Effects of Temperature and Atmosphere on Pellets Reduction Swelling Index

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,():,JOURNALOFIRON ANDSTEELRESEARCH,INTERNATIONAL.20121910071219    -

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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

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

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

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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