Sintering studies of Iron Ore Fines of Hospet-Sandur-Bellary sector, Karnataka, India

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1 744 Sintering studies of Iron Ore Fines of Hospet-Sandur-Bellary sector, Karnataka, India Anand V.Kulkarni*, H.M.Jayasheela** *(Manager-Geology, Hospet Steel Limited, Koppal, Karnataka. ** (Department of studies in geology, Karnatak University, Dharwad, Karnataka ABSTRACT Sintering is a technology for agglomeration of iron ore fines into useful blast furnace burden material. In sintering, a shallow bed of fine particles is agglomerated by heat exchange and partial fusion of the mixed mass. Heat is generated by combustion of solid fuel and mixed with the bed of fines being agglomerated. The combustion is initiated by igniting the fuel exposed at the surface of the bed, so that the bonding is effected by a combination of fusion, grain growth and slag liquidation. The formation of Sinter is caused by an incipient fusion of ore particles at the contact surface which binds them together and formation of diffusion bonds through recrystallization and crystal growth of hematite and magnetite which keep the particles together without melting. Keywords Agglomeration, Sintering, Tumbler Index, Basicity, I. INTRODUCTION The paper constitutes the results of sintering studies, to find out the optimum parameters utilising the iron ore fines of Hospet-Sandur-Bellary sector, as sintering has many advantages in blast furnaces like a) Use of iron ore fines, coke breeze, metallurgical waste, lime and dolomite fines for hot metal production, b) Better reducibility, c) Increased blast furnace productivity, d) Improved quality of hot metal and e) Reduction in Coke consumption rate in blast furnaces. II. STUDY AREA The Sandur schist belt has rich iron ore and manganese deposits in the Bellary district, Karnataka, India. The Schist belt trends North North West-South South East, with a length of about 53 kms spreading over an area of 930 square kilometres. The hills of schist belt are "Canoe" shaped, due to the valley on either side of the hill ranges, which extends towards each other with diminishing width, in an attempt to close up at both ends, resulting in the formation of a boat shaped structure. The iron ore deposits of the area fall within "Survey of India" toposheet number 57/8 and 57/12, falling between the longitude to E and latitude to N. III. EXPERIMENTAL WORK (a) Preparation of the feed sample Iron ore fines from M/s H R G mines of Donimalai range generated from the crushing/screening plant were collected for taking up the sintering studies. Representative sample of iron ore fine was drawn for the bulk quantity received and was subjected to chemical analysis and size analysis. The results are given in Table 1. The size analysis indicated that-100 # fraction constitutes 10% of the bulk sample. The samples of following additives v i z., a) dolomite, b) limestone, c) mill scale, d) fluedust, e) manganese ore, f) lime dust and g) Coke breeze were obtained from M/s Hospet Steel Plant site. All the additives received are chemically analysed and the results are given in Table 2. (b) Preparation of Sinter Charge The Sinter charge was prepared on the basis of basicity (CaO/ SiO2). Initial tests were conducted at low basicity of 1.6. Subsequent studies were conducted at varying basicity of Sinter. The charge composition from each test condition was calculated, keeping the MgO content in the charge composition fixed at 3% as per the practice followed in existing Indian Steel plants. Based on these charge composition, the required amount of iron ore fines and additives were drawn to form the Sinter charge. The amount of return Sinter required for the charge was collected from the Sinter fines generated from preceding heat. All materials other

2 745 than return fines and coke breeze, were fixed manually in a mixing and nodulising drum (disc pelletizer). (c) Experimental details On completion of mixing, the charge was unloaded from the pelletizer and transferred into the pot grate Sinter (Figure 1). This sintering unit has a grate area of 400 square centimetre and 400 mm height. The unit consists of a combustion chamber with a gas burner for igniting the Sinter mix of about 30 to 35 kgs with cast iron grate and a wind box. Wind box is connected by a pipe to the suction blower for operating at 1000 mm WG. Suction is maintained by means of controlling the aperture and opening. Windbox is provided with suction measurement unit and thermocouple for measuring exhaust gas temperature. L P G is used for igniting the Sinter mix. Sinter of-20 mm, mm size was used as a material for hearth layer of 40 mm height. The prepared Sinter charge was loaded into the Sinter pot over the hearth layer. The height of the bed excluding the hearth layer was maintained at 300 mm. The Sinter charge was ignited using a layer of Coke Breeze and saw dust spread uniformly over the bed. The ignition was maintained for a period of 120 seconds to ensure uniform start of firing, on the top portion of the bed. Suction was applied using the double stage blower after completion of the ignition period and was maintained at 1000 mm WB throughout the sintering period. The temperature of the exhaust gas was noted continuously using a thermometer in the suction line. Sintering was taken to be complete one minute after exhaust gas temperature reached the maximum. The Sinter was then allowed to cool under suction till the exhaust gas temperature came down below C. The Sinter was then unloaded from the pot. (d) Sinter analysis The cooled Sinter cake was manually broken down to-50 mm size and was screened at +10 mm. The -50 mm, + 10 mm fraction was weighed and weight of this fraction less the weight of the hearth layer gave the quantity of useful sinter produced. The yield was calculated as the ratio of useful Sinter to the total Sinter produced and expressed in percentage. The productivity was calculated as the tonnage of useful Sinter produced per square metre of the grate area, per hour. The -10 mm fines were used as return Sinter for subsequent tests. The-50 mm to + 10 mm product was stabilized by dropping two times from a height of 2000 mm. The Sinter was manually crushed to pass -40 mm size. The feed samples of -40 mm, + 10 mm size were drawn for determining tumbler index. The Tumble test on Sinter product was carried out as per the standard procedure. Accordingly 15 kg of rifle -40 mm + 10 mm size fraction was taken and tumbled in the drum for 200 revolutions. The tumbled material was screened at 6.3 mm and 0.5 mm (500 Micron) size. The weight percent of mm was taken as tumbler index. IV. RESULTS AND DISCUSSIONS Sintering studies were carried out with a view to optimise the moisture, Coke rate and basicity. The Steel Plant metallurgical waste namely flue dust and mill scale were also added to the Sinter feed as per the practice. Manganese ore was incorporated to the extent of 4% of the feed to meet the Mn requirement of pig iron eliminating its direct addition in the blast furnace burden. (a) Optimisation of moisture Sinter feeds with different levels of moisture addition were prepared while maintaining the basicity at 1.6, Coke rate at 5.0 and return centre at 30%. The Sinter produced were analysed for their physical and chemical characteristics. The results are given in the Table 3 and plotted in graphs (Figure 2 A and B). Based on the above, the moisture addition was optimised at 7.5%. Since at this level the product has higher strength and higher yield. (b) Optimisation of Coke addition To study the effect of variation of Coke rate, sintering tests were conducted with sinter mix prepared at variant levels of Coke addition. The basicity, moisture, return Sinter and lime additions were maintained at 1.6, 7.5, 30 and 1% respectively. The results are given in Table 4 and plotted in graphs figure 3 A and B. Results are better with 5.5% coke. (c) Effect of variation of lime on Sinter quality To study the effect of variation of lime addition, Sinter tests were conducted with Sinter mixes prepared at different levels of lime addition. The basicity, moisture and return Sinter addition were maintained at 1.6, 7.5% and 30% respectively and the Coke was maintained at 5.0 and 5.5% respectively. The results are given in Table 5 and plotted on graphs figure (4 A, B and C). Lime addition of 2% with Coke at 5.5% has given better results.

3 746 (d) Effect of variation of basicity on Sinter quality Keeping the addition of moisture, coke, return Sinter and lime at optimum levels of 7.5%, 5.5%, 30% and 2% respectively, Sinter feeds were prepared at different basicity levels of 1.6, 1.8 and 2.0. Sinter test carried out with charges thus prepared. Results are given in Table 6 and plotted on graphs (Figure 5 A and B). The experimental results at different basicity show that, there is no substantial change in the yield and productivity of the Sinter. The tumbler index at the basicity level of 1.6 is better than that at 1.8 and 2.0. [9] M.C.Chang Pellet quality and blast furnace performance and steel plants V. CONCLUSION The moisture addition was optimised at 7.5% where yield and strength of Sinter were optimum. Addition of lime helps in improving the strength of the Sinter. The results show that at 2% lime addition, Sinter of adequate strength could be produced. The experimental results show that acceptable Sinter would be produced at a basicity (CaO/SiO2) level of 1.6 with 7.5% moisture, 5.5% Coke rate and 2.0% of lime addition. The overall optimum results obtained have been tabulated in Table 7 A, B and C. REFERENCES [1] Dawson PR Research studies on sintering and sinter quality, Ironmaking Steelmaking, 20, [2]Kumar CU, Ramana RV, Ali S, Das AK, De AK and Mukherjee T Quality of sinter in the light of blast furnace performance. Tata search, India, pp [3] A.V.Kulakarni, Pelletisation of iron fines of Sandur-Hospet-Bellary Setor, Unpublished Ph.D thesis submitted to Gulbarga University,Karnataka [4]Loo CE and Leung W Factors influencing the bonding phase structure of iron ore sinters,isij Intl., 43, (9), [5]Mukherjee T and Whitemen JA Structure of fluxed sinter, Ironmaking steelmaking</emph>, 12, [6] C.Bryk and W.K.Lu, Iron making and steel making, vol.12, No. 2, pp [7]Nicola V and Scaelett Y Reaction sequences in the formation of silico ferrites of calcium and aluminium in iron ore sinter, Metall. Mater. Trans. B, 35B, [8]Pownceby MI and Clout JMF Importance of iron ore chemical composition and temperature phase relations: applications to iron ore sintering and pelletizing, Miner. Process. Extr. Metall., 112,

4 747 Table-1: Chemical and size analysis of iron ore fines from M/s H R G mines in Donimalai range. A, Chemical Analysis Constituents Assay Percentage Fe SiO Al2O3 1.6 LOI 1.6 P S 0.01 FeO 0.12 B. Size Ananlysis Size in Tyler Mesh Mesh opening Size (mm) Weight Percentage , , , Mean Size mm: 2.32 Table-2: Chemical Analysis of the Additives A. Chemical Analysis of the Coke Breeze Constituents Assay Percentage Volatile Matter 5% Fixed Carbon 61% Ash 34%

5 748 B Other Additives (Assay Percentage) Constituent Dolomite Limestone Millscale Fluedust Mn Ore Limedust Fe FeO SiO Al2O CaO MgO Mn LOI Table-3: Effect of Variation in Moisture Moisture Addition % Yield % Productivity t/m 2 /hour Tumbler Index Table-4: Characterisitics of Sinter at different Coke rate Coke addition Yield % Productivity t/m 2 /hour Tumbler Index Table-5: Effect of variation of Lime on Sinter quality Lime % Coke % Yield % Productivity t/m 2 /hour Tumbler Index

6 749 Table-6: Effect of variation of Basicity on Sinter quality Basicity Yield % Productivity t/m 2 /hour Tumbler Index % Table-7: a) Overall results under optimum conditions Moisture % 7.5 Coke % 5.5 Return Sinter 30.0 Basicity (CaO/MgO) 1.6 Max. exhaust gas temp. in 0 C C Sintering time in min 16 Table-7: b) Quality of Sinter Yield 73.5 % Productivity t/m2/hour 1.45 Tumbler Index 65 % Table-7: c) Chemical analysis of Sinter Fe % 55.2 SiO Al2O CaO 9.18 MgO 3.02 MnO 1.93

7 750 Fig 1 Grate Sinter Pot FIG. 2A Fig. 2 A

8 751 Fig. 2 B Fig 3 A Fig.3 B

9 752 Fig. 4 A Fig.4 B Fig. 4 C

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