Article
Metallurgy & Metallurgical Engineering
Dhanraj Patil, Akhil Singh, Vinayak Bhosekar, Nageswar Rao, C. B. Dayanand, Rameshwar Sah
Summary: The study examined the impact of undersized pellet fines on the sintering process. 5 experiments were conducted with varying pellet fines content in the iron ore blend. The results showed that increasing pellet fines led to a decrease in productivity from 1.65 to 1.17 t/hr/m(2) and an increase in sintering time from 27.5 to 34.5 min. The sinter product yield (+ 5 mm) decreased from 86.70 to 79.70%. Sinter strength also decreased with higher pellet fines content, as indicated by a decrease in tumbler index from 66.20 to 59.87%.
TRANSACTIONS OF THE INDIAN INSTITUTE OF METALS
(2023)
Article
Engineering, Chemical
Qiangjian Gao, Hui Wang, Xiangyang Pan, Xin Jiang, Haiyan Zheng, Fengman Shen
Summary: In this study, a mathematical model was built using artificial neural network technology to predict the Tumble Strength (TS) of iron ore sinter, with the optimization done through principal component analysis and genetic algorithm. The accuracy of the model was verified with a forecast precision of 95.1%, demonstrating its effectiveness in describing the TS of sinter based on various influencing factors.
Article
Environmental Sciences
Hao He, Shengyong Lu, Yaqi Peng, Minghui Tang, Mingxiu Zhan, Siping Lu, Li Xu, Wei Zhong, Liming Xu
Summary: The co-sintering method is one of the most ideal ways to dispose of municipal solid waste incineration fly ashes containing dioxins. In this study, it was found that during co-sintering, a significant amount of dioxins brought in by the fly ashes was decomposed and then re-synthesized with a distinct distribution characteristic originating from the sintering process. Possible pathways for the formation of dioxins were identified, with the main pathways being recombination and condensation reactions in the preheating and dry zone.
Review
Metallurgy & Metallurgical Engineering
Lele Niu, Jianliang Zhang, Yaozu Wang, Jian Kang, Sida Li, Changdong Shan, Zhen Li, Zhengjian Liu
Summary: Iron ore granulation is a crucial process in sinter production, influencing and regulating yield, efficiency, and quality. Despite extensive research on granulation, the current and future development of this process still need to be considered, as sinter is essential in ironmaking blast furnace. This paper reviews granulation theory, evaluates existing evaluation methods, and analyzes the role of iron ore, fuel, fluxes, and moisture. Advanced granulation equipment and processes for industrial production and their applications are summarized. Challenges in the field are identified, and suggestions for future development in sintering granulation are proposed.
ISIJ INTERNATIONAL
(2023)
Article
Metallurgy & Metallurgical Engineering
Satendra Kumar, Arvind Jaiswal, M. Siddaraju, Rameshwar Sah
Summary: This study proposes a new process for sintering porous iron ore with improved productivity and quality. The process involves pre-processing the iron ore in the presence of calcined lime to temporarily close the pores and prevent water absorption during granulation. The coated iron ore with calcined lime enhances reaction kinetics, inhibits water absorption, and prevents early slag formation during sintering. Pot sintering experiments using this proposed process show significant improvement in sinter productivity, product yield, and cold strength property.
MINING METALLURGY & EXPLORATION
(2022)
Article
Metallurgy & Metallurgical Engineering
Liang-ping Xu, Hui-bo Liu, Yu-chao Zhao, Qiang Zhong, Zhong-lin Dong, Guang-hui Li, Tao Jiang
Summary: The super-high bed sintering process is significant for its lower emissions and higher yield in iron ore sintering. However, there is a lack of understanding about the uneven quality of super-high bed sintering products, as well as the deterioration of reduction disintegration performance, thickening of hearth layer, and reduction in energy-saving effect. This study analyzed samples from ten sintering machines with different areas and bed depths to identify the problems. The results showed significant unevenness in chemical composition, macrostructure, mechanical strength, and metallurgical performance of the super-high bed sintering products.
JOURNAL OF IRON AND STEEL RESEARCH INTERNATIONAL
(2023)
Article
Materials Science, Multidisciplinary
Xinying Ren, Chaoyi Gao, Hanchen Wang, Shilong Feng, Tao Xue, Aimin Yang
Summary: This article proposes an automatic batching algorithm based on a Cartesian product to solve the sintering batching problem. The algorithm can generate a complete batching scheme, reduce manpower and material costs, and is of great significance for the comprehensive use of iron ore resources.
Review
Materials Science, Multidisciplinary
Yifan Li, Bin Wang, Zixing Zhou, Aimin Yang, Yunjie Bai
Summary: This study investigates an intelligent ore blending model with an intelligent algorithm as the core, which has a decisive influence on the development of China's steel industry.
Article
Metallurgy & Metallurgical Engineering
Tejbir Singh, Huibin Li, Guangqing Zhang, Subhasish Mitra, Geoffrey Evans, Damien O'Dea, Tom Honeyands
Summary: In this study, the resistance to air flow and pressure drop in iron ore sintering process were investigated using milli-pot sintering. It was found that the lower half of the milli-pot bed provided a reasonable representation of the standard pilot-scale sintering process, and at 5.5-8.0% coke rate, the results were similar to those of the pilot-scale sintering tests at corresponding coke rates ranging from 3.5 to 5.5%.
ISIJ INTERNATIONAL
(2021)
Article
Engineering, Chemical
Zhenya Lai, Laiquan Lv, Hanxiao Meng, Mingxi Zhou, Pengnan Ma, Kefa Cen, Hao Zhou
Summary: The study shows that pregranulation is an effective method in the sintering industry, which can alleviate the deterioration of sinter quality, increase sinter yield, and productivity. Substituting coke with biomass char for combustion can decrease the content of calcium ferrite in sinter and increase sinter porosity, while pregranulation has the opposite effect, leading to an improvement in sinter quality.
ASIA-PACIFIC JOURNAL OF CHEMICAL ENGINEERING
(2021)
Article
Engineering, Environmental
Xiaohui Fan, Yuanjie Zhao, Zhiyun Ji, Haorui Li, Min Gan, Haoyu Zhou, Xuling Chen, Xiaoxian Huang
Summary: This study focused on the relationship between surface ignition and sintering performance, and found that adjusting ignition parameters can effectively improve the quality of sinter in the surface layer, leading to reduced solid fuel consumption and emissions. Optimizing the ignition process benefits sintering performance enhancement and decreases environmental impact.
PROCESS SAFETY AND ENVIRONMENTAL PROTECTION
(2021)
Article
Metallurgy & Metallurgical Engineering
S. Kumar, A. Jaiswal, R. Sah
Summary: Specular iron ores are limited in their use in the agglomeration process due to their undesirable characteristics, but blending them with goethite iron ore can improve sintering rate and quality. Introducing goethite iron ore helps counter the poor melt assimilation of specularite, resulting in better sintering performance and productivity.
JOURNAL OF MINING AND METALLURGY SECTION B-METALLURGY
(2022)
Review
Energy & Fuels
Sahib Mohammad, Satyananda Patra, Barun Harichandan
Summary: The iron and steel industry needs alternative fuels to limit CO2 emissions, and coke breeze can be substituted by other options.
Article
Geochemistry & Geophysics
Siyu Cheng, Peter Charles Hayes, Evgueni Jak
Summary: A systematic analysis was conducted on industrial iron ore sinter product and associated sinter returns, characterizing the major macro- and micro-structural types. The correlation between mechanical sinter strength and sinter microstructure was found, particularly in materials with high porosity and isolated hematite grains. The formation of microstructure types was explained by non-equilibrium solidification in the Fe2O3-Al2O3-CaO-SiO2 system.
Article
Materials Science, Ceramics
Lukas Engelke, Lothar Brendel, Dietrich E. Wolf
Summary: We propose a new numerical model that accurately describes the transformation process of crystalline powder into dense poly-crystalline material. It considers the key phenomena of shrinkage and grain coarsening in sintering, driven by minimizing the free energy. The model represents each grain as a truncated sphere and takes into account the complex and changing shape of grains to determine thermodynamic driving forces and kinetic coefficients. Through validation with experimental data and comparisons with mesh-based methods, the model demonstrates its accuracy and ability to reproduce grain size distribution evolution.
JOURNAL OF THE AMERICAN CERAMIC SOCIETY
(2023)
Article
Engineering, Chemical
Benjamin De Castro, Mostafa Benzaazoua, Soumali Roychowdhury, Aurelie Chopard, Francis Quintal Lauzon, Benoit Plante
Summary: This study proposes an innovative method using deep learning algorithm and reflected light optical imaging to automatically detect all particles and minerals in acrylic resin polished sections. The experimental results show that this method can accurately detect all mineral particles, including transparent minerals, under reflected light optical microscopy, and provide unbiased mineralogical quantification.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Qiushi Song, Xinyu Du, Changlu Shan, Hongwei Xie, Zhiqiang Ning, Kai Yu
Summary: This study investigated the effect of magnetic stirring on the microstructure of Co deposits during electrowinning in a chloride solution. It was found that magnetic stirring effectively reduced the negative influence of H2 bubbles on the structure of Co deposits and changed their nucleation and growth behavior, resulting in the preparation of high-quality columnar Co crystals.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Tao Ge, Xiaowei Zhou, Liang Xu, Yan Sun, Cheng Yang, Yongpan Tian, Zhuo Zhao
Summary: In this study, the extraction performance and complexation mechanism of p-di-ethyl-amino-methylthiacalix[4]arene (L) towards Pt(IV) were investigated. The results indicated that L had excellent complexation ability towards Pt(IV) and could selectively extract it from a solution containing multiple competing ions.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Yuan Li, Dirk van Zyl
Summary: This paper presents a modified Kynch's approach to explain the hindered settling behavior of suspensions impacted by segregation. The experimental data and predicted results confirm the effectiveness of the proposed method.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Yi Fang, Aurora Robledo-Cabrera, Changsheng Peng, Shan Huang, Qi Xiao, Alejandro Lopez-Valdivieso
Summary: With the assistance of mechanical ball milling, the partially oxidized micro-sponge iron (micro-Fe0@Fe2O3) achieves significantly improved removal of Cr(VI) across a broad pH range. Mechanical force eliminates the surface oxide layer and exposes the Fe0 core, leading to sustained reduction of Cr(VI). The efficiency of micro-Fe0@Fe2O3 is strongly influenced by dissolved oxygen, with higher DO resulting in the generation of stable reductant Fe(II) under acidic conditions, while DO consumption hinders the reduction of Cr(VI) under alkaline conditions due to increased pH. Parameters of ball milling operation, especially rotation speed, have a significant impact on the removal of Cr(VI).
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Alton F. Grabsch, Phillip D. Fawell, Michael G. Davies
Summary: High molecular weight partially hydrolysed polyacrylamide (PHPA) is commonly used in mineral exploration drilling to increase fluid viscosity and help maintain the suspension of fine particles. However, clarifying these suspensions can be difficult, and previous studies have found that anionic flocculants are ineffective. This study confirmed that nonionic flocculants can successfully aggregate the particles, indicating that the charged tails of adsorbed PHPA prevent anionic flocculants from accessing the particle surfaces.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
J. S. Guiral-Vega, L. Perez-Barnuevo, J. Bouchard, A. Ure, E. Poulin, C. Du Breuil
Summary: This paper introduces an approach that combines particle properties and process modeling to describe the behavior of iron ore in a laboratory-scale drum-type magnetic separator. Early information on iron ore processing behavior can be obtained through laboratory testing, automated mineralogy analysis, and process modeling.
MINERALS ENGINEERING
(2024)
Review
Engineering, Chemical
Sayed Janishar Anzoom, Ghislain Bournival, Seher Ata
Summary: This review discusses the benefits and challenges of coarse particle flotation, as well as recent developments in improving the process. Coarse particle flotation has various applications and offers advantages in technical, economic, and sustainability aspects. However, it also faces challenges such as particle detachment, transfer between phases, and persistence in the froth phase. Technological advancements, such as fluidized-bed flotation and processes enhancing bubble-particle attachment, have shown promising results in efficiently recovering larger particles.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Yimei Xiao, Jinchan Feng, Bingqiao Yang, Huihua Luo, Fang Zhou
Summary: In this study, the use of fulvic acid as a depressant for the flotation separation of chalcopyrite from arsenopyrite was investigated. It was found that fulvic acid strongly depressed arsenopyrite while having little influence on chalcopyrite flotation. The addition of calcium hypochlorite facilitated the adsorption of fulvic acid on arsenopyrite surface.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Bo Hao, Minqiang Fan
Summary: Particle-bubble attachment is crucial in coal and mineral flotation processes. In this study, the attachment process of low-rank coal particles to the bubble surface was simulated, revealing the important role of water film rupture in particle attachment.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Shuwei Wu, Shuai Wang, Guoqiang Wang, Longfei Fan, Jianbo Guo, Zhengbin Liu, Haoyan Zhang, Wei Guan, Yukuan Wang, Yewei Wu
Summary: This study analyzes the motion mode of eccentric roller crushers and proposes a calculation method for productivity. Through laboratory experiments, the results indicate that the proposed method can effectively estimate the productivity of eccentric roll crushers.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Hanna Miettinen, Malin Bomberg, Ozlem Bicak, Zafir Ekmekci, Paivi Kinnunen
Summary: Mineral processing requires large amounts of water, and reducing water consumption through recirculation and closing water loops is important. However, this can lead to the accumulation of contaminants in the process water, which can negatively affect the process performance. In this study, the impact of microorganisms on flotation performance was investigated, and ion exchange was evaluated for removing dissolved sulfur species and microorganisms from water. The results showed that adding microorganisms had a positive effect on flotation selectivity, especially for nickel. Different water types, process water and final tailings water, behaved slightly differently. Ion exchange proved to be effective in removing sulfur species and microorganisms, and dissolved air flotation was a successful pretreatment for ion exchange in removing microorganisms.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Canneng Chen, Song Zhang, Quanjun Liu, Luzheng Chen, Yongjun Xian, Yijie Wang
Summary: This study introduces the use of ultrasonic pretreatment to enhance the flotation separation of elemental sulfur and silver-bearing lead minerals from ultrafine residue. The results show that ultrasonic pretreatment effectively liberates associated sulfur and improves the separation of sulfur and silver-bearing lead minerals. Under optimized conditions, ultrasonic pretreatment significantly improves the recovery and grade of sulfur in the concentrate, as well as the recovery of lead and silver in the tailings.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Genzhuang Li, Fisher Wang, Bern Klein, Michael Deal, Aaron Wright, Hector Mezquita
Summary: This paper presents a stress-based approach for predicting and improving large-scale HIG mill performance through experimental testing and model calibration.
MINERALS ENGINEERING
(2024)
Article
Engineering, Chemical
Runpeng Liao, Shuming Wen, Jian Liu, Shaojun Bai, Qicheng Feng
Summary: This study demonstrates that the use of a DDA/DDTC mixed collector system can significantly improve the flotation performance of smithsonite. The synergistic effect between DDA and DDTC is confirmed, and the mixed collector system contributes to a decrease in solution surface tension. The use of FT-IR and XPS confirms the simultaneous physisorption and chemisorption of DDA and DDTC on the smithsonite surface, and contact angle measurements show that the mixed collector effectively enhances the hydrophobicity of smithsonite. Molecular dynamics simulations reveal the multilayer adsorption of DDTC and DDA on the smithsonite surface, with DDTC promoting the adsorption of DDA.
MINERALS ENGINEERING
(2024)