Effects of Temperature and Atmosphere on Pellets Reduction Swelling Index
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,():,JOURNALOFIRON ANDSTEELRESEARCH,INTERNATIONAL.20121910071219 -
EffectsofTemeratureandAtmoshereon pp
PelletsReductionSwellinIndex g
, CHU , L,WANGZhaocaiManshenIUZhenen -- -ggg
CHENShuanin, XUEXianxin - -gyg
(,N,,)SchoolofMaterialsandMetallurortheasternUniversitShenan110819,LiaoninChina gyyygg
:A,Abstractftertakinintoaccounttheconditionsofthedomesticironresourcesandthenoncokincoalresources - gg
rocessasificationtheofcoalshaftfurnaceisaneffectivewatodevelodirectreductionironinChina.Thefollow- - pgyp
,intasksarevercriticaltochoosesuitablerocessofshaftfurnaceandasificationincludintheroductionofoxi -gygpgp
elletsroertiesdizedwithexcellentcomrehensiveaswellasthestudofthereactionbehaviorandmechanismof ppppy
swellin.Theresultsshowedthattheoxidizedofusindomesticmaneticironconcentrateasraw materialsellets gggp
,,roertieshavefavorablecomrehensiveincludinhihermechanicalstrenthbothbeforeandafterreductionfaster pppggg
)rateandlowerreductionswellinindex(RSI.Alloftheseroertiescanmeettheshaftfurnaceieldinreduction gppyg
reuirement.Whenthetemeraturewasbelow1223K,thewaslowerthan20%.Withincreasinofellets′RSI qpgp
,,theelletscontentofH2inatmosherethereactionrateacceleratedcrushinstrenthenhancedandRSIde -ppgg
,creased.TheRSIdroedto10.26%at1323Kin100%H2atmoshereanditisuto39.88%in100%COat -pppp
,moshere.TheironmainlinwhenwerereducedbH2,howeverinCOatmosrainsresentedlatelikeellets -pyygppp
hererainsreciitatedrainstheironwereinflocculent.Thewhiskershaeofironandheatineffectsofreduction pgppgpg
arethemaorfactorsleadintotheoorelletsstrenthandincreaseofRSI.Aroriatelcontrollinthereaction jgppgpppyg
andincreasintheratioofH2toCOinatmosherearefordrointheRSI.temeratureood gpppgpg :;;;elletKewordsoxidizedshaftfurnacedirectreductionreductionswellin pgy
heinternationalexerienceindicatedthatthe T p
shaftfurnacerocessisaneffectivetechnolofor pgy
)directreductioniron(DRIcaextendinroduction -gp
,sacitbecauseofitsfasterreductionratetable py
,,hiherdereeofautomationlarerroductualit gggpqy
sinlecaacitandlowerenerconsumtion,butit gpygyp
natureasreducinaent.Viewedfromneedsas ggg
,enerstructurethenatureasresources′feature gyg
,u,aitsinadeuatesulnevendistributionndis qppy
nationalconomicndustriesemandorare. e i d f lg
severellimitthedevelomentofshaftfurThese -yp
,nacedirectreductioninChina.Asaresultthereis
[]1-4
industrialuntilnow.noroduction p
,ncourainlwithincessantandim-rowin E ggygg
,rovinofshaftfurnacesomenewrocessesofdi -pgp
rectreductionironmakincometruewiththetideof g fashion,suchasHYLZRandMIDREXwhichcanuse -
,cokeovenCOREXoffandcoalformedasasasas -g - gg
,reducinaent.Inadditiontheasificationrocesshas gggp
alreadbecomerieandconventionaltechniuein ypq
,thechemicalindustrandtheirstabilitandeconom yyy
aredemonstratedbroductionractice.Thecoal -ypp formedcanbecomletelusedasreductantforas pyg
,shaftfurnace.Sothenewrocessofdirectreduc -p
tionironmakinwasthrouhcombinationresented ggp
andshaftfurnace.Thiswouldoenofasification pg
uanew waofdeveloinDRItorealizeener pypggy savinandemissionreductionandachievelowcarbon g ironmakininChinawherenatureasresourceisdefi -gg
[]1-4
cientbutnoncokincoalresourceislentiful. gp
,gurrentlbasedshaftfurnaceisasrocess C- yp
dominatedbMIDREXrocessandHYLrocess. ypp Bothofthemhavesuccessfulroductionexerience pp
,althouhtheirHoCOratioisdifferent.Meanwhile g2t
);FoundationItem:ItemSonsoredbNationalNaturalScienceFoundationofChina(51090384FundamentalResearchFundsforCentral py
(,)ofChinaN090602005N110202001Universities
:(—),,;:m:SBiorahZhaocai1983MaleDoctorCandidate E-mailidrex63.com;eceivedDateetember8,201
1 - @1 R pgpyWANG
·8·,ournalofIronandSteelResearchInternationalol.19 J V
therearemanremarkabledifferencesamonthe yg
asificationmainmethodsintermsofcomositionof gp
,,,caitalizedcostenvironmentalloadasreducin pgg []
andsoon5.Thesetwoasectsmakeitimortantto pp
rocessasificationmatchtheshaftfurnaceand pg
[]6-8
,rocessreasonabl.What′smoreshaftfurnace py
reductionrocessasarshetalluricaldirect p h h mg
,sroertreuirementsoftheuchasironellets ppyqp
,ccontentrushinstrenthandreductionswellin ggg
)RSI.Thedevelomentofsteelindustrmaindex( pyy
beenslavedifresourceisonldeendentonimort. ypp
,ihereforenthisstudacertaindomestic T y
ironconcentrateisusedasraw materialstomanetic g
,oxidizedandthereductionreareelletsroer -ppppp
tiesofelletsatdifferenttemeraturesandatmos -pp
aswellasitsswellinmechanism werefurheres -gp
,therstudied.Thusitwilltheoreticalbasisrovide p
forasificationrocessrationallchoosintheand gpyg
determininthearoriatereductionconditionsof gppp
bbasedshaftfurnace.elletsasoxidized - ypg
1 ExerimentalMaterials p
ronoreconcentratefromShanxiinChina I
addin1%bentonitewererolledandelletizedwith gp b1000mmdiscballinmachine.Afterdrinin ygyg theoven,theballswereto1173Kreenreheated gp
roastedinthefurnaceundertheoxenenrichedand -ygatmoshere.Theroastintemeratureis1523K pgp andthetimeis20min.Thechemicalcomositionof p
oreconcentrateandoxidizedelletsarelistediron pinTable1.Theoforeis83%ranularitower gyp whichislessthan0.074mm.Thechemicaland hsicalindicesofexerimentalbentoniteareiniven pypg
2andTable3resectivel.Table py
,%)able1 Chemicalcomositionofironorefineandoxidizedelletsmassercent T ( ppp
TFe
Ironoreconcentrate xidizedellets O p
70.449 67.90
FeO 24.635 0.19
SiO20.940 1.72
MO g1.012 1.09
CaO 0.123 0.20
S 0.057 0.004
P0.0030.002
,%)able2 Chemicalcomositionsofbentonitemassercent T ( pp
Comosition pContent
FeO 0.04
SiO254.98
CaO 2.88
Al2O314.70
MO g2.08
TiO20.24
Na 2O0.98
K2O0.88
Table3 Phsicalroertiesofbentonite ypp
/Blueabsortionower pp
-1)(·100gg
33
/Swellinvolumeg
-1)(mL·g
50
/Colloidindex
-1)(mL·15g
600
/Waterabsortion p
(2h·%-1)
354
Massercent p
(/%sizelessthan0.074mm)
98
,ccordintonationalstandardandcorrelationtradementaldemandformassismore.Moreoverellets A gp
,criterionstheandmetalluricalhewerereducedunderrotarmotionwithhsicalroertiestellets gypyppp
,ubularofoxidizedelletshavebeentested.Theexerimenreactorwhichisthesocalled“dnamicre -t - -ppy
talconditionsoflowtemeraturereductiondisinteuction”.Alloftheseareconsistentwithfeaturesof - -d prationtestaccordintonationalstandardandHYLoxidizedelletsdirectreductionbHYLshaftfurnace ggpy
[5]
standardarelistedinTable4.Comaredwiththatwithnaturalas. pg
,inthenationalteststandardintheexerimental Theroertiesofexerimentaloxidizedellets ppppp,conditionsofHYLstandardtheatmoshereconrelistedinTable5.Thetestresultindicatethatall -a p
,wtainsmassesofH2besidesCO,theflowrateispofoxidizedhichareasroertarametersellets gpypp
,larerthereductiontimeislonerandtheexeriroducedbmanetiteconcentrateresourcesathome -p ggpyg
Table4 ExerimentalconditionsofreductiondisinterationtestaccordintonationalstandardandHYLstandard pgg
ConditionsNationalstandard HYLstandard
/Gasflowrate
-1(L·min)
15 20
/Temeraturep
K
773 773
Samlep
/massg500 1000
Reduction
/timeh
1 2
/Seedofreactiontube p
-1(·mrin))0(staticreduction
)18(dnamicreduction y
Gascomositionin p
/%volumeercent pH20 55
OCO2 C20 21
20 14
N26010
Issue10 EffectsofTemeratureandAtmoshereonPelletsReductionSwellinIndex ppg
elletsTable5 Proertiesofoxidized pp
/%temeraturereductiondisinterationindexLow- pg
Crushing
strenthg
oreShanxi Standard
2985 000≥2
Nationalstandard +6.395.68 -
+3.1597.03 0≥7
-0.52.43 -
+6.392.12 0≥8
HYLstandard
+3.22.63 0≥9
1)
Up
·9·
/ReductionindexReduction
/%%swellinindexg
93.51 0≥6
75.74 0≥7
16.780≯2
:)Tote1heercentaesofnumberofunbrokenelletsinthetotalexerimentalelletsafterreduction. N pgppp
,combinedwitharoriatemethodsaresatisfiedor ppp
totheHYLstandard.Theexerimentalsuerior pp
elletscanbeusedinasbasedshaftfurnacetoro - -pgpduceDRI.
2 ExerimentalProcedures p
aoutofreductionexerimentaleuimentis L ypqpshowninFi.1. g
hedirectreductiontestwascarriedoutunder T
temeratures(1123,1173,1223,1273different p
and1323K)anddifferentascomositions(100% gpH2,.5,.4andφH2/φCO=2φH2/φCO=1,φH2/φCO=0100%CO).
3 ResultsandDiscussion
3.1 Effectsoftemeratureandatmoshereonellets ppp
behaviorreduction heeffectsoftemeratureandatmoshereon T ppofreductionratiowithtimeareshowninvariation canbeseenthattheincreasedcontentofFi.2.It g
oodH2inreducinatmoshereisforacceleratin ggpg
,reactionrateduetothatthemoleculardiffusionthe
coefficientandreducinofH2athihtemerower -ggpp
[]9
ature(083K)arebetterthanthoseofCO.>1
,turthermorehereductionrateisincreased F
,withtherisintemeratureeseciallinH2atmos -gppy
theinfluenceisslihtat100%COathere.Yet -gp
mosherebecausethereductionreactionisexother -p
,micdesitethednamicsconditionsareimroved pyp
,tbrisintemeraturehethermodnamiccondi -ygpy
tionsareimairedatthesametime.Thefinalreduc -ptionratioisonlmaintainedatabout80%in100% y COatmosherewhichissinificantllowerthanthat pgy theatmosherecontaininH2.in pg
hecontentofTFeandMFeinelletsafterre T -pductionat1223Kindifferentreducinatmoshere gp weretestedandlistedinTable6.Thedereeofel -gpletsmetallizationisachievedabove94%whentheratio
,wHoCOintheatmoshereexceeds0.4hichacof -p2t
cordswiththereuirementsofnationalstandardand qHYLstandardfordirectreductionroduction. p
i.3showsthecoldcrushinstrenthofel F -gggp letsafterreductionat1223Kindifferentreducin gatmoshere.Alltheresultsaremorethan250Nand pdecreasinwithincreasincontentofCOintheatmos -gg here.Thereasonscanbelistedasfollows.Theoxide′s p
,reductionreactionbCOisanexothermicrocess yp
whichcausesatemeratureradientdifferencebe -pgtweeninsideandoutsideoftheellets.Thisnotonl pyresultsinstructuralstressbutalsodecreasestheel -p
; 2—C; 3—T1—Electronicbalanceomuteremeraturecontrol pp
; 4—F; 5—S; 6—Pcabineturnacebodieswinieellets gpp ; 7—P; 8—G; 9—Dsamlesorcelainbeadasflowmeterrier. p
Fi.1 Laoutofreductionexerimentaleuiment gypqp
,irstlinordertoobtainevenairflow,the F y
iebottomofswinhasbeencoveredwith50mm ppg
,orcelainlacethicklaerofsmallbead.Nextthe ppy
elletssamlesintoswinieandheattoreuired ppppgq
,reductiontemeraturebrotectionatmoshere pypp
maintainthetemeraturefor30min,andthen pchanetoreducinasforreduction.Durinreduc -gggg
,tionthewasrecorrocessellets′weihtlessness -ppg
dedinrealtimewithbmeansoftheoodrecision - ygp electronicbalancefeedbacksstem.Whenthebal -y
,c,anceindicationwasstableutoffreducinas gg
switchtoNndlowertheelletssamles′temera -ppp2aturebelow353K.
Inordertodeterminethecriticalvalueofreduc -invelocitandavoidtheeffectsofflowrateasas gygg
reductionreactinandafonrocesselletsualit -gppqy
,aterreactionseriesofexerimentsweredere - -pp
sinedviachaninasflowatconstanttemerature ggggp of1223K.Thetestresultsshowthatwhentheas g
/,rateishiherthan4Lminthereactionrateflow g
,willnolonerbeaffected.Thereforetheexeri -gp/mentalasflowratewasselectedas4Lmin. g
·10·,ournalofIronandSteelResearchInternationalol.19 J V
())))a1123K; (b1173K; (c1223K; (d1273K.
Fi.2 Effectsofreductionatmoshereandtemeratureonvariationofreductionratiowithtime gpp
Table6 ContentofTFeandMFeinelletsafterreductionat p
1223Kunderdifferentreducinatmoshere gp
,%) massercent ( p
TFe
100%H2
2.5 CO=φH2/φ
1 CO=φH/φ
2
MFe 90.51 89.16 88.85 88.20 --
Metallization96.4696.2094.9094.354.00≥93.0
0>9
93.83 92.69 93.62 93.48 --
letsstrenth.Duetothedeositionofcarbondurin gpg
,reactionrocessofCOreductionthestructurethe p
becomesmorelooseafterreduction.Theofellets p
bindinowerrainsbetweentheironisworse gpg
elletswhenarereducedbCO,thusresultsinthe py orosithiherandlowerstrenthafterreduction. gpyg 3.2 Effectsoftemeratureandatmoshereonel -ppp
letsreductionswellin g
heeffectsoftemeratureandatmoshereon T pp
theRSIareshowninFi.4.TheRSIislessellets gpthan20%inanotherconditionsexcetwhenthe yp temeratureishiherthan1273Kandthecontent pgofCOinatmoshereishiherthan71.4%,which pg
roduction.canmeetreuirementoftheshaftfurnace pq
3.2.1 Eectotemeratureonelletsreduction fffpp swelling
,,sshowninFi.4inthesameatmosherethe A gp
RSIincreaseswithtemeraturerisin.Whentheellets pgp
temeraturefallsbelow1223K,theenreduction -p
tiresamlesshowlowerRSI.Ifthereductiontem -peratureistoohih,theelletsvolumeexansion pgpp
besinificantlincreased.Intheatmoshereofwill gyp
,hihtemeratureandhihreductiontheotentialel -gpgpp
0.4 CO=φH2/φNationalstandard HYLstandard
Fi.3 Coldcrushinstrenthofafterreductionatellets gggp
1223Kunderdifferentreducinatmoshere gp
Issue10 EffectsofTemeratureandAtmoshereonPelletsReductionSwellinIndex ppg ·11·
Fi.4 EffectoftemeratureandatmoshereonRSI gpp
letswillexand.Whentheinternalstressesarehih pg
,enouhtocausecrstaltissuelidinellets′local gyggp,bedamaedcontinuouslandthecracksinthewill gy
rainswillincreaseandfinallrushouttothesurfaceof gy
,theelletsleadintothefractureorevensallin. pgpg
,pnracticaloerationroertemeratureis I pppp
deendinonthebasiccharacteroftheraw material pg
roductionefficiencofshaftfurnace.and py
ellets3.2.2 Eectoatmoshereonreduction pfffp
swelling
,sshowninFi.4,atthesametemerature A gp
,withincreasincontentofCOinatmosherethe gp
RSIisincreasedobviousl.Under100%COreducin yg
,elletstheevenshowabnormalswellinconditions pgthetemeratureishiherthan1273K.Thewhen pgRSIdroedto10.26%at1323Kin100%H2at -pp
,moshereanditisuto39.88%in100%COat -pp
,moshere.Durinthereductiontherocessreci -pgppp
itationformofironraindeterminesthesizeofel -gpletsRSI.Fi.5showstheSEM microorholo -mgpgyironoreelletsafterreductionat1223Kin100%of pH2,nd100%COatmosheresresec -ppφH2/φCO=1ativel.y
enreductionisH2,thankstoitsbetteras Wh g
moleculardiffusionandreductionkineticsthanCO,
,ironrateisfasterandironrains′preciitationrains gpgraidlateachdirectioneuall.Theironrainsrow pyqygg
resentedlatelikearemainlinandhavehiherad -ppyg
,hesivestrenth.Inthemacroscoictheareellets gpp
noteastoexand. yp
; B—S,,,A—MetalironilicatemineralconsistsmainlofFeSiOandwithalittleCaP,S. y
()H2; ())ab1∶1; (cCO.CO=φH∶φ
2
Fi.5 SEM microorholoofironoreelletsafterreductionat1223Kwiththreekindsofatmoshere-m gpgypp
henreductionasisCO,therateofironrains W gg
;reciitationislowermostoftheironrainsreciitate ppgpp
inrainbulkfibrousorflocculentform.Anumberof gy
areformedandhaveobviousdirectivit.branches y
,wDurintherowinrocesshenrainsencounter gggpg
borderuonrains′block,thewillchanedirec -pygg
resentrowth.Ationreeatedlandfoldinnum- pgpyg
berofirreularintersacesandstronerinnerstress gpg
continuallemered.Thatinreturnwouldleadare yg tothedecreaseoftheellets′reductionstrenthand pgtheincreaseoftheRSI.ellets p
,wdditionallhenreductionasisCO,there A yg
iscarbonevolutionreactionintheinnerartofel -pplets.ThecarbonsreadstotheinterfacebetweenFe p
Feandivesoffasthrouhboudouardreacand -gggxOtion.Theresultinasressureinelletswillde -ggpp
stroearlformedFefilmsanddamaetheintrinsi- -yyg
calcrstalstructureofelletsandcauselowerre -ypductionstrenthandhiherRSI. gg
,urthermoresinceCOreductionreactionisan F ,exothermicthesamles′realreducrocessellets -ppp
rearametiontemeratureis15Khiherthanset - -pgpp
ters.Thisisanotherimortantinfluencinfactorof pg
resultthattheelletsRSIincreaseswithincreasthe -pincontentofCOinatmoshere. gp
nordertofurtherstudtheeffectofatmos I -y
,ontheRSItheoxidizedwerehereelletsreared pppp
Fehemicalreaentand1.5%oranicbinderwith gg2O3catroastintemeratureof1573K,too.Reducedat gp 1223Kwith100%COand100%H2,bothofthe elletshavehiherRSI(reductionswellinindex) pgg (RSI1.90%;RSI5%).Intheatmos>3 -HCO>42
·12·,ournalofIronandSteelResearchInternationalol.19 J V
hereelletsofCO,thereductionstrenthisalmost ppg
,owder.Aftertotalllostandbecomesreductionin py
,atmosherethewhicharebelletsroducedCO pypp
Feelletshemicalreaenthavethefollowin pgg2O3c
:extremellowcomressionstrenth,serifeatures -ypg ulerizationousandhihreductionindex.Itisbe -pgcausetheelletsarelackofsilicatebondedhasein pp
,roastinonlrelonFeFeecrsrocess -gyyyp2O3-2O3r
tallizationtoenhancethestrenth,andcontainalot g
,dwithinthem.Moreoverurintheoforosit gpy
,rocessofFehemicalreaentelletsreduction pgp2O3c
hasethechanefromhematitetomanetiteisso pggthatinnerstructureisbadldestroed.Malifast -yyg nanceswellinaearsatthesametime. gpp
i.6showstheSEM microorholoof F -mgpgy
Fehemicalreaentafterreductionatellets gp2O3c
1223Kin100%COand100%H2atmoshere.The p
resultisthesameasforeoinanalsis.Whenre -ggy ductionisCO,theironindenasrainsreciitate -ggpp
rainsdriticandcontactsurfacebetweentheis g
,elletssmallbothofwhichleadtodecreaseofthe p
;reductionelletsstrenthandincreaseoftheRSI pg
whenreductionasisH2,theironrainsreciitate ggpp
,s,sinblockshaetructureiscomacttrenthis ppg
,hiherandRSIissmaller. g
,InconclusiontheratioofH2toCOintheat -
moshereshouldbeincreasedashihasossibleand pgp
remisebelowthethatraw materialcharacterand p
inshaftfurnace′practicaloerationarecomrecost -pp
,whensivelconsideredhichnotonlcanenhance yy ,broductionefficiencutalsodecreasethesur -py
roundinload.g
; B—HA—Metalironoles.
()H2; ()abCO.
elletsFi.6 SEM microorholoofFehemicalreaentafterreductionat1223K-m 2O3cpgpgyg
4 Conclusions
)Theoxidizedelletsofusindomesticmanetic 1 pgg
ironconcentrateasraw materialshavefavorablecom -
,includinhihermechanicalrehensiveroerties ggppp
,strenthbothbeforeandafterreductionfasterre -g
ductionrateandlowerRSI.Alloftheseroerties pp
ieldinmeettheshaftfurnacereuirements.can ygq
)T2heRSIincreasedwiththerisintemellets -gp erature.Whenthereductiontemeraturewasbelow pp223K,theentiresamles′RSIwaslowerthan20%.1 p
ithincreaseofthecontentofHnatmos 3)W -2i,,thereductionreactionrateacceleratedhereellets ppandeductiontrenthtrenthened.TheSI r s s Rgg
tobelow10.26%at1323Kin100%H2droed pp
,atmoshereanditisuto39.88%in100%COat -pp
moshere.Aroriatelcontrollinthereduction ppppyg temeratureandincreasintheratioofH2toCOin pg atmoshereareoodfordrointheRSI. pgppg
)Theironmainlinrainsresentedlatelike 4 ygpp
whenelletswerereducedbH2,howeverinCO py
theironweremainlatmoshererainsreciitated pgypp
flocculent.Theironshaeandinrains′whisker pgreductionreaction′heatineffectsarethemaorfac -gj
oorelletstorsleadintothestrenthandincrease ppgg
ofRSI.
heauthorswouldliketothank Proessor T fZHAO ieorQinin Northeastern Universithis jfg-y
uidancehelulandsuestionsinthiswork, gpfgg
romandacknowledethe HYL TechnoloiesInc fgg
Monterrein Mexicoorsulinoerational yfppygp arameters.p
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