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Sinter Reducibility
Brett Couch, 12 Month Technical
• Task overview
• Background
Sinter
Reducibility
Reduction-disintegration
ISO 4695
HOSIM
• Analysis
• Difficulties and next steps…
Objectives
2
• Prereading / Discussion material
• Data Analysis
• Preparing / Organising meetings for discussion
Project Outline
3
Sinter
• Agglomerate
• Ferrous Material
• Coke breeze
• Fluxes
Reducibility
• The extent of which oxygen is removed from the iron oxides in the
burden.
Reduction-disintegration
• Haematite → Magnetite
• Weakened structure
4
Definitions
ISO 4695
Reducibility 5
• Heated at 950oC
• Reducing gas: 40% CO (4.5 L/m), 60% N2 (10.5L/m)
• Reducibility Index, RI = 33.9 / (t60 – t30)
• t60 – time taken to achieve 60% reduction, t30 – time taken to achieve 30% reduction
• Aim: ~1
HOSIM
Reducibility 6
• Programmable temperature function up to 900oC
• Gas composition adjusted throughout, made up of CO, CO2, H2 and N2
• Reducibility = Time taken to achieve pre-determined end-point
• HOSIM value / Reduction disintegration = Percentage of fines under 3.15 mm
• HOSIM value aim: 24%
Predicted vs Measured HOSIM?
7
R² = 0.6191
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
0 5 10 15 20 25 30 35 40
Meas.HOSIM
Pred. HOSIM
0
5
10
15
20
25
30
35
40
20/10/11
20/12/11
20/2/12
20/4/12
20/6/12
20/8/12
20/10/12
20/12/12
20/2/13
20/4/13
20/6/13
20/8/13
20/10/13
20/12/13
20/2/14
20/4/14
20/6/14
20/8/14
20/10/14
20/12/14
HOSIM
MEAS HOSIM PRED HOSIM
• Simplified equation
• Good prediction
RI VS HOSIM
8
• Does ‘Good’ HOSIM = ‘Good’ RI?
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
0
5
10
15
20
25
30
RI
HOSIM
HOSIM VS RI
HOSIM %<3.15mm Reducibility
R² = 0.40990
5
10
15
20
25
30
0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30
HOSIM
RI
HOSIM %<3.15mm
R² = 0.0617 R² = 0.104
0
1
2
3
4
5
6
470.00 475.00 480.00 485.00 490.00 495.00 500.00 505.00
MgO
Coke Eq.
MgO Source vs Coke Equivalent (Fuel)
OLIVINE DOLOMITE
Magnesia
9
12
14
16
18
20
22
24
26
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.61
1.67
1.69
1.71
1.71
1.72
1.73
1.74
1.74
1.75
1.76
1.78
1.78
1.79
1.80
1.80
1.81
1.82
1.82
1.83
1.84
1.86
1.89
1.90
1.90
1.91
1.93
1.93
1.97
HOSIM
RI
MgO
MgO VS Reducibility
ISO HOSIM %<3.15mm Linear (ISO) Linear (HOSIM %<3.15mm)
R² = 0.0111R² = 0.0043
0
1
2
3
4
5
6
10 15 20 25 30
MgO
HOSIM
MgO vs HOSIM
DOLOMITE OLIVINE
Linear (DOLOMITE) Linear (OLIVINE)
• Noise?
• Secondary additions?
Magnetite
10
R² = 0.6458
0
5
10
15
20
25
30
0.00 2.00 4.00 6.00 8.00 10.00
HOSIM
FeO
FeO / HOSIM %<3.15mm
R² = 0.1194
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
RI
FeO
FeO / RI (ISO)
• Magnetite is less
reducible than haematite
• Is decreased HOSIM
always good?
• Overall reducibility
decreases
• Shows the need for both
tests alongside each
other
Difficulties
• Confounding variables
• Sample size
Next Steps
• Start work on developing our own.
Difficulties / Next Steps
11
Any questions?
• M. Geerdes, H. Toxopeus and C. Vliet, Modern blast furnace
ironmaking, IOS Press, Amsterdam, 2009.
• U. Yadav, B. Pandey, B. Das and D. Jena, Ironmaking & Steelmaking,
2002, 29, 91-95.
• F. Shen, X. Jiang, G. Wu, G. Wei, X. Li and Y. Shen, ISIJ International,
2006, 46, 65-69.
• T. Umadevi, K. Nelson, P. Mahapatra, M. Prabhu and M.
Ranjan, Ironmaking & Steelmaking, 2009, 36, 515-520.
• T. Umadevi, P. Karthik, P. Mahapatra, M. Prabhu and M.
Ranjan, Ironmaking & Steelmaking, 2012, 39, 180-189.
References
13

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end of placement

  • 1. Sinter Reducibility Brett Couch, 12 Month Technical
  • 2. • Task overview • Background Sinter Reducibility Reduction-disintegration ISO 4695 HOSIM • Analysis • Difficulties and next steps… Objectives 2
  • 3. • Prereading / Discussion material • Data Analysis • Preparing / Organising meetings for discussion Project Outline 3
  • 4. Sinter • Agglomerate • Ferrous Material • Coke breeze • Fluxes Reducibility • The extent of which oxygen is removed from the iron oxides in the burden. Reduction-disintegration • Haematite → Magnetite • Weakened structure 4 Definitions
  • 5. ISO 4695 Reducibility 5 • Heated at 950oC • Reducing gas: 40% CO (4.5 L/m), 60% N2 (10.5L/m) • Reducibility Index, RI = 33.9 / (t60 – t30) • t60 – time taken to achieve 60% reduction, t30 – time taken to achieve 30% reduction • Aim: ~1
  • 6. HOSIM Reducibility 6 • Programmable temperature function up to 900oC • Gas composition adjusted throughout, made up of CO, CO2, H2 and N2 • Reducibility = Time taken to achieve pre-determined end-point • HOSIM value / Reduction disintegration = Percentage of fines under 3.15 mm • HOSIM value aim: 24%
  • 7. Predicted vs Measured HOSIM? 7 R² = 0.6191 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 0 5 10 15 20 25 30 35 40 Meas.HOSIM Pred. HOSIM 0 5 10 15 20 25 30 35 40 20/10/11 20/12/11 20/2/12 20/4/12 20/6/12 20/8/12 20/10/12 20/12/12 20/2/13 20/4/13 20/6/13 20/8/13 20/10/13 20/12/13 20/2/14 20/4/14 20/6/14 20/8/14 20/10/14 20/12/14 HOSIM MEAS HOSIM PRED HOSIM • Simplified equation • Good prediction
  • 8. RI VS HOSIM 8 • Does ‘Good’ HOSIM = ‘Good’ RI? 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 0 5 10 15 20 25 30 RI HOSIM HOSIM VS RI HOSIM %<3.15mm Reducibility R² = 0.40990 5 10 15 20 25 30 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 HOSIM RI HOSIM %<3.15mm
  • 9. R² = 0.0617 R² = 0.104 0 1 2 3 4 5 6 470.00 475.00 480.00 485.00 490.00 495.00 500.00 505.00 MgO Coke Eq. MgO Source vs Coke Equivalent (Fuel) OLIVINE DOLOMITE Magnesia 9 12 14 16 18 20 22 24 26 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.61 1.67 1.69 1.71 1.71 1.72 1.73 1.74 1.74 1.75 1.76 1.78 1.78 1.79 1.80 1.80 1.81 1.82 1.82 1.83 1.84 1.86 1.89 1.90 1.90 1.91 1.93 1.93 1.97 HOSIM RI MgO MgO VS Reducibility ISO HOSIM %<3.15mm Linear (ISO) Linear (HOSIM %<3.15mm) R² = 0.0111R² = 0.0043 0 1 2 3 4 5 6 10 15 20 25 30 MgO HOSIM MgO vs HOSIM DOLOMITE OLIVINE Linear (DOLOMITE) Linear (OLIVINE) • Noise? • Secondary additions?
  • 10. Magnetite 10 R² = 0.6458 0 5 10 15 20 25 30 0.00 2.00 4.00 6.00 8.00 10.00 HOSIM FeO FeO / HOSIM %<3.15mm R² = 0.1194 0 0.2 0.4 0.6 0.8 1 1.2 1.4 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 RI FeO FeO / RI (ISO) • Magnetite is less reducible than haematite • Is decreased HOSIM always good? • Overall reducibility decreases • Shows the need for both tests alongside each other
  • 11. Difficulties • Confounding variables • Sample size Next Steps • Start work on developing our own. Difficulties / Next Steps 11
  • 13. • M. Geerdes, H. Toxopeus and C. Vliet, Modern blast furnace ironmaking, IOS Press, Amsterdam, 2009. • U. Yadav, B. Pandey, B. Das and D. Jena, Ironmaking & Steelmaking, 2002, 29, 91-95. • F. Shen, X. Jiang, G. Wu, G. Wei, X. Li and Y. Shen, ISIJ International, 2006, 46, 65-69. • T. Umadevi, K. Nelson, P. Mahapatra, M. Prabhu and M. Ranjan, Ironmaking & Steelmaking, 2009, 36, 515-520. • T. Umadevi, P. Karthik, P. Mahapatra, M. Prabhu and M. Ranjan, Ironmaking & Steelmaking, 2012, 39, 180-189. References 13

Editor's Notes

  1. For the past six months I have been working with the ironworks technical team on several different projects, with a main focus in discussions about sinter reducibility testing. At present, sinter reducibility here is tested using the ISO 4695 procedure, which is a standard method used at many different sinter plants. However, there is also another method of testing, known as the HOSIM test that was developed my Ijmuiden in the Netherlands who we have previously sent samples to for testing, but this ceased a few years ago and was replaced by a predicted HOSIM value which is generated by a modelled formula.
  2. During this presentation I will talk about what it was I was tasked to do, some background on the tests and reducibility, analysis, outcomes, difficulties I came across and future steps I believe would be beneficial.