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ferromanganese ore
with particle sizes less
than 4mm an
introduction
TC Kruger and JD Steenkamp
Introduction
Principles
Principles
Consolidation and growth
Principles
Breakage and attrition
Pellet growth
Growth pellets is controlled by two properties:
plasticity of the green pellet and
the viscosity of the superficial water layer
Pellet growth
Binder liquid is squeezed to the pellet surface
The viscosity of the binder liquid influences the
rate
The viscosity has to be low enough for colliding
pellets to combine within the time available
during collision (uncontrolled growth if too low)
Viscosity of binder liquid is influenced by:
Binder dosage;
Temperature;
Material properties of the binder
Process parameters
Processes
Pressure
Briquetting, compaction, tableting
Tumbling
Drum, disc, cone and pin agglomerator
Extrusion
Screw and gear pelletiser as well as pellet mills
Thermal
Sintering, prilling, pastillating and flaking processes
Binders
Binders accomplish two important
functions in pelletisation, namely:
Makes the moist ore plastic; and
During drying and sintering, the binder holds
the particles in the pellets together
Binders
Types of binders
Characterisation
Equipment
Disc pelletiser
Drum pelletiser
Extruder
Pin agglomerator
Briquette making machines
Sintering machines
High-intensity mixers
Case studies
Mexico
Purpose of Study
Material Pelletised
Particle Sizes
Equipment / Process
Binder and quantity
Moisture and quantity
Curing / Drying
Firing
Testing
Drop Tests
Cold crushing strength
Tumble index
Case studies
Brazil (INCOMI)
Purpose of Study
Material Pelletised
Particle Sizes
Equipment / Process
Binder and quantity
Moisture and quantity
Curing / Drying
Firing
Testing
Drop Tests
Cold crushing strength
Tumble index
Case studies
Brazil (University of Sao Paulo)
Purpose of Study
Material Pelletised
Particle Sizes
Equipment / Process
Binder and quantity
Moisture and quantity
Curing / Drying
Firing
Testing
Drop Tests
Cold crushing strength
Tumble index
Case studies
India (Visvesvaraya regional college of Engineering)
Purpose of Study
Material Pelletised
Particle Sizes
Equipment / Process
Binder and quantity
Moisture and quantity
Curing / Drying
Firing
Testing
Drop Tests
Cold crushing strength
Tumble index
Mexico2
Brazil (INCOMI)3
Trials
Aim
Experimental design
porosity was used as design control variable
literature was used as reference for aim porosity
less than 30 per cent
Samples
Sample 1 consisted of material smaller than
4mm which represented fines screened from
ore at the mines prior to transportation and at
smelter plants prior to processing.
Sample 2 consisted of material smaller than
1400 microns; and
Sample 3 consisted of material smaller than
250 microns
Porosity
Bulk porosity of the ore was measured using
the method of volume displacement
Manganese Sample
% Porosity
Sample 1 (4mm)
Sample 2 (1.4mm)
Sample 3 (250 m)
32.2%
33.3%
30.6%
Binder
Where:
b
P
SVb
m
=
=
=
=
bentonite in grams
aim porosity in ml
Swelling Volume of bentonite = 22-26 (ml/2g)23
mass of material to be pelletised in grams
Calculated bentonite content of each pelletising mix was thus calculated as:
Sample 1 0.53 mass per cent;
Sample 2 0.57 mass per cent; and
Sample 3 0.55 mass per cent.
Pelletising
5 kilogram sample of each size fraction
Measured bentonite
Placed in the Eirich RV02 high intensity mixer
and mixed for 60 seconds
1.2m diameter Radicon disc pelletiser
Angle of 35and a rotation speed of 75 rpm
Pellet diameter was controlled between 10 and
12.5mm
Testing
Compression strength:
30 balls of each sample
Instron Technologies crushing strength
machine, model 1011
Impact strength:
30 balls of each sample
Drop height of 450mm
Compression strength
Sample
Sample 1
Average
5.7
Min
3.7
Max
8.3
Std Dev
1.3
Sample 2
4.4
1.8
6.9
1.4
Sample 3
1.5
0.4
2.2
0.8
Impact strength
Sample
Sample 1
Average Min
6.1
3
Max
12
Std Dev
2.9
Sample 2
8.4
17
5.2
Sample 3
1.5
0.5
Conclusion
Larger particles can be pelletised
Characteristics improved with increase in
top size
Results show that pellets produced may
have adequate strength for sintering
processes
Further work is required to produce
pellets suitable for SAF operations
Recommendations
Increasing the size range of particles
Increasing the -250 micron material content of pellets
in increments;
Expanding the range of binders;
Increasing the range of the quantity of binder added;
Using a single, experienced operator to produce all
pellets in the test program;
Characterising pellets by microscopic analyses;
Studying the effect of bulk porosity of pellets on the
strength of pellets
Acknowledgements
Mr. L Lourens, Manager, Technology and IP,
Exxaro Resources, Alloystream
Mr. A Dippenaar; Kumba Iron Ore, R&D Raw
Material Technology
Dr. A-M Bonthuys, Independent Contractor
(Editor, Translator, Proof reader, Writer)
Mr B Allison, contractor, Exxaro Resources,
Alloystream
Questions