Iron ore sinter is produced from fine-grained ore in order to provide a direct charge to the blast furnace. During the sinter production process fine sinter is produced that is not acceptable as feedstock for the blast furnace. This fine material is screened off and returned to the sinter plant to be recycled. The production of these recirculating fines therefore results in loss of revenue for the sinter producing facility. The aim of this study is to compare the composition and phase chemistry of the fine and normal sinter to determine if chemical or operational changes can be made to reduce the amount of fine sinter formed. This will be achieved through the analyses of real industrial sinter samples, synthetically produced lab-based samples and sinter test pot samples. Iron ore sinter was collected from the Vanderbijl Park sinter plant in South Africa. The samples were prepared for X-ray diffraction (XRD) and X-ray fluorescence (XRF) analysis to test the reproducibility of the equipment used as well as the reproducibility of the sample preparation method. The results obtained showed that the methods applied produced accurate results and the preparation method was then applied on all samples that were analyzed. The XRD analyses show that the sinter contains spinel (mainly magnetite with variable Mg), hematite, dicalcium silicate (C2S) and silico ferrite of calcium and aluminum (SFCA) and that there are distinct differences between the fine and normal sinter. Fine sinter contains more hematite and less SFCA than normal sinter. The presence of the SFCA is considered to be essential for the production of strong sinter. The XRF analyses show that there are no distinctive differences in the chemistry of fine and normal sinter. The samples were then analyzed with an electron microprobe. It was found that the compositions of some of the SFCA phases present in the samples do not correspond to those described in the literature. Optical microscopy combined with point counting was conducted on the fine and normal sinter in order to determine differences and to compare the point counting data to the XRD results. The point counting results showed that the hematite present in the fine sinter is largely relict or unreacted hematite. Sinter pot test samples were analyzed with XRD and XRF. It was found that the pot test samples exhibited similar trends as the samples taken at the sinter plant. This shows that it is not only plant parameters such as sample transport that result in the formation of fines, but that carbon addition, flame temperature and reaction time may also play a role in the formation of fine sinter material. It has been concluded that the production of fine sinter is a direct function of the amount of hematite present in the sinter. The proposed hypothesis for this phenomenon involves the incomplete reaction of the sinter material during processing. Suggestions to decrease the amount of fine sinter formed include: uniform heat distribution during ignition, pO2 alteration by reductant addition, lower ignition temperature, regulating the cooling regime and decreasing the grain size of lime. / Dissertation (MSc(Applied Science))--University of Pretoria, 2008. / Materials Science and Metallurgical Engineering / unrestricted

The effect of replacing fine ore by coarse ore on sintering reactions was investigated using an infrared furnace on laboratory scale and sinter pots on pilot plant scale. Five sinter mixes were prepared by changing the percentage coarse ore from 0% to 100% in 25% increments. Coarse ore fraction, sintering temperature, holding time and oxygen partial pressure were selected as sintering parameters, and two-level factorial design was used for identification of parameters that significantly influence the formation of sinter phases. Experimental results showed that the coarse ore fraction has a higher effect on the sintering process compared to those of other parameters. The experiment design also enabled to set these parameters to their optimum values. The porosity of compacted pellets was measured using a helium pycnometer. The replacement of fine ore by coarse ore resulted in a decrease in porosity (increase in packing density) of compacted pellets. The particles are closer to each other in pellets consisting of more coarse particles than fine particles. Laboratory experiments were performed at 1300°C in air, using a high heating rate (15°C/s). The holding time was set to 2.5 minutes. X-ray diffraction (XRD), reflected light microscopy (RLM), scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) were used to characterize sintering reactions and sinter phases. XRD analysis revealed that sintered pellets consisted of hematite, SFCA, SFCA-I and calcium silicate. The proportions of SFCA slightly increased when the fraction of coarse ore varied from 0% to 25%, but decreased with a further increase in percentage coarse ore. At 25% coarse ore fraction, the porosity of the compacted pellets decreased, resulting in an increase in packing density and sintering rate. More hematite reacted, resulting in the formation of high amounts of SFCA. Above 25% coarse ore fraction, the amount of hematite increased, and the concentrations of columnar SFCA decreased despite a further decrease in porosity. This was attributed to the decrease in reaction surface area for coarse ore, and the short reaction time, which limited the extent of reaction of the coarse particles. The variation of SFCA-I and calcium silicate was not significant under laboratory conditions. Reflected light microscopy and SEM analysis easily identified two major sinter phases: hematite and SFCA. A clear distinction between the different types of SFCA could not be made using EDS analysis. Sinter pot tests were carried out in order to examine the effect of coarse ore fraction on physical and metallurgical properties of sinters. The tumbler and reduction disintegration indexes increased with increasing coarse ore fraction in the sinter bed. This was presumably due to the increase in amounts of hematite and decrease in surface area for reaction. Consequently, the reducibility of sinter decreased as the percentage coarse ore increased. This study has concluded that the presence of 25% coarse ore in the sinter mix led to enhance sintering reactions. The amounts of SFCA increased, and sinter quality was improved. It is recommended that in future work, sintering reactions should further be investigated by also measuring the permeability of the sinter bed and the reaction surface area of solid particles. Copyright / Dissertation (MSc)--University of Pretoria, 2012. / Materials Science and Metallurgical Engineering / unrestricted