CASE 1: Recycling in the Blast Furnace

 Short blast dust, along with other iron-bearing materials like iron ore or sinter, can be
reintroduced into the blast furnace.
 The dust is typically injected into the hot air blast entering the furnace, using tuyeres
(nozzles) located near the bottom of the furnace.
 As the dust particles are carried upward by the hot gases in the blast furnace, they undergo
reduction reactions due to the high temperatures.
 The iron content present in the dust is reduced to metallic iron, which collects at the bottom
of the furnace as molten iron.
 The molten iron is periodically tapped from the furnace and further processed for
steelmaking.

CASE 2: Agglomeration
 Agglomeration involves compressing the fine particles of short blast dust into larger, more
manageable forms like pellets or briquettes.
 Binders or additives may be added to the dust to improve its handling and stability during the
agglomeration process.
 The dust is mixed with other iron-bearing materials and binders, and the mixture is fed into a
pelletizing or briquetting machine.
 In the pelletizing process, the mixture is rolled into small spheres under high pressure, creating
iron ore pellets.
 The pellets can then be used as a feed material in the blast furnace, where they undergo
reduction to produce molten iron.

CASE 3: Sintering
 Sintering involves the agglomeration of fine iron ore particles, fluxes (materials that promote
the fusion of particles), and other additives into a porous mass called sinter.
 Short blast dust can be mixed with these materials and incorporated into the sintering
process.
 The dust and other components are mixed together and then granulated using water or
other binding agents to form a feed mixture.
 The mixture is then spread onto a sintering bed or sinter strand and heated in a sintering
furnace.
 During sintering, the mixture undergoes a series of physical and chemical transformations,
resulting in the formation of a solid sinter with a porous structure.
 The sinter can be crushed and used as a feed material in the blast furnace, where it
contributes to the production of molten iron.
CASE 4: Pelletization
 Pelletization is a process similar to sintering, where fine particles of iron ore, binders, and
additives are agglomerated into small, spherical pellets.
 Short blast dust can be combined with iron ore fines and binders to form iron ore pellets.
 The mixture is thoroughly mixed and then pelletized using a pelletizing disc or drum, which
rotates and agglomerates the materials under high pressure.
 The pellets formed are then dried and hardened in a pelletizing furnace or kiln.
 The resulting iron ore pellets have improved handling characteristics, reduced dust
generation, and enhanced permeability, making them suitable for use in the blast furnace.

CASE 5: Direct Reduced Iron (DRI) Production

 Short blast dust can be used in the production of direct reduced iron (DRI), also known as
sponge iron.
 DRI is produced by reducing iron oxide pellets or lumps in a furnace using a reducing agent
such as natural gas or coal.
 The short blast dust, along with other iron-bearing materials and additives, is mixed and
formed into pellets or lumps.
 The pellets/lumps are then fed into a direct reduction furnace, where they come into contact
with the reducing agent at high temperatures.
 The reducing agent reacts with the iron oxide.

Chemical reactions related to the processes mentioned earlier:

1. Recycling in the Blast Furnace:

 Reduction of Iron Oxides:

Fe2O3 (hematite) + 3CO (carbon monoxide) → 2Fe (iron) + 3CO 2 (carbon dioxide)

Fe3O4 (magnetite) + 4CO → 3Fe + 4CO2

2. Agglomeration (Pelletization/Briquetting):

 Formation of Iron Ore Pellets/Briquettes:

 Mixing of short blast dust, iron ore fines, binders, and additives.
 Formation of pellets/briquettes through pressure and binding.
 No specific chemical reactions involved in the agglomeration process itself.
3. Sintering:

 Formation of Sinter:
 Mixing of short blast dust, iron ore fines, fluxes, and additives.
 Heating the mixture in the sintering furnace.
 Melting and solidification of fluxes to form a bonding phase.
 Formation of iron oxide sinter:
 Fe2O3 + CO → 2FeO + CO2
 3FeO + CO → Fe3O4 + CO2

4. Pelletization:

 Formation of Iron Ore Pellets.

 Mixing of short blast dust, iron ore fines, binders, and additives.
 Pelletizing under high pressure.
 Drying and hardening of pellets in a pelletizing furnace.
 No specific chemical reactions involved in the pelletization process itself.

5. Direct Reduced Iron (DRI) Production:

 Reduction of Iron Oxide Pellets/Lumps.

 Fe2O3 + 3H2 (hydrogen) → 2Fe + 3H2O (water)
 Fe3O4 + 4H2 → 3Fe + 4H2O
 CO (carbon monoxide) can also be used as a reducing agent.

These are simplified representations of the chemical reactions involved in the processes. It's
important to note that the actual reactions occurring in the steelmaking process can be more
complex, considering the presence of various impurities, different reducing agents, and additional
reactions related to the specific composition of the raw materials used.