Mast Term1 Iron 2

Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate

Ironmaking Diploma
26 Co
Iron Preparation
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
… Vision 2050 … Ironmaking 1726 Co
Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 1
Eng. Dr. Hesham Saad
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma
26 Co
Part 1 - The Blast furnace raw material and their beneficiation

Part 2 – Theory of Iron Ore Sintering
… Vision 2050 …
1726 Co

Master's student
Ironmaking Diploma
26 Co
Name Compositiion average of Iron

Max Min
Magnetite Fe3O4 72.4
Hematite Fe2O3 69.9
Martite Fe2O3 70.0
Magnemite Fe2O3 69.0
Ilmenite FeTiO3 36.8
… Vision 2050 …
Geothite Fe2O3 62.9 1726 Co
Limonite 2Fe2O3.nH2O 66.3 52.3
Turgite 2Fe2O3.H2O 50.0 40.0
Siderite FeCO3 43.2
Pyrite FeS2 46.6
Pyrrhotite Fe(1-x)S 63.5 57.0
Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
Blast furnace Capacity / Productivity THM/day 26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
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… Vision 2050 …
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Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
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… Vision 2050 …
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Master's student
Ironmaking Diploma
Iron Carbon diagram

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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
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Theoretical % of Fe in Theoretical % of Fe in Fe3O4
Fe2O3 Fe3O4
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ 2x56 / (2x56 + 3x16) = 70% 3x56 / (3x56 + 4x16) = 72.4%
… Vision 2050 … Roughly Roughly 1726 Co

Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
Properties of important manganese Ores

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… Vision 2050 …
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Master's student
Ironmaking Diploma
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… Vision 2050 …
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Master's student
Ironmaking Diploma
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… Vision 2050 …
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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
The Sintering Process of Iron Ore Fines

26 Co
Sintering plants are normally associated with the production of hot
metal in blast furnaces in integrated steel pants. The process of sintering is
basically a pre-treatment process step during iron making for the production
of the charge material called sinter for the blast furnace from iron ore fines
and also from metallurgical wastes (collected dusts, sludge and mill scale
etc.)
The sintering technology was originally developed for the purpose
of utilizing in the blast furnace the iron ore fines and the iron present in the
metallurgical waste of a steel plant. But currently the focus has changed.
Now the sintering process aims to produce a high quality burden for the blast
… Vision 2050 … furnace. Today sinter is the main metallic burden for a large blast furnace 1726 Co

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Ironmaking Diploma
Types of Sinter
26 Co
Acid sinter:-
The sinter mix does not contain flux at all. Flux is added in the furnace
separately. The production of this type is fast declining and most modern
practices produce self fluxing or super flux sinter.
Fluxed sinter :-
The amount of flux added in the mix in such that the basicity of the mix is
equal to that of the slag to be produced in the furnace. Separate addition
of flux would be required only in proportion to the amount of natural
lumpy ore charged in the furnace. In case of fluxed sinter, the
replacement of lime should be done by incorporating dolomite in the
… Vision 2050 … sinter itself since the use of any dolomite will be associated with a 1726 Co
sufficient slag fluidity and maximum possible desulphurisation by MgO,
On the other hand, with high CaO, a limy slag will be formed with increase
in viscosity and if Al2O3 is incorporated in slag the case will be worse. 3.
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Ironmaking Diploma
Types of Sinter
26 Co
Super fluxed Sinter :-
The entire amount of flux required to be otherwise charged in the
furnace, when run on 100% natural ore charged is added in the mix. The
basicity in the mix would be obviously more than that of the slag in the
furnace, since a part of the charged would neither be natural lumpy ore
or sinter of lower basicity than that of the normal blast furnace slag.
… Vision 2050 …
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Master's student
Ironmaking Diploma
The following are the advantages of adding flux to the sinter.

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•It generates slag with the impurities present in the iron ores and
solid fuels producing a suitable matrix for cohesion of the particles.
•It improves the physical and metallurgical properties of the sinter
•It reduces the melting temperature of the sinter mix.
•It reduces/eliminates the addition of limestone in the blast furnace

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ thus saving the fuel needed for the calcination reaction of the
… Vision 2050 …
limestone (CaCO3 =CaO + CO2) in the blast furnace hence reduces 1726 Co
the coke rate in the blast furnace.

Master's student
Ferrous Metallurgy
Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate
Diploma
26 Co
1726 Co
Master's student
22
Ironmaking Diploma
26 Co
Two types of bonds may be formed during sintering:-
1. Solid state bond:-It is formed as a result of recrystallization of the

parent phase at the point of contact of two particles in solid state.
2. It is formed as a result of formation of low melting slag or glass at
the point of contact of the two particles, depending upon the
mineral constitution, flux addition.
… Vision 2050 …
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Master's student
Ironmaking Diploma
26 Co
The sinter can have three different constituents:-
(a) Original mineral which has not undergone any chemical or physical
change during sintering, more at the core of individual particles.
(b) Original mineral constituents which have undergone changes in their
physical structure without any change in chemistry.
(c) Secondary constituents formed due to dissolution or reactions between
two or more of the original constituents
i.e. formations of ferrites, spinel's, silicates, etc.
… Vision 2050 …
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Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
Factors Affecting Efficiency of Sinter

Size:- 26 Co
If all other things are similar the strength of sinter is directly
related to size distribution of the charge mix. If the size will be large the
contact area will be less & the strength of the sinter will be low &
conversely if size is too small the contact area of particle will be large
&the strength will less.
Fuel content:-
The proportion of fuel in the charge has a bearing on the
constitution of the sinter .Fuel content is usually in the range of 6 – 8%.
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ With the progress of sintering the air gets preheated to an increasingly
higher level so that the fuel required to achieve the same sintering 1726 Co
… Vision 2050 …
temperature decreases in the lower region of the bed. The use of
extended hood, gas sintering have been developed to decrease the
solid fuel requirements in sintering.
Master's student
Ironmaking Diploma
Factors Affecting Efficiency of Sinter

Moisture:- 26 Co
It maintains proper permeability in the bed during sintering. The rate
rise of temperature at higher temperatures levels is more rapid than dry mix. The
presence of moisture increases the specific volume of air required for sintering.
Circulating load:-
For higher output of the sinter strand the circulating load should be low.
A low circulating load reduces the permeability of the bed & consequently the
input rate to the strand has to be reduced. The circulating load the permeability &
the bed thickness should in fact be related to the fan size , amount of leakage
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ before the optimum values are established for efficient operation. The top layer is
generally more friable & the return fine arises from the portion. The circulating 1726 Co
… Vision 2050 …
load can thus be reduced by decreasing the proportion of the top layer in the
overall thickness by just increasing bed thickness.

Master's student
Ferrous Metallurgy
Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate
Master's student
28
Ironmaking Diploma
Functions of coke
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Source of thermal energy (Fuel)
Produces and regenerates reducing agent (CO)
Coke maintains permeability of the burden (Spacer)
Reduces the melting point of iron
In the raceway (in front of the tuyeres) C in coke is combusted together with
C from injected material such as oil or PC (pulverized coal) as follows:

C + O2 (air) (g) + N2 (g) = CO2 (g) + N2 (g) 1726 Co
… Vision 2050 …
N2 is inert but carries heat which is released during the ascending of the gas.

Master's student
Ironmaking Diploma
O2 from hot blast is consumed and produces CO2,

26 Co
which is unstable at temperatures above 1000°C in the presence of carbon,
reacts further in the raceway with C of coke, and
CO gas is formed by the following endothermic (solution loss) reaction
CO2 + C = 2CO
Coke consumption varies from 500 - 550 kg/ton of hot metal.

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ Modern blast furnaces with
… Vision 2050 …
pulverized coal injection work with 300 - 350 kg/ton of hot metal. 1726 Co

Master's student
Ironmaking Diploma
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Master's student
31
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
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Master's student
Ironmaking Diploma
26 Co
There are four zones

which are identified in the sinter bed height. These are given below.
•Cold and wet zone – It includes the zone of the sinter bed with a temperature of
less than 100 deg C. This area is formed by the charge mix to be sintered, with
upper limit saturated in water/water vapor.
•Drying zone – It includes the sinter bed area with temperatures ranging between
100 deg C and 500 deg C. The evaporation of the sinter mix moisture and
… Vision 2050 … subsequent dehydration of hydroxides take place in this zone. 1726 Co

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Ironmaking Diploma
•Reaction zone – It includes the zone of the sinter bed with a temperature 26 Co
ranging between 500 deg C (coke ignition beginning) and 900 deg C (cooling
period beginning). The maximum temperature which reaches in this zone is in the
range of 1300 deg C to 1400 deg C.
The main processes which happen in this zone are
•(i) coke combustion (exothermic),
•(ii) carbonates decomposition (endothermic),
•(iii) solid phase reactions,
•(iv) reduction and re-oxidation of iron oxides, and
•(v) reactions of formation of the sintered mass.
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ •Cooling zone – This zone is found immediately after the reaction zone. In this
… Vision 2050 …
zone, cooling and re-crystallization of the sintered product take place. There is a 1726 Co
superficial zone where the sinter layer is brittle than in the rest of the sinter bed.

Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
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Master's student
Ironmaking Diploma
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… Vision 2050 …
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Master's student
Ironmaking Diploma
Equilibrium compositions
between iron oxides and reducing gases 26 Co
Carbon monoxide and hydrogen are the most common reducing agents used
in commercial processes. Some thermodynamic data are given below as
examples.
Heat of reactions for the stoichiometric equations (per gram moles at 25°C)
are included.
3Fe2O3 + CO = 2Fe3O4 + CO2, ΔH°= -52,869 J/g-mole

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ 2Fe3O4 + CO = 3 FeO + CO2, ΔH°= 36,250 J/g-mole
FeO+ CO = Fe+ CO2, ΔH°= 36,250 J/g-mole
… Vision 2050 …
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At a temperature below 570°C, magnetite is reduced directly to metallic iron,
¼ Fe3O4 + CO = ¾ Fe + CO2, ΔH°= 3,916 J/g-mole

Master's student
Ironmaking Diploma
Salient kinetic features that need to be noted are as follows:

26 Co
Lump ore, sinter and pellets are porous solids. Reduction is characterized by
the formation of a porous product layer.
Fe₂O₃ is reduced in stages viz,
Fe₂O₃ → Fe₃O₄ → FeₓO → Fe
Additional porosity develops during reduction owing to density differences of
the product solids.
The relative volume per unit mass of Fe are:
Fe :Fe2O3 : Fe₃O₄ : Fe₂O₃ = 1 : 1.79 : 2.08 : 2.14 As a result,
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ when hematite is reduced to magnetite, additional porosity develops,
enhancing further reduction of hematite.
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… Vision 2050 …
A measure of rate of reduction (r₀) is dF₀/dt, where t is the time after
reduction starts.
The higher the reducibility of an iron oxide bearing solid, the faster is the
reduction of reduction.
Master's student
Ironmaking Diploma
26 Co
… Vision 2050 …
1726 Co

Master's student

Mast Term1 Iron 2

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Iron Prparation Ferrous Metallurgy

& Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 … Ironmaking 1726 Co

Green – Lean - Clean

Part 1 - The Blast furnace raw material and their beneficiation

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Name Compositiion average of Iron

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Blast furnace Capacity / Productivity THM/day 26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Iron Carbon diagram

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Theoretical % of Fe in Theoretical % of Fe in Fe3O4

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Properties of important manganese Ores

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

The Sintering Process of Iron Ore Fines

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

The following are the advantages of adding flux to the sinter.

•It improves the physical and metallurgical properties of the sinter

•It reduces the melting temperature of the sinter mix.

•It reduces/eliminates the addition of limestone in the blast furnace

Green – Lean - Clean

Two types of bonds may be formed during sintering:-

1. Solid state bond:-It is formed as a result of recrystallization of the

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

Factors Affecting Efficiency of Sinter

Factors Affecting Efficiency of Sinter

Green – Lean - Clean

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Green – Lean - Clean

O2 from hot blast is consumed and produces CO2,