Utilisation of by-products of an integrated steel plant improves productivity with diverse mix of raw materials used for iron making. The strength of a briquette made with Blast furnace flue dust and iron oxide with fly ash as a binder depends upon the briquetting pressure, particle size of fly ash, fly ash quantity, and curing temperature. In this study, the effect of process variables on the strength was investigated with ANOVA. The correlation between the process parameters and the strength was examined experimentally and RSM-based optimisation was performed during the preparation of briquettes. The RSM provided optimisation with a confidence level of 95% using the CCD design. This paper demonstrates the correlation between applied pressure, particle size, fly ash quantity, and curing temperature. The developed mathematical model would help in predicting the variation in the compressive strength with the change in the level of different parameters. This model can be useful for setting the optimum value of the parameters for achieving the target compressive strength.
Get full access to this article
View all access options for this article.
References
1.
AyyanduraiAPalJ.Blast furnace flue dust as a potential carbon additive in hematite ore pellet. Miner Process Extr Metall Rev. 2022;43(5):633–647.
2.
SahRDuttaSK.Effects of binder on the properties of iron ore-coal composite pellets. Miner Process Extr Metall Rev. 2010;31(3):73.
3.
LiuHXieBQinYL.Effect of bentonite on the pelleting properties of iron concentrate. Hindawi J Chem. 2017: Article ID 7639326.
4.
NaritaCYMouraoMBTakanoC.Development of composite briquettes of iron ore and coal hardened by heat treatment. Ironmak Steelmak. 2014;42(7):548–552.
5.
HanHDuanDYuanP.Binders and bonding mechanism for RHF briquette made from blast furnace dust. ISIJ Int. 2014;54(8):1781–1789.
6.
SomervilleMA.The strength and density of green and reduced briquettes made with iron ore and charcoal. J Sust Metall. 2016;2(3):228–238.
7.
RipkeSJKawatraSK.Can fly-ash extend bentonite binder for iron ore agglomeration?Int J Miner Process. 2000;60:181–198.
8.
MishraSRoyGG.Effect of amount of carbon on the reduction efficiency of iron ore-coal composite pellets in multi-layer bed Rotary Hearth Furnace (RHF). Metall Mater Trans B. 2016;47B:2347–2356.
9.
El-GeassyAAKhedrMHNasrMIet al.Behaviour of iron ore–fuel oil composite pellets in isothermal and non-isothermal reduction conditions. Ironmak Steelmak. 2001;28(3):237–243.
10.
ManYFengJXLiFJet al.Influence of temperature and time on reduction behaviour of iron ore-coal composite pellet. Powder Technol. 2014;256:361–366.
11.
GuoDHuMPuCet al.Kinetics and mechanisms of direct reduction of iron ore-biomass composite pellets with hydrogen gas. Int J Hydrogen Energy. 2015;40:4733–4740.
12.
HalimKSA.Isothermal reduction behaviour of Fe2O3/MnO composite materials with solid carbon. Mater Sci Eng A. 2007;452-453:15–22.
13.
ChatterjeeA.Beyond the blast furnace. Boca Raton: CRC Press; 1994.
14.
HoffmanGE. A closer look at Fastmet and Fastmelt. In: Proceedings of electric Furnace Conference, AIST. 2000; Warrendale,PA.
15.
JimboJMiyagawaYFujitomiMet al.Development of FASTMET process as an iron unit. Kobelco Technol Rev. 1997;20:6–10.
16.
NogamiT.ITmk3: premium iron making process for the new millennium. Direct from Midrex. 2001;1st Quarter:7–9.
17.
GeorgeHDBoardmanEB.IMS-Grang cold pelletizing system for steel mill waste material. Iron Steel Eng. 1973;50(11):60–64.
18.
YuWSunTCLiuZZet al.Study on the strength of cold-bonded high phosphorus oolitic hematite-coal composite briquettes. Int J Miner Metall Mater. 2014;21(5):423.
19.
Xi-LunH.Cold consolidation of iron-ore pellets and their direct reduction in rotary kiln. Iron Steel (China). 1979;14:45. [Met. A: 8002 42-0157].
20.
WeiYXSunTCYuWet al.Mechanism of carboxymethyl cellulose for improving the strength of briquettes made of hematite ore and coal. J Univ Sci Technol Beijing. 2013;35(4):432.
21.
TakahashiR. Proc. 6th Int. Iron and Steel Congress, Nagoye, 1990;1:108.
22.
ShivaramakrishnaNAgrawalBBRayAKet al.Production of high carbon sponge iron from ore-coal composite pellets. Trans Ind Inst Met. 1990;43(2):95–101.
23.
AgrawalBBVijayavergiaRKPrasadKKet al. Development of cold bonded ore-coal composite pellets for sponge ironmaking. Proc. Int. Conf. on Recent Advances in Metallurgical Processes, IISc, Banglore. 1997:259–63.
24.
RavalSRDuttaSK. Utilization of iron ore fines by innovated cold bonded technique. Proc. Int. Conf. on Recent Advances in Metallurgical Processes, IISc, Banglore. 1997:269–274.
25.
ChatterjeeDOraonBSutradharGet al.Prediction of hardness for sintered HSS components using response surface method. J Mater Process Technol. 2007;190(1-3):123–129.
26.
BoxesGEPDraperNR.Emperical model building and response surfaces. New York: Wiley; 1987.
27.
MontgomeryDC.Design and analysis of experiments. New York: John Wiley & Sons; 1991.
28.
KungKYHorngJTChiangKT.Material removal rate and electrode wear ratio study on the powder mixed electrical discharge machining of cobalt-bonded tungsten carbide. Int J Adv Manuf Technol. 2009;40(1-2):95–104.
29.
AdyanadkaVMadhavraoR.Multi-response optimization and modelling of wedm using grey–fuzzy and response surface methodology. Int J Mod Manuf Technol. 2021;XIII:1/2021.
30.
DasRMondalMKPramanikS.Comparison of compressive strength of fly ash bonded flue dust briquettes with that of briquettes made with bentonite, sodium silicate, lime, starch, pitch, molasses and dextrin binder. Trans Indian Inst Met. 2022. doi:10.1007/s12666-022-02829-6.
31.
DasRMondalMKPramanikS.Study on reduction of blast furnace flue dust briquette made with fly ash as binder. J Inst Eng (India): Ser D. 2021;102:173–183.
32.
EiseleTCKawatraSK.A review of binders in iron ore pelletization. Miner Process Extr Metall Rev. 2003;24(1):1–90.
