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

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Eng. Dr. Hesham Saad 1
 Iron Prparation Ferrous Metallurgy
& 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

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

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Eng. Dr. Hesham Saad 2
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
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
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
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
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Eng. Dr. Hesham Saad 3
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 4
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

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Eng. Dr. Hesham Saad 5
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

Blast furnace Capacity / Productivity THM/day 26 Co

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… Vision 2050 …
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Eng. Dr. Hesham Saad 6
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 7
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 8
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 9
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

Properties of important manganese Ores

26 Co

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… Vision 2050 …
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Eng. Dr. Hesham Saad 10
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 11
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 12
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 13
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
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.)

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ 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 1726 Co
… Vision 2050 …
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
furnace. Today sinter is the main metallic burden for a large blast furnace
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Eng. Dr. Hesham Saad 14
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

Types of sinter
Sinters are classified into acid sinter, 26 Co

self-fluxing sinter, and

super fluxed sinter.

Self-fluxing sinter has sufficient content of CaO (lime) in it which

is required to flux its acid components (SiO2, and Al2O3).

Super-fluxed sinter has additional content of CaO for fluxing of

the acid components introduced in the blast furnace through
other burden materials.
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
In case of self-fluxing and super-fluxed sinter, the lime reduces 1726 Co
the melting temperature of the sinter mix and at relatively low
temperatures (1100 deg C to 1300 deg C) strong bonds are
formed in the presence of FeO.
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Eng. Dr. Hesham Saad 15
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

The following are the advantages of adding flux to the sinter. 26 Co

•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 limestone
(CaCO3 =CaO + CO2) in the blast furnace hence reduces the coke rate in
… Vision 2050 … the blast furnace. 1726 Co

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Eng. Dr. Hesham Saad 16
 Ferrous Metallurgy
Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate
Diploma

26 Co

1726 Co

Master's student
Eng. Dr. Hesham Saad 17
 Ferrous Metallurgy
Prof. Dr. M. Gamal Khakifa , Dr.Abd Alrahman Ebrahim Postgraduate

Master's student
Eng. Dr. Hesham Saad 18
Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

1726 Co

Master's student
Eng. Dr. Hesham Saad 19
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

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Eng. Dr. Hesham Saad 20
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 21
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 22
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
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.

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

•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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Eng. Dr. Hesham Saad 23
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
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.

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Eng. Dr. Hesham Saad 24
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
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Eng. Dr. Hesham Saad 25
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

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Eng. Dr. Hesham Saad 26
 Iron Prparation Ferrous Metallurgy
& Prof. Dr. M. Gamal Khakifa , Dr. Abd Alrahman Ebrahim Postgraduate
Ironmaking Diploma

26 Co

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
1726 Co

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad 27