Abstract: Cluster formation is an essential phenomenon during direct reduction processes at shaft furnaces. Decreasing the reducing temperature to avoid this problem can cause a significant drop in throughput. In order to prevent sticking of pellets, a coating material basically inactive under the reducing conditions prevailing in the shaft furnace, should be applied to cover the outer layer of the pellets. In the present work, steel dust is used as coating material for iron ore pellets to explore dust coating effectiveness and determines the best coating conditions. Steel dust coating is applied for iron ore pellets in various concentrations. Dust slurry concentrations of 5.0-30% were used to have a coated steel dust amount of 1.0-5.0 kg per ton iron ore. Coated pellets with various concentrations were reduced isothermally in weight loss technique with simulated gas mixture to the composition of reducing gases at shaft furnaces. The influences of various coating conditions on the reduction behavior and the morphology were studied. The optimum reduced samples were comparatively applied for sticking index measurement. It was found that the optimized steel dust coating condition that achieve higher reducibility with lower sticking index was 30% steel dust slurry concentration with 3.0 kg steel dust/ton ore.
Abstract: Clustering phenomenon of pellets was observed frequently in shaft processes operating at higher temperatures. Clustering is a result of the growth of fibrous iron precipitates (iron whiskers) that become hooked to each other and finally become crystallized during the initial stages of metallization. If the pellet clustering is pronounced, sometimes leads to blocking inside the furnace and forced shutdown takes place. This work clarifies further the relation between metallic iron whisker growth and iron ore mineralogy. Various pellet sizes (6 – 12.0 & +12.0 mm) from three different ores (A, B & C) were (completely and partially) reduced at 985 oC with H2/CO gas mixture using thermos-gravimetric technique. It was found that reducibility increases by decreasing the iron ore pellet’s size. Ore (A) has the highest reducibility than ore (B) and ore (C). Increasing the iron ore pellet’s size leads to increase the probability of metallic iron whisker formation. Ore (A) has the highest tendency for metallic iron whisker formation than ore (B) and ore (C). The reduction reactions for all iron ores A, B and C are mainly controlled by diffusion reaction mechanism.
Abstract: The conventional ceramic route was utilized to
prepare a hard magnetic powder (M-type strontium ferrite,
SrFe12O19). The stoichiometric mixture of iron oxide and strontium
carbonate were calcined at 1000oC and then fired at various
temperatures. The influence of various reaction parameters such as
mixing ratio, calcination temperature, firing temperature and firing
time on the magnetic behaviors of the synthesized magnetic powder
were investigated. The magnetic properties including Coercivity
(Hc), Magnetic saturation (Ms), and Magnetic remnance (Mr) were
measured by vibrating sample magnetometer. Morphologically the
produced magnetic powder has a dense hexagonal grain shape
structure.
Abstract: Strontium hexaferrite (SrFe12O19; Sr-ferrite) is one of
the well-known materials for permanent magnets. In this study, Mtype
strontium ferrite was prepared by following the conventional
ceramic method from steelmaking by-product. Initial materials;
SrCO3 and by-product, were mixed together in the composition of
SrFe12O19 in different Sr/Fe ratios. The mixtures of these raw
materials were dry-milled for 6h. The blended powder was presintered
(i.e. calcination) at 1000°C for different times periods, then
cooled down to room temperature. These pre-sintered samples were
re-milled in a dry atmosphere for 1h and then fired at different
temperatures in atmospheric conditions, and cooled down to room
temperature. The produced magnetic powder has a dense hexagonal
grain shape structure. The calculated energy product values for the
produced samples ranged from 0.3 to 2.4 MGOe.