The iron ore production has significantly expanded in recent years, owing to increasing steel demands in developing countries. However, the content of iron in ore deposits has deteriorated and low-grade iron ore has been processed. The fine ores resulting from the concentration process must be agglomerated for use in iron and steelmaking. Bentonite is the most used binder due to favorable mechanical and metallurgical pellet properties, but it contains impurities especially silica and alumina. Better quality wet, dry, preheated, and fired pellets can be produced with combined binders, such as organic and inorganic salts, when compared with bentonite-bonded pellets. While organic binders provide sufficient wet and dry pellet strengths, inorganic salts provide the required preheated and fired pellet strengths.

1. IRON ORE PELLETIZING PROCESS
Dr. Hassan Z. Harraz
hharraz2006@yahoo.com
Autum 2023
@Hassan Harraz 2023
Pelletizing Process

2. Keywords:

3. Abstract

4. 1. INTRODUCTION

5. 1. INTRODUCTION

6. 1. INTRODUCTION

7. 1. INTRODUCTION

8. 1.1. Straight Grate Induration Process

10. Figure 3. Schematic diagram of the straight grate induration process /straight grate pelletizing process
(Mourão et al., 2013).

11. 1.2. Grate-Rotary kiln Induration Process

12. Figure 4. Schematic diagram of the grate-rotary kiln induration process/ grate-kiln pelletizing
process (also known as the rotary-kiln process) (Mourão et al., 2013).

13. 1.2. Iron Ore Pelletizing Rotary Kiln

14. Figure 2: Ratios of pellets produced by different
pelletizing processes in China in 2000 and 2011.
Table 1: Main producers of iron ore pellets in
the world between 2010 and 2012 (Mt per
year) (Narciso, 2013)

15. 2. PREPARATION IRON ORE PELLETS

16. Fig. 1: Process flow chart of preparation of pellets

17. Iron pellets

18. 2.1. Iron Ore Pellets Produced Worldwide

20. 2.2. Potential Future Iron Ore Pellets

21. Figure 1. World installed pelletizing capacity (millions of tonnes/year).
Source: Prepared by the author with data from Tuck and Virta [2011].

22. 2.3. Potential Future Suppliers of DR Grade Pellet Feed

23. 2.4. Iron Ore Pellets Market Forecast 2023-2033
IronOre Pellets MarketSize, 2022-
2032

24. 3. IRON ORE PELLETIZING PROCESS

26. Figure 2. Schematic diagram of the pelletizing process.

27. 3.1. Pelletizing Process and Raw Materials

28. Table 1. Iron ore products classification for ironmaking (after Mourão, 2008).

29. 4. SPECIFICATION REQUIREMENTS OF PELLET FEED

30. 4. SPECIFICATION REQUIREMENTS OF PELLET FEED

31. 5. GREEN BALL FORMATION AND PROPERTIES
5.1. Green Ball Formation

32. 5. GREEN BALL FORMATION AND PROPERTIES
5.1. Green Ball Formation

33. 5. GREEN BALL FORMATION AND PROPERTIES
5.2. Pretreatment of Pellet Feed

34. 6. BINDERS

35. 6.1. Binders and Additives Used in the Pelletizing Process

37. 6.1. New Binders

38. 4.1. New Binders

39. Table 3. Patents about organic binders in the iron ore pelletizing process.

40. 6.1. New Binders

41. 6.2. Evolution of Binder for Iron Ore Pelletizing

42. 7. INDURATION TECHNOLOGIES

43. 7. INDURATION TECHNOLOGIES…(Cont.)

44. 8. INDURATION OF GREEN PELLETS

45. 8. INDURATION OF GREEN PELLETS

46. 9. QUALITY REQUIREMENTS FOR FIRED PELLETS

47. Table 2. Quality specification of iron ore pellets.

48. 10. CHALLENGES AND INNOVATIONS IN IRON ORE PELLETIZING

49. 11. DISCUSSIONS

50. 11. DISCUSSIONS

51. 11. DISCUSSIONS

52. CONCLUSIONS

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