Detail of palletization process. Difference between Disc and drum pelletizer. Properties parameters and Norms for testings. List of difference agglomerates testings.
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
This is Blast Furnace ppt for steel plant.
this is my web site : http://btechadvanceproject.blogspot.in/
this is my Youtube - https://youtu.be/l0blxo-t_cg
Follow On Instagram : https://www.instagram.com/md.raza72/
My linkedin profle https://www.linkedin.com/in/md-raza-ansari-78a6ba116/
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
This is Blast Furnace ppt for steel plant.
this is my web site : http://btechadvanceproject.blogspot.in/
this is my Youtube - https://youtu.be/l0blxo-t_cg
Follow On Instagram : https://www.instagram.com/md.raza72/
My linkedin profle https://www.linkedin.com/in/md-raza-ansari-78a6ba116/
SIZE REDUCTION AND FACTORS AFFECTING SIZE REDUCTION IN PHARMACEUTICAL INDUSTRYAkankshaPatel55
In the realm of pharmacy, size truly matters! Particle size reduction, often referred to as comminution, plays a crucial role in transforming raw materials into effective and readily absorbable medications. It's like shrinking giants - turning bulky substances into microscopic warriors ready to combat ailments.
Why is size reduction so important? Imagine trying to swallow a whole apple compared to taking a bite. The smaller the pieces, the greater the surface area exposed, and the faster and more efficiently something dissolves or reacts. In the world of medicine, this translates to:
Enhanced drug bioavailability: Smaller particles dissolve quicker and more readily in the digestive system, leading to faster absorption and action of the medication. Think of it as opening wider doors for the drug to enter the bloodstream and reach its target.
Improved drug stability: Smaller particles tend to be more stable and less prone to degradation, ensuring the medication's potency and effectiveness over time.
Uniformity and mixing: Precise size control allows for consistent drug distribution within a dosage form, guaranteeing accurate and reliable dosing.
Tailored drug delivery: Size reduction facilitates the development of specialized drug delivery systems, like inhalers or sublingual tablets, where minute particles are crucial for targeted action.
How is size reduction achieved? A variety of techniques are employed, each with its own advantages and best suited for specific materials:
Milling: Mechanical grinding using ball mills, hammer mills, or jet mills physically breaks down larger particles into smaller ones.
Micronization: Specialized techniques like air jet milling or fluidized bed milling achieve ultra-fine particle sizes in the micron range (1-10 micrometers).
Cryo-milling: Grinding at cryogenic temperatures minimizes heat generation, preserving sensitive drug compounds.
Size reduction isn't just about brute force. Choosing the right technique and particle size depends on various factors, including the drug's physical and chemical properties, desired release profile, and dosage form. It's a delicate dance between effectiveness, stability, and manufacturability.
The impact of size reduction extends far beyond individual medications. It enables the development of innovative drug delivery systems, like controlled-release tablets or transdermal patches, that improve patient compliance and treatment outcomes. It also plays a vital role in research and development, allowing scientists to study drug interactions and optimize formulations at the microscopic level.
So, the next time you pop a pill, remember the invisible giants behind it - the power of size reduction silently working its magic to deliver healing and hope.
Wear behavior of stepped austempered ductile iron balls in grinding iron oreeSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
STUDIES ON ALUMINIUM-SILICON EUTECTIC ALLOY CASTING AND DESIGN APPROACH OF IT...IAEME Publication
LM-6 alloy, an eutectic alloy of Aluminium and Silicon is widely used in automobile industries and aircraft industries due to its high strength to weight ratio, high wear resistance, corrosion resistance etc. In this project work, to improve the mechanical properties of LM-6 alloy such as tensile strength, hardness and percentage elongation, modification treatment is carried out along with grain refinement, fluxing and degassing. Modification is a treatment of metal in molten condition which leads to the formation of fine grain structure improves the mechanical properties of the metal.
This presentation I got from OSTP- IEPM online summer training.
Grab excellent knowledge in this area by prof. sarkar sir from BBIJ college. I hope anyone can see this helpful pdf file for this presentation.
“A study on the accretion formation in DRI kilns and possible ways for its re...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
Contact with Dawood Bhai Just call on +92322-6382012 and we'll help you. We'll solve all your problems within 12 to 24 hours and with 101% guarantee and with astrology systematic. If you want to take any personal or professional advice then also you can call us on +92322-6382012 , ONLINE LOVE PROBLEM & Other all types of Daily Life Problem's.Then CALL or WHATSAPP us on +92322-6382012 and Get all these problems solutions here by Amil Baba DAWOOD BANGALI
#vashikaranspecialist #astrologer #palmistry #amliyaat #taweez #manpasandshadi #horoscope #spiritual #lovelife #lovespell #marriagespell#aamilbabainpakistan #amilbabainkarachi #powerfullblackmagicspell #kalajadumantarspecialist #realamilbaba #AmilbabainPakistan #astrologerincanada #astrologerindubai #lovespellsmaster #kalajaduspecialist #lovespellsthatwork #aamilbabainlahore#blackmagicformarriage #aamilbaba #kalajadu #kalailam #taweez #wazifaexpert #jadumantar #vashikaranspecialist #astrologer #palmistry #amliyaat #taweez #manpasandshadi #horoscope #spiritual #lovelife #lovespell #marriagespell#aamilbabainpakistan #amilbabainkarachi #powerfullblackmagicspell #kalajadumantarspecialist #realamilbaba #AmilbabainPakistan #astrologerincanada #astrologerindubai #lovespellsmaster #kalajaduspecialist #lovespellsthatwork #aamilbabainlahore #blackmagicforlove #blackmagicformarriage #aamilbaba #kalajadu #kalailam #taweez #wazifaexpert #jadumantar #vashikaranspecialist #astrologer #palmistry #amliyaat #taweez #manpasandshadi #horoscope #spiritual #lovelife #lovespell #marriagespell#aamilbabainpakistan #amilbabainkarachi #powerfullblackmagicspell #kalajadumantarspecialist #realamilbaba #AmilbabainPakistan #astrologerincanada #astrologerindubai #lovespellsmaster #kalajaduspecialist #lovespellsthatwork #aamilbabainlahore #Amilbabainuk #amilbabainspain #amilbabaindubai #Amilbabainnorway #amilbabainkrachi #amilbabainlahore #amilbabaingujranwalan #amilbabainislamabad
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
RAT: Retrieval Augmented Thoughts Elicit Context-Aware Reasoning in Long-Hori...
Iron making - Palletization process- Types of palletizers
1. PELLETIZATION PROCESS
Chapter 3
F.S. BE III
(Metallurgy & Materials Engg.)
Prepared by
Mr. Utkarsh V Prajapati
Assistant Professor
(Metallurgy & Materials
Engg. Dept.)
2. CONTENT
Pelletization process
Disc and drum pelletizer
Theory of bonding
Mechanism of ball formation
Induration of pellets
Cold bonding technique
Testing of agglomerates
3. INTRODUCITON
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 fines resulting from the concentration process must be
agglomerated for use in iron and steelmaking.
4. CONT…
Iron ore and iron ore pellets are important sources of iron for
manufacturing steel. The iron ore production has significantly
expanded in recent years, owing to increasing steel demands
in developing countries, such as China and India.
However, the content of iron ore in deposits has deteriorated
and low-grade iron ore has been processed. The fines resulting
from the enrichment by separation after liberation by size
reduction must be agglomerated in a pelletizing plant.
Consequently, the number of pelletizing plants is expected to
increase in the future.
5. CONT..
The quality requirements of pellet, such as physical, chemical and
metallurgical specifications, depend on each ironmaking furnace
and those requirements influence the operation of the iron ore
pelletizing plant.
The idea of rolling moist fine ore in a drum to form balls and then
drying and firing it was first patented by A. G. Andersson in Sweden
in 1912.
Further development was performed to bring the idea to reality. In
1943, E. W. Davies and co-workers demonstrated the process using
an experimental shaft furnace. Commercial operation started in the
1950s in Sweden using vertical-shaft-kilns for firing the pellets. Plant
capacities were between 10,000 and 60,000 tons/year .
6. Pelletizing
process & Raw
materials
The iron ore is mined mostly from open pit deposits through
mining operations and the raw product, “run of mine,” is
subjected to mineral processing.
Thus, the material is exposed to a series of operations of
fragmentation, separation by size, concentration, dewatering,
etc., aiming to adequate the chemical, physical, and
metallurgical characteristics to meet the demands of
ironmaking processes.
The particle size distribution of iron ore is a very important
requirement to be characterized after its mineral processing.
7. Cont..
Materials containing a very fine particle size distribution are not
adequate to be used directly in the reduction reactors, requiring
to be agglomerated by different processes such as sintering or
pelletizing.
The main used reduction reactors are the blast furnace (BF) and
direct reduction reactors (DR). In the blast furnace, iron is
reduced and melted and the most common product is liquid
iron called hot metal. In direct reduction, iron remains in solid
state and the product is the so-called direct reduced iron (DRI).
8. Cont..
Pellets are balls formed by rolling moist concentrates and fines
iron ores of different mineralogical and chemical composition,
with the addition of additives and binder, in a horizontal drum
or in an inclined disc.
Pellets produced to be used in ironmaking processes must have
characteristics that meet the list of quality specifications
regarding physical, chemical, and metallurgical properties.
9. Process steps
Pelletizing feed preparation and mixing: the raw material
(iron ore concentrate, additives—anthracite, dolomite—and
binders are prepared in terms of particle size and chemical
specifications, dosed, and mixed together to feed the
pelletizing process;
Balling process: the green pellet is the rolled pellet without any
thermal process. It is obtained under strict control of moisture
and has a spherical shape and diameter of 8–16 mm;
Induration process: the green pellets are hardened in a high
temperature (1250 – 1350⁰C) processing at controlled heating
rates, and aiming to achieve the physical and metallurgical
requirements for handling, transportation, and final
application.
10. Properties &
standards
Type of specification Norm Description
Physical
ISO 4701 Determination of size distribution by sieving
ISO 4700 Determination of the crushing strength
ISO 3271 Determination of the tumble and abrasion index
JIS M 8711 Determination of shatter strength
Internal
procedures
(pelletizing
companies)
Determination of crashed resistance by the number of drop falls
Chemical Chemical property of the pellets
Metallurgical
ISO 4698 Determination of the free-swelling index
ISO 13930
Determination of low-temperature reduction-disintegration index
by dynamic method
ISO 11257
Determination of the low-temperature reduction-disintegration
index and degree of metallization
ISO 11256 Determination of the clustering index
ISO 7992 / ISO
7215 / ISO 11257
Determination of reduction under load/Determination of the
reducibility by the final degree of reduction index/Determination of
the low-temperature reduction-disintegration index and degree of
metallization
Internal
procedures
(pelletizing
companies)
Porosity
11. Binders
Aiming to achieve those specifications, binders and additives are
used in the pelletizing process.
Additives such as limestone, dolomite, and hydrated lime are
used to modify the chemical composition of the pellets, most
often for correction of the basicity.
Certain substances such as hydrated lime serve as both additive
and binder.
Fines of anthracite or coke are also added during the pelletizing
process for reducing the consumption of fuel required for
internally heating the ball
12. Pellets are obtained by adding an appropriate amount of water
to the iron ore concentrate; this is a fundamental factor in the
formation and growth of pellets, which creates a surface
tension that holds the mineral grains cohesive, thus allowing
their handling.
This cohesive tension of fine particles due to water is called
neutral tension. Neutral tension, however, is not sufficient to
keep cohesive grains as dense as iron minerals.
Furthermore, when the pellet is heated, the vaporization of
water occurs and the pellets tend to disintegrate.
13. Importance of
binders
To avoid such effects, binders are added to the material to be
pelletized, aiming to:
1. increase the strength of pellets before heating (green
strength);
2. prevent the collapse of pellets during the initial stages of
heating, when a large volume of gas generated by water
vaporization tends to crack the pellets.
Evenly distributed moisture and binder in the feeding process is
decisive to improve the characteristics of pellets, especially to
avoid the formation of undesirable agglomerates before the
pellet formation.
14. Effective
binders
Bentonite is an effective, widely used binder in the iron ore
pelletizing process. Its low price is an important factor for its
extensive use.
However, bentonite incorporates silica and alumina, which are
undesirable contaminants to pellets.
Additionally, it is a natural material with variable composition
depending on its origin. Obtaining a suitable binding effect
requires a relatively large amount of material, around 0.5% by
weight, which makes handling more difficult and increases
logistics costs.
16. Green ball
production
• Green ball agglomeration are economically produce in balling
drums or discs equipment.
• The balling equipment would require –
a. Rotating surface
b. Facilities for addition of moisture
c. Removal of balls of desired size
d. Recirculation of undersize and oversize should be provided.
17. Balling
technologies
• The balling equipment that can be either a disc or a
drum produces green pellets in a variable size
distribution.
I. Disc pelletizer or Balling disc
II. Drum pelletizer
18. Ballingdisc or disc pelletizer
Fig. schematically shows a laboratory disc pelletizer.
The balling disc basically consists of a pan with a
peripheral wall, which rotates with a certain
inclination to the horizontal.
In general, in a balling disc, the pan angle can be
adjusted between 40 and 60°.
These discs resemble flying saucers and are normally
3.6-5.6 m in dia.
19. Working
principle
When the disc rotates, the feed material with less moisture than
that required for the pellets formation, is charged to the bottom
of the disc, where it get in contact with the water from the
sprayers, initiating the nucleation stage.
At this stage, the nuclei begin to take the form of small pellets,
which by rolling action, occur in the lower section to the left of
the disc, toward the top.
As the added ore aggregates unto the surface of the pellets,
they increase in size and the coefficient of friction is reduced
causing the pellets to acquire a centrifugal force that carries
them out of the nucleation zone.
20. Size range This movement takes the pellets to the top of the disc following a
semicircular trajectory before returning to the base of the disc.
The height and width of the trajectory increase as the ball size
increases until the balls hit the scraper blades. After that, they
move down and pass under the water sprayers so that they can
find fresh feed.
The balling disc works in close circuit with the screening step,
where pellets smaller than 8 mm or larger than 16 mm are
desegregated and the material is recirculated to the balling
process.
21. The finer is the feed i.e more the specific size better is the
quality and higher is the growth rate of pellets.
The disc pelletizing circuit may have one ore more discs and
their operation have to be synchronized to obtain a uniform
rate of production so induration unit works smoothly.
22. Variables
Diameter of the disc
Height of the peripheral wall
Angle of inclination of disc with horizontal
Speed of rotation
Place on the disc where mix is fed.
Place where water is sprayed on the disc.
Rate of feed
Rate of moisture addition
Rate of withdrawal of the product
Nature and size of feed
Desired size range of pellets and % recycled load
Others additions like binder , flux, etc.
23. Drum pelletizer
The balling drum equipment fundamentally consists of an
inclined rotating cylindrical shell with water sprays in its inlet
end, where the feed material is introduced to make balls.
All formed pellets are discharged, regardless of particle size,
which is different from the disc where only balls larger than a
certain size are discharged.
Because of this, the product has to be screened by a roller
screen, which has increasingly replaced vibrating screen to
extract undersize and oversize.
24. Drum
pelletizer
The drums usually have a length-to-diameter ratio of 2.5–3.5
and very low slope with angles of inclination of the drum axis
to the horizontal between 2 - 10°.
The optimum rotating speed is generally between 25 and 35%
of the critical speed that is the speed in which balls will
centrifuge causing their degradation.
Speed control is necessary to develop a correct rolling and
tumbling action to produce balls.
26. Variables
Speed of rotation
Angle off inclination
Diameter of drum
Rate of feed
Depth of material in residence (loading)
Moisture content
Nature and size of feed
Any other additions such a binder and flux.
27. Comparison
Disc pelletize
High speed – 15-30 rpm
Pellet growth by layering
Closed size product
Circulating load is less (15%
less)
Screening is adopted if close
size range is required
Space required will be less
Cost is less
Commonly use for iron ore
Drum pelletizer
Low 10-15 rpm
Mostly growth by
assimilation
Wide range product
Circulating load more
Screening is must
More space is required
Cost is more for installation
28. Theory of
bonding
Production of hardened pellets starts with the production of
green balls in the first place.
The nature of bonds and how these are formed need to be
properly understood for proper designing of the equipment
and the process of palletization.
29. Theory of
balling
1. Dry material does not pelletize and presence of moisture is
essential to roll the powder into balls.
2. Surface tension of water in contact with the particles plays a
dominant role in binding the particles together in green
condition.
3. Rolling of moisture material leads to the formation of balls of
very high densities.
4. The ease with which material can be rolled into balls is
almost directly proportional to the surface area of particles
i.e fineness.
30. Water particle
system
1. The pendular state , when water is present just at the point of
contact of the particles and surface tension holds the
particles together as shown in figure.
2. The funicular state, when some pores are fully occupied by
water in an aggregate system.
3. The capillary state, when all the pores are filled with water
but there is no coherent film covering the entire surface of
the particles.
31. So the bond strength under these three conditions of green ball
produced from a given material will be obtained by compacting
the material to the minimum porosity and with just sufficient
water to saturate the voids.
The critical moisture can be assessed by determining the
porosity of an aggregate.
The factors that alter the porosity also affect its critical
moisture level and an efficient balling process is required to
produce balls of uniform properties in spite of these non
uniformities.
33. Cont…
The formation of balls on a pelletiser depends primarily on the
moisture content.
If moisture is less than the critical amount its distribution tends
to be non uniform , major amount being present in the
granulated material leaving the non granulated material
relatively dry.
If the moisture level is more than the critical amount ,growth
rate is more but the balls produced are liable to deformation
because of their plasticity.
34. Cont.…
The seeds generally have slight excess of water.
It imparts a certain degree of plasticity which is necessary for
its growth.
Growth takes place by either layering or assimilation.
It has been observed that the size of the balls produced in a
pelletiser from a charge containing right amount of moisture
depends on the time and speed of the pelletiser, i.e. the
number revolution.
The general nature of the variation is shown in figure.
35. Figure shows three regions
can be observed
1. Nucleation formation
2.Transition region
3. Ball growth region
36. Nuclei
formation
region
When a wet particle comes in contact with another wet or dry
particle a bond is immediately formed between the two .
Similarly several such particles initially join during rolling to
form a highly porous loosely held aggregate and crumbs which
undergo re-arrangement and partial packing in short duration
to form small spherical , stable nuclei.
This nuclei later to grow into balls.
Surface tension of water alone is the binding force in these
nuclei.
37. Transition
region
After nuclei are formed they pass through a transition period in
which the plastic nuclei further re-arrange and get compacted
to eliminate the air voids present in them.
The system moves from a pendular state through funicular
state to the capillary state of bonding.
Rolling action causes the granules to densify further.
The granules are still plastic with a water film on the surface
and capable of coalescing with other granules. The size range
of granules in this region is fairly wide.
38. Growth
The plastic and relatively wet granules grow if they are
favourite oriented. In this process some granules may even
break because of impacts ,abrasion , etc.
i. Growth by assimilation is possible when balling proceeds
with out the addition of fresh feed material.
ii. Growth by layering is possible when balling proceeds with
the addition of fresh feed material.
39. Growth by
Assimilation
If no fresh feed material is added for balling the rolling action
may break some of the granules , particularly the small ones,
and the material coalesces with those which grow.
The bigger the ball the larger it will grow under these
conditions. Since smaller granules are weaker they are the first
victim and growth of the bigger balls takes place at their
expense.
The ball with the higher % of moisture therefore grow to larger
size but the strength of the resulting balls is low.
40. Growth by
layering
Growth of the seeds is said to be taking place by layering when
the balls pick up material while rolling on a layer of fresh feed.
The amount of material picked up by the balls is directly
proportional to its exposed surface.
In practice fresh material is always supplied to the pelletiser
continuously while withdrawing equivalent amount of balls
from the circuit.
The conditions are , therefore more suitable for growth to take
place by layering.
41. Induration of
pellets
The final use of iron ore pellets in ironmaking reactors requires
minimum mechanical properties. Pellets must withstand
tumbling and falling during transport and mechanical loading
inside the reactors due to the charge weight. In order to
increase its mechanical strength, green pellets are thermally
treated in the induration process.
Pellets undergo drying, firing, and cooling steps.
First, the water in the form of moisture is removed from the
pellets in the drying steps. There is water in the pores and
capillaries of pellets, that is, between different ore particles. In
the case of porous ores, water may also be found in the pores
of individual grains.
42. Cont..
Since this type of pores are normally smaller in size than the
pellet pores, the temperature required to eliminate this water is
expected to be higher.
In the industrial process, the maximum temperatures reached
in the solid phase during the drying steps are approximately
300°C.
To finalize the induration process, pellets are cooled down by
contact with flow of ambient air. The resulting heated air is
used in the upstream steps of firing and drying.
43. Vertical shaft
furnace
It was developed in the 1950s and is shown in principle in
figure. The green or dried pellets are fed vertically
downwards in a central shaft of usually a rectangular cross
section.
Vertical shaft furnace system is the most traditional facility.
However, vertical shaft furnaces are not as common as the
traveling grate or grate kiln systems.
Fuel is burned in two fire chambers , one on each long side of
the shaft, and the hot gases are allowed to enter the main
shaft through multiple flues.
It is in a way counter current gas solid heater.
The fired pellets are cooled in the lower portion and if any
chunks are formed these are broken by the chunk breakers
and cooled pellets discharge form the bottom .
44. Cooling air , introduced from below , gets pre heated and is
either taken out to burn the fuel in the chamber or to make
available preheated gas for completing the combustion in the
firing zone of the shaft.
A furnace has a shaft of around 4x2 m c/s and is nearly 20m in
height from discharge rates.
The temperature of combustion chamber is 1300 C.
The furnace contains nearly 200t of pellets and production rate
of hardened pellets is around 1200-1200 t per day.
45. Shaft furnaces are more energy efficient than the
traveling grate or grate-kiln systems. The shaft furnace is
well suited for pelletizing magnetite, but not hematitic or
limonitic ore materials
Disadvantages of shaft furnaces are low unit productivity
and difficulty in maintaining uniform temperature in the
combustion zone.
Hot spots may occur which cause pellets to fuse together
into large masses, producing discharge problems. It is
also very difficult to produce fluxed pellets in a shaft
furnace.
46. Straight grate
process
The most widely used industrial processes for pellet induration
are the straight grate and the grate-kiln.
The straight grate process is composed of a single furnace
where an endless line of pallet cars moves. A layer of indurated
pellets is arranged at the bottom of each car to protect it
against the heat.
The green pellets are then charged on top of the hearth of
indurated pellets. A schematic diagram of this process is shown
in Figure.
49. Cont.…
The process is designed to enhance heat recovery. Therefore,
two flows of ambient air are heated while cooling the hot
indurated pellets. These flows are directed to other zones of the
furnace.
The drying of green pellets is performed in two stages by
blowing warm air through the bed of pellets.
In the first stage, the hot air from the cooling zone is blown
from the bottom. In the second drying stage, hot air from the
firing zone is blown on the top of the car.
The use of both updraft and downdraft drying ensures a more
uniform treatment along the height of the bed of pellets.
50. Cont.…
The high temperature phase is divided into three steps: pre-
heating, firing, and after-firing. In all these phases, pre-heated
air is fed into burners to produce flue gases that flow through
the bed of pellets from the top.
The burners are usually fired with gaseous fuels, such as natural
gas or atomized liquid fuels, such as diesel.
Pellets close to the top are treated at higher temperatures for
longer times, while pellets at the bottom reach lower peak
temperatures for shorter residence times. It is been reported.
51. Cont.…
That pellets at the top may reach 1300°C for 6 minutes while
pellets at the bottom peak at 1200°C with no residence time.
These values may vary, but the difference is large enough to
generate pellets with different mechanical strengths and
different metallurgical properties.
This is a disadvantage for the straight grate in comparison to
the grate-kiln process.
52. Grate-kiln
process
In the grate-kiln process, shown in Figure, there are three
different reactors. The drying, pre-heating, and cooling steps
are similar to that of the straight grate process.
The general concept of heat recovery by using hot gases from
downstream in the process for drying and for feeding the
burners is also present. However, a rotary kiln is used for the
firing step.
The pre-heating zone is divided into two steps: tempered pre-
heating zone and pre-heating zone, where maximum
temperatures may reach between 1000 and 1100°C.
54. Cont.…
Pellets need to gain some mechanical strength during pre-
heating to withstand the tumbling inside the rotating kiln
where firing is performed.
The firing in the rotating kiln generates pellets with more
uniform properties. The movement of the kiln causes pellets to
mix during the firing treatment and the temperature is more
even among different pellets.
The furnace is heated with a flame on the discharge side.
Besides gaseous and liquid fuels, solid fuels such as coal may
also be used.
55. Cont.…
After firing, pellets are discharged in a pallet car for the cooling
stages.
Therefore, pellets undergo more charging and discharging
operations during the grate-kiln process than in the straight
grate.
This causes a greater generation of fines during the process.
However, the final pellet properties are more uniform, and
fines generation during transport for final use is therefore
expected to be lower for pellets produced in the grate-kiln
process.
56. Cont.…
The worldwide pelletizing capacity is divided into 60% for
the straight grate process and 40% for the grate-kiln.
Both systems are used to produce quality blast furnace
and direct reduction pellets.
57. Comparison
The induration time for continuous grate is very short, next is
that for grate kiln and shaft furnace require to long.
Fuel consumption of shaft furnace is only slightly less than that
of others.
Power consumption is much higher than that of a cont. grate
and which itself is higher than that of the grate kiln machine.
Capital outlay is much higher than others.
Maintenance cost of travelling grate is more.
Overall production cost is highest for continuous grate, lowest
for shaft furnace and intermediate for grate kiln.
58. Introduction
An important factor that affects the output and
efficiency of blast furnace operati0n in the quality of
burden charge in the furnace.
Some tests have been carried out to establishment of
these tests also helps to identify those materials which
would jeopardize efficient and smooth furnace
operation.
59. Testing
Shatter tests
Tumbling and abrasion test
Compression test
Porosity
Reducibility
Low temperature breakdown
Reduction degradation index test (RDI)