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Ferrous Metals Waste Production and Recycling
Published in Sehliselo Ndlovu, Geoffrey S. Simate, Elias Matinde, Waste Production and Utilization in the Metal Extraction Industry, 2017
Sehliselo Ndlovu, Geoffrey S. Simate, Elias Matinde
According to Lu and Ishiyama (2016), sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. The sinter plant is an essential step in the integrated iron and steelmaking process and is typically used in the agglomeration of iron ores and fine-grained recycled iron-bearing materials such as dusts, sludge and mill scales (Lanzerstorfer, 2015). In essence, sintering is an agglomeration process achieved through the combustion of coke fines mixed with moist iron ore fines around 1300°C–1480°C in a sinter grate, resulting in the incipient fusion of ore particles containing interspaced hematite and magnetite phases (Ball et al., 1973; Biswas, 1981; Remus et al., 2013; Lanzerstorfer, 2015; Lu and Ishiyama, 2016). The typical raw materials for the sinter process consist of a mixture if fine ores, coke breeze, fluxes (e.g. lime and olivine) and recycled iron-bearing materials from downstream operations such as coarse dust and sludge from off-gas cleaning systems (Ball et al., 1973; Biswas, 1981; Remus et al., 2013; Lu and Ishiyama, 2016). Coke breeze is used as fuel to supply the thermal energy required for the incipient fusion of feed materials (Lanzerstorfer et al., 2015) and is usually consumed at a rate of about 44–64 kg/ton of sinter (Remus et al., 2013).As the raw materials mixture is ignited in the sinter grate, a series of solid state and heterogeneous physicochemical reactions take place between the melt, solids and gaseous phases in the sintering zone to produce a product possessing the requisite size and strength characteristics suitable for feeding into the blast furnace (Ball et al., 1973; Biswas, 1981).
Material Metabolism and Environmental Emissions of BF-BOF and EAF Steel Production Routes
Published in Mineral Processing and Extractive Metallurgy Review, 2018
Xiaoling Li, Wenqiang Sun, Liang Zhao, Jiuju Cai
With regard to environmental emissions, the sintering and ironmaking processes are the two main processes creating dust emissions. The main emission sources of dust in the sintering process are the sintering machine head and the discharge end of the tail. The cast house is the main source of dust emissions in the blast furnace process. The maximum DSO2 and DNO2 values occur in the iron ore sinter plant. The SO2 in the sintering flue gas mainly comes from the combustion of sulphur compounds, primarily introduced by the coke. Therefore, SO2 emissions can be reduced by using raw materials with low sulphur content and saving the fuel consumption. In addition, the particle size distribution has a very important effect on SO2 emissions. Replacing the conventional particle size (<3 mm) with a larger particle size (5~6 mm), as recommended by BAT, can significantly reduce SO2 emissions. The combustion of organic nitrogen in the sinter materials is the main reason for the formation of NO2. The results of this study are consistent with the results of an equivalent pollution load analysis from seven iron and steel enterprises (Yang, 2013) for each process.
Accidents and injuries in workers of iron and steel industry in West Bengal, India: Prevalence and associated risk factors
Published in International Journal of Occupational Safety and Ergonomics, 2022
Rahul Rajak, Aparajita Chattopadhyay, Priya Maurya
The study was conducted only on male workers (N = 505). Workers in the age group 18–60 years who continuously worked for more than 1 year on a permanent or contractual basis were included in the study. Additionally, workers who consented were included in the study. Female workers were excluded from this study due to the minuscule sample in the industry. The study participants were involved in the following seven departments of the industrial unit representing the overall scenario of work characteristics: coke oven, blast furnace, continuous casting plant (CCP) and coal handling plant (CHP), rolling mill, sinter plant, basic oxygen furnace (BOF) and maintenance department.
Reagents types in flotation of iron oxide minerals: A review
Published in Mineral Processing and Extractive Metallurgy Review, 2018
Fardis Nakhaei, Mehdi Irannajad
The adverse effect of alumina on sinter strength productivity and its reduction degradation characteristics are well documented. The blast furnace productivity is also significantly influenced by the presence of alumina in the feed. The high alumina content in iron ore results in highly viscous slag and high coke rate and thus is harmful to blast furnace and sinter plant operations. In the blast furnace burden, 1% increase of alumina content increases coke rate by 2.2%, decreases the productivity by 4%, and increases flux consumption by 30 kg/t of hot metal production.