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NationalInstituteofTechnology,
Rourkela
Department of Metallurgy and Materials
Engineering

PROCESS METALLURGY LAB

EXPERIMENT – 4

GUIDED BY
Prof. Archana Mallik

SUBMITTED BY
Avvaru Sai Bharadwaja
120MM0764
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TITLE: Analysis of physical properties of Iron ore and Coke Date : 08/02/2022

1) AIM: PART 1: Strength evaluation of coke

2) INTRODUCTION:
It is a measure of the resistance Of coke to degradation by impact and abrasion The micum
indices M40 gives an idea about strength of the coke while M10 Gives an idea about abrasion
resistance of coke. The formulae used for calculation of M40 and M10 indices are as follows:

❖ M40 = Total wt. (in%) of Coke retained on 40 mm. screen after the test
❖ M10 = Total wt.(in%) of Coke passing through 10 mm screen after the test

Coke is a grey, hard, and porous fuel with a high carbon content and few impurities, made by
heating coal or oil in the absence of air—a destructive distillation process. It is an important
industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when
air pollution is a concern. The unqualified term "coke" usually refers to the product derived
from low-ash and low-sulphur bituminous coal by a process called coking The industrial
production of coke from coal is called coking. The coal is baked in an airless kiln, a "coke
furnace" or "coking oven", at temperatures as high as 2,000 °C (3,600 °F) but usually around
1,000–1,100 °C (1,800–2,000 °F).[19] This process vaporise or decomposes organic substances
in the coal, driving off volatile products, including water, in the form of coal-gas and coal-tar.
Coke is the non-volatile residue of the decomposition, the cemented together carbon and
mineral residue of the original coal particles in the form of a hard and somewhat glassy solid.

❖ COKE STRENGTH
➢ High Cohesion (regular distribution of pores, crack free, adequate thickness and
hardness of walls between pores)
➢ High compressive force
➢ High temperature strength
➢ Fluidity and degree of Coalification
❖ COKE STRENGTH IS INFLUENCED BY
➢ Blending ratio of coals
➢ particle size and distribution of Charging coal
➢ Coke oven temperature and Combustion conditions
➢ Moisture and addition of oil.
➢ Soaking Time
➢ Width, Height and Method of Heating

MICUM DRUM:
A welded mild steel drum of 100 ± 0.5 cm internal diameter and 100 ± 0.5 cm internal
length, and made of plate of 6 mm thickness and the plate shall not wear to less than 5 mm
with a horizontal shaft of about 6.5 cm diameter not passing through the drum, and mounted
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on suitable bearings. Four angle-irons with legs of 100 x 50 x 10 mm are fitted longitudinally 90”
apart at the periphery of the drum so that the legs point away from the direction of rotation of
the drum. The drum is provided on the side with a door, 60 x 50 cm for introducing and
removing the sample, the door being made dust-tight with a rubber washer and so fastened as
to give a smooth inner surface. The bearings are mounted on suitable side supports to allow a
clearance of not less than 60 cm below the drum for convenient emptying after a test.
Calculation of M40 and M10 values. They have been calculated as follows:

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 𝑜𝑛 40 𝑚𝑚 𝑠𝑐𝑟𝑒𝑒𝑛

𝑀40 = × 100 ……………(1)
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑡𝑎𝑘𝑒𝑛 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 𝑜𝑛 10 𝑚𝑚 𝑠𝑐𝑟𝑒𝑒𝑛

𝑀10 = × 100 ……………(2)
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑡𝑎𝑘𝑒𝑛 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡

INDUSTRIAL IMPORTANCE:
The results on M40 and M10 Values are very important for ironmaking industries. For use of
coke in iron blast furnace, M40 value should be more than 85% and M10 value showed be less
than 7%.
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3) APPARATUS AND MATERIALS

REQUIRED:
❖ Apparatus used are
1. Micum drum
2. Load pan
3. Tray
4. Mesh size 40 mm and 10mm
5. Weighing machine
❖ Materials used are
1. 15 kg of coke

4) Procedure:
❖ Coke Sample is screened and 15 kg of air-died Coke of size +40-50 mm is charged in a drum
of size 100cm Internal dia. and 100 cm internal length.
❖ Now, the drum in rotated for 100 revolutions at the rate of 25rpm.
❖ After the test, the coke in screened on 40 and 10 mm screens and the results are expressed
in terms of M40 and M10.

5) RESULTS:
❖ Initial weight of coke before the test = 15 kg
❖ Coke retained on 40 mm sieve size = 13.1 kg
❖ Coke retained on 10 mm sieve size = 0.8 kg
❖ Weight loss due to spilling out from the drum =1.1kg

The results obtained should be reported in the following manner: Calculation of M40 and M10
values. They have been calculated as follows:

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 𝑜𝑛 40 𝑚𝑚 𝑠𝑐𝑟𝑒𝑒𝑛

𝑀40 = × 100 = (13.1/15)*100 = 87.34
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑡𝑎𝑘𝑒𝑛 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡
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𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 𝑜𝑛 10 𝑚𝑚 𝑠𝑐𝑟𝑒𝑒𝑛

𝑀10 = × 100 = (0.8/15)*100 = 5.34
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑘𝑒 𝑡𝑎𝑘𝑒𝑛 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡

M40 and M10 Values were found to be 87.34 & 5.34

6) CONCLUSIONS:
The results obtained have been summarized as follows:

➢ M40 value of the coke has found to be more than 80%.

➢ M10 value of the coke has found to be less than 7%.
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1) AIM: PART 2: Strength evaluation of iron ore lumps

2) INTRODUCTION:
TUMBLER INDEX :
The cold strength of the sinter is determined by the Tumbler test. This para-meter is related
with the tendency to fines formation during the handling and transportation from the sintering
machine to the blast furnace throat. It has large importance because Tumbler index informs
about the raw materials loss as fines and the disruptions in the furnace operation. TI depends
on the strength of each single component, the strength of the bonding matrix components and
the ore composition. The apparatus used for Tumbler test consists of a drum 1000 mm in
diameter and 500 mm width fitted with two lifters of 50 mm size. The drum rotates at 25 rpm.
15 kg sample are subjected to 200 revolutions. At the end, the material is screened by 6.3 mm
and 0.5 mm size screens and >6.3 mm and <0.5 mm material is weighed. The indices are
represented as follows:
Tumbler index(% > 6.3mm) = [ Weight of > 6.3mm fraction in kg/15kg
(initial simple weight)]*100
Abrasion Index(% < 0.5mm ) = [ Weight of < 0.5mm fraction in kg/15kg
(initial sample weight)]*100
It is the most popular test to assess the strength and abrasion resistance of iron ore
lumps/pellets/sinters. The tumbler index gives an idea about the strength of the iron ore while
the abrasion index gives an idea about the abrasion resistance of iron ore. Tumbler index (T) is
the weight percentage of iron ore sample retained on 6.3 mm screen after the test. Abrasion
index (A) is the weight percentage of iron ore passing through 500 µm screen after the test.
2.1) OBJECTIVES: To have an idea about the strength and abrasion resistance of iron ore
lumps.
2.2) INDUSTRIAL IMPORTANCE:
The results on Tumbler and Abrasion indices are especially important for iron making industries.
For use of iron ore lump in iron in blast furnace or rotary kilns, tumbler index should be more
than (82wt%-91wt%) and abrasion index value should be less than (1.27wt%-4.87wt%).
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3) APPARATUS AND MATERIALS REQUIRED:

❖ Apparatus required are
1. Tumbler drum [Size: Internal Diameter (100 cm) x Length (50 cm)]
2. Weighing Machine
3. Sieves of Sizes 40 mm, 10 mm, 6.3 mm, and 500 µm
❖ Materials required are
1. Iron Ore Lumps : 15kgs

4) procedure:
➢ Air dried iron ore lump is first screened and 15kg of air-dried iron ore lump of size –
40+10 mm is charged in a tumbler drum and the door is tightly closed.
➢ Now, the drum is rotated for 200 revolutions at the speed of 25 ± 1 rpm.
➢ All the materials are then removed from the drum by opening the door and sieved on
6.3 mm and 500 µm sieves.
➢ Iron ore retained on 6.3 mm sieve and passing through 500 µm sieve are weighed.
5) RESULTS:
▪ Initial weight of iron one = 15kg
▪ Weight of iron ore retained on 6.3mm screen after the test = 14kg
▪ Weight of iron ore retained on 500 µm screen = 0.171kg
▪ Weight loss due to spilling out from drum = 0.829kg
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑟𝑜𝑛 𝑜𝑟𝑒 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 𝑜𝑛 6.3 𝑚𝑚 𝑠𝑐𝑟𝑒𝑒𝑛 𝑎𝑓𝑡𝑒𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡
𝑇= × 100
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑟𝑜𝑛 𝑜𝑟𝑒 𝑙𝑢𝑚𝑝 𝑏𝑒𝑓𝑜𝑟𝑒 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡

= (14/15)*100 = 93.34
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑟𝑜𝑛 𝑜𝑟𝑒 𝑝𝑎𝑠𝑠𝑒𝑑 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 500 𝜇𝑚 𝑠𝑐𝑟𝑒𝑒𝑛 𝑎𝑓𝑡𝑒𝑟 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡
𝐴= × 100
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑟𝑜𝑛 𝑜𝑟𝑒 𝑙𝑢𝑚𝑝 𝑏𝑒𝑓𝑜𝑟𝑒 𝑡ℎ𝑒 𝑡𝑒𝑠𝑡
= (0.17/15)*100 = 1.14
Tumbler Index and Abrasion indices were found to be 93.34 & 1.14
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6) CONCLUSION:
The results obtained are being summarized as follows:
❖ The Tumbler index has been found to be 93.33, which is more than the value required for
the use of iron ore in iron blast furnace.
❖ The Abrasion index has been found to be 1.14, which is less than the value required for the
use of iron ore in iron blast furnace.

REFERENCES :
❖ https://law.resource.org/pub/in/bis/S11/is.1354.1992.pdf
❖ https://www.researchgate.net/publication/316639230_Iron_Ore_Sintering_Quality_Indices
❖ https://law.resource.org/pub/in/bis/S10/is.6495.1984.pdf