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Simultaneous Energy Saving and Production Rate Improvement in Pelletizing

Process by Solid Fuel Addition

Article  in  International Journal of Mineral Processing · May 2015

DOI: 10.1016/j.minpro.2015.04.023

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 International Journal of Mineral Processing 140 (2015) 26–31

Contents lists available at ScienceDirect

International Journal of Mineral Processing

journal homepage: www.elsevier.com/locate/ijminpro

Simultaneous energy saving and production rate improvement in

pelletizing process by solid fuel addition
Mohammad Hussein Golmakani a,⁎, Younes Lagzian b, Mohammad Reza Ghazanfari b, Ali Saidi c
a
Department of Material Science and Ceramics, Mashhad Branch, Islamic Azad University, Mashhad, Iran
b
Department of Material Science and Engineering, Ferdowsi University of Mashhad, 9177948974 Mashhad, Iran
c
Department of Material Science and Engineering, Isfahan University of Technology, Isfahan, Iran

a r t i c l e i n f o a b s t r a c t

Article history: Generally, in pelletizing process, the magnetite ore is oxidized to hematite during induration as an exothermic
Received 24 June 2014 reaction; thereby the magnetite ore requires less energy compared to hematite ore. This form of heat generation
Received in revised form 2 March 2015 inside the pellet is much more efficient than the transferred one from hot gases heated by external burners. This
Accepted 28 April 2015
mechanism leads to higher production rates with lower total energy consumption. In order to achieve these
Available online 1 May 2015
improvements, different amounts of anthracite as the solid fuel (0 to 0.95 wt.%) were added to the initial mixture
Keywords:
of hematite (60%) and magnetite (40%) ores. The portion of hematite was reduced to magnetite phase by anthracite,
Pelletizing process and then the produced magnetite re-oxidized again to secondary hematite. Afterwards, the studies of mechanical
Solid fuel and reducibility behaviors of pellets were performed by the tumbler/abrasive indexes and the Linder experimental
Secondary hematite tests. Furthermore, the microstructural evaluation was carried out by scanning electron microscope (SEM). The
Deep bed practice results demonstrated that by anthracite addition to the mixture, the production rate was significantly increased
Energy saving (more than 30%) while the natural gas consumption was reduced at least 35%. Moreover, based on the strength
Anthracite and reducibility analyses, the anthracite addition up to 0.78% (as an optimal amount) caused considerably to the
betterment of fired iron ore pellet properties.
© 2015 Elsevier B.V. All rights reserved.

1. Introduction
In the last decades, the access to higher production rates parallel to
energy consumption decrease has become the main interest of steel
industries (Hasenack et al., 1985; Langley, 1986; Li and Zhu, 2014; Xu
et al., 2014; Porzio, 2013). Considering that pelletizing is a key stage of
iron-making procedure that can influence on reduction process and the
amounts of required energy for induration steps, the modifications of its
conditions can be valuable. Typically, the pelletizing efficiency depends
on some parameters such as compositions of raw materials, addition
of specific matters, and the induration procedure's changes (Aubrey
and Ketter, 1967; Beal, 1968; Hutter, 1977; Sharma, 1992; Jiang et al.,
2008). In general, the increase of pelletizing bed depth in firing step is
one of the most important techniques to improve the yield capacity of
pelletizing. Accordingly, the following equation shows the effect of
some parameters on pelletizing process (Meyer, 1980).
P ¼ K:ð F=AÞ½H=ΔP n
where P, F, A, H, and Δp are the heat permeability, gas flow rate (m3/min),
surface of pelletizing bed (m2), bed depth (cm), and pressure drop of gas
⁎ Corresponding author.
E-mail address: Hos.glgh@gmail.com (M.H. Golmakani).
flow (mbar), respectively. Thus by assumption of laminar gas flow rate
(n = 1), the amount of pressure drop can be expressed as subsequent
equation.
ΔP ¼ K :ð F:HÞ=ðA:P Þ ð2Þ
Moreover, the amount of pressure drop in each firing machine
depends on some technical parameters like the potency of air suction
fans that have negligible tolerance in this research. According to the
limitation of pressure drop variations, in order to increase bed depth,
the enhancement of permeability or/and the decreasing of gas flow
flux density are absolutely necessary. In fact, the elevation of P amount
and the reduction of the flow rate are the main effective strategies to
increase bed depth that can lead to production capability augmentation.
Furthermore, in the fixed rate of firing conveyor, the amount of gas flow
rate is proportional to the hot gas volume that is required in the firing
process. In addition, while the gas flow rate has a fixed quantity the
ð1Þ increase of bed depth can cause the gas volume to decline (per unit
volume of pellet); so the required energy to the pellet firing should be
provided through other mechanisms. Obviously, the required energy
in firing the magnetite pellet is lesser than the required amount for
hematite pellet firing process (Jiang et al., 2008; Meyer, 1980;
Seaton et al., 1983; Loo, 1991; Elhajjar and Shams, 2014; Shams
and El-Hajjar, 2013a, 2013b). Consequently, the higher amounts of

http://dx.doi.org/10.1016/j.minpro.2015.04.023
0301-7516/© 2015 Elsevier B.V. All rights reserved.
 M.H. Golmakani et al. / International Journal of Mineral Processing 140 (2015) 26–31 27

magnetite in pelletizing initial mixtures can lead to the increase of the Table 2
bed depth due to the lower required thermal energy to pellet firing Chemical compositions and basicity of fired pellets with 0.78% anthracite in different bed
depth samples.
(Jiang et al., 2008; Meyer, 1980; Li et al., 2009). On the other hand,
because of raw materials and economical restrictions, the utilization Bad depth Chemical composition (%) Basicity
of magnetite ores as initial materials has some limits. Although by FeO SiO2 Al2O3 TiO2 CaO MgO P S FeTotal
increasing the pelletizing bed's thickness can cause the growth of the
30 cm 0.75 1.86 0.27 0.16 0.76 0.69 0.03 0.00 67.31 0.41
production capacity, there are some technical limitations to consider. 35 cm 0.65 1.99 0.33 0.19 0.76 0.46 0.04 0.00 67.27 0.38
In another consideration, the final composition of pelletizing process 40 cm 0.23 2.02 0.33 0.20 0.76 0.51 0.05 0.00 67.21 0.37
is completely hematite. There are two kinds of hematite, the primary 45 cm 0.30 2.00 0.34 0.20 0.80 0.41 0.04 0.01 67.30 0.40
hematite from ores and the secondary hematite that is the result of
magnetite re-oxidation (Meyer, 1980; Applyby and Shaw, 1985). The
kinds and amounts of hematite have sensitive influences on subsequent cooled. The amount of the produced green pellet in disk (with a diameter
processes because of the better secondary hematite reducibility (Meyer, of 80 cm) was 65–70 kg. The firing process was done at 1250 °C as a
1980). The addition of solid fuels to raw materials is one of the approaches maximum temperature in the top section of pot grate for 7 min. After
for bed depth augmentation and evolution of secondary hematite the induration process, some laboratory tests i.e. cold compression
(Applyby and Shaw, 1985; Hohensee, 1983; Haque et al., 1992; strength (CCS), porosity amount, tumbler index and abrasive index
Yang et al., 1995). In fact, during induration process, the solid fuels (according to ISO-3271 standards) were performed. Reduction properties
cause the reduction of the atmosphere creation, and thereby reducing of the pellets have been studied by well known Linder experimental tests.
the hematite of raw materials to magnetite phase; hence in the incipient The amount of samples for the Linder tests was 500 g. In order to carry out
firing stage (temperature above 1000 °C), the composition of pellets these tests, the mixtures of 500 g dried pellet and 200 g coke were placed
would be completely magnetite and behaves similarlt to 100% magnetite in the reduction furnace for 5 h while the rotating rate was 30 rpm.
pellets induration regime (Meyer, 1980; Yang et al., 1995; Srivastava and Furthermore, the reduction and metallization degrees were calculated
Sharma, 1988; Huang and Loo, 1993; Janowski and Sadowski, 1996). according to the theoretical equations that are presented in related
Although, recently the solid fuel addition in composite pellets using sections. Moreover, the FeO concentration in each section was deter-
their released heat from re-oxidation of magnetite to hematite in various mined by applying the X-ray diffraction (XRD) method. In addition,
pelletizing processes, especially in rotary kiln furnaces, has attracted a lot in order to accurately evaluate reduced and oxidized pellets, the
of researchers' attention (Hasenack et al., 1985; Jiang et al., 2008; Li et al., studies of microstructural properties were carried out by scanning
2009; Hohensee, 1983; Chakravorty et al., 1991), the studies about solid electron microscope (SEM (JEOL JSM-6340 F)).
fuel utilizations in pelletizing process by Dwight Lloyd machine method
have been rarely done. 3. Results and discussion
The present work is focused on the effect of anthracite solid fuel
employment (with different amounts) on the properties of green and 3.1. Physical and mechanical properties of pellets
fired pellets, and the reduction conditions of pellets in Dwight Lloyd
straight grate machine. As mentioned previously in this work, anthracite is used as a solid
fuel and its specifications are presented in Table 1. In order to achieve
2. Materials and methods the optimum state of performance i.e. at least 80% efficiency of hematite
reduction to magnetite, the different amounts (0, 0.78, 0.88, and
In this research, a series of tests and studies were conducted to 0.95 wt.%) of anthracite have been added in initial mixtures. Fig. 1
determine the optimum parameter amounts for usage of solid fuel in shows the variations of porosity amounts and CCS of pellets as a function
pelletizing process. Based on literature, these studies include the general of anthracite percentages. Accordingly, by increasing the anthracite up to
property evaluation of used concentrates, fired and green pellet property 0.95 wt.% (approximately equal to 100% reduction of hematite to
assessment i.e. strength mechanisms, porosity, Linder reducibility tests, magnetite), the porosity percentage is increased in the range of 21 to
and the microstructural analyses. The mixed hematite (60%) and magne- 25% owing to the porosity creation instead of consumed anthracite
tite (40%) concentrates were used to produce oxide pellets. Furthermore, (Meyer, 1980; Clout and M., 2003). On the other hand, the growing of
0.7 wt.% of bentonite was added to the mixture as an adhesive agent. anthracite amounts is caused to CCS decreasing due to the gradual
Water content (moisture) was also adjusted by infrared dryer and increasing of porosities. In addition, it can be seen that the decrease of
added in ratio of 8 wt.%, and finally according to practical testes, the CCS has various slops in each part of anthracite elevation; in fact, by
various amounts of solid fuel have been used. The chemical composition variations of anthracite in the range of 0 to 0.78 wt.%, the amount of
and some physical properties of these raw materials and fired pellets are CCS is decremented only by about 3%, whereas it is equal to 40% in the
presented in Tables 1 and 2, respectively. Moreover, the chemical analyses range of 0.78 to 0.95 wt.%. Based on these results, it can be concluded
and physical properties of anthracite that has been used as a solid fuel are that the 0.78 wt.% anthracite is the optimum amount of solid fuel in
shown in Table 3. order to achieve the acceptable mechanical properties (Jiang et al.,
Upon completion of raw pellet production, the green pellets are sieved 2008; Applyby and Shaw, 1985; Hegdi et al., 1990).
by +10 mm screen and placed in the pilot pot grate; subsequently, In addition, the variations of created FeO percentage and oxidation
according to the defined thermal cycle, they were dried, fired and then degree of fired pellets with 0.78 wt.% anthracite as a function of bed

Table 1
Chemical compositions and some physical properties of raw materials.

Raw material Chemical composition (%) Physical properties

FeO SiO2 Al2O3 TiO2 CaO MgO P S Fe2O3 Na2O FeTotal K2O Particle size Surface area

Hematite 10.34 1.94 0.35 0.28 0.39 0.15 0.06 0.03 N.D. N.D. 67.58 N.D. 80% (−40 μm) N.D.
Magnetite 13.65 1.06 0.18 0.08 1.16 0.92 0.04 0.08 N.D. N.D. 68.42 N.D. 80% (−40 μm) N.D.
Mix (60%H + 40%M) 11.66 1.58 0.28 0.2 0.69 0.32 0.05 0.05 N.D. N.D. 67.92 N.D. 80% (−40 μm) 2525 cm2/g
Bentonite N.D. 66 15.7 0.6 3.3 2 N.D. N.D. 3 2 N.D. 1 83% (−45 μm) 2670 cm2/g

N.D.: not detectable in these analyses.

28 M.H. Golmakani et al. / International Journal of Mineral Processing 140 (2015) 26–31
Table 3
Chemical compositions and particle size of anthracite solid fuel.
Components Fixed Volatile Ash Sulfur Moisture Particle
type carbon matter size
Amount (wt.%) 80 to 85 5 to 6 10 to 11 1.5 to 2 0.8 to 1 80%(−74 μm)
depths are shown in Fig. 2. Oxidation degree of pellets is calculated
based on the following equation (M.S.C., 1992).
FeOgreen pellet −FeOfired pellet
Oxidation Degree % ¼  100
FeOgreen pellet
As a result of this figure, by increasing depth, the FeO percentage is
dramatically dropped owing to achieving higher temperature in the
thinner bed compared to deeper one caused by adding solid fuels.
Thereby in thinner beds, the probability of simultaneous transformations
of hematite to magnetite and magnetite to wustite is increased by
thermodynamic view (Meyer, 1980). However, because of the more
amount of FeO in crude pellets, the minor rising in the FeO percentage
by increasing depth from 40 to 45 cm can be seen. Furthermore, the
oxidation degree is augmented gradually with depth increasing up to
40 cm and then is decreased due to more amount of FeO in crude pellets.
As is shown in Fig. 3, by increasing bed depth, although the porosity
amounts of fired pellets are varied negligibly, their strength is slightly
increased in the range of 30 to 40 cm due to the porosity declination,
and then it is decreased by depth rising to 45 cm owing to the absence
of re-crystallization bonding and slag components caused by low bed
temperature and therefore incomplete firing process (Yang et al., 1995).
The abrasive index (equal to the percentage of particles with size
less than 0.5 mm) of fired pellets is slightly increased by bed depth
augmentation due to the bed temperature decreasing, while the tumbler
index (equal to the percentage of particles with size more than 6.3 mm)
of fired samples demonstrates insignificant variations.
In the next section, these two parameters have been compared
simultaneously for fired pellets and produced DRI.
3.2. Reducibility
Fig. 4 illustrates the results of Linder test of samples with 40 cm bed
depth. The effect of solid fuel amounts on FeO percentage and reduction
degree of fired pellets is shown in this figure. Consequently, by increasing
the anthracite amount, especially above 0.78 wt.%, the FeO percentage is
raised due to further progress of reduction reaction toward formation of
wustite from magnetite (Chakravorty et al., 1991; Bandyopahyay et al.,
1987; Sharma, 1990). Actually, by improvement of reduction condition ,
the reduction of magnetite to wustite is done beside the hematite to mag-
netite reduction process. Furthermore, as is shown in Fig. 2, 0.78 wt.%
Fig. 1. The variations of porosity amounts and compression cold strength (CCS) of pellets
as a function of anthracite percentage.
anthracite is the best amount to prepare the most appropriate reduction
situation owing to the simultaneous improvement of reduction process
(due to increasing of porosities) and secondary hematite creation
by the magnetite phase re-oxidation (that is formed from primary
hematite phase). By increasing anthracite percentage above 0.78 wt.%
the fall of reduction degree is amplified from the FeO creation and
subsequent formation of non-reducible fayalite phase (by reaction of
FeO and silica) in fired pellets (Hutter, 1977; Meyer, 1980; Huang and
Loo, 1993; Misra and Gupta, 1994).
Fig. 5 shows the effects of bed depths on reduction and metallization
degrees that are calculated in Linder tests based on the following
ð3Þ
equations.
Femetal
Metalization Degree ðMZ degree %Þ ¼  100 ð4Þ
Fetotal
and
MZ degree þ 50
Reduction Degree ð%Þ ¼  100 ð5Þ
150
The above equation of reduction degree is used according to pilot
plant instructions of Mobarakeh Steel Company “MSCo” (M.S.C., 1992).
The results of Fig. 5 indicate that the increasing bed depth in the
range of 30 to 40 cm can lead to enhancement of both reduction and
metallization degrees owing to the lessening of FeO percentage
(Fig. 3) and fayalite phase creation (Huang and Loo, 1993). In other
words, when the depth of bed is less than 40 cm, by increasing bed
temperature, the reduction process and creation of FeO and SiO2 spinel
phases are intensified (Yang et al., 1995). By continuing bed depth
increment from 40 to 45 cm, the reduction and metallization degrees de-
creased because of the higher pellet feed weight in depth of 45 cm, and
thereby decreasing their mechanical properties due to the decreasing
bed temperature and absence of hematite bonding (that is created by
re-crystallization mechanisms) (Clout and M., 2003). Accordingly,
the subsequent reduction process is disrupted which is caused by the
formation of more cracks and further fragmentation of pellets which act
as barriers to the reduction gas passage.
In Fig. 6, the variations of abrasive properties of fired pellets and
produced DRI (Linder tests) as a function of bed depth are shown. By
increasing bed depth, the tumbler index of fired samples demonstrates
insignificant variations due to the decreasing induration temperature
while in DRI samples it is increased by depth growing from 30 to
35 cm and then gradually decreased by reason of bed temperature
drop and subsequent falling of mechanical properties. In fact, in the
depth of 30 cm due to the creation of fayalite phase in fired pellets,
Linder reduction process is disrupted that can be caused by the decrease
of mechanical properties like abrasive properties of samples.
Fig. 2. The variations of created FeO percentages and oxidation degree of fired pellets with
0.78% anthracite as a function of bed depths.
 M.H. Golmakani et al. / International Journal of Mineral Processing 140 (2015) 26–31 29

Fig. 5. The effect of bed depths on reduction and metallization degrees.

Fig. 3. The variations of porosity and CCS amounts as a function of bed depths.
3.4. Economical evaluations

Finally, Fig. 8 indicates the effects of bed depth variations on the gas
The abrasive index of DRI samples behaves based on two different
consumption and efficiency of productions. The efficiency levels are
approaches by depth augmentation. At first, in depths lower than
calculated based on the production increase in comparison with the
40 cm, the abrasive index is decreased as a result of the lowering of
production capacity in 30 cm depth as a reference level. Accordingly,
FeO amounts and the heightening of metallization and reduction
the mentioned benefits of solid fuel addition can lead to the increase
degrees (Fig. 4) that can be directly affected from the amounts of
of bed depth; hence, the gas consumption is decreased while the pro-
fayalite and other created slag components like FeO in each depth.
duction efficiency is significantly elevated (Payab, 2003; Sadrnezhaad
Afterward, by depth rising from 40 to 45 cm, the abrasive index is
et al., 2008). In other words, with the addition of the solid fuels and its
enhanced due to the less strength of pellets in depth of 45 cm than
effects on the increase of depth, greater portion of the required heat
their strength in depth of 40 cm as be mentioned before.
for firing process is provided, and consequently gas consumption is de-
creased. Logically, due to the increase of bed depth and production ton-
nage, the production efficiency is heightened. However, as regards the
3.3. Microstructural analyses
increasing of bed depth above 40 cm the mechanical properties of fired
pellets are dramatically diminished; it can be concluded that, by using
The scanning electron microscope (SEM) micrographs of created
anthracite as the solid fuel, the optimum bed depth is equal to 40 cm
cracks and porosities in the samples with different amounts of anthracite
in order to achieve appropriate efficiency with suitable properties.
are shown in Fig. 7. In Fig. 7(a) without any added anthracite, the
porosity amount is relatively negligible; hence, the CCS and reducibility
4. Conclusion
show high and low amounts, respectively. Moreover, oxidation degree
is in the low level due to more difficult gas penetration in this sample.
In this work, the pelletizing process was successfully done by adding
By adding anthracite fuel up to 0.78% in Fig. 7(b), the amounts of porosi-
various amounts of anthracite as a solid fuel to the mixture of hematite
ties are augmented that caused to lower CCS and higher reducibility
(60%) and magnetite (40%) concentrates as raw materials. Afterwards,
amounts. Then, by further increasing the added anthracite to 0.88 and
the microstructural, mechanical, oxidation, and reducibility behaviors
0.95% in Fig. 7(c) and (d), the porosity percentage is considerably in-
of pellets were evaluated. The most important results can be concluded
creased while the reducibility has maximum amount in sample with
as follows:
0.88% solid fuel. Based on these results, in higher amounts of anthracite
percentage, the amount of cracks is increased due to the rising of porosi- 1. By anthracite addition to the initial mixture, the production rate of
ties and volatile gases in microstructure and their strength declination induration machine was significantly increased (more than 30%)
(Alizadeh, 2012). without modification of grate area and/or fan capacity.

Fig. 4. The Linder tests (reduction degree and FeO amounts) results of samples as a Fig. 6. The variations of abrasive properties of fired pellets and produced DRI (Linder tests)
function of anthracite percentage with 40 cm bed depth. as a function of bed depths.
30 M.H. Golmakani et al. / International Journal of Mineral Processing 140 (2015) 26–31
Fig. 7. The SEM micrographs of different samples with (a) 0%, (b) 0.78%, (c) 0.88%, and (d) 0.95% of anthracite. In panel (a) without any added anthracite, the porosities amount is relatively
negligible. By adding anthracite fuel up to 0.78% in panel (b), the amounts of porosities are augmented. Then, by increasing the added anthracite to 0.88 and 0.95% in panels (c) and (d), the
porosity percentage is considerably increased.
2. The overall energy consumption (natural gas and electricity) of
pelletizing process was considerably reduced (at least 35%) due to
the partial supplement of required energy for pelletizing process by
solid fuel addition.
3. The reducibility of pellets was noticeably increased owing to achieve
products with tangible amounts of secondary hematite (that is
formed by re-oxidation of magnetite).
4. To further mention valuable results, in fired iron ore pellets (up
to 0.78 wt.%) the strength properties were relatively improved.
Furthermore, based on these results, the optimum amount of
anthracite addition was determined to be equal to 0.78 wt.% due
to the growing porosity and FeO percentages by anthracite
amount augmentation of more than 0.78 wt.%.
5. Finally, in the fixed optimum amount of anthracite (0.78 wt.%),
the optimal depth of pelletizing bed was determined to be equal to
40 cm because of the maximum metallization degree achievement
(up to 98%) in this depth that could lead to the access of the most
appropriate reduction degree (about 99%) compared to other bed
depths.
Fig. 8. The effect of bed depth variation on the gas consumption and efficiency of
productions.
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