Process Metallurgy

Effect of Iron Ore Pellet Size on its Properties and Microstructure

T. Umadevi, Prasanna Kumar, Naveen F Lobo, P.C. Mahapatra, M. Prabhu and Madhu Ranjan

JSW Steel Limited, Toranagallu – 583119, Bellary, Karnataka, India, uma.devi@jsw.in

The properties of the pellets and their microstructure mainly depend on the raw material mix proportion, raw material chemical composition
and the physicochemical conditions like the temperature and oxygen partial pressure within the induration machine. The pelletising plant
products are in the size range of 8 to 16 mm. With increasing pellet size, the sintering intensity, thermo-chemical conditions and formation
of different phases vary across its cross section. The time required for varies reactions within the pellet is directly proportional to the pellet
size. Because of differences in pellet size, the reduction and oxidation process takes place under different conditions resulting in different
phases and microstructures. In this work, detailed studies were carried out on pellets of different size (8 to 16 mm) produced from a
4.2 Mtpa pellet plant for their physical, metallurgical and microstructural properties. It was observed that the pellets in the size range
of +8 to -12 mm showed good strength and lower RDI. It was observed that the amount of hematite, magnetite, porosity, pore density, pore
size and slag phase play a significant role on pellet strength and RDI.

Keywords: iron ore pelletizsation, pellet size, microstructure, physical properties, metallurgical properties

DOI: 10.2374/SRI08SP169; submitted on 4 November 2008, accepted on 26 March 2009

Introduction Pelletization Process at JSW Steel Limited

During processing of pellets in a blast furnace, their
physical, metallurgical and microstructural properties have
a major influence on their reduction behaviour. The firing
time, temperature, oxidation time and oxygen partial
pressure are decisive for the structural changes within the
pellets; the nature of the changes affects, in turn, the
physical and metallurgical properties of the pellets. Based
on the above conditions in the induration machine, the
fired pellets often have non-uniform phases and structures
from the core to the shell of the pellet depending upon
their size. The outer part of the pellet differs distinctly
from the core. The time difference between the reduction
and oxidation of the pellet surface and the pellet core
increases with increasing pellet size. For bigger pellets, a
concentric duplex and triplex microstructure has been
observed. Thus, pellet size has a marked effect on the
formation of different phases and microstructure.
Some models were developed for straight grate
induration machines [1-3] and for grate kiln machines [4].
More recent advances in modelling of straight grate pellet
induration have been achieved by Corem [5]. This
includes the prediction of the pellet metallurgical
properties from green ball composition and thermal history.
All these models assume that for given ore chemistry,
green pellet properties and thermal history, the quality of
the fired pellets is the same. Even keeping the above
variables constant, the pellet quality varies depending on
the pellet size. This study was carried out to understand
the effect of pellet size on microstructural, physical and
metallurgical properties. The pellets for the present study
were collected from a 4.2Mtpa pellet plant. Pellets of
different size ranging from 8 to 16 mm were tested for
physical and metallurgical properties. The microstructural
and phase distribution studies were carried out by using
optical microscopy and image analyzer technique. From
the above data an attempt was made to correlate the pellet
properties with their microstructures.
Production of iron oxide pellets from iron ore fines
involves different steps from drying to induration. The ore
fines are initially dried to a moisture content of less than
1% before being sent to a ball mill for grinding to the
required fineness. The ground ore fines are now mixed
with other additives like bentonite, limestone, carbon
bearing sludge and iron ore slurry and then sent to
pelletising / balling discs to prepare green pellets/balls.
These green pellets are fired in the indurating machine to
get the required physical, mechanical and metallurgical
properties, making them suitable feed material to iron
making units. Figure 1 shows the schematic diagram of
the iron ore pelletization process.
Figure 2 schematically shows the induration process in
a straight grate machine. The green pellets, after sizing
through a roller conveyor, are discharged onto the
travelling grate induration machine on top of the hearth
layer and between the side layers of the fired pellets. The
hearth layer pellets protect the grate bars from high gas
temperatures. The green pellets contain 8 to 9% free
moisture and are 8 to 16 mm in size. The travellling grate
carries the pellets through the indurating furnace where
they are subjected to the sequential zones of updraft drying,
downdraft drying, preheating firing and after firing and
first and second cooling. The first stage of drying is
updraft to prevent the condensation of the water and pellet
deformation in the bottom layer of the pellet bed. For
updraft drying the hot gas is recycled from the cooling
zone 2. The drying is continued in a subsequent downdraft
stage to remove free water of the top of the bed by
relatively hot gases coming from the firing zone of the
furnace. In these two zones it is necessary to use drying air
of sufficient temperature to cause rapid water evaporation
yet not so high that the pellets are destroyed by high
internal pressures. In the preheating zone, the pellets are
heated to about 500 to 1000oC by downdraft air flowing
through the bed and the hot gas is recycled from the

steel research int. 80 (2009) No. 10 709

Process Metallurgy
Figure 1. Schematic diagram of iron ore pelletization process.
Fuel
Green pellets
DDD WB draft
CZ-2 Outlet gas flow
Figure 2. Schematic diagram of the induration process for iron ore pellets (UDD: updraft drying; DDD: downdraft drying).
cooling zone 1. During this stage, pellets are completely
dried and reactions such as removal of combined moisture,
decomposition of carbonates, coke combustion and con-
version of iron oxide to hematite take place.
The reactions from the preheating zone continue in the
firing stage. Here pellet charge is heated to an optimum
temperature for a controlled period, and temperature is
raised to 1300°C. The strength of the pellets increases at
710
FZ Wood temp profile
Cooloing
zone - 2
FZ draft Cold air flow
this stage because of re-crystallization and formation of
slag phase. Some of the off-gas from the firing zone is
recuperated to the drying zone. Five interconnected
process fans are provided to circulate air throughout the
different zones of the indurating machine. After firing, the
fired pellets undergo cooling where ambient air is drawn
upward through the bed. The off-gas leaving the first stage
of cooling has a temperature of around 1000°C, and this
steel research int. 80 (2009) No. 10
 Process Metallurgy

gas is directed to the firing and preheating zones where it preceding shifts to ensure stable operating conditions. The
is further heated by the burners with COREX gas fuel. The raw material chemical analysis, mix proportion, and green
gases from the cooling stage 2 are of lower temperature pellets size analysis are shown in Tables 1 to 3,
and used for drying of pellets. respectively. The induration process parameters during the
sample collecting shift were given in Table 4. The
composite pellet sample was screened to get five different
Experimental fractions: +16, -16+12.5, -12.5+10, and -10+8mm.
Cracked (<1.0%) and unfired pellets (<4%) were removed
Around one ton of fired pellets were collected from the from the sample lot to avoid erratic results. Representative
product conveyor of the plant in one shift at an interval of samples from all these fractions were tested in the
one hour. The sample collecting shift was managed in such laboratory for chemical, physical, metallurgical and micro-
a way that there was no production interruption in the structural properties.
Tumbler and Abrasion Index were measured as per ISO
3271 whereas Cold Crushing strength (CCS) was
Table 1. Raw material chemical analysis in wt%.
measured as per ISO 4700.
Iron ore fines Limestone Bentonite Corex sludge
For microstructural studies 4 pellets from each size
fraction were collected representatively. Pellets with more
Fe 63.51 1.13 15.78
SiO2 4.02 1.6 47.36 irregular and non-uniform shape were not selected for the
Al2O3 2.23 0.54 15.96 microstructure analysis as they undergo uneven heat
CaO 0.097 52.89 2.62 treatment across their cross section.
MgO 0.015 0.69
LOI 2.35 41.98 7.85
P 0.038
FeO 0.53 Results and Discussion
C 29.51
The chemical analysis of the fired pellets is shown in
Table 2. Raw material mix feed per t pellet produced. Table 5.

kg/t Microstructural properties. Microstructural investiga-

Iron ore fines 994.0 tions were carried out by dividing the pellets into four
Limestone 38.0 imaginary segments as shown in Figure 3. They are
Coke 3.3 defined as:
Bentonite 8.0
Corex sludge 13.0
- Shell – It extends from the surface to 200 µm below
Gp2 Carbon, % 1.15 - Outer mantle – Just below the shell and 2 mm thick
- Inner mantle – Just below the outer mantle and 4 mm thick
Table 3. Green pellet size distribution. - Core – Innermost part of the pellet, 4-5 mm diameter
In each size fraction four different regions were selected
Size classification vol% to represent the whole pellet cross section. For image
+16 mm 1.8 analysis studies, four pellet samples were processed for
+12.5 mm 37.0
each test condition.
+10 mm 39.2
+8 mm 20.0 Primary phases present in iron ore pellets are hematite
-8 mm 2.1 (grey white) magnetite (grey white with pinkish), slag
Mean Size 11.9 phase (grey), and pores (black). Complex slag phases like
silico ferrite of calcium and alumina (SFCA) were
Table 4. Induration machine parameters. considered as slag phase only.
Feed rate, t/hr 439
Machine speed, m/min 2.3
Bed height, mm 525
Hearth layer, mm 30
Firing temp, oC 1280
Burnthrough temp, oC 392
Corex gas flow, m3/hr STP 23662
Specific gas consumption, m3/t STP 54.06
Corex gas pressure, bar 0.68

Table 5. Chemical analysis of different size pellets.

Pellet size, -10+8 -12.5+10 -16+12.5 +16 Bulk

Fe, % 63.23 63.28 63.18 63.15 63.2
SiO2, % 3.65 3.67 3.46 3.76 3.64
Al2O3, % 2.66 2.60 2.36 2.67 2.57
CaO, % 1.79 1.84 1.70 1.87 1.80
MgO, % 0.41 0.40 0.75 0.41 0.49
FeO, % 0.30 0.42 1.88 3.02 1.41
B2 =
0.49 0.50 0.49 0.50 0.50
CaO/SiO2 Figure 3. Segmented inner structure of a pellet.

steel research int. 80 (2009) No. 10 711

Process Metallurgy
Microstructures of pellets of size classes +8mm, +10mm,
+12mm and +16mm are shown in Figures 4 to 7,
respectively. The phase analysis of +8 to +16 mm pellets
are shown in Figure 8.
With increasing pellet size, the amount of hematite
phase decreases whereas the amount of magnetite, pores
and slag/silicate melt phase increases. In the core and the
inner mantle of +12mm and +16mm pellets magnetite
phase is in the majority. Owing to insufficient supply of
oxygen, the conversion of magnetite to hematite seems to
have not been completed and distinct internal and external
zones are formed. More slag is produced in the presence of
magnetite at low temperature due to faster diffusion of
CaO in the magnetite phase. More slag and magnetite were
observed in the inner part of the fired pellets in bigger size
pellets (+12 and 16mm). In +8mm and +10mm pellets
proper slag bonding is observed between the hematite
grains from core to shell. But in +12mm and +16 mm
pellets proper bonding is not observed in the core and
inner mantle although the volume of slag phase is higher.
In bigger size pellets (+12mm and +16mm) cracks
(fracturation) are formed during cooling due to slag
Figure 4. Microstructure of -10 + 8 mm size pellet.
Figure 5. Microstructure of -12.5 +10 mm size pellet.
712
vitrification (Figure 6 and Figure 7). In +8 mm and +10
mm pellets hematite phase is in the majority and the
pellets contain hematite from core to shell. In +8mm
+10mm pellets the pore size is small and pores are
interconnected. In +16mm pellet pores are assimilated to
form bigger pores. But the shapes of these pores are
irregular.
Macroscopic studies were carried out on pellets of
different size. The macroscopic phase differences of
+16mm to +8mm pellets are shown in Figure 9 (a to d).
The pellets with +8 and +10mm size exhibit an even
hematite structure over the whole area from core to rim but
the pellets with +12mm and +16mm size exhibit a non-
uniform structure, i.e. magnetite and more slag phase in
the centre and hematite phase in the outer region.
Shrinkage of +12mm and +16mm pellets during cooling
due to a high fraction of slag and magnetite phase inside
the pellet are shown in Figure 10 (a-b).
FeO% in fired pellets of different size. The influence
of magnetite content on FeO percentage is shown in
Figure 11. The variation of magnetite and FeO content in
Figure 6. Microstructure of -16 +12.5 mm size pellet.
Figure 7. Microstructure of +16 mm size pellet.
steel research int. 80 (2009) No. 10
 Process Metallurgy

Magnetite Pore 3.5

70 Slag Hematite 3.0
60
2.5
50

FeO, %
Phase, %

2.0
40
1.5
30

20 1.0

10 0.5

0 0.0
-10+8 -12.5+10 -16+12.5 +16 0 10 20 30 40
Magnetite phase, %
Pellet Size, mm

Figure 8. Influence of pellet size on microstructural phases. Figure 11. Effect of magnetite phase on FeO content.

40 3.5
35 3.0
FeO Magnetite
30
2.5
Magnetite, % 25

FeO, %
2.0
20
1.5
15
1.0
10
5 0.5
0 0.0
+8 mm +10 mm +12.5 mm +16 mm
Pellet size, mm

Figure 9. Macrostructure of pellets depending on size class. Figure 12. Effect of pellet size on magnetite and FeO content.
A – Slag + Magnetite, B – Hematite + Slag
97 6.0

96 5.5
T.I (+6.3mm), %

A.I (-0.5mm), %
95 5.0

94 Tumbler index 4.5

Abrasion Index
93 4.0

92 3.5

91 3.0
+8 mm +10 mm +12.5 mm +16 mm
Pellet size, mm

Figure 10. Shrinkage of +16 and +12mm pellets. Figure 13. Effect of pellet size on T.I and A.I.

different sized pellet is shown in Figure 12. Higher FeO
content in pellets is a result of insufficient oxidation of
magnetite during induration and this effect is not desirable.
The FeO content of the pellet increases with increasing its
size from 8mm to 16mm due to the increase in magnetite
phase. The FeO content of the pellet increases with
increasing magnetite content in the fired pellets for the full
size range from 8 to 16mm.
The control of FeO content in iron ore pellets is rated as
a key point of pellet quality. Chemical analysis of pellets
of different size groups shows high FeO content in bigger
size pellets. Kotrmann et al. also confirmed this observa-
tion with pellets imported to Germany from Canada,
Brazil and Scandinavia [6]. The magnetite is produced
during pellet firing. In the pelleltization process COREX
sludge is used as solid fuel to balance the internal heat, and

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Process Metallurgy
250
240
230
CCS, kg/p
220
210
200
190
180
+8 mm +10 mm +12.5 mm +16 mm
Pellet Size, mm
Figure 14. Effect of pellet size on CCS.
250
240
230
CCS, kg/p
220
210
200
190
180
0.00 1.00 2.00 3.00
FeO, %
Figure 15. Effect of FeO on pellet CCS.
external heat is supplied by COREX gas. The origin of the
FeO in the pellets from the hematitic pellet feed is the
added carbon in the green pellets. Low oxygen partial
pressure inside the bigger size pellets, especially in the
core and inner mantle during pellet firing causes reducing
conditions and results in the formation of magnetite
(Fe2O3˜FeO). With increase of size, the availability of
oxygen in the core region is lower compared to the core
region of small size pellets. The lower available oxygen
potential in the core region may not convert magnetite
(Fe2O3˜FeO) fully to a higher oxide hematite (Fe2O3) but
may leave it magnetite (Fe2O3˜FeO) only. Hence with
increase in size the FeO content of pellets increases.
Physical properties of different size pellets. Figure 13
shows the tumbler and abrasion index of pellets of the
different size groups. The tumbler index (T.I.) is a measure
of resistance to generate fines during handling and
transportation. The tumbler index of the pellets decreased
with increase in pellet size. In contrast, the abrasion index
(A.I.) is a measure of dust generating tendency, and it is
increased with increase in pellet size. Up to the size class -
12.5+10 mm both the tumbler and the abrasion indices
remain unchanged but beyond this size both deteriorate.
The influence of pellet size on cold crushing strength
(CCS) of the pellet is shown in Figure 14. The cold
crushing strength of the pellet mainly depends on its FeO
content. The influence of the FeO content on CCS of the
pellet is shown in Figure 15. Increase in FeO content
714
Figure 16. Distribution of phases in pellets of bigger size.
10000
2
Pore density, No of pores/mm
9600
9200
8800
8400
8000
4.00 -10+8 -12.5+10 -16+12.5 +16
Pellet size, mm
Figure 17. Influence of pellet size on pore density.
results in a decrease of the pellet cold crushing strength.
The cold crushing strength of the pellet decreases with
increase in pellet size due to the increase in FeO content.
FeO content is a function of pellet size and cold crushing
strength of the pellet is a function of FeO content.
It was observed that addition of carbon in the pellet mix
and other induration conditions like temperature and
oxygen partial pressure vary the FeO content in the fired
pellets.
With increasing pellet size, the thermo-chemical condi-
tions like temperature or oxygen partial pressure change
across the pellet cross section [7]. Oxidation takes place
under different conditions resulting in different phases and
microstructures because the time difference between the
oxidation of the pellet surface and core depends on the size
of the pellet. Figure 16 shows the distribution of phases in
pellets of bigger size. As the volume of the core increases
with increasing pellet size, the distribution of different
phases also changes accordingly. The time required for
oxidation increases with increase in pellet size. Hematite
dominates the oxidized shell and magnetite and slag
prevail in the core. The slag phase distribution also
changes markedly across the cross section. The solid
diffusion of CaO and MgO in magnetite is faster than in
hematite. Due to the availability of more slag in the core
along with magnetite, the core and internal parts of a pellet
are more densely sintered than the external zones of the
pellet [8]. Bond and lattice strength and thus pellet
strength are reduced caused due to the differential
steel research int. 80 (2009) No. 10

15 RDI(-6.3mm), %
RDI(-0.5mm), %
14
RDI (-6.3mm), %
13
12
11
10
9 4.0
8 3.5
+8 mm +10 mm +12.5 mm +16 mm
Pellet size, mm
Figure 18. Effect of pellet size on RDI.
contraction of these phases in the bigger size pellets [9].
Increase in the size increases the tendency towards large
shrinkage gradients in the radial direction from the pellet
surface to its core, which results in a defective pellet
texture [10]. The formation of cracks as a result of
differential shrinkage reduces the pellet strength as well
(Figures 7 and 8). The CCS of the pellets dropped
drastically with a size increase to more than 10 mm
because of structural differences from core to shell and
shrinkage of the inner part of the pellet (Figures 9 and 10).
In addition to the above factors, distribution of the pores,
pore size and pore density also influence the pellet
strength. The formation of bigger size pores and magnetite
phase also mainly depend on solid fuel content in the
green pellet as well as size of the fuel and induration
machine conditions. Pore density of the pellet is shown in
Figure 17. Large pores with irregular shape and low pore
density as observed in the -16+12.5mm and +16mm
fractions could also contribute to poor strength compared
to small pores with high pore density and round shape as
in -12.5+8mm pellets. The higher amount of magnetite in
bigger size pellets, especially in the core, would have
promoted diffusion bonding [11] leading to the
assimilation of small pores into larger pores. Long
stretched pores deteriorate the quality of pellets [12]. With
bigger pores present, the load bearing capacity of pellets
decreases due to large strain by the stress concentration at
the pore wall. Smaller and rounded pores do not allow
stress concentration and lead to good strength [13].
Depending on the pellet carbon content and firing
conditions, secondary magnetite may or may not be
completely re-oxidised to hematite after cooling. Because
of the increase in carbon addition as well as size of the
pellet the FeO content increases. The process of oxidation
of magnetite to hematite is the most important aspect since
it has a decisive influence on the strength of the pellets.
Due to lack of sufficient oxygen in bigger pellets core,
inner mantle, and outer mantle of the pellet are not
completely oxidised, so full strength is not attained and
hence pellets with high-retained Fe2O3˜FeO show lower
strength.
Metallurgical properties of different size pellets. The
reduction degradation index (RDI) of pellets indicates
steel research int. 80 (2009) No. 10
Process Metallurgy
7.5
7.0 15
RDI (-0.5mm), %
6.5
14
Slag melt, %
6.0
13
5.5
5.0 12
4.5
11
10
-10+8mm -12.5+10mm -16+12.5mm +16mm
Pellet Size, mm
Figure 19. Effect of pellet size on slag phase.
their tendency to generate fines (RDI -6.3mm) and dust
(RDI -0.5mm) during reduction in the shaft furnace. This
test is the combination of LTBT test (ISO 4696) and
reduction under load (ISO 7992). RDI of the pellet is
shown in Figure 18. Both RDI of the pellets increased
with increase in pellet size.
Volume change during reduction of iron oxide takes
place at low temperatures, which leads to disintegration of
iron ore and causes irregularities in a blast furnace. The
primary cause of low temperature disintegration is thought
to be crystal transformation from hexagonal hematite to
cubic magnetite [14]. The crystal transformation within the
pellet changes its anisotropic dimensions, leading to severe
stresses in certain planes, which can cause cracks at grain
boundaries. Hematite is the main iron oxide in the
indurated pellets, therefore, generation of internal stresses
is in principle and unavoidable. Bonding between the
particles plays a crucial role in the strength and shape
stability of the pellets during pelletization, transport and
reduction. The bonds which form during the firing can be
divided into two types; iron oxide bonds (H, M) and
silicate bonds. Hematite bonds are common and strong but
they are not stable during reduction. However, when H
bonds are reduced to M, silicate bonds remain unaltered [7].
The remedy against disintegration is essentially that
enough liquid slag must form during the process and this
relatively small melt volume should be uniformly
distributed throughout the pellet to give good solid silicate
bonds during cooling with proper crystallographic state
and chemical composition.
From the phase analysis, it was found that the amount
and distribution of hematite, magnetite and slag phase is
different in pellets of different size, as is shown in Figure 8
and Figure 19.
With increase in pellet size hematite dominates the
oxidized shell and magnetite and slag prevail in the core.
The slag phase distribution also changes markedly across
the cross section. Because of formation of more magnetite
and slag in the core in the bigger size pellets, the core and
internal parts of a pellet are more densely sintered than the
external zones. This effect deteriorates the metallurgical
properties of pellets like RDI.
Superior RDI values in pellet groups of +8mm and
+10mm can be attributed to better distribution of slag
715
Process Metallurgy
phase compared to the fractions of -16+12.5 and +16mm.
The melt wets the solid particles and facilitates diffusion
and grain growth. The liquid between the particles exerts
pressure on them and pulls them together due to interfacial
forces. Smaller particles are absorbed into large ones and
as a result the shape and size of the pore changes.
Conclusions
The FeO content in the fired pellets increased from 0.30
to 3.02 % with increase in pellet size from 8 to 16mm. The
increase is very noticeable for sizes of more than +10mm.
Reducing atmospheres inside the bigger size pellets due to
low oxygen partial pressure cause increasing FeO contents.
The Tumbler and Abrasion indices do not change in the
size range of 8-12.5 mm. However, they undergo a drastic
deterioration above this size range.
The cold crushing strength of the pellets decreased from
240 to 185 kg/p with increase in pellet size from 8 to
16mm. This effect results from structural differences from
core to shell and from shrinkage of the inner part of a
pellet.
RDI of the pellets increased with increase in pellet size.
Superior RDI was found for +8mm and +10mm pellets. It
can be attributed to the high mount and better distribution
of slag phase.
The pellets in the range of -12.5 to +8mm size showed
good chemical, physical and metallurgical properties due
to uniform structure from core to shell and uniform
distribution of slag phase with high pore density.
716
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