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EP1423545B1 - Briquetage de minerai de fer - Google Patents

Briquetage de minerai de fer Download PDF

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Publication number
EP1423545B1
EP1423545B1 EP02764361A EP02764361A EP1423545B1 EP 1423545 B1 EP1423545 B1 EP 1423545B1 EP 02764361 A EP02764361 A EP 02764361A EP 02764361 A EP02764361 A EP 02764361A EP 1423545 B1 EP1423545 B1 EP 1423545B1
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EP
European Patent Office
Prior art keywords
ore
method defined
briquette
flux
briquettes
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP02764361A
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German (de)
English (en)
Other versions
EP1423545A4 (fr
EP1423545A1 (fr
Inventor
Geoffrey Stuart Beros
John Francis Gannon
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Commonwealth Scientific and Industrial Research Organization CSIRO
Robe River Mining Co Pty Ltd
Original Assignee
Commonwealth Scientific and Industrial Research Organization CSIRO
Robe River Mining Co Pty Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/16—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using pocketed rollers, e.g. two co-operating pocketed rollers
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/2413—Binding; Briquetting ; Granulating enduration of pellets
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/242—Binding; Briquetting ; Granulating with binders
    • C22B1/243—Binding; Briquetting ; Granulating with binders inorganic
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/14—Agglomerating; Briquetting; Binding; Granulating
    • C22B1/24—Binding; Briquetting ; Granulating
    • C22B1/248—Binding; Briquetting ; Granulating of metal scrap or alloys

Definitions

  • the present invention is concerned with the production of iron ore briquettes suitable for transport and use in iron making processes.
  • Pelletising consists of two distinct operations; forming pellets from moist ore fines and then firing them at a temperature in the region of 1300°C. It is critical in order to prepare suitable pellets that the ore be ground very fine, generally to a size where in the order of 60% of the ore passes 45 ⁇ m. It is then formed into pellets in either a horizontal drum or an inclined disc, generally with the addition of a suitable binder. The formed pellets are then fired in a process sometimes referred to as induration in shaft kilns, horizontal travelling grates, or a combination of travelling grates and rotary kilns.
  • Pelletising is a practicable and commercially attractive method of agglomerating fine concentrates, but requires substantial grinding in order to achieve the required particle sizing which is an energy intensive process.
  • Pellets made from goethite-hematite ores require extended induration times, affecting process economics.
  • Solid fuel, in the form of coke, is often added to reduce induration time which results in the production of noxious emissions (including dioxins, NO x and SO x ).
  • Sintering consists of granulating moist iron ore fines and other fine materials with solid fuel, normally coke breeze, and loading the granulated mixture onto a permeable travelling grate. Air is drawn downwards through the grate as the temperature is raised. After a short ignition period, external heating of the bed is discontinued and as the solid fuel in the bed burns a narrow combustion zone moves downwards through the bed, each layer in turn being heated to approximately 1300°C. Bonding takes place between the grains during combustion, and a strong agglomerate is formed.
  • traditional sintering processes result in high levels of noxious emissions, particularly sulfur oxides and dioxins, and therefore the process is undesirable and unsustainable on environmental grounds.
  • Briquetting is a process in which there was commercial interest in the late 1800's and early 1900's, but production of iron ore briquettes for use as a blast furnace feed material never reached any significant levels, decreased after 1950, and had ceased by about 1960.
  • the process as practised involved the pressing of ore fines into a block of some suitable size and shape, and then indurating the block.
  • binders such as tar and pitch and/or other additives such as organic products, sodium silicate, ferrous sulfate, magnesium chloride, limestone and cement were tested.
  • the Gröndal process simply involved mixing iron ore with water and pressing into oblong blocks the size of building bricks. These were then hardened by passing them through a tunnel kiln heated to 1350°C.
  • JP 60-243232 describes briquettes that have a flat shape in order to provide for stable distribution in a blast furnace.
  • the Japanese specification discloses that the flat-shaped briquettes are much more easily reduced at higher temperatures than conventional spherical pellets.
  • the briquettes are made with a volume between 2 and 30cc in order to balance a relatively high compression strength against an inferior rotary or tumble strength and impact resistance with increasing size.
  • the Japanese specification discloses that larger briquettes are less easily reduced in a blast furnace.
  • there is no other factor described as critical and, indeed, there is no detailed description of any other aspect of the production of the briquettes.
  • the applicant has carried out extensive research work into the production of briquettes from iron ore and has invented a method that can produce briquettes that have suitable properties for use in blast furnaces and other direct reduction vessels.
  • a method of producing an iron ore briquette that is suitable for use as a blast furnace or other direct reduction furnace feedstock which includes the steps of:
  • predetermined particle size distribution of ore particles that is mixed with flux in step (a) can be produced without grinding ore.
  • the method includes crushing and screening ore to form the predetermined particle size distribution that is mixed with flux in step (a).
  • the top size of the predetermined particle size distribution that is mixed with flux in step (a) is 3.5 mm.
  • the top size is 3.0 mm.
  • the top size is 2.5 nm.
  • the top size is 1.5 mm.
  • the top size is 1.0 mm.
  • the particle size distribution includes less than 30% passing the 45 ⁇ m screen.
  • the particle size distribution includes less than 10% passing the 45 ⁇ m screen.
  • the ore is a hydrated iron ore.
  • the hydrated ore is a goethite-containing ore.
  • the flux has a particle size distribution that is predominantly less than 100 ⁇ m.
  • the particle size distribution of the flux includes more than 95% passing a 250 ⁇ m screen.
  • the flux is limestone.
  • the ore/flux mixture produced in step (a) is selected so that the basicity of the fired briquette is greater than 0.2.
  • the basicity is greater than 0.6.
  • the term "basicity.” is understood herein to mean (%CaO + %MgO)/(%SiO 2 + %Al 2 O 3 ) of the fired briquette.
  • Step (b) includes adjusting the water content of the ore so that the moisture content of the ore/flux mixture is 2-12% by weight of the total weight of the ore/flux mixture.
  • total weight of the ore/flux mixture means the total of the (a) dry weight of the ore/flux mix, (b) the weight of the inherent moisture of the mixture, and (c) the weight of the moisture (if any) added to the mixture in the method.
  • moisture content is the total of (b) and (c) above.
  • step (b) includes adjusting the water content of the ore so that the moisture content of the ore/flux mixture is 2-5% by weight of the total weight of the ore/flux mixture for ores that are dense hematite ores.
  • step (b) includes adjusting the water content of the ore so that the moisture content of the ore/flux mixture is 4-8% by weight of the total weight of the ore/flux mixture for ores containing up to 50% geothite.
  • step (b) includes adjusting the water content of the ore so that the moisture content of the ore/flux mixture is 6-12%by weight of the total weight of the ore/flux mixture for ores that are predominantly, ie contain more than 50%, goethite ores.
  • pressing step (c) produces briquettes that are 10 cc or less in volume.
  • More preferably pressing step (c) produces briquettes that are 8.5cc or less in volume.
  • More preferably pressing step (c) produces briquettes that are 6.5 cc or less in volume.
  • pressing step (c) includes pressing the ore/flux mixture using a low roll pressure.
  • the low roll pressure is sufficient to produce briquettes having a green compressive strength of at least 2kgf.
  • the green compressive strength is at least 4kgf.
  • the green compressive strength is at least 5kgf.
  • the low roll pressure is generated by a roll pressing force of 10-140 kN/cm on the mixture of ore/flux.
  • the roll pressing force is 10-60 kN/cm.
  • the roll pressing force is 10-40 kN/cm.
  • Preferably indurating step (d) includes heating the briquette to a firing temperature with 40 minutes.
  • Preferably indurating step (d) includes heating the briquette to a firing temperature within 35 minutes.
  • More preferably indurating step (d) includes heating the briquette to the firing temperature within 30 minutes.
  • step (d) includes heating the briquette to the firing temperature within 20 minutes.
  • step (b) includes heating the briquette to the firing temperature within 15 minutes.
  • the firing temperature is at least 1200°C.
  • the firing temperature is at least 1260°C.
  • the firing temperature is at least 1320°C.
  • the firing temperature is at least 1350°C.
  • the firing temperature is at least 1380°C.
  • the fired briquette has a crush strength of at least 200kgf.
  • the fired briquette has a crush strength of at least 200kgf.
  • Iron ore fines are broadly characterised into four groups on the basis of petrological characteristics, such as mineralogy, mineral association and particle texture, porosity, size distribution and chemistry.
  • the groups are:
  • the bonding mechanism in green briquettes involves a combination of bonds including the mechanical interlocking of particles, van der Waal's forces, and in the case of raw material types GC and G, hydrogen bonding to varying degrees is dependent on the percentage of hydrated iron species present, eg goethite.
  • characteristics of the feed material have been identified as having a significant influence on the formation of such bonds that affect the quality and processing performance of the green and fired briquettes. These characteristics are the moisture level of the feed material and its flow characteristics, the chemical composition of the ore, its size distribution and petrological characteristics and porosity.
  • the feed materials are of the widest size distribution possible in order to achieve a high packing density and increased bonding of the ore particles.
  • the bonding mechanism of green briquettes is believed to be through a combination of bonds arising from the mechanical interlocking of particles, van der Waal's forces, and hydrogen bonding in the cases of raw material types GC and G.
  • a broad size distribution increases the packing density and improves the strength of the green briquette, it is possible to briquette closely sized iron ores.
  • the top size of the particles is determined by the crushing process but is preferably less than 2.5 mm in order to produce briquettes of acceptable fired properties following the induration process. Generally, ore types HC and HG can be briquetted with coarser top sizes due to the lower heat requirements of these raw materials to attain acceptable fired strength.
  • the top size of the raw material can be reduced through either crushing or screening processes.
  • the bottom size of the particles has no absolute limit, but it is not necessary or desirable, to grind the ore into very fine particles (as required for pelletising) as this is an additional economic burden rendered unnecessary by the present invention. Preferably less than 10% of the particles pass a 45 ⁇ m sieve.
  • the pocket dimensions of the briquetting apparatus should be selected on the basis of the maximum particle size to be briquetted, as well as for adequate induration performance, to ensure that satisfactory briquetting can be achieved.
  • the maximum particle size to achieve satisfactory briquetting is 25-30% of the minimum pocket dimension. If the maximum particle size exceeds this specification it may be necessary to select a larger pocket size.
  • a moisture content of between 2 and 12 wt % for the feed material is used to optimise green briquette quality and product yield.
  • Dense hematite concentrates have low optimum briquetting moistures, generally in the range of 2-5 wt %. These concentrates are often made up of closely sized particles with a smooth surface texture that generates low strength briquettes because of decreased interlocking of particles. More porous goethite-containing ores with up to 50% goethite (GC) briquette well in the range of 4-8 wt % moisture and more porous predominantly goethite ores (G) briquette well in the range of 6-12 wt% moisture. Such ores have a rough surface texture and shape enhancing their briquetting characteristics.
  • Conventional briquetting apparatus may be used in the method of the invention.
  • such apparatus includes two adjacent rolls with pockets which come together at a nip zone in order to compress the feed material into adjacent, aligned pockets to produce briquettes.
  • the rolls are preferably horizontally aligned to achieve the required throughput for economic feasibility.
  • briquetting of iron ores is preferably conducted at roll pressing forces of 10-140 kN/cm and more preferably at the low end of this range, typically from 10-60 kN/cm.
  • Such low pressure operation for iron ore briquetting is significant and makes it possible to achieve high production rates by the use of wide rolls on the briquetting machine up to 1.6m in length.
  • the roll pressure is carefully controlled within the low pressure range in order to optimise the briquetting operation. If the roll pressure is too low, the rolls are forced apart producing a thick web and distorted briquettes impairing the product yield and the quality of the briquette, particularly after induration. If the roll pressure exceeds the optimum, poor closure of the briquettes occurs because of the "clamshell" effect on release of the briquettes from the pocket. The clamshell effect is more pronounced for small roll diameters and excess roll pressures, which also cause pocket binding/jamming. Although the density and crush strength of the green briquettes will be increased, the impact resistance of the fired briquettes will be severely impaired.
  • the moisture level is selected to influence the flow characteristics of the material through the feed system, and moisture levels of 2-12 wt % for the feed material are generally suitable. If the moisture level is too high for the feed system, the feed pressure is adversely affected resulting in a decreased yield and some impairment of briquette quality, characterised by a lower green strength. It the feed material is too low in moisture for the feed system the resultant feed pressure will cause clamshelling which may result in decreased yields, increased wear rates of the roll pockets, and inferior fired properties.
  • the briquetting apparatus may be operated with a pre-compactor feed system or with a gravity feed system.
  • the latter system is advantageous where high tonnages are to be briquetted, as in the iron ore industry.
  • a roll diameter is selected in order to ensure that briquette quality is obtained at an economic production rate.
  • Large diameter rolls increase production rates, however they also increase the area of the nip zone. Careful control of the nip zone facilitates formation of quality green briquettes and avoids formation of briquettes with an excessively thick web.
  • Alterations in roll diameter may also alter the optimum moisture level for feed material where increased roll diameters represent increases in feed moisture.
  • Roll diameters typically vary from 250 mm - 1200 mm. In order to maximise production, preferably the rolls are operated at the fastest speed possible whilst maintaining briquette quality. However, a very low roll speed may be used if productivity is of a secondary concern.
  • roll speeds in the range of 1 rpm to 20 rpm are employed. It is desirable in order to maintain quality, particularly at high roll speeds, that the feed material be presented to the rolls at a rate that matches the briquette production rate and with a nip zone area that produces the forces required to form quality briquettes.
  • Any suitable roll width may be selected provided that it is within the pressure capabilities of the briquetting machine. As briquetting of iron ores is a low pressure operation, wide rolls are preferred, increasing the capacity of the machine. The rolls are preferably horizontally aligned to allow for use with a gravity feed system.
  • the flow characteristics of iron ores, whether HC, GC (including HG and GH), or G, are suitable for gravity feeding at the moisture ranges specified above for each classification.
  • the pocket shape should not generally be of a sharp angular nature, but be more smooth and rounded to improve handling characteristics. By way of example, a length/width and width/depth ratio of approximately 0.65 is suitable. Pocket shapes also have specific release angles, 110-120° that combat the tendency for sticking in the pockets.
  • the pocket size can be optimised according to the requirements for the induration process and the raw material top size and the iron making blast furnace.
  • the briquettes have a volume of between 2 and 30 cc.
  • the volume is 10 cc or less. More preferably the volume is 8.5 cc or less. More preferably the volume is less than 6.5 cc.
  • a staggered pocket configuration is preferred as this makes the optimum use of the available space on the face of the rolls, and hence maximises throughput.
  • the induration method and conditions are selected having regard to the complex relationship between raw material characteristics and the influence of the briquette dimensions.
  • the feed material includes the iron ore made up of iron oxide and gangue minerals, with the required flux added to give the required basicity level in the fired briquette.
  • Test results have shown that the flux should preferably be finely sized, typically >95% passing 250 ⁇ m, in order to achieve the required properties in the fired briquette.
  • Induration may be carried out using a straight grate, grate-kiln or a continuous kiln type process.
  • An important characteristic of the briquette of the present invention is the ability to withstand high temperatures on heating at fast rates, such as heating to a firing temperature within 30 minutes, more preferably within 20 minutes. This is in direct contrast with conventional understanding of how goethitic ores respond in induration situations, where is has been shown that they spall when heated too fast through the dehydroxylation and free water removal zones.
  • the thermal stability of the briquettes of the present invention has been found to be much greater than pellets and they may be heated at much faster rates than pellets without spalling. This allows a much shorter heating cycle. Consequently, briquette productivity can be significantly higher than for pellets using the same material. For instance, briquette productivities potentially in the order of 30t/m 2 .day in a straight grate kiln can be achieved, compared to pellet productivities of 16t/m 2 .day for HG ores in the same kiln.
  • Briquetting was performed using three different roll presses with varying roll diameter, width and feed systems.
  • the briquettes produced were pillow-shaped with nominal dimensions of 13x19x28 mm and a volume of 4 cc. There was a single row of 30 pockets around the circumference of each roll.
  • Briquetting was also performed using a Komarek BH400 double roll press, with a roll diameter of 450 mm and a roll width of 75 mm. Feed material was gravity fed into the nip zone from a feed hopper located above the rolls. A schematic of its main components can be seen in Figure 2 .
  • Briquetting was also conducted using a Köppern 52/6.5 double roll press with a diameter of 650 mm and a roll width of 130 mm. Feed material was gravity fed into a nip zone from a hopper located above. Nip zone area was controlled through use of a 'nip zone adjuster'. A schematic of its main components can be seen in Figure 3 .
  • the briquettes produced were ⁇ pillow'shaped with nominal dimensions of 30x24x16 mm and forms a volume of 7.5 cc. There were four rows of 77 pockets arranged symmetrically across the face of the roll.
  • Figure 4 illustrates that feed moisture had a significant effect on the yield of 6 cc and 4cc briquettes produced by the briquetting press with 450 mm rolls as described in Example 1.
  • the feed material was gravity fed to the rolls while the rolls operated at a fixed roll speed of 20 rpm and a roll pressure of 90kg/cm 2 .
  • Feed moisture control is also important as variation in moisture content affects green properties such as green strength, abrasion resistance and shatter strengths. This is illustrated in Figures 5 and 6 .
  • Figure 5 shows the relationship between feed moisture level and strength for briquettes made with HG using the 450 mm rolls, a gravity feed system, and a variety of pocket sizes.
  • Figure 6 shows the same relationship for briquettes made with the 650 mm rolls and 7.5 cc pockets for HG material.
  • Green strength tended to increase to a maximum for the optimum moisture content of approximately 6%. At moisture levels exceeding 7.5% the green strength was unacceptably low.
  • Feed moisture had less of an influence on shatter strength and the green abrasion resistance of the briquettes.
  • briquetting operations can be carried out over a wide range of rolls pressures, it is preferred that briquetting be carried out at low pressures.
  • Such low pressure operation for iron ore briquetting is significant and opens up the possibility of achieving high production rates with wide rolls on a briquetting machines.
  • roll pressure should be carefully controlled within this low pressure range if the briquetting operation is to be optimised. If roll pressure is too low and nip zone area is not carefully controlled, the rolls are forced apart producing a thick web and distorted briquettes impairing the product yield and the quality of the briquette, particularly after induration. If roll pressure exceeds the optimum, poor closure of the briquettes occurs because of the "clamshell" effect on release of the briquette from the pocket. Although the density and crush strength of the green briquette will be increased, the impact resistance of the fired briquette will be severely impaired.
  • Figure 7 shows the effect of roll pressure on briquette thickness and quality (measured in terms of crush strength) for raw material HG produced in a gravity fed machine with 450mm diameter rolls with nominal 9 cc pockets. The figure shows that acceptable green strength was obtained at roll pressures as low as 60 kg/cm 2 .
  • Figures 8 and 9 show the effect of pressing force and resultant green strength that was obtained using the 650 mm diameter rolls.
  • the work was carried out on HG and GH raw material types and illustrates a similar relationship between roll pressure and green strength as with the 450 mm work. Specifically, the figures show that acceptable green strengths were obtained at pressing forces of 20 kN/cm.
  • Pressing force was also found to exert a significant influence on the shatter strength and the green abrasion resistance of the briquettes, with both variables increasing in response to increased roll pressure.
  • Roll pressure can be used primarily to control the amount of pressure exerted on feed material and roll speed can be altered to maximise the production rate. However, it is important to consider the effects of roll speed on briquette thickness and green strength when optimising the green briquetting operation.
  • the Figure shows that thickness and green strength decreased as roll speed increased.
  • the diagram shown in Figure 11 is an example of an operating window for briquetting with 250 mm rolls to form nominally 4 cc briquettes out of HG material on the Taiyo press.
  • roll pressure was fixed at 150 kg/cm 2 and precompactor speed was fixed at 20 rpm.
  • a series of curves are shown for feed moisture from 4 wt % to 12 wt %. Each represents conditions that resulted in the formation of whole briquettes.
  • Green briquettes produced under optimised conditions were found to be thermally very stable compared to pellets formed from the same material. This is shown in Figures 12 and 13 .
  • Figure 12 shows the temperature profiles for the inlet and outlet gas and three positions within the bed of briquettes during laboratory-scale induration trials simulating a straight grate process.
  • the bed temperatures were measured by thermocouples placed at 100, 250 and 500 mm from the top of the bed.
  • the briquettes were found to be be thermally stable when heated at fast rates shown in the figures.
  • the excellent drying performance allowed the inlet gas temperature to be raised from ambient to 1340°C in ten minutes without spalling the briquettes.
  • Figure 13 shows the temperature profiles for briquette induration that produced nominal 4 cc briquettes of HG ore at productives of 32 t/m 2 . d and 25 t/m 2 .d.
  • the figure also shows, by way of comparison, a typical induration temperature profile for pellets.
  • the pellet profile was an optimised profile so that pellet spalling was minimised and fired properties were maximised.
  • the pellet profile produced pellets with a productivity of 16t/m 2 .d, which is considerably lower than the productivities of the briquettes.
  • the briquettes and the pellets were made from the same ore type.
  • the high productivities for the briquettes was due to the thermal stability of the green briquettes which enabled the briquettes to be heated at fast rates.
  • the thermal stability of the briquettes was found to be not exclusive to one induration method and to one ore type.
  • a pilot scale grate-kiln system was used to determine the properties of briquettes as they exited a grate prior to entry to a kiln.
  • the equipment consisted of a pot grate and a batch kiln. To simulate the travelling grate a LGP gas burner was used to generate the flame temperature. The pot grate was capable of up and down draught gas flow. The temperature of the material was measured throughout the bed using thermocouples set into and through the wall of the pot. These measurements were assumed to be the briquette temperature during the firing cycle. Due to the size of the briquettes tested, it may be that the temperature measurement shows the external briquette temperatures and not the internal temperatures. The temperature measured is most likely a mixture of briquette outside temperature and gas temperature at that location in the bed.
  • the bed height selected for the induration process was found to be not critical and not inhibited by gas permeability generally selected to avoid deformation of the briquettes at the lower parts of the bed while achieving a reasonable productivity.
  • gas permeability generally selected to avoid deformation of the briquettes at the lower parts of the bed while achieving a reasonable productivity.
  • permeability of the bed was not greatly compromised by bed height. Consequently, the induration process is not restricted by this variable as is the case with pelletising operations.
  • Green briquette bed depth can be selected to optimise productivity without compromising quality.
  • a grate-kiln process may offer certain advantages in terms of producing a better fired product compared to products obtained from other induration processes. It also heats the briquettes more uniformly through high temperature ranges in a way that reduces temperature gradients within the briquette and avoids differential shrinkage of the briquette that may lead to cracking. Also, as all the briquettes are subject to similar firing temperatures and time in the rotating kiln, briquette quality is more uniform compared to the straight grate process.
  • Figure 15 also shows that tumble strength (Tumble Index - TI) and abrasion resistance (Abrasion Index - AI), improved with firing temperature.
  • the grate firing profile was the same, with only the firing time in the kiln at the firing temperature being changed from 6 to 9 minutes.
  • the total firing time in the kiln remained the same, the extra time for the firing was taken from the rate of heating in the kiln, so that the 9 minutes firing time had a quicker heating rate to 1380° compared to the 6 minutes firing time.
  • Tests were also conducted with 6.3cc GH briquettes using the same firing profile as that used for the 7.5cc case.
  • Results are illustrated in Figures 16 and 17 .
  • the fired strength increased significantly from the longer firing time in the kiln. This was due to greater heat penetration of the briquettes during the firing cycle.
  • Figure 18 shows that the fired properties improved with increasing residence time, suggesting the importance of heating the product thoroughly to achieve the final properties required.
  • the reducibility index (RI) remained relatively stable across the range of basicity levels.
  • the RI varied from 53.8% at a basicity of 0.20 to just over 62.2% at a basicity of 1.00.
  • the swell index showed some response and varied from 11% at the lowest basicity to 14.8% in the mid-ranges, decreasing to zero at a basicity of 1.20.
  • the crush strength after reduction (CSAR) showed a large response to changes in the basicity level, ranging from 22 kgf at 0.20 basicity to 121 kgf at 1.20 basicity. This change in reduced strength reflects the fired crush strength results and is again related to variation in the bonding phases of the fired briquettes.
  • the low basicity briquettes were predominantly bonded by iron oxide-iron oxide bonds, which degrade during reduction. At increased basicity levels, slag bonding becomes more significant. These bonds are more stable during reduction, accounting for the higher reduced strengths and little or no swell at a basicity of 1.20.
  • Slag bonding also becomes a more important form of bonding in briquettes made from GH and G where higher SiO 2 and Al 2 O 3 levels result in increased flux additions.
  • Such briquettes generally prove stronger after reduction as the reduction process does not result in the breakdown of non-ferrous bonding phases.
  • High grade ores, such as HC, which require low flux addition rely almost solely on oxide-oxide bonding and hence have lower strength after reduction values.

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Claims (37)

  1. Procédé de fabrication d'une briquette de minerai de fer qui est appropriée pour une utilisation comme matériau de base d'un haut-fourneau ou d'un autre four de réduction directe qui comprend les étapes de :
    (a) mélange : (i) d'un minerai présentant une distribution prédéterminée de tailles de particules avec une dimension supérieure de 4,0 mm ou moins et dont moins de 50 % traverse un tamis de 45 µm ; et (ii) d'un fondant ; pour former un mélange minerai/fondant ;
    (b) ajustement de la teneur en eau du minerai avant ou pendant l'étape de mélange (a) de telle sorte que le taux d'humidité du mélange minerai/fondant est de 2-12 % en poids, rapporté au poids total du mélange minerai/fondant ;
    (c) compression du mélange minerai/fondant en une briquette verte ; et
    (d) durcissement de la briquette verte pour former une brique cuite.
  2. Procédé selon la revendication 1 comprenant en outre le broyage et le criblage du minerai pour obtenir la distribution prédéterminée de tailles de particules qui est mélangée au fondant à l'étape (a).
  3. Procédé selon la revendication 1 ou la revendication 2 dans lequel la dimension supérieure de la distribution prédéterminée de tailles de particules de minerai qui est mélangée au fondant à l'étape (a) est de 3,5 mm.
  4. Procédé selon la revendication 3 dans lequel la dimension supérieure est de 3,0 mm.
  5. Procédé selon la revendication 3 dans lequel la dimension supérieure est de 2,5 mm.
  6. Procédé selon la revendication 3 dans lequel la dimension supérieure est de 1,5 mm.
  7. Procédé selon la revendication 3 dans lequel la dimension supérieure est de 1,0 mm.
  8. Procédé selon l'une quelconque des revendications précédentes dans lequel la distribution de tailles de particules de minerai prédéterminée comprend moins de 30 % traversant le tamis de 45 µm.
  9. Procédé selon l'une quelconque des revendications précédentes dans lequel la distribution de tailles de particules de minerai prédéterminée comprend moins de 10 % traversant le tamis de 45 µm.
  10. Procédé selon l'une quelconque des revendications précédentes dans lequel le minerai est un minerai de fer hydraté.
  11. Procédé selon la revendication 10 dans lequel le minerai hydraté est un minerai contenant de la goethite.
  12. Procédé selon l'une quelconque des revendications précédentes dans lequel le fondant présente une distribution de tailles de particules qui est principalement inférieure à 100 µm.
  13. Procédé selon l'une quelconque des revendications précédentes dans lequel la distribution de tailles de particules du fondant comprend plus de 95 % traversant un tamis de 250 µm.
  14. Procédé selon l'une quelconque des revendications précédentes dans lequel le mélange minerai/fondant fabriqué à l'étape (a) est choisi de telle sorte que la basicité de la briquette cuite fabriquée à l'étape (d) est supérieure à 0,2.
  15. Procédé selon la revendication 14 dans lequel la basicité est supérieure à 0,6.
  16. Procédé selon l'une quelconque des revendications précédentes dans lequel il n'y a pas de liant dans le mélange minerai/fondant.
  17. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape (b) comprend l'ajustement de la teneur en eau du minerai de telle sorte que le taux d'humidité du mélange minerai/fondant est de 2-5 % en poids, rapporté au poids total du mélange minerai/fondant, pour les minerais qui sont des minerais d'hématite denses.
  18. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape (b) comprend l'ajustement de la teneur en eau du minerai de telle sorte que le taux d'humidité du mélange minerai/fondant est de 4-8 % en poids, rapporté au poids total du mélange minerai/fondant, pour les minerais contenant jusqu'à 50 % de goethite.
  19. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape (b) comprend l'ajustement de la teneur en eau du minerai de telle sorte que le taux d'humidité du mélange minerai/fondant est de 6-10 % en poids, rapporté au poids total du mélange minerai/fondant, pour les minerais qui sont principalement de la goethite, c'est-à-dire qui en contiennent plus de 50 %.
  20. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape de compression (c) produit des briquettes qui ont un volume de 10 cm3 ou moins.
  21. Procédé selon la revendication 20 dans lequel les briquettes ont un volume de 8,5 cm3 ou moins.
  22. Procédé selon la revendication 20 dans lequel les briquettes ont un volume de 6,5 cm3 ou moins.
  23. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape de compression (c) comprend la compression du mélange minerai/fondant en utilisant une faible pression de laminage.
  24. Procédé selon la revendication 23 dans lequel la faible pression de laminage est suffisante pour produire des briquettes ayant une résistance à la compression à l'état vert d'au moins 2 kgf.
  25. Procédé selon la revendication 23 dans lequel la faible pression de laminage est générée par une force de compression d'un rouleau de 10-140 kN/cm sur le mélange minerai/fondant.
  26. Procédé selon la revendication 23 dans lequel la force de compression du rouleau est de 10-40 kN/cm.
  27. Procédé selon l'une quelconque des revendications précédentes dans lequel l'étape de durcissement (d) comprend le chauffage de la briquette à une température de cuisson dans les limites de 40 minutes.
  28. Procédé selon la revendication 27 dans lequel l'étape (d) comprend le chauffage de la briquette à la température de cuisson pendant 35 minutes.
  29. Procédé selon la revendication 27 dans lequel l'étape (b) comprend le chauffage de la briquette à la température de cuisson dans les limites de 30 minutes.
  30. Procédé selon la revendication 27 dans lequel l'étape (d) comprend le chauffage de la briquette à la température de cuisson dans les limites de 20 minutes.
  31. Procédé selon la revendication 27 dans lequel l'étape (d) comprend le chauffage de la briquette à la température de cuisson dans les limites de 15 minutes.
  32. Procédé selon l'une quelconque des revendications 27 à 31 dans lequel la température de cuisson est d'au moins 1200 °C.
  33. Procédé selon la revendication 32 dans lequel la température de cuisson est d'au moins 1260 °C.
  34. Procédé selon la revendication 32 dans lequel la température de cuisson est d'au moins 1320 °C.
  35. Procédé selon la revendication 32 dans lequel la température de cuisson est d'au moins 1350 °C.
  36. Procédé selon la revendication 32 dans lequel la température de cuisson est d'au moins 1380 °C.
  37. Procédé selon l'une quelconque des revendications précédentes dans lequel la briquette cuite a une résistance à l'écrasement d'au moins 200 kgf.
EP02764361A 2001-08-02 2002-08-02 Briquetage de minerai de fer Expired - Lifetime EP1423545B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUPR678301 2001-08-02
AUPR6783A AUPR678301A0 (en) 2001-08-02 2001-08-02 Iron ore briquetting
PCT/AU2002/001033 WO2003012153A1 (fr) 2001-08-02 2002-08-02 Briquetage de minerai de fer

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EP1423545A1 EP1423545A1 (fr) 2004-06-02
EP1423545A4 EP1423545A4 (fr) 2004-08-18
EP1423545B1 true EP1423545B1 (fr) 2010-04-28

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EP (2) EP1423545B1 (fr)
JP (3) JP5253701B2 (fr)
KR (4) KR20040053106A (fr)
CN (2) CN100430496C (fr)
AT (2) ATE473303T1 (fr)
AU (4) AUPR678301A0 (fr)
BR (2) BR0211944B8 (fr)
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DE (2) DE60236945D1 (fr)
WO (3) WO2003012153A1 (fr)
ZA (2) ZA200400957B (fr)

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JP5253701B2 (ja) 2013-07-31
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DE60236945D1 (de) 2010-08-19
KR20100122961A (ko) 2010-11-23
KR20100113177A (ko) 2010-10-20
US20050126343A1 (en) 2005-06-16
EP1425427B1 (fr) 2010-07-07
US20050050996A1 (en) 2005-03-10
AUPR678301A0 (en) 2001-08-23
AU2002325621B2 (en) 2008-10-23
JP2004536968A (ja) 2004-12-09
KR101067460B1 (ko) 2011-09-27
DE60236172D1 (de) 2010-06-10
CA2456191A1 (fr) 2003-02-13
CN1564874A (zh) 2005-01-12
WO2003012153A1 (fr) 2003-02-13
ATE466112T1 (de) 2010-05-15
BR0211944B8 (pt) 2013-04-16
CN100430496C (zh) 2008-11-05
BR0211944B1 (pt) 2012-09-04
CN1307317C (zh) 2007-03-28
JP5389308B2 (ja) 2014-01-15
WO2003012152A1 (fr) 2003-02-13
BR0211877A (pt) 2004-09-21
KR101068600B1 (ko) 2011-09-30
AU2002328650B2 (en) 2008-01-17
EP1423545A4 (fr) 2004-08-18
EP1425427A4 (fr) 2004-08-18
AU2002322154B2 (en) 2008-01-31
BR0211944A (pt) 2004-09-28
ZA200400957B (en) 2005-04-26
ZA200400955B (en) 2005-04-26
WO2003012154A1 (fr) 2003-02-13
EP1423545A1 (fr) 2004-06-02
JP2004536969A (ja) 2004-12-09
BR0211877B1 (pt) 2011-07-26
CA2456191C (fr) 2010-10-26
ATE473303T1 (de) 2010-07-15
CA2456188A1 (fr) 2003-02-13
KR20040044189A (ko) 2004-05-27
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EP1425427A1 (fr) 2004-06-09

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