematical Model of the Sintering Process …………………………….</p><p> 1.5.5 Calculation of the Specific Yield of the Sintering Gas …………………………………………</p><p> 1.5.6 Vertical Sintering Speed ……………………………………………………………………….</p><p> References …………………………………………………………………………………………………..</p><p> 1.6 The Gas Dynamics of the Sintering Process ………………………………………………………………</p><p> 1.6.1 The Basic Equation of Dynamics of the Porous Layer ………………………………………….</p><p> 1.6.2 Gas-dynamic Resistance Coefficients …………………………………………………………..</p><p> 1.6.3 Porosity of the Sintering Layer ………………………………………………………………….</p><p> 1.6.4 Gas Dynamics of Sintering Technology …………………………………………………………</p> 1.6.5 Sintering Machine Performance …………………………………………………………………<p></p><p> 1.6.6 Ways to Improve the Performance of Sintering Machines ………………………………………</p><p> 1.6.6.1 Modernization to Increase Sintering Capacities ……………………………………….</p><p> 1.6.6.2 Increasing Sinter Yield …………………………………………………………………</p><p> 1.6.6.3 Intensification of the Sintering Process ………………………………………………..</p><p> References ……………………………………………………………………………………………………..</p><p> 1.7 Quality of the Sinter in Terms of Influence on the Performance of Blast Furnace Smelting ……………..</p><p> 1.7.1 Sinter Quality Indicators …………………………………………………………………………</p><p> 1.7.2 Influence of Sinter Quality on Gas-dynamic Parameters of Blast Furnace Smelting ……………</p><p> 1.7.3 Requirements for Sinter Quality ………………………………………………………………….</p><p> 1.7.4 Basic Solutions to Improve Quality of Sinter ……………………………………………………</p><p> 1.7.4.1 Production of Low-silicon Sinter ………………………………………………………</p><p> 1.7.4.2 Control of the Porous Structure of the Sinter ………………………………………….</p><p> 1.7.4.3 Introduction of Low-melting Additives ……………………………………………….</p> 1.7.4.4 Return Mode ……………………………………………………………………………<p></p><p> 1.7.4.5 Regulation of the Thermal Level of the Sintering Process …………………………….</p><p> 1.7.5 Technology of Sintering under Pressure …………………………………………………………</p><p> References ………………………………………………………………………………………………………</p><p> 1.8 Energy Efficiency of the Sintering Technology ……………………………………………………………</p><p> References ………………………………………………………………………………………………………</p><p> 1.9 Environmental Aspects of Sinter Production (Best Available Technologies) ……………………………..</p><p> 1.9.1 Thermodynamic Modeling of Emissions in the Sintering Process ……………………………….</p><p> 1.9.2 Characteristics of Emissions from Sinter Production …………………………………………….</p><p> 1.9.3 Influence of Technological Factors on the Emission of Pollutants during Sintering …………….</p><p> 1.9.4 Environmental Requirements as the Main Priority of Production Modernization ……………….</p><p> 1.9.5 Waste Gas Recirculation Concept ………………………………………………………………..</p><p> 1.9.6 Recommendations on the Best Available Technologies (BAT) in Sintering …………………….</p><p> 1.9.7 Sinter Plant without Chimney……………………………………………………………………..</p><p>References ………………………………………………………………………………………………….......</p><p><br></p><p>2 Pellets Production ……………………………………………………………………………………………</p><p>2.1 General Information about Pellets Production …………………………………………………………….</p><p>2.1.1 Technological Scheme of the Production of Pellets ……………………………………………….</p><p>2.1.2 Formation of Raw Pellets ………………………………………………………………………….</p><p>2.1.3 Strengthening of Raw Pellets ………………………………………………………………………</p><p>2.1.3.1 Pellet Drying …………………………………………………………………………………..</p><p>2.1.3.2 Roasting of Pellets ……………………………………………………………………………..</p><p>References ……………………………………………………………………………………………………..</p><p>2.2 Charge Components for the Production of Pellets ……………………………………………………………..&nbsp;</p><p>References ……………………………………………………………………………………………………….</p><p>2.3 Formation of Raw Pellets……………………………………………………………………………………</p><p>2.3.1 Interaction between Wetted Particles during the Formation of a Raw Pellet ……………………..</p><p>2.3.2 The Nature of the Action of Binding Additives in the Strengthening of Raw Pellets ……………..</p><p>2.3.3 The Effectiveness of Various Strengthening Additives in Pelletizing ……………………………..</p><p>References ………………………………………………………………………………………………………</p><p>2.4 Cold Bonded Pellets Production ……………………………………………………………………….. …</p><p>2.4.1 General Information about Cold Agglomeration ………………………………………………….</p><p>2.4.2 Strengthening Mechanism of Portland cement Binders …………………………………………..</p><p>2.4.3 Cold Strengthening under Normal Conditions ……………………………………………………</p><p>2.4.4 Cold Agglomeration at Moderate Temperatures …………………………………………………</p><p>2.4.5 Cold Agglomeration with Accelerated Strengthening …………………………………………….</p><p>2.4.6 Advantages of Cold Agglomeration Method ………………………………………………………</p><p>References ………………………………………………………………………………………………………</p><p>2.5 Strengthening Pellets with Thermal Methods................................................................................................</p><p>2.5.1 Phenomenology of Mass Transfer Processes during Heat Treatment of Pellets …………………..</p><p>2.5.2 Simulation of Mass Transfer Processes during Heat Treatment of Pellets ………………………..</p><p>2.5.3 Pellet Roasting as a Complicated Case of Sintering ……………………………………………….</p><p>2.5.3.1 The Main Laws of Sintering Kinetics ……………………………………………………</p><p>2.5.3.2 Sintering Mechanism of Iron Oxides ………………………………………………………</p><p>2.5.3.3 Characteristics of Iron Oxide Structure Defects ……………………………………………</p><p>2.5.3.4 Dependence of the Defectiveness of the Hematite Structure on the Genesis of Oxide ……</p><p>2.5.3.5 Defects in the Crystal Structure of Iron Oxides and Sintering Processes ………………….</p><p>2.5.4 The Pellet Macrostructure and Strength ……………………………………………………………</p><p>References ………………………………………………………………………………………………………</p><p>2.6 Metallurgical Properties of Iron Ore Pellets ……………….…………………………………………..…</p><p>2.6.1 Pellet Quality Test Methods ………………………………………………………………………….</p><p>2.6.2 Quality Requirements for Pellets …………………………………………………………………….</p><p>2.6.3 Basic Solutions for Improving the Quality of Pellets ………………………………………………..</p><p>2.6.3.1 Optimization of the Ratio of Fine and Coarse Fractions of the Concentrate …………………….</p><p>2.6.3.2 Minimization of the Zonal Structure of the Pellet ……………………………………………….</p><p>2.6.3.3 Introduction of Modifying Additives …………………………………………………………….</p><p>2.6.3.4 Oxide Structure Defect Management …………………………………………………………….</p><p>2.6.3.5 Regulation of Liquid-phase Sintering ………………………………………………………………</p><p>References …………………………………………………………………………………………………..</p><p>2.7 Resource Saving in the Production of Pellets ………………………………………………………………..</p><p>2.7.1 Resource Consumption in the Production of Pellets …………………………………………………..</p><p>2.7.2 Energy Efficiency of Conveyor Machines as Units for Pellets Roasting ……………………………………….</p><p>2.7.3 Best Available Technologies (BAT) in the Production of Pellets aimed at Improving Energy Efficiency..</p><p>2.7.3.1 General BAT Solutions ……………………………………………………………………………</p><p>2.7.3.2 Improving Thermal Schemes of Roasting Conveyor Machines ………………………………………</p><p>References ……………………………………………………………………………………………………………….</p><p>2.8 Environmental Aspectss of Pellets Production ………………………………………………………………………</p>2.8.1 General Characteristics of Emissions to the Environment in the Production of Pellets …………………….<p></p><p>2.8.2 Sources of Emissions from Technological Operations in the Production of Pellets ……………………….</p><p>2.8.3 The Best Available Technology in the Production of Pellets ……………………………………………….</p><p>References ……………………………………………………………………………………………………………….</p><p><br></p>3 Briquetting ……………………………………………………………………………………………………………<p></p><p>3.1 General Information on Briquetting of Natural and Anthropogenic Raw Materials …….………………………..</p><p>References ……………………………………………………………………………………………………………..</p><p>3.2 History of the Industrial Briquetting in Ferrous Metallurgy ………………………………………………………</p><p>3.2.1 Beginning of the 20th Century - the 20s of the 20th Century …………………..…………………………</p><p>3.2.2 30-50s of the 20th Century …………………………………………………………………………………</p><p>3.2.3 60-70s of the 20th Century …………………………………………………….…………………………..</p><p>3.2.4 The 80s - the end of the 20th Century …………………………………………………………………….</p><p>3.2.5 21st Century ……………………………………………………………………………………………….</p><p>References ……………………………………………………………………………………………………………..</p><p>3.3 Basic Materials for Briquetting ………………………………………………………………………..………….</p><p>References ……………………………………………………………………………………………………………..</p><p>3.4 Basic Industrial Technologies of Briquetting in Ferrous Metallurgy ………………………....…………………..</p><p>3.4.1 Briquetting Using Roller-presses ………………………………………………………………………….</p><p>3.4.2 Vibropressing for Briquetting …………………………………………………………………………….</p><p>3.4.2.1 The Physical Essence of Vibropressing and the Structure of the Briquette ………………………….</p><p>3.4.2.2 Technology of Vibropressing, Transportation, Heat Treatment and Storage of Briquettes …………</p><p>3.4.3 Stiff Vacuum Extrusion Briquetting Technology …………………………………………………………</p><p>3.4.3.1 Preparation of Burden Materials for SVE Briquetting ………………………………………………..</p><p>3.4.3.2 Technological Process of Briquetting by Method of Stiff Vacuum Extrusion ……………………….</p><p>3.4.3.3 The Movement of the Briquetted Mass in the Extruder ………………………………………………</p><p>References ………………………………………………………………………………………………………………</p><p>3.5 Requirements to metallurgical properties of briquettes ………………………………………………………..</p><p>3.5.1 Briquetting of natural and anthropogenic materials in blast furnace (BF) production …………………</p><p>3.5.1.1 Metallurgical Properties of Vibropressed Blast Furnace Briquettes …………………………….</p><p>3.5.1.2 Metallurgical Properties and Optimization of Extrusion Briquette (brex) Compositions&nbsp;</p><p>for Blast-furnace Production (Experimental Work) ………………………………………………..</p><p>3.5.1.3 Metallurgical Properties of Industrial Brex used as the Main Component of a Blast Furnace Charge …</p><p>3.5.1.4 Blast Furnace Operation with 100% Brex in Charge ………………………………………………..</p><p>3.5.1.5 Assessment of Prospects for the Use of Carbon-containing Briquettes from Iron Ore Concentrate&nbsp;</p><p>3.5.2 Briquetting of Natural and Anthropogenic Raw Materials for Ferroalloys Production ……………………</p><p>3.5.2.1 Metallurgical Properties of Brex on the Basis of Manganese Ore Concentrate ……………………….</p><p>3.5.2.2 Metallurgical Properties of Brex on the basis of Manganese Ore Concentrate and Baghouse&nbsp;</p><p>Dusts of Silicomanganese Production …………………………………………………………………</p><p>3.5.2.3 Full-scale Testing of Silicomanganese Smelting with Brex in the Charge of Submerged EAF ………</p><p>3.5.2.4 Metallurgical Properties of Briquettes on the Basis of Chromium-containing Materials …………….</p><p>3.5.3 Briquetting in Direct Reduced Iron (DRI) Production ……………………………………………………</p><p>References ………………………………………………………………………………………………………….</p><p><br></p><p>4 Best Available Technologies for Agglomeration of the Raw Materials for Blast Furnaces ………………………</p><p>4.1 Production of sinter as a BAT ……………………………………………………………………………………….</p><p>4.2 Production of pellets as a BAT ………………………………………………………………………………………</p><p>4.3 Stiff Extrusion Briquetting as a BAT ………………………………………………………………………………..</p><p>References ………………………………………………………………………………………………………………..</p><p><br></p><p></p>

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<p>Chapter 1 Sinter Production</p> 1.1&nbsp;&nbsp; General information on the agglomeration process<p></p>

<p>1.2&nbsp;&nbsp; Raw components of agglomeration process (ore, flux, fuel)</p>

<p>1.3&nbsp;&nbsp; Preparation of the components of the charge for sintering (crushing, batching, mixing, pelletizing) </p>

<p>1.4&nbsp;&nbsp; Mass transfer processes in the sintered layer (types and kinetic characteristics of processes, models)</p>

<p>1.5&nbsp;&nbsp; Heat transfer in sintered layer</p>

<p>1.6&nbsp;&nbsp; Gas dynamics of the sintering process</p>

1.7&nbsp;&nbsp; Quality of sinter and its relationship with indicators of blast furnace smelting (main solutions to improve the quality of sinter)<p></p>

<p>1.8&nbsp; Brief description of sinter plant equipment</p>

<p>1.9&nbsp;&nbsp; Energy efficiency of sintering technology</p>

<p>1.10&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; Environmental aspects of sinter production (best available technologies)</p>

<p>&nbsp;</p>

<p>Chapter 2 Pellet production</p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp; 2.1 General information on pellets production</p>

<p>2.2 Charge components for the production of pellets</p>

<p>2.3 Production of raw pellets (technologies, methods for improving strength characteristics)&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; </p>

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

2.5 Mass transfer processes in the thermal strengthening of the pellets<p></p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 2.6 The metallurgical properties of the burnt pellets</p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp; 2.7 Equipment of workshops for the production of pellets</p> &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp; 2.8 Resource saving in the production of burnt pellets<p></p>

&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp; 2.9 Environmental aspects of the production of pellets (best available technology)<p></p>

<p>&nbsp;</p>

<p>Chapter 3 Briquetting </p>

<p>3.1 General information on briquetting of natural and anthropogenic raw materials</p>

<p>3.2 Basic Materials for Briquetting</p>

<p>&nbsp;3.3 Main industrial technologies of briquetting</p>

&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 3.3.1. Briquetting using roller presses<p></p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 3.3.2. Vibropressing for briquetting</p>

&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 3.3.3. Stiff vacuum extrusion briquetting technology <p></p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp; 3.4 Requirements to metallurgical properties of briquettes</p>

<p>3.4.1 Briquetting of natural and anthropogenic raw materials in blast furnace production</p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;3.4.2 Briquetting of natural and anthropogenic raw materials for ferroalloys production</p>

&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 3.4.3 Briquetting is the process of direct reduced iron production&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; <p></p>

<p>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; 3.6 </p>

<p>&nbsp;</p>

<p>Chapter 4 Environmental aspects of briquetting by stiff extrusion (best available technologies)</p>

<p>&nbsp;</p>

<p>&nbsp;</p>

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