AISTech 2019 — Proceedings of the Iron & Steel Technology Conference

6–9 May 2019, Pittsburgh, Pa., USA

DOI 10.1000.377.053

Optimizing Sinter Chemistry to Counter Alumina Effect

Chandra Shekhar Verma

Jindal Steel and Power Limited,

Raigarh (INDIA)

Phone: (+91) 9109137532

Email: chandra.verma@jspl.com, csverma.aa@gmail.com

Keywords: Sinter, B2, B3, B4

1. INTRODUCTION:
Depleting quality of iron ore fines especially increase in alumina is the major concern in sinter making process as alumina is
a refractory material. Therefore study of preventive actions to counter the effect of alumina is a pre requisite to maintain
and/or improve the sinter strength. Various trials by regulating the B2, B, B4 and Al2O3/SiO2 ratio has been done for
improvement in sinter strength. In addition mineralogy test of both iron ore fines and sinter product were also conducted.

2. MINERALOGY OF IRON ORE FINES:

Tensa iron ore is a weathered iron ore. Mother rock of banded magnetite quartzite is altered to banded hematite quartzite and
the magnetite phase is found ~10%

H G
H

H
G
Q

Figure (above): Micrographs of Tensa iron ore fines

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 Table: Phase analysis of minerals.

Minerals %
Hematite 64.67
Magnetite 10.00
Goethite 6.00
Limonite 2.00
Quartzite 6.20
Kaolinite/Clay 9.63
Others 1.50

Hematite is the major iron bearing mineral. This ore is mainly banded hematite quartzite (BHQ). The quartzite mineral was
totally leached out due to weathering. But hematite and dark leached quartzite bands are clearly visible. Due to leaching
process, the hematite particles are associated with pores. The quartzite band is fully occupied by pores due to leaching
process. Morphology of hematite particles are needle shaped. Hematite has been altered to goethite and subsequently
goethite has been altered to limonite.

3. X-RAY DIFFRACTION
X-ray diffraction analysis of feed sample was carried out and phase analysis is presented in below table

Table 2

Tensa iron ore is a weathered iron ore and is mainly banded hematite quartzite (BHQ). Phase analysis indicates that hematite
is the major iron bearing mineral with presence of magenite (~10%) and goethite (~6%). The ore is highly porous caused by
extensive leaching process (weathering).
Action Taken at Mines End: Mining of Ore bench having goethite has been restricted.

IMPROVEMENT IN SINTERING PROCESS

To counter the effect of alumina we had regulate the basicity B2, B3, B4 and alumina/silica ratio so that desired sinter
strength (Drum index) can be achieved.

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 PHASE ANALYSIS OF PRODUCT SINTER WITH TUMBLER INDEX > 76

Sample-1: with Al2O3/SiO2: 0.68 & B4:1.53

Calcium Silicate Calcium Silicate

Hematite
Hematite

SFC
SFCA

In both images, the sinter matrix comprises of SFCA, Calcium silicate and Hematite phases. The presence of SFCA in the
matrix gives strength to the sinter, whereas calcium silicate phase being brittle in nature decreases the sinter strength.

Pores distributions in sinter at 50X magnification:

Note: The coloured image is the replica

of black and white image for the purpose
of phase determination

Phases in Sinter:
Matrix
1. Pores: 18-20%( approx.)
2. Silicates: 15-20% ( approx.)
Pore+Silicates 3. Remaining: SFCA/hematite/magnetite/
calcium ferrite(60-67%)

Sample-2: with Al2O3/SiO2: 0.66 & B4:1.56

SFCA Calcium Silicate

Calcium Silicate
SFCA

Hematite

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In both images, SFCA is found homogenously distributed throughout the sinter matrix. Interlocking of hematite, SFCA and
calcium silicate phases are observed. The predominant presence of SFCA phase is responsible for the sinter high strength.

Pores distributions in sinter at 50X magnification:

Phases in Sinter:
1. Pores: 22-25 %( approx.)
Matrix 2. Silicates: 15-20% (approx.)
3. Remaining: SFCA/hematite/magnetite/
Pore+Silicates calcium ferrite (75-78%)

Sample-3: with Al2O3/SiO2: 0.67 & B4:1.58

Pore Hematite

Magnetite
Pore Calcium Silicate
SFCA

In both images, columnar SFCA phase and pores are observed in the sinter structure which is indicative of both cold strength
and higher reducibility. The presence of magnetite in second image may be attributing to improved RDI (i.e., lower RDI
value).

Pores distributions in sinter at 50X magnification:

Phases (%) in sinter

Matrix 1. Pores: approx 15-20% in sinter structure.
2. Remaining : SFCA/hematite/magnetite/
calcium-ferrite approx. 80 - 85%.
Pore+ Silicates

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 Sample-4: with Al2O3/SiO2: 0.66 & B4:1.57

Pore SFCA

Hematite

SFCA Calcium Silicate

In above images, hematite, magnetite and SFCA phases are uniformly distributed throughout the matrix.

Phases (%) in sinter

1. Pores: approx. 22-25% in sinter
Matrix structure.
2. Remaining:
SFCA/hematite/magnetite/calcium-
Pore+ Silicates
ferrite approx. 72-75%.

CONCLUSION:
Study concludes with the establishment and combination of B4 and Al2O3/SiO2 ratio in between 1.53-1.60 and 0.63- 0.70
respectively and have achieved tumbler index (Drum Index) 76 plus with the plant productivity of 1.58-1.6 t/m2/hr. even at
reduced carbon rate by 5kg/ton of gross sinter by reducing the FeO level (from 10.51%- 9.79%) at JSPL, Raigarh.

Figure (above): comparison of sinter cold strength (T.I.) (Before and after)

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 Figure (below): sinter cold strength (T.I.) with high alumina and low FeO

REFERENCES:
1. L.Lue, R.J. Holmes and J.R. Manuel :Effect of Alumina on Sintering Performance of Hematite Iron Ores
2. Yuri Kapelyushin, Yasushi Sasaki, Jiangiang Zhang, Sunkwane Jeong and Oleg Ostroyaki: Magnetite Doped with
Alumina Using High Temperature XRD Analysis

506 © 2019 by the Association for Iron & Steel Technology.