Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing ...Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing iron ore pellet is an innovative burden of direct reduction ironmaking due to its excellent self-reducing property,and the thermal strength of pellet is a crucial metallurgical property that affects its wide application.The carbon-bearing iron ore pellet without binders(CIPWB)was prepared using iron concentrate and anthracite,and the effects of reducing agent addition amount,size of pellet,reduction temperature and time on the thermal compressive strength of CIPWB during the reduction process were studied.Simultaneously,the mechanism of the thermal strength evolution of CIPWB was revealed.The results showed that during the low-temperature reduction process(300-500℃),the thermal compressive strength of CIPWB linearly increases with increasing the size of pellet,while it gradually decreases with increasing the anthracite ratio.When the CIPWB with 8%anthracite is reduced at 300℃for 60 min,the thermal strength of pellet is enhanced from 13.24 to 31.88 N as the size of pellet increases from 8.04 to 12.78 mm.Meanwhile,as the temperature is 500℃,with increasing the anthracite ratio from 2%to 8%,the thermal compressive strength of pellet under reduction for 60 min remarkably decreases from 41.47 to 8.94 N.Furthermore,in the high-temperature reduction process(600-1150℃),the thermal compressive strength of CIPWB firstly increases and then reduces with increasing the temperature,while it as well as the temperature corresponding to the maximum strength decreases with increasing the anthracite ratio.With adding 18%anthracite,the thermal compressive strength of pellet reaches the maximum value at 800℃,namely 35.00 N,and obtains the minimum value at 1050℃,namely 8.60 N.The thermal compressive strength of CIPWB significantly depends on the temperature,reducing agent dosage,and pellet size.展开更多
The Langrial iron ore deposits,located in the villages of Dubran and Darkot in Hazara,Pakistan,were evaluated using remote sensing,magnetic,and geochemical investigations.Data from ASTER,Landsat-8,and Sentinel-2 satel...The Langrial iron ore deposits,located in the villages of Dubran and Darkot in Hazara,Pakistan,were evaluated using remote sensing,magnetic,and geochemical investigations.Data from ASTER,Landsat-8,and Sentinel-2 satellites were utilized and processed through techniques such as band ratio analysis,band compositing,and NDVI masking to reduce vegetation effects and to delineate various lithological units and mineralogical signatures within the study area.Magnetic anomalies revealed multiple levels of iron mineralization,with the hematite zone showing the most significant potential for high-grade iron ore.Geochemical analyses confirmed the presence of iron,along with minerals such as chromium,calcium,magnesium,and lead.In Dubran,mean iron concentrations are recorded at 370.94 mg/kg,whereas in Darkot,they reach up to 2052 mg/kg.The integration of remote sensing,magnetic,and geochemical data delineates key mineralized zones in the various parts of the study area.This research highlights the importance of combining geophysical and geochemical methodologies to refine mineral exploration efforts.The findings enhance our understanding of the Langrial iron ore deposits and highlight their economic potential for sustainable mining practices.This study will contribute to meeting the growing demand for iron ore resources and reducing Pakistan's reliance on imports,thereby promoting the sustainable development of local industries.展开更多
Magnetization roasting technology is one of the most representative ways to improve the magnetic separation efficiency and iron recovery of refractory weakly magnetic iron ores.However,utilization of CO-rich or H_(2)-...Magnetization roasting technology is one of the most representative ways to improve the magnetic separation efficiency and iron recovery of refractory weakly magnetic iron ores.However,utilization of CO-rich or H_(2)-rich gas of strong reducibility as reducing agent for magnetization roasting would lead to over-reduction of Fe_(2)O_(3) in the ore to non-magnetic FeO,which makes the magnetism of the roasted ore be lower than its maximum,and hence leads to a lower iron recovery than expected.To explore the possibility of using CH_(4) as reducing agent for controllable reduction of Fe_(2)O_(3) in iron ores to selectively forming magnetic Fe_(3)O_(4),i.e.,for maximizing the magnetism of the reduced ore for efficient iron separation and recovery,a series of fluidized bed reduction tests in CH_(4) were carried out on two iron ores of 55%and 33%iron at different temperatures for different periods of time,and the resultant reduced ore particles were magnetically separated for recovery of iron concentrate.XRD and ICP analyses were performed on all recovered iron concentrates to identify the crystal forms of their iron species and to quantify their iron contents.The results have shown that the controllable reduction by CH_(4) of Fe_(2)O_(3) in the iron ores to strongly magnetic Fe_(3)O_(4) can be realized by controlling the reduction temperature and time condition applied.The resultant concentrates can be fully recovered by magnetic separation in a weak magnetic field of 60 kA/m to attain a maximum iron recovery of 98% for the high-grade ore and that of 65% for the low-grade ore.Besides,the results have also shown that the most critical factor affecting the controllability of the ore reduction process and the selectivity to the generation of magnetic Fe_(3)O_(4)-containing particles is the reduction temperature,and that the upper temperature threshold for the controllable reduction and selective generation of strongly magnetic iron concentrate is about 650℃.展开更多
Iron tailings are a common solid waste resource,posing serious environmental and spatial challenges.This study proposed a novel hydrogen-based reduction roasting(HRR)technology for the processing of iron tailings usin...Iron tailings are a common solid waste resource,posing serious environmental and spatial challenges.This study proposed a novel hydrogen-based reduction roasting(HRR)technology for the processing of iron tailings using a combined beneficiation and metallurgy approach.Pilot-cale experiment results indicated that under the gas composition of CO:H_(2)=1:3,and optimal roasting conditions at a reduction temperature of 520℃,the majority of weakly magnetic hematite transforms into strongly magnetic magnetite during the reduction process.Combining roasting products with a magnetic separation-grinding-magnetic selection process yields a final iron concentrate with a grade of 56.68%iron and a recovery rate of 86.54%.Theoretical calculations suggested the annual production value can reach 29.7 million USD and a reduction of 20.79 tons of CO_(2) emissions per year.This highlights that the use of HRR in conjunction with traditional beneficiation processes can effectively achieve comprehensive utilization of iron tailings,thereby reducing environmental impact.展开更多
Sintering is a critical process in steel production that facilitates the efficient utilization of iron ore resources.However,compared to advanced sintering technologies,China’s sintering methods still exhibit high en...Sintering is a critical process in steel production that facilitates the efficient utilization of iron ore resources.However,compared to advanced sintering technologies,China’s sintering methods still exhibit high energy consumption,with typical solid fuel consumption for sintering of about 55 kg/t.In response,a pellet sintering process has been developed and its behavior has been investigated at sintering bed heights of 750 and 1500 mm.Additionally,a technical and economic comparison with traditional sintering methods has been conducted.The results indicate that at a bed height of 750 mm,the pellet sintering method can significantly reduce solid fuel consumption by approximately 30.82%,dropping from 70.75 to 48.95 kg/t.Additionally,the coke rate decreased from 4.55%to 3.20%,and harmful emissions in the flue gas were also reduced.As the bed height increases to 1500 mm,sintering performance improves even further.The coke rate is reduced to 3.00%,and solid fuel consumption decreases to 41.27 kg/t,approaching the world’s advanced level(≤40 kg/t).Technical and economic analysis also indicates that adopting the pellet sintering process can lower sintering costs by about 2.18 dollars/t.展开更多
Steel rolling sludge,an oil-containing waste generated during steel production,was difficult to manage.Prolonged storage poses significant environmental and health hazards.Most steel enterprises in China use steel rol...Steel rolling sludge,an oil-containing waste generated during steel production,was difficult to manage.Prolonged storage poses significant environmental and health hazards.Most steel enterprises in China use steel rolling sludge directly as a raw material for sintering.However,its adhesive nature caused poor mixing with other materials,affecting the quality of the sinter.Herein,the incorporation of steel rolling sludge incineration slag into the sintering process was investigated for experimental purposes.The results indicated that adding 1%incinerated steel rolling sludge to the sintering raw material was feasible.At this proportion,both the yield and the tumbler index of the sinter have improved,primarily due to the oxidation reaction of Fe_(3)O_(4)present in the steel rolling sludge incineration slag during the sintering process,which significantly increases the sensible heat of the sinter and enhances the sintering mineralization reaction.Notably,the addition of steel rolling sludge incineration slag reduced dioxin concentrations in the sintering flue gas.Although CO,NO_(x),and SO_(2)emission concentrations slightly increased,the existing flue gas treatment system effectively controlled their emissions.展开更多
The implementation of embedded selective catalytic reduction(SCR)denitration in chain grate during iron ore pelletizing process obviates additional flue gas heating.However,the influence of gas components and alkali m...The implementation of embedded selective catalytic reduction(SCR)denitration in chain grate during iron ore pelletizing process obviates additional flue gas heating.However,the influence of gas components and alkali metal on SCR denitration requires attention.The SCR denitration behavior in the preheating section of chain grate was investigated,and the combined influence mechanisms of H_(2)O(g),SO_(2),and potassium were revealed.The results show that the presence of H_(2)O(g)and SO_(2) in the flue gas decreases the NO conversion rate of the catalyst from 96.3%to 79.5%,while potassium adsorbed on the catalyst surface further reduces the NO conversion rate to 74.1%.H_(2)O(g),SO_(2),and potassium in the flue gas form sulfate and potassium salt on the catalyst surface,blocking the pore structure,thereby decreasing the gas adsorption capacity of the catalyst.Moreover,SO_(2) and potassium engage in competitive adsorption and reaction with NH_(3) and NO at the active sites on the catalyst surface,reducing the content and activity of the catalyst effective component.Increasing the flue gas temperature can promote the decomposition of ammonium sulfate and ammonium bisulfate on the catalyst surface,but it has little effect on potassium.Additionally,potassium will exacerbate sulfur poisoning of the catalyst.Hence,the embedded SCR denitration process requires electrostatic precipitation to eliminate the adverse impacts of potassium and thermal regime optimization to raise flue gas temperature to 350℃,thereby increasing NO conversion rate exceeding 85%.展开更多
Controlling the adhesion of potentially corrosive substances from flue gas on grate bar is crucial for extending the operational lifespan of the equipment.The adhesive behaviour and mechanism of ultrafine particulate ...Controlling the adhesion of potentially corrosive substances from flue gas on grate bar is crucial for extending the operational lifespan of the equipment.The adhesive behaviour and mechanism of ultrafine particulate matters(UPM)throughout the sintering process were elucidated,and measures to control adhesion on grate bars were developed.Research findings indicated that a small quantity of UPM were found on grate bar during the initial sintering stages(ignition stage and middle stageⅠandⅡ).The main compositions of UPM were FexOy-rich,CaO-rich,and aluminium silicate-rich particles.In contrast,corrosive substances like alkali metal compounds were almost absent.These UPM adhered onto grate bar primarily through inertial impaction.When moving to the final sintering stages(middle stageⅢand temperature rising stage),many UPM rich in corrosive substances like NaCl and KCl adhered to the grate bar.These UPM adhered to grate bar through thermal diffusion and vortex deposition.Solid waste water washing technology can greatly decrease the quantity of UPM(rich in NaCl and KCl)on the grate bar due to vortex deposition and thermal diffusion,and it represents a potentially promising way to control adhesion and corrosion on grate bars.展开更多
The high stress levels in tall tailings dams can lead to particle crushing.Understanding the compressibility and breakage characteristics of tailings particles will contribute to the advancement to the design and cons...The high stress levels in tall tailings dams can lead to particle crushing.Understanding the compressibility and breakage characteristics of tailings particles will contribute to the advancement to the design and construction processes of high-rise tailings dams,as well as the accurate evaluation of the stability of tailings storage facilities(TSFs).This paper presents the results of a series of detailed one-dimensional oedometer compression tests conducted to investigate the compression behavior and particle breakage of iron ore tailings(IOTs)collected from two typical TSFs,with different initial particle size distributions and a wide range of initial specific volumes,under effective vertical stresses of up to 4.8 MPa.The results show that the compression paths of the IOTs were slowly convergent,and this nontransitional mode of compression behavior experienced a significant amount of particle breakage.The relative breakage(Br)was used to quantify the amount of breakage and the input specific work(W)was adopted to evaluate the factors influencing Br.The initial breakage stress of the IOTs was less than 0.2 MPa.For the finer tailings,Br increased with increasing vertical stresses until it reached a threshold,after which Br tended to remain constant.However,coarser IOTs continued to experience crushing even at 4.8 MPa.The particle breakage in the coarser IOTs is much more significant than it in the finer IOTs overall.It was also observed that the tailings grains within the loose specimens broke more easily than those within the dense specimens.Additionally,three types of particle crushing modes were identified for IOTs under one-dimensional compression,namely,abrasion,chipping,and splitting.展开更多
The superconducting high gradient magnetic separation(S-HGMS)technology can be used to effectively extract silica from iron ore tailings(IOTs).However,particle agglomeration in strong magnetic fields poses a challenge...The superconducting high gradient magnetic separation(S-HGMS)technology can be used to effectively extract silica from iron ore tailings(IOTs).However,particle agglomeration in strong magnetic fields poses a challenge in achieving optimal performance.In this study,we investigated the agglomeration of IOT particles and the mechanisms for its inhibition through surface analysis,density functional theory(DFT),and extended Derjaguin-Landau-Verwey-Overbeek(EDLVO)theory.Hematite was found to exhibit the highest magnetic moment among the minerals present in IOTs,making it particularly prone to magnetic agglomeration.The addition of the dispersant SDSH into the slurry was essential in promoting the dispersion of IOT particles during the S-HGMS process.This dispersant hydrolyzed to form HPO_(4)^(2-)and RSO_(3)^(-)groups in the solution,which then chemically adsorbed onto the metal ions exposed on the surfaces of non-quartz particles,increasing interparticle electrostatic repulsion.Furthermore,the RSO_(3)^(-)groups physically adsorbed onto the surface of quartz particles,resulting in strong steric repulsion and enhancing the hydrophilicity of the particle surfaces,thereby inhibiting magnetic agglomeration between the particles.Under optimal conditions,the SiO_(2)grade of the obtained high-grade silica powder increased from an initial value of 76.32%in IOTs to 97.42%,achieving a SiO_(2)recovery rate of 54.81%,which meets the requirements for quartz sand used in glass preparation.This study provides valuable insights into the magnetic agglomeration of IOT particles and its inhibition while providing a foundation for regulating S-HGMS processes.展开更多
Predicting NO_(x)in the sintering process of iron ore powder in advance was helpful to adjust the denitrification process in time.Taking NO_(x)in the sintering process of iron ore powder as the object,the boxplot,empi...Predicting NO_(x)in the sintering process of iron ore powder in advance was helpful to adjust the denitrification process in time.Taking NO_(x)in the sintering process of iron ore powder as the object,the boxplot,empirical mode decomposition algorithm,Pearson correlation coefficient,maximum information coefficient and other methods were used to preprocess the sintering data and naive Bayes classification algorithm was used to identify the sintering conditions.The regression prediction model with high accuracy and good stability was selected as the sub-model for different sintering conditions,and the sub-models were combined into an integrated prediction model.Based on actual operational data,the approach proved the superiority and effectiveness of the developed model in predicting NO_(x),yielding an accuracy of 96.17%and an absolute error of 5.56,and thereby providing valuable foresight for on-site sintering operations.展开更多
The variation of the O_(2) content in the suction gas,in the range from 7 to 30 vol.%,during the iron ore sintering process,is investigated.Miniaturized laboratory-scale sintering experiments are carried out using an ...The variation of the O_(2) content in the suction gas,in the range from 7 to 30 vol.%,during the iron ore sintering process,is investigated.Miniaturized laboratory-scale sintering experiments are carried out using an industry-like raw mixture to study the effects of O_(2) variation on the sintering process with particular emphasis on the off-gas composition,specific sintering parameters and the sinter strength as well as the chemical composition of the sinter.After the ignition at the bed surface,the gas hood is placed on the sintering column,allowing a synthetic gas mixture to be drawn through the sinter bed until the burn-through point is reached.For additional interpretation of the experimental results,the theoretical coke combustion rate as a function of the oxygen partial pressure was calculated and plotted against the experimentally measured peak temperature in the sinter bed of the respective sinter series.An increasing O_(2) content in the suction gas results in a faster flame front speed combined with a more gradual temperature rise of the heat wave and longer dwell time in the melt phase formation temperature range.Due to the more pronounced flame front,both sinter yield and strength increase,resulting in lower return rates.Below 12 vol.%O_(2),a sharp decrease in sinter yield and strength can be observed,probably due to the low extent of melt phase formation and the associated minor formation of silico ferrite of calcium and aluminum(SFCA).The carbon burnout as well as the calcination increases with increasing the O_(2) content in the suction gas,resulting in higher levels of CO_(2) in the off-gas,with more or less constant amounts of CO above 15 vol.%O_(2).The amounts of NO and SO_(2) show a similar trend with a continuous increase with increasing O_(2) supply,with the SO_(2) breakthrough starting earlier and being released over a shorter period.The chemical analysis of the sinter indicates the highest Fe(II)values in the range of 12–21 vol.%O_(2) in the suction gas.展开更多
Oolitic iron ore is one of the most important iron resources. This paper reports the recovery of iron from high phosphorus oolitic iron ore using coal-based reduction and magnetic separation. The influences of reducti...Oolitic iron ore is one of the most important iron resources. This paper reports the recovery of iron from high phosphorus oolitic iron ore using coal-based reduction and magnetic separation. The influences of reduction temperature, reduction time, C/O mole ratio, and CaO content on the metallization degree and iron recovery were investigated in detail. Experimental results show that reduced products with the metallization degree of 95.82% could be produced under the optimal conditions （i.e., reduction temperature, 1250℃; reduction time, 50 min; C/O mole ratio, 2.0; and CaO content, 10wt%）. The magnetic concentrate containing 89.63wt% Fe with the iron recovery of 96.21% was obtained. According to the mineralogical and morphologic analysis, the iron minerals had been reduced and iron was mainly enriched into the metallic iron phase embedded in the slag matrix in the form of spherical particles. Apatite was also reduced to phosphorus, which partially migrated into the metallic iron phase.展开更多
China is abundant in iron-ore resources, with proven ore reserves of 576.62×10^8 t and proven reserves of 210×10^8 t, containing an average iron content of 33%. However, the rich iron-ore reserves of 10.85&#...China is abundant in iron-ore resources, with proven ore reserves of 576.62×10^8 t and proven reserves of 210×10^8 t, containing an average iron content of 33%. However, the rich iron-ore reserves of 10.85×10^8 t only account for 1.9% of all proven reserves. China＇s iron-ore resources are characterized by many lean ores and a few rich ones.展开更多
The slurry settling characteristics are the most important to design a thickener in process industries. In this work, the iron ore slurry from the screw classifier overflow was used for the settling study. It was obse...The slurry settling characteristics are the most important to design a thickener in process industries. In this work, the iron ore slurry from the screw classifier overflow was used for the settling study. It was observed that the original slurry exhibited a low settling velocity and a turbid supernatant during the settling process. Commercial flocculating agents with anionic, cationic, and nonionic characters were used to improve the settling behavior of suspensions, which were added into the slurry at different ranges of slurry pH values, respectively. The settling results show that the use of flocculants increase the settling rate by several times. Compared with the cationic and non-ionic flocculants, the anionic flocculant is more effective in enhancing the slurry settling rate. The small dose of the anionic flocculant is found to be more effective, but the other flocculants are less effective even at higher dosages. The simulation of an industrial thickener was carried out based on the laboratory settling data, and the appropriate design and selection parameters of the industrial thickener were estimated.展开更多
The selective HCl leaching method was used to remove phosphorus from high phosphorus iron ores. The hydroxyapatite in high phosphorus iron ores was converted into soluble phosphate during the process of HCl leaching. ...The selective HCl leaching method was used to remove phosphorus from high phosphorus iron ores. The hydroxyapatite in high phosphorus iron ores was converted into soluble phosphate during the process of HCl leaching. The effects of reaction time,particle size,hydrochloric acid concentration,reaction temperature,liquid-solid ratio and stirring strength on the dephosphorization ratio were studied. The results showed that the dephosphorization ratio can exceed 98% under the conditions of reaction time 30-45 min,particle size 0.147 mm,hydrochloric acid concentration 2.5 mol/L,reaction temperature 25 ℃,liquid-solid ratio 5：1 and stirring strength 5.02-12.76 s-1. After dephosphorization reaction,the content of phosphorus in iron ore complied completely with the requirements of steel production.展开更多
A new method （gas-based separation plus melt separation） has been proposed to remove phosphorus of the high phosphorus iron ore which was 1.25 % of phosphorus content and 50. 0% of iron content. HSC chemistry packag...A new method （gas-based separation plus melt separation） has been proposed to remove phosphorus of the high phosphorus iron ore which was 1.25 % of phosphorus content and 50. 0% of iron content. HSC chemistry package and the coexistence theory of slag structure were adopted for theoretical analysis. The gas-based reduction was carried out using a fixed bed reactor and the ore sample of 80 g with an average particle size of 2 mm were reduced using CO or H2 at temperature of 1 073 K for 5 hours. 50 g of the reduced sample with 3.0% CaO as additive was then subjected to melt separation in an electric furnace at temperature of 1 873 K under Ar atmosphere. In each run, SEM, EDS, optical microscopic examination and chemical analysis of the reduced ore sample, the metal sample and the slag sample were conducted. Results of all gas-based reduction experiments showed that iron metallization ratios were some 65% and the phosphorus compounds in the ore remained unchanged. It was agreed well with the simula- tions except for the iron metallization rate being less than predicted value; this difference was attributed to kinetics. Results of melt separation experiments showed that P content in metal samples is 0.33% （metal sample from H2 reduction product） and 0.27% （metal sample from CO reduction product）. The phosphorus partition ratios of both cases were less than predicted values. Some P in the metal samples existed as slag inclusion was considered to be the reason for this discrepancy.展开更多
In the background of little reuse and large stockpile for iron ore tailings, iron ore tailing from Chinese Tonghua were used as raw material to prepare cementitious materials. Cementitious properties of the iron ore t...In the background of little reuse and large stockpile for iron ore tailings, iron ore tailing from Chinese Tonghua were used as raw material to prepare cementitious materials. Cementitious properties of the iron ore tailings activated by compound thermal activation were studied. Testing methods, such as XRD, TG-DTA, and IR were used for researching the phase and structure variety of the iron ore railings in the process of compound thermal activation. The results reveal that a new cementitious material that contains 30wt% of the iron ore tailings can be obtained by compounded thermal activation, whose mortar strength can come up to the standard of 42.5 cement of China.展开更多
An ore-blending optimization model for the sintering process is an intelligent system that includes iron ore characteristics, expert knowledge and material balance. In the present work, 14 indices are proposed to repr...An ore-blending optimization model for the sintering process is an intelligent system that includes iron ore characteristics, expert knowledge and material balance. In the present work, 14 indices are proposed to represent chemical composition, granulating properties and high temperature properties of iron ores. After the relationships between iron ore characteristics and sintering performance are established, the ＂two-step＂ method and the simplex method are introduced to build the model by distinguishing the calculation of optimized blending proportion of iron ores from that of other sintering materials in order to improve calculation efficiency. The ore-blending optimization model, programmed by Access and Visual Basic, is applied to practical production in steel mills and the results prove that the present model can take advantage of the available iron ore resource with stable sinter yield and quality performance but at a lower cost.展开更多
Six additives,i.e.,limestone,lime,magnesite,magnesia,dolomite and light-burned-dolomite,were added for investigating their influences on the pellet quality.For green balls,adding lime and light-burned-dolomite makes t...Six additives,i.e.,limestone,lime,magnesite,magnesia,dolomite and light-burned-dolomite,were added for investigating their influences on the pellet quality.For green balls,adding lime and light-burned-dolomite makes the wet drop strength decrease firstly,and then increase with further increase of additive dosage.Ca(OH)2 affects the bentonite properties at the beginning,but the binding property of Ca(OH)2 will be main when the dosage is higher.The other four additives decrease the drop strength for their disadvantageous physical properties.For preheated pellets,no mater what kind of additive is added,the compressive strength will be decreased because of unmineralized additives.For roasted pellets,calcium additives can form binding phase of calcium-ferrite,and suitable liquid phase will improve recrystallization of hematite,but excessive liquid will destroy the structure of pellets,so the compressive strength of pellet increases firstly and then drops.When adding magnesium additives,the strength will be decreased because of the oxidation of magnetite retarded by MgO.展开更多
基金support of the National Natural Science Foundation of China(52074080,52004001,and 51574002).
文摘Against the background of“carbon peak and carbon neutrality,”it is of great practical significance to develop non-blast furnace ironmaking technology for the sustainable development of steel industry.Carbon-bearing iron ore pellet is an innovative burden of direct reduction ironmaking due to its excellent self-reducing property,and the thermal strength of pellet is a crucial metallurgical property that affects its wide application.The carbon-bearing iron ore pellet without binders(CIPWB)was prepared using iron concentrate and anthracite,and the effects of reducing agent addition amount,size of pellet,reduction temperature and time on the thermal compressive strength of CIPWB during the reduction process were studied.Simultaneously,the mechanism of the thermal strength evolution of CIPWB was revealed.The results showed that during the low-temperature reduction process(300-500℃),the thermal compressive strength of CIPWB linearly increases with increasing the size of pellet,while it gradually decreases with increasing the anthracite ratio.When the CIPWB with 8%anthracite is reduced at 300℃for 60 min,the thermal strength of pellet is enhanced from 13.24 to 31.88 N as the size of pellet increases from 8.04 to 12.78 mm.Meanwhile,as the temperature is 500℃,with increasing the anthracite ratio from 2%to 8%,the thermal compressive strength of pellet under reduction for 60 min remarkably decreases from 41.47 to 8.94 N.Furthermore,in the high-temperature reduction process(600-1150℃),the thermal compressive strength of CIPWB firstly increases and then reduces with increasing the temperature,while it as well as the temperature corresponding to the maximum strength decreases with increasing the anthracite ratio.With adding 18%anthracite,the thermal compressive strength of pellet reaches the maximum value at 800℃,namely 35.00 N,and obtains the minimum value at 1050℃,namely 8.60 N.The thermal compressive strength of CIPWB significantly depends on the temperature,reducing agent dosage,and pellet size.
文摘The Langrial iron ore deposits,located in the villages of Dubran and Darkot in Hazara,Pakistan,were evaluated using remote sensing,magnetic,and geochemical investigations.Data from ASTER,Landsat-8,and Sentinel-2 satellites were utilized and processed through techniques such as band ratio analysis,band compositing,and NDVI masking to reduce vegetation effects and to delineate various lithological units and mineralogical signatures within the study area.Magnetic anomalies revealed multiple levels of iron mineralization,with the hematite zone showing the most significant potential for high-grade iron ore.Geochemical analyses confirmed the presence of iron,along with minerals such as chromium,calcium,magnesium,and lead.In Dubran,mean iron concentrations are recorded at 370.94 mg/kg,whereas in Darkot,they reach up to 2052 mg/kg.The integration of remote sensing,magnetic,and geochemical data delineates key mineralized zones in the various parts of the study area.This research highlights the importance of combining geophysical and geochemical methodologies to refine mineral exploration efforts.The findings enhance our understanding of the Langrial iron ore deposits and highlight their economic potential for sustainable mining practices.This study will contribute to meeting the growing demand for iron ore resources and reducing Pakistan's reliance on imports,thereby promoting the sustainable development of local industries.
基金supported by National Natural Science Foundation of China(U21A20316).
文摘Magnetization roasting technology is one of the most representative ways to improve the magnetic separation efficiency and iron recovery of refractory weakly magnetic iron ores.However,utilization of CO-rich or H_(2)-rich gas of strong reducibility as reducing agent for magnetization roasting would lead to over-reduction of Fe_(2)O_(3) in the ore to non-magnetic FeO,which makes the magnetism of the roasted ore be lower than its maximum,and hence leads to a lower iron recovery than expected.To explore the possibility of using CH_(4) as reducing agent for controllable reduction of Fe_(2)O_(3) in iron ores to selectively forming magnetic Fe_(3)O_(4),i.e.,for maximizing the magnetism of the reduced ore for efficient iron separation and recovery,a series of fluidized bed reduction tests in CH_(4) were carried out on two iron ores of 55%and 33%iron at different temperatures for different periods of time,and the resultant reduced ore particles were magnetically separated for recovery of iron concentrate.XRD and ICP analyses were performed on all recovered iron concentrates to identify the crystal forms of their iron species and to quantify their iron contents.The results have shown that the controllable reduction by CH_(4) of Fe_(2)O_(3) in the iron ores to strongly magnetic Fe_(3)O_(4) can be realized by controlling the reduction temperature and time condition applied.The resultant concentrates can be fully recovered by magnetic separation in a weak magnetic field of 60 kA/m to attain a maximum iron recovery of 98% for the high-grade ore and that of 65% for the low-grade ore.Besides,the results have also shown that the most critical factor affecting the controllability of the ore reduction process and the selectivity to the generation of magnetic Fe_(3)O_(4)-containing particles is the reduction temperature,and that the upper temperature threshold for the controllable reduction and selective generation of strongly magnetic iron concentrate is about 650℃.
基金National Natural Science Foundation of China(52104249)Liaoning Joint Fund General Support Program Project(2023-MSBA-126)the Fundamental Research Funds for the Central Universities(N2401019).
文摘Iron tailings are a common solid waste resource,posing serious environmental and spatial challenges.This study proposed a novel hydrogen-based reduction roasting(HRR)technology for the processing of iron tailings using a combined beneficiation and metallurgy approach.Pilot-cale experiment results indicated that under the gas composition of CO:H_(2)=1:3,and optimal roasting conditions at a reduction temperature of 520℃,the majority of weakly magnetic hematite transforms into strongly magnetic magnetite during the reduction process.Combining roasting products with a magnetic separation-grinding-magnetic selection process yields a final iron concentrate with a grade of 56.68%iron and a recovery rate of 86.54%.Theoretical calculations suggested the annual production value can reach 29.7 million USD and a reduction of 20.79 tons of CO_(2) emissions per year.This highlights that the use of HRR in conjunction with traditional beneficiation processes can effectively achieve comprehensive utilization of iron tailings,thereby reducing environmental impact.
基金financially supported by Huxiang Youth Talent Program of Hunan Province(No.2024RC3008)National Natural Science Foundation China(Nos.52274343 and 52474370)National Key R&D Program of China(Nos.2023YFC3903900 and 2023YFC3903904).
文摘Sintering is a critical process in steel production that facilitates the efficient utilization of iron ore resources.However,compared to advanced sintering technologies,China’s sintering methods still exhibit high energy consumption,with typical solid fuel consumption for sintering of about 55 kg/t.In response,a pellet sintering process has been developed and its behavior has been investigated at sintering bed heights of 750 and 1500 mm.Additionally,a technical and economic comparison with traditional sintering methods has been conducted.The results indicate that at a bed height of 750 mm,the pellet sintering method can significantly reduce solid fuel consumption by approximately 30.82%,dropping from 70.75 to 48.95 kg/t.Additionally,the coke rate decreased from 4.55%to 3.20%,and harmful emissions in the flue gas were also reduced.As the bed height increases to 1500 mm,sintering performance improves even further.The coke rate is reduced to 3.00%,and solid fuel consumption decreases to 41.27 kg/t,approaching the world’s advanced level(≤40 kg/t).Technical and economic analysis also indicates that adopting the pellet sintering process can lower sintering costs by about 2.18 dollars/t.
基金supported by the National Natural Science Foundation of China(52204331)Natural Science Foundation of Anhui Province Youth Project(2208085QE145)the Open Project Program of Key Laboratory of Metallurgical Emission Reduction&Resources Recycling(Anhui University of Technology),Ministry of Education(JKF20-03).
文摘Steel rolling sludge,an oil-containing waste generated during steel production,was difficult to manage.Prolonged storage poses significant environmental and health hazards.Most steel enterprises in China use steel rolling sludge directly as a raw material for sintering.However,its adhesive nature caused poor mixing with other materials,affecting the quality of the sinter.Herein,the incorporation of steel rolling sludge incineration slag into the sintering process was investigated for experimental purposes.The results indicated that adding 1%incinerated steel rolling sludge to the sintering raw material was feasible.At this proportion,both the yield and the tumbler index of the sinter have improved,primarily due to the oxidation reaction of Fe_(3)O_(4)present in the steel rolling sludge incineration slag during the sintering process,which significantly increases the sensible heat of the sinter and enhances the sintering mineralization reaction.Notably,the addition of steel rolling sludge incineration slag reduced dioxin concentrations in the sintering flue gas.Although CO,NO_(x),and SO_(2)emission concentrations slightly increased,the existing flue gas treatment system effectively controlled their emissions.
基金financially supported by the National Key Research and Development Program of China(No.2023YFC3707002)Hunan Provincial Innovation Foundation for Postgraduate(No.QL20220069)Postgraduate Innovative Project of Central South University(No.1053320214756).
文摘The implementation of embedded selective catalytic reduction(SCR)denitration in chain grate during iron ore pelletizing process obviates additional flue gas heating.However,the influence of gas components and alkali metal on SCR denitration requires attention.The SCR denitration behavior in the preheating section of chain grate was investigated,and the combined influence mechanisms of H_(2)O(g),SO_(2),and potassium were revealed.The results show that the presence of H_(2)O(g)and SO_(2) in the flue gas decreases the NO conversion rate of the catalyst from 96.3%to 79.5%,while potassium adsorbed on the catalyst surface further reduces the NO conversion rate to 74.1%.H_(2)O(g),SO_(2),and potassium in the flue gas form sulfate and potassium salt on the catalyst surface,blocking the pore structure,thereby decreasing the gas adsorption capacity of the catalyst.Moreover,SO_(2) and potassium engage in competitive adsorption and reaction with NH_(3) and NO at the active sites on the catalyst surface,reducing the content and activity of the catalyst effective component.Increasing the flue gas temperature can promote the decomposition of ammonium sulfate and ammonium bisulfate on the catalyst surface,but it has little effect on potassium.Additionally,potassium will exacerbate sulfur poisoning of the catalyst.Hence,the embedded SCR denitration process requires electrostatic precipitation to eliminate the adverse impacts of potassium and thermal regime optimization to raise flue gas temperature to 350℃,thereby increasing NO conversion rate exceeding 85%.
基金supported by the National Natural Science Foundation of China(No.52274344)the Provincial Natural Science Foundation of Hunan(Nos.2022JJ30723 and 2023JJ20068)the Science and Technology Innovation Program of Hunan Province(2023RC3042).
文摘Controlling the adhesion of potentially corrosive substances from flue gas on grate bar is crucial for extending the operational lifespan of the equipment.The adhesive behaviour and mechanism of ultrafine particulate matters(UPM)throughout the sintering process were elucidated,and measures to control adhesion on grate bars were developed.Research findings indicated that a small quantity of UPM were found on grate bar during the initial sintering stages(ignition stage and middle stageⅠandⅡ).The main compositions of UPM were FexOy-rich,CaO-rich,and aluminium silicate-rich particles.In contrast,corrosive substances like alkali metal compounds were almost absent.These UPM adhered onto grate bar primarily through inertial impaction.When moving to the final sintering stages(middle stageⅢand temperature rising stage),many UPM rich in corrosive substances like NaCl and KCl adhered to the grate bar.These UPM adhered to grate bar through thermal diffusion and vortex deposition.Solid waste water washing technology can greatly decrease the quantity of UPM(rich in NaCl and KCl)on the grate bar due to vortex deposition and thermal diffusion,and it represents a potentially promising way to control adhesion and corrosion on grate bars.
基金supported by the National Natural Science Foundation of China(Grant Nos.41630640,41790445)the National Key Research and Development Program of China(Grant No.2022YFC3003205).
文摘The high stress levels in tall tailings dams can lead to particle crushing.Understanding the compressibility and breakage characteristics of tailings particles will contribute to the advancement to the design and construction processes of high-rise tailings dams,as well as the accurate evaluation of the stability of tailings storage facilities(TSFs).This paper presents the results of a series of detailed one-dimensional oedometer compression tests conducted to investigate the compression behavior and particle breakage of iron ore tailings(IOTs)collected from two typical TSFs,with different initial particle size distributions and a wide range of initial specific volumes,under effective vertical stresses of up to 4.8 MPa.The results show that the compression paths of the IOTs were slowly convergent,and this nontransitional mode of compression behavior experienced a significant amount of particle breakage.The relative breakage(Br)was used to quantify the amount of breakage and the input specific work(W)was adopted to evaluate the factors influencing Br.The initial breakage stress of the IOTs was less than 0.2 MPa.For the finer tailings,Br increased with increasing vertical stresses until it reached a threshold,after which Br tended to remain constant.However,coarser IOTs continued to experience crushing even at 4.8 MPa.The particle breakage in the coarser IOTs is much more significant than it in the finer IOTs overall.It was also observed that the tailings grains within the loose specimens broke more easily than those within the dense specimens.Additionally,three types of particle crushing modes were identified for IOTs under one-dimensional compression,namely,abrasion,chipping,and splitting.
基金supported by USTB Institute for International People-to-People Exchange in Mining,Metallurgy and Metals Industries(No.FRF-IPPE-2404)Scientific Research Platform Construction Fund for the Introduction of High-Level Talents at Kunming University of Science and Technology(No.CA25073M246A).
文摘The superconducting high gradient magnetic separation(S-HGMS)technology can be used to effectively extract silica from iron ore tailings(IOTs).However,particle agglomeration in strong magnetic fields poses a challenge in achieving optimal performance.In this study,we investigated the agglomeration of IOT particles and the mechanisms for its inhibition through surface analysis,density functional theory(DFT),and extended Derjaguin-Landau-Verwey-Overbeek(EDLVO)theory.Hematite was found to exhibit the highest magnetic moment among the minerals present in IOTs,making it particularly prone to magnetic agglomeration.The addition of the dispersant SDSH into the slurry was essential in promoting the dispersion of IOT particles during the S-HGMS process.This dispersant hydrolyzed to form HPO_(4)^(2-)and RSO_(3)^(-)groups in the solution,which then chemically adsorbed onto the metal ions exposed on the surfaces of non-quartz particles,increasing interparticle electrostatic repulsion.Furthermore,the RSO_(3)^(-)groups physically adsorbed onto the surface of quartz particles,resulting in strong steric repulsion and enhancing the hydrophilicity of the particle surfaces,thereby inhibiting magnetic agglomeration between the particles.Under optimal conditions,the SiO_(2)grade of the obtained high-grade silica powder increased from an initial value of 76.32%in IOTs to 97.42%,achieving a SiO_(2)recovery rate of 54.81%,which meets the requirements for quartz sand used in glass preparation.This study provides valuable insights into the magnetic agglomeration of IOT particles and its inhibition while providing a foundation for regulating S-HGMS processes.
基金financially supported by the Natural Science Basic foundation of China(Program No.52174325)the Key Research and Development Program of Shaanxi(Grant No.2020GY-166 and Program No.2020GY-247)the Shaanxi Provincial Innovation Capacity Support Plan(Grant No.2023-CX-TD-53).
文摘Predicting NO_(x)in the sintering process of iron ore powder in advance was helpful to adjust the denitrification process in time.Taking NO_(x)in the sintering process of iron ore powder as the object,the boxplot,empirical mode decomposition algorithm,Pearson correlation coefficient,maximum information coefficient and other methods were used to preprocess the sintering data and naive Bayes classification algorithm was used to identify the sintering conditions.The regression prediction model with high accuracy and good stability was selected as the sub-model for different sintering conditions,and the sub-models were combined into an integrated prediction model.Based on actual operational data,the approach proved the superiority and effectiveness of the developed model in predicting NO_(x),yielding an accuracy of 96.17%and an absolute error of 5.56,and thereby providing valuable foresight for on-site sintering operations.
基金Open access funding provided by Montanuniversität Leoben.
文摘The variation of the O_(2) content in the suction gas,in the range from 7 to 30 vol.%,during the iron ore sintering process,is investigated.Miniaturized laboratory-scale sintering experiments are carried out using an industry-like raw mixture to study the effects of O_(2) variation on the sintering process with particular emphasis on the off-gas composition,specific sintering parameters and the sinter strength as well as the chemical composition of the sinter.After the ignition at the bed surface,the gas hood is placed on the sintering column,allowing a synthetic gas mixture to be drawn through the sinter bed until the burn-through point is reached.For additional interpretation of the experimental results,the theoretical coke combustion rate as a function of the oxygen partial pressure was calculated and plotted against the experimentally measured peak temperature in the sinter bed of the respective sinter series.An increasing O_(2) content in the suction gas results in a faster flame front speed combined with a more gradual temperature rise of the heat wave and longer dwell time in the melt phase formation temperature range.Due to the more pronounced flame front,both sinter yield and strength increase,resulting in lower return rates.Below 12 vol.%O_(2),a sharp decrease in sinter yield and strength can be observed,probably due to the low extent of melt phase formation and the associated minor formation of silico ferrite of calcium and aluminum(SFCA).The carbon burnout as well as the calcination increases with increasing the O_(2) content in the suction gas,resulting in higher levels of CO_(2) in the off-gas,with more or less constant amounts of CO above 15 vol.%O_(2).The amounts of NO and SO_(2) show a similar trend with a continuous increase with increasing O_(2) supply,with the SO_(2) breakthrough starting earlier and being released over a shorter period.The chemical analysis of the sinter indicates the highest Fe(II)values in the range of 12–21 vol.%O_(2) in the suction gas.
基金supported by the National Natural Science Foundation of China(Nos.51134002 and 51074036)
文摘Oolitic iron ore is one of the most important iron resources. This paper reports the recovery of iron from high phosphorus oolitic iron ore using coal-based reduction and magnetic separation. The influences of reduction temperature, reduction time, C/O mole ratio, and CaO content on the metallization degree and iron recovery were investigated in detail. Experimental results show that reduced products with the metallization degree of 95.82% could be produced under the optimal conditions （i.e., reduction temperature, 1250℃; reduction time, 50 min; C/O mole ratio, 2.0; and CaO content, 10wt%）. The magnetic concentrate containing 89.63wt% Fe with the iron recovery of 96.21% was obtained. According to the mineralogical and morphologic analysis, the iron minerals had been reduced and iron was mainly enriched into the metallic iron phase embedded in the slag matrix in the form of spherical particles. Apatite was also reduced to phosphorus, which partially migrated into the metallic iron phase.
文摘China is abundant in iron-ore resources, with proven ore reserves of 576.62×10^8 t and proven reserves of 210×10^8 t, containing an average iron content of 33%. However, the rich iron-ore reserves of 10.85×10^8 t only account for 1.9% of all proven reserves. China＇s iron-ore resources are characterized by many lean ores and a few rich ones.
文摘The slurry settling characteristics are the most important to design a thickener in process industries. In this work, the iron ore slurry from the screw classifier overflow was used for the settling study. It was observed that the original slurry exhibited a low settling velocity and a turbid supernatant during the settling process. Commercial flocculating agents with anionic, cationic, and nonionic characters were used to improve the settling behavior of suspensions, which were added into the slurry at different ranges of slurry pH values, respectively. The settling results show that the use of flocculants increase the settling rate by several times. Compared with the cationic and non-ionic flocculants, the anionic flocculant is more effective in enhancing the slurry settling rate. The small dose of the anionic flocculant is found to be more effective, but the other flocculants are less effective even at higher dosages. The simulation of an industrial thickener was carried out based on the laboratory settling data, and the appropriate design and selection parameters of the industrial thickener were estimated.
基金Item Sponsored by Natural Science Foundation Project of CQ CSTC of China (2009BA7071)
文摘The selective HCl leaching method was used to remove phosphorus from high phosphorus iron ores. The hydroxyapatite in high phosphorus iron ores was converted into soluble phosphate during the process of HCl leaching. The effects of reaction time,particle size,hydrochloric acid concentration,reaction temperature,liquid-solid ratio and stirring strength on the dephosphorization ratio were studied. The results showed that the dephosphorization ratio can exceed 98% under the conditions of reaction time 30-45 min,particle size 0.147 mm,hydrochloric acid concentration 2.5 mol/L,reaction temperature 25 ℃,liquid-solid ratio 5：1 and stirring strength 5.02-12.76 s-1. After dephosphorization reaction,the content of phosphorus in iron ore complied completely with the requirements of steel production.
基金Sponsored by National Natural Science Foundation of China and Baosteel(50834007)
文摘A new method （gas-based separation plus melt separation） has been proposed to remove phosphorus of the high phosphorus iron ore which was 1.25 % of phosphorus content and 50. 0% of iron content. HSC chemistry package and the coexistence theory of slag structure were adopted for theoretical analysis. The gas-based reduction was carried out using a fixed bed reactor and the ore sample of 80 g with an average particle size of 2 mm were reduced using CO or H2 at temperature of 1 073 K for 5 hours. 50 g of the reduced sample with 3.0% CaO as additive was then subjected to melt separation in an electric furnace at temperature of 1 873 K under Ar atmosphere. In each run, SEM, EDS, optical microscopic examination and chemical analysis of the reduced ore sample, the metal sample and the slag sample were conducted. Results of all gas-based reduction experiments showed that iron metallization ratios were some 65% and the phosphorus compounds in the ore remained unchanged. It was agreed well with the simula- tions except for the iron metallization rate being less than predicted value; this difference was attributed to kinetics. Results of melt separation experiments showed that P content in metal samples is 0.33% （metal sample from H2 reduction product） and 0.27% （metal sample from CO reduction product）. The phosphorus partition ratios of both cases were less than predicted values. Some P in the metal samples existed as slag inclusion was considered to be the reason for this discrepancy.
基金supported by the National Nature Science Foundation of China (No.50674062)the National Key Technologies R&D Program of China (No.2006BAC21B03)the Post doctoral Science Foundation (No.20070420354)
文摘In the background of little reuse and large stockpile for iron ore tailings, iron ore tailing from Chinese Tonghua were used as raw material to prepare cementitious materials. Cementitious properties of the iron ore tailings activated by compound thermal activation were studied. Testing methods, such as XRD, TG-DTA, and IR were used for researching the phase and structure variety of the iron ore railings in the process of compound thermal activation. The results reveal that a new cementitious material that contains 30wt% of the iron ore tailings can be obtained by compounded thermal activation, whose mortar strength can come up to the standard of 42.5 cement of China.
文摘An ore-blending optimization model for the sintering process is an intelligent system that includes iron ore characteristics, expert knowledge and material balance. In the present work, 14 indices are proposed to represent chemical composition, granulating properties and high temperature properties of iron ores. After the relationships between iron ore characteristics and sintering performance are established, the ＂two-step＂ method and the simplex method are introduced to build the model by distinguishing the calculation of optimized blending proportion of iron ores from that of other sintering materials in order to improve calculation efficiency. The ore-blending optimization model, programmed by Access and Visual Basic, is applied to practical production in steel mills and the results prove that the present model can take advantage of the available iron ore resource with stable sinter yield and quality performance but at a lower cost.
基金Project(2008BAB32B06) supported by the Key Projects in the National Science and Technology Pillar Program during the 11th Five-year Plan PeriodProject(2009ybfz20) supported by the Program for Excellent Doctor’s Degree Paper in Central South University,ChinaProject(1343/74333001114) supported by the Postgraduate’s Paper Innovation Fund of Hunan Province,China
文摘Six additives,i.e.,limestone,lime,magnesite,magnesia,dolomite and light-burned-dolomite,were added for investigating their influences on the pellet quality.For green balls,adding lime and light-burned-dolomite makes the wet drop strength decrease firstly,and then increase with further increase of additive dosage.Ca(OH)2 affects the bentonite properties at the beginning,but the binding property of Ca(OH)2 will be main when the dosage is higher.The other four additives decrease the drop strength for their disadvantageous physical properties.For preheated pellets,no mater what kind of additive is added,the compressive strength will be decreased because of unmineralized additives.For roasted pellets,calcium additives can form binding phase of calcium-ferrite,and suitable liquid phase will improve recrystallization of hematite,but excessive liquid will destroy the structure of pellets,so the compressive strength of pellet increases firstly and then drops.When adding magnesium additives,the strength will be decreased because of the oxidation of magnetite retarded by MgO.
