Use of boron based binders in pelletization of iron ores

Sivrikaya, Osman
Bentonite is the most preferred silicate-based binder in iron ore pelletizing. However, it is considered as an impurity due to its high SiO2 and Al2O3 content. The iron-making economy is adversely affected by the addition of bentonite or other silicate-based binders. In recent years, impurity-free alternative binders have been tested in order to replace bentonite or to lower the bentonite dosage. Organic binders yield good quality green and dry pellets. However, they fail to impart enough mechanical strength to the preheated and fired pellets as a result of insufficient slag bonding. Thus, they have not found widespread application in the industry. The addition of boron compounds into pellet mix is proposed as a potential solution to overcome the insufficient compressive strengths of preheated and fired pellets produced with organic binders. During the experiments, some organic binders and boron compounds were tested as alternative binders to bentonite either alone or in combination, for both magnetite and hematite pellets. The performances of the tested binders on pellet qualities: balling, wet pellet moisture content, drop number, pellet compressive strengths (wet - dry - preheated - fired), dustiness, porosity, mineralogy, morphology, chemical contents, reducibility and swelling index have been compared with the performances of reference bentonite binder. The results of the tests showed that, the quality of pellets are insufficient when organic binders or calcined colemanite used as binder alone. The former failed to provide sufficient preheated and fired pellet strengths, the latter failed in terms of wet and dry pellet quality. However, good quality wet, dry, preheated and fired pellets could be produced with combination of these two binders. Calcined colemanite addition into pellets made with organic binders was tested in different dosages (0.25-1.00%). Results showed that with increasing dosage of calcined colemanite both strengths of preheated and fired pellets increased linearly. It was found that as low as 0.50% calcined colemanite addition equally-performed on magnetite fired magnetite pellets at 1300oC when compared with the performance of the reference bentonite binder. However, its performance was better on hematite pellets in order to improve the pellet compressive strengths. In addition, stronger pellets could be produced at lower firing temperatures like 1100oC with the addition of calcined colemanite. The reason of the improved preheated and fired compressive strengths of pellets bonded with calcined colemanite was due to the physical melting of calcined colemanite at the contact point of iron oxide grains during thermal treatment. It was found that bentonite bonded pellets fired at 1300oC were more reducible than those of produced with calcined colemanite addition. Swelling indices of these pellets were determined in the industrially acceptable limits. The chemical and mineralogical analyses results showed that the combined binders did not contaminate the pellet composition since the organic binders burnt-out without residue and colemanite does not contain much impurity.


Use of boron compounds as binders in iron ore pelletization
Sivrikaya, Osman; Arol, Ali İhsan (2010-05-01)
Low grade iron ores with impurity gangue minerals containing silica and alumina must be upgraded to an acceptable level of iron content. Concentrates, due to their fine sizes, are not suitable to be directly charged to the iron-making processes such as the blast furnace or the DR-plant. Hence, an agglomeration technique should be applied to fine concentrate. The most commonly employed one is pelletizing in iron ore industry. In pelletizing, iron ore, water and a binder are balled in a mechanical disc or dru...
SİVRİKAYA, OSMAN; Arol, Ali İhsan (2012-01-01)
In this study the separation possibility of gangue minerals from a low grade magnetite ore with 45% Fe from an iron ore deposit located near Erzincan-Turkey was investigated. The iron ore deposit consists of mainly magnetite mineral. Hematite is the second iron oxide found in the deposit. The gangue minerals contain mainly SiO2 and Al2O3 impurities. The main object of the research is to investigate the production of a concentrate suitable for iron ore pellet production. The concentrate for pellet production...
Sivrikaya, Osman; Arol, A. I. (Instituto Federal de Educacao, Ciencia e Tecnologia do Rio Grande do Norte (IFRN), 2014-7-3)
<jats:p>The use of conventional bentonite binder is favorable in terms of mechanical and metallurgical pellet properties, however, because of its acid constituents bentonite is considered as impurity especially for iron ores with high acidic content. Therefore, alternative binders to bentonite have been tested. Organic binders are the most studied binders and they yield pellets with good wet strength; they fail in terms of preheated and fired pellet strengths. This study was conducted to investigate how ins...
Kutlu, Burak Temel; Toksoy Köksal, Fatma; Akata Kurç, Burcu; Department of Geological Engineering (2022-8-29)
Kaolin is a mineral with industrial value and can be used as a raw material in different areas. In most uses, pure quality kaolin is required. However, not all the kaolin occurrences are pure as much as needed and additional processes are applied before use. Nevertheless, some occurrences are accepted as gangue material due to their poor quality and low reserve. Kaolin-rich layers are widespread in coal deposits, but their quality is low. The presence of clay-rich layers with kaolin content in coal deposits...
Pelletization of magnetite ore with colemanite added organic binders
Sivrikaya, O.; Arol, Ali İhsan (2011-06-10)
A new generation binder consisting of an organic binder and a borate salt was tested as an alternative to bentonite in magnetite ore pelletization. Carboxyl methyl cellulose (CMC),Ciba DPEP06-0007 and corn starch, and calcined colemanite were used as organic binders and the borate salt, respectively. They were added to the pellet feed separately and in different combinations at several addition levels. It was found that the use of organic binders is sufficient in terms of wet pellet quality; however, they f...
Citation Formats
O. Sivrikaya, “Use of boron based binders in pelletization of iron ores,” Ph.D. - Doctoral Program, Middle East Technical University, 2011.