Tata Search 2013 .Vol. I (ISSN 0971-5975) P.

89-94

Effect of Ores Granulometry and related Parameters

on the Sintering Indices
R. P. Bhagat1, S. K. Pradhan1, M.C. Goswami2 BIkash Nandi3
and T. Venugopalan3
1: Mineral Processing Division
2: Metal Extraction & Forming Division
CSIR-National Metallurgical Laboratory
Council of Scientific and Industrial Research
Jamshedpur-831 007, INDIA
3: Office of the Chief Technology Officer
Tata Steel Limited
Jamshedpur - 831 001, INDIA
Corresponding e.mail: rpb@nmlindia.org

ABSTRACT
The effect of granulometric composition of ores vis--vis that of sinter mix, on the
sintering indices namely, productivity, reduction degradation index (RDI) and tumbler
index (TI) was studied through the pot sintering experiments with Joda and Noamundi
ores of Tata Steel. These ores had LOI content 3.8% and 2.9% and +6.3 mm content
45% and 26% respectively. Sinter basicity (CaO/SiO2) and MgO content were varied in
the 2.1-2.5 and 1.4% to 1.8% range, respectively according to the blast furnace
requirement.

At 2.1 sinter basicity and 4 % coke (ash: 22%) in the mix the productivity with Noamundi
ore was lower than that with Joda ore. In case of Noamundi ore the RDI value was high
at 4% coke which decreased significantly to 29% with 5% coke. The size parameter of
ore fines and its LOI content do influence the sintering speed and the sinter properties.
At 2.1 basicity ratio, the sinter with Joda ore having coarser granulometry had highest TI
(=70.2%). The RDI (27%) in this case was inferior to that (23.2%) when Joda ores with
finer size was sintered. Better RDI with finer sized ore could be attributed to better
assimilation of CaO/MgO with more balanced and uniformly distributed hematite
minerals. With the lower mean sized Joda ore improvement in sinter RDI (23%) and
productivity {42.9 T/(sq m*d)} could be achieved when the percentage of solid fuel in mix
increased from 4% to 5%. An attempt to reduce the coke in the mix from 5% to 4% with
respect to both the ores was not successful as it resulted higher RDI and lower strand
productivity.
The present study has revealed that sinter RDI decreased with decrease in sintering
time, while such correlation was absent between TI of sinter and speed of sintering.
Besides, higher FeO sinters has displayed excellent RDI, however cold strength of sinter
was not correlated with its FeO content. The TI and RI parameters of sinter improves
marginally with increase in its MgO content while RDI got worsened. Such correlations
could be useful to decide the levels of parameters (at fixed sinter chemistry) to increase
the sinter productivity without affecting its strength.

INTRODUCTION

The reduction-degradation index (RDI) and reducibility(RI) are important properties of

sinter which do influence the blast furnace performance significantly when charged as
[1-2].
burden material A close relationship between the coke rate and RDI of sinter has been
[3].
established Understandably, the fines generated inside in the stack zone of the furnace
or during reduction from the sinter with poorer RDI affect the permeability of the stack
zone, increase the pressure drop and disturb the gas distribution. These factors adversely
affect the CO utilization with ultimate consequence of higher coke rate and lower
productivity.

The sinter properties, strength and reducibility are influenced by the mineralogical and
[4],
morphological characteristics of sinter besides its chemical composition , especially with
[5].
respect to the gangue content (intrinsic water) Calcium ferrite happens to be the main
bonding phase in the fluxed sinter which increases with the increase in sinter basicity.
Shigaki et al. [6] report that increase in calcium ferrite(s) and magnetite are some of the crucial
factors which affect the RDI value of sinter positively which is greatly influenced by its
basicity[7] . Satokha et al. [8]
observed that influence of sinter basicity on its porosity. The fact
that calcium- rich ferrites with increase in basicity impart beneficial properties of strength and
reducibility to the fluxed sinter has been accepted[9]. The particle size of the mix ingredients,
flux and coke breeze, particularly do influence the reduction properties of sinter and its
[10].
strength The mineralogical and morphological characteristics of ore have crucial role in
deciding sinter mineralogy including the pore structure of sinter since the reaction between
the lime and iron bearing minerals is facilitated by limiting the grain size of the feed materials.
It is reported earlier that the sintering of ore fines having reduced size resulted in sinter with
increased micro-porosity and decreased size of pores [11].
In Tata Steel the ore requirement for its sintering plants are catered by its captive mines
namely, Noamundi and Joda. Broadly, these belong to banded iron formation (BIF) and can be
[12].
classified into hard ore (massive/ laminated), friable/flaky ore, laterite ore and blue dust
Their proportion in the ore decides its LOI content. These ores have different mineralogical
and morphological characteristics[13]. As a consequence, the sintering characteristics of these
[14]
ores on individual basis are expected to be different. Nandy et al. studied the effect of ore
quality on sinter strength and correlated the difference in LOI in case of Noamundi and Joda
[15]
ores with sinter strength. Pandey et al. outlined the influence of hematite and other mineral
[16]
phases in sinter on its RDI characteristics. Bhagat et al. have reported that a significant
improvement in the reduction properties of sinter could be achieved at sinter basicity
(Cao/SiO2 : 2.1) by narrowing down the flux size and use of proper sized solid fuel.

During the recent years a continuous shift has been made by Tata Steel towards the use of
higher proportion of Joda fines in their sintering plants. In view of this, it becomes necessary to
study the sinterability of Joda ores vis-a-vis Noamundi ore and optimise the process
parameters. These have been attempted in the present work. The exercise to optimise the
size parameter of the ore in the sintering, perhaps, bridges the gap in the studies made so far.

MATERIALS AND METHODS

Raw Materials

The ore fines from Noamundi mines and Joda mines (two different sources) of Tata Steel,
India, was used in the present study. The + 10 mm size fraction of Joda ores were crushed to
10 mm and then mixed to the remaining 10 mm size fractions and homogenized (Joda I).
In order to study the size effect in relation to ore fines, +6.3 mm size fraction of Joda ore (~ 45
wt.%) was crushed to -6.3 mm size fraction, mixed and homogenised (Joda I#). Another ore
sample was taken from the recent lot having higher LOI . It consisted of 100 wt.% -10 mm
size fraction (and 78.5 wt.% -6.3 mm size fraction). The sample was homogenised uncrushed
(Joda II). Similarly the Noamundi ore (containing 4.8 wt.% +10 mm size fraction) was
homogenised (Noa).

Other raw material ingredients namely, limestone, dolomite, coke breeze were collected from
Tata Steel and prepared according to the sinter plant practice for the pot sintering
experiments. These materials were homogenized and characterized in terms of sieve and
chemical analyses.
Figures 1 and 2, respectively show the size analysis of these samples. The median size and
harmonic mean diameter (Dp) of these samples are given in Table 1. Dp, has been calculated
from the weight percent , Wi, having the average size Di : Dp = 100/ (Wi/Di). Table 2 shows
the chemical analysis of iron ore fines and other mix ingredients used in the sintering studies.

[17] [18]
The mineralogy of Noamundi and Joda Ores has been described elsewhere. Noamundi
ore consisted of hematite and goethite inter-mixed with limonite as main mineral phase,
whereas gibbsite was present in minor amount. Other minerals that were present in minor to
trace amount include magnetite, quartz/ chert, feldspar, clay, mica (muscovite) and amphibole/
pyroxenite. The Joda ore contained hematite and goethite as main mineral phases. The
goethite contained oxides of aluminium and silicon within its matrix as impurities [19] .

Sintering

Sintering experiments were planned according to the conventional design in order to select the
levels of the variable in the range acceptable to the operators of sinter plant. The technique of
continual search for the optimum result of sinter quality namely, TI, RDI, RI was followed.

Sintering tests were carried out in a batch square shaped sintering unit of 30*30 sq. cm cross
sectional area with 550 mm high sinter box having removable grate bar at the bottom. The
sinter mix prepared in a disc pelletiser was put into the pot up to the top layer level and ignited
for 2 minutes. Heat input for ignition: 24 thousand Kcal /m2* min. (100*106 J/m2 *min). Vacuum
was maintained by operating the exhaust fan till the completion of sintering which was known
from the temperature of the wind box (burn through point). The sinter was allowed to cool
under suction till the temperature of exhaust gas reaches 100oC. The sinter cake was then
dislodged and subjected to stabilisation / shatter test. Lime in mix was fixed at 1 wt.%

Phyisco-Chemical Tests of Sinter

IS 9963:1981 and IS 6495:1984 were followed for the shatter and tumbler tests respectively.
+10 mm size sinter was dropped from a height of two meters on a steel plate three times The
material was screened on 10 mm screen. The percentage of +10 mm was taken as shatter
strength. Representative samples of +10 mm size was collected for Tumbler test. followed for
the tumbler test. 11.4 kg + 10 mm sized sinter sample was subjected to tumbling for 200
revolutions in a 1000 mm dia. * 500 mm width drum. The material was then taken out and
screened on a 10 mm/ 6.3 mm screens. Percentages of +6.3 mm size fraction were taken as
tumbling index
Stabilized-15+10 mm sized sinter sample was collected for reducibility and reduction
degradation index tests.
Reducibility test were carried out at 900c by passing 30%CO+70%N2 gas at 5 dm3 / min for
period of 180 minutes. The reducibility index is calculated as follows.
RI= (loss in weight of the sample/weight of available oxygen in sample)100
RDI test is carried out at 550c under the flow of N2 gas and is stabilized for 10 minutes,
followed by 70% N2 and 30% Co gas low for thirty minutes and is cooled under N2 gas flow at
the rate of 5 lit./min.The cold sample is then taken in a rotated drum (200mm length and
130mm ID) having two lifters for 30 minutes at 30 rpm.It is screened through 3.15mm and RDI
value is computed as follows.
RDI= (Wt. of -3.15mm fraction/ Wt.of sample taken for experiment) 100

RESULTS AND DISCUSSIONS

Response Variables
The response variables are as follows:

Vertical speed of sintering, VSS (mm/min) : the ratio of average bed height (in mm)
and the time of sintering (in minute).

Tumbling index (TI) : The percentage of +6.3 mm remained after tumbling the 11.4 Kg
mass of sinter (+10 mm) in a standard tumbler test apparatus (ASTM E279-97) for a
total of 200 revolutions.

Strand productivity (P+10):

Charge weight *Yield of sinter (%+6.3 mm after 3 drops) # (T)
Cross sectional area of pot (sq.m) *100 * Time of sintering (d)
Yield of sinter: Wt. % +6.3 mm size fraction of after 3 drops in shatter test on steel plate
from 2 m height.
Time of sintering (in minute) : Completion of the sintering process in pot .
RDI : Percentage of 3.15 mm size fraction generated after tumbling in a standard
tumbler for 900 revolutions following reduction under standard condition
RI: % loss in weight of the sinter sample after reduction under (30%+70%) CO+N2
atmosphere for 3 h at 900 deg.C to the total weight of available oxygen in the sample
Effect of Nature of Ore fines

Assimilation Characteristics The sinter-ability of ore fines varies which depends, besides its
granulometric composition, on its nature. A higher assimilation is observed for porous ore and/
[20] [14]
or ore with high gangue content which is reflected through the study by Nandy et al. who
report that the tendency of melt formation of Joda ore was faster than Noamundi ore.

Table 3 shows the results with Joda and Noamundi ores. It is evident from Table 3 that the
productivity as well as sinter RDI with Noamundi ore fines was inferior to that when Joda I ore
[13]
fines was used in the mix. The result is similar to that observed previously . Noamundi ore,
although had higher +6.3 mm size fraction (than Joda ore), had lower median size and much
lower harmonic mean diameter (than Joda Ore) (See Table 1). This shows that size distribution,
in case of Noamundi ore was skewed towards higher size. That is, dispersion of size modulus
in case of Noamundi ore was larger than that in case of Joda ore, similar to that of previous
[16].
sample Besides, Noamundi ore was purer than Joda ore with lower LOI content. It is
[13].
reported that Noamundi ore has higher assimilation temperature than Joda Ore Increase in
assimilation temperature results in lower amount of melt which might have resulted in sinter
having higher reducibility and consequently higher RDI.

It is reported that the sinter mix at 2.5 basicity ratio consisting of higher proportion of massive to
hard laminated hematitic ore had lower permeability than that which consisted of higher
[21].
proportion of soft-laminated to goethite mineral This resulted in poorer productivity (in case
of hard laminated ore) although a marginal increase in the sinter yield was observed. The
massive to laminated ore when blended in higher proportion with laminated to soft-laminated
[21].
ore had increased green permeability and subsequently an improved productivity This has
been reflected in our earlier studies: Noamundi ore and Joda ore, when blended in 70 : 30
proportion has resulted in improved sintering indices [16].. Similar results have been made in the
previous studies [13]

Interaction with Solid Fuel Content It is apparent from Table 3 that the sintering indices were
highly poor for both the ores at 4% coke [Ash: 22%] in the mix. When the amount of coke
increased to 5% a significant improvement in productivity, mainly through lowering of sintering
time and sinter RDI was observed for both Noamundi and Joda ores (Table 4). In the present
case Joda ore crushed to -6.3 mm size [Joda 1#] was used. The present observation is similar
[22]
to Kasai et al. who report that the sintering time had a minimum value at about 4.2 wt. % of
coke and is prolonged with increase in coke content.
Effect of Size Parameters of Ore Fines
The size parameters of ore fines do influence the sintering process because it affects the
[22].
granulation process and in turn the sinter bed permeability It is generally accepted that with
the increase in percentage of fine grains in the sinter mix the permeability of sinter mix and
[23,24].
hence the sintering speed decreases On the other hand, if the proportion of coarse grain is
high, the heat content of the waste cannot be sufficiently absorbed by the solid, besides, the
bonding by diffusion decreases.

Table 5 indicates that at 4 wt.% coke in the mix the sinter RDI decreased whereas TI increased
with decrease in +6.3 mm size fraction from 17.3 wt.% (Joda I ) to 0.3 wt.% (Joda I#), besides
the productivity improves mainly through increased sinter yield. Similar to the results achieved
[25],
earlier this can be attributed to better assimilation characteristics at reduced median size
from 2.3 mm to 1.9 mm (Table 1). The sinter RDI reduced further to a significant low value
(23.3 %) when the coke breeze amount increased to 5 wt.%. Besides, the strand productivity
increased (at 5 % coke) significantly (at 5 % coke).

The grain size of the feed material does have crucial role in deciding sinter mineralogy since the
reaction between the lime and iron bearing minerals is facilitated by limiting the grain size of the
[23].
feed materials. Besides, the heat content of the gas is absorbed more effectively By limiting
the particle size of feed materials, the reaction between lime and other constituents is greatly
facilitated. The period of fusion need not be prolonged; therefore less coke is required. This also
increases shatter index of the sinter since the heat content of the gas is absorbed more
effectively. It is reported earlier that the sintering of ore fines having reduced size resulted in
sinter with increased micro-porosity and decreased size of pores .

Table 5 shows that the speed of sintering decreased marginally when the size of ore fines was
reduced to 100% -6.3 mm size (Joda I#), from 83% -6.3 mm (Joda I) at 4 wt.% coke in the mix.
However, the sintering time was significantly lower (18 min.) with 5% coke even for finer sized
Joda ore (Joda I#). Perhaps the kinetics of assimilation of finer sized ore could be higher at
higher than 4% coke breeze (ash 22 wt.%) and 5 wt. coke could be near to optimum

Relationship between Speed of Sintering and Sinter Properties

The cold strength of sinter did not have any correlation with the sintering speed (Fig. 3). This
reflects that the sinter of high cold strength could be produced with simultaneous enhancement
of the productivity. One need to take advantage of other stronger process parameters by
optimizing them. Interestingly, a trend has been established in the present work where RDI
increased with the increase in the time of sintering (Fig. 3). This means the permeability of the
bed which undergoes the process of sintering has significant influence on sinter RDI.

Relationship between Sinter FeO and its Properties

The degradation of sinter at lower temperature is caused by the structural modifications during
[28]
reduction of hematite to magnetite. Volume expansion in the process could be around 4%
which results in development of mechanical stresses which are relaxed by crack propagation. In
the present study the cold strength of sinter bears no direct correlation with the FeO content of
sinter (Fig.4). Interestingly a feebly indirect correlation has been observed in case of sinter RDI.
Higher FeO sinters display excellent RDI property (Fig. 4): the result is similar to that obtained
earlier in case of Tata steel ores [17].

CONCLUSIONS

The ores from captive mines of Tata Steel namely, Noamundi and Joda vary in terms of their
granulometric composition , besides the mineralogical characteristics which do affect their
sinter-ability.
The vertical speed of sintering (VSS), productivity and RDI of sinter in case of Noamundi ore
are marginally inferior to those in case of Joda ore. This may be attributed to poorer
assimilation characteristics of Noamundi ore compared to Joda ore (Noamundi ore has
higher assimilation temperature than Joda)

The size parameter do play a crucial role in affecting the sintering characteristics of the ore
fines. In general the hematite ore has higher TI. The apparent effect of such increase in TI
and productivity could be contributed by the ore itself part of which may remain un-sintered
in the sinter mass.
The reduction degradation index (RDI) of sinter and its productivity improves significantly
with the (Joda) ore of reduced median size from 2.3 mm to 1.9 mm ( 6.3 mm size fraction).
5 wt. Of coke (ash 22.14%) in the sinter mix seems to be minimum possible solid fuel
requirement in the present study as a decrease in coke to 4 wt.% reduces the productivity of
sinter and deteriorates the RDI.
The requirement of coke is inter-influenced by the size parameter of ore fines. With lower
sized Joda ore (100% -6.3 mm) the sinter RDI as low as 23.3% and productivity as high as
43 T/ (sq.m*d) has been achieved with 5wt. coke in the mix. Besides, the sintering time
 decreases significantly in case of Joda (also Noamundi) ore with the increase in amount of
coke in the mix from 4% to 5%.

A direct, but weak correlation has been observed between the time of sintering and RDI of
sinter (both increases) while such correlation was absent between TI of sinter and speed of
sintering. Corollary to this observation, one can take advantage other stronger parameters
to increase the sintering speed without affecting the sinter strength.
In the present study higher FeO sinters has displayed excellent RDI, however cold strength
of sinter was not correlated with its FeO content. The Ti and RI parameters of sinter
improves marginally with increase in its MgO content. However sinter RDI got worsened.

Acknowledgement
The authors express their deep sense of gratitude and appreciation to the Management of Tata
Steel and Director, NML for the support to the present research. They thank Mr. T Chakraborty,
Tata Steel for discussion on the work. The assistance rendered by Mr. D. P. Singh MEF-NML
and Dr. Jayant Konar and his team ANC-NML for RDI / RI measurement and chemical analysis
respectively.

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CONCLUDED
List of Figure Captions

Fig. No. Caption

1 Size analysis of Noamundi and Joda Ores

2 Size analysis of other mix gradient

3 Relation between VSS and sinter properties

4 Relation between FeO and sinter properties

List of Table Titles

Table No. Title

1 Size parameters of iron ore fines and other mix ingredients

2 Chemical analysis of iron ore fines and other mix ingredients

3 Indices of sintering with Joda ore fines I and Noamundi fines

(Basicity ratio 2.1, Moisture in mix 5%, Bed height 550 mm, Coke 4%)

4 Indices of sintering with Joda ore fines I and Noamundi fines

(Basicity ratio 2.1, Moisture in mix 5%, Bed height 550 mm)

5 Indices of sintering with Joda ore fines of varied size

(Basicity ratio 2.1, Bed height 550 mm, Coke 4%)
 Table 1: Size parameters of iron ore fines and other mix ingredients
Parameter Iron ore fines Lime- Dolo Coke
stone mite
Joda I Joda I# Joda II Noa
Median size , mm 2.3 1.9 3.3 2.0 1.05 1.65 2.12
Harmonic mean 0.58 0.49 0.81 0.30 0.26 0.47 0.57
diameter, mm

Joda I : contains 17.28 wt.% +6.3 mm

Joda I# + 6.3 mm size fraction was crushed to -6.3 mm and mixed

Table 2: Chemical analysis of iron ore fines and other mix ingredients
Constituents Fe% Al2O3% SiO2% CaO % MgO % LOI %
Iron Ore, Joda I 63.62 2.84 1.58 0.13 Nil 3.82
Iron Ore, Joda II 63.01 2.40 1.65 ND ND 4.34
Iron Ore, Noa 64.85 2.27 1.73 0.16 Nil 2.91
Coke breeze (Ash: 22.14%) 14.36* 21.24* 42.20*
Limestone 1.12 0.86 2.43 52.50 1.18 40.39
Dolomite 2.88 0.88 1.91 31.42 16.86 43.50
Table.3: Indices of Sintering with Joda ore fines I and Noamundi fines
(Basicity ratio 2.1, Moisture in mix 5%, Bed height 550 mm, Coke =4% )

Ore fines Tumbler RDI RI % Sinter Prod.

Type + 6.3mm LOI index % FeO T/m2/d
Joda I 17.3% 3.82 49.6% -39.4 88.5 %12.3 27.7
Noa. 26.5% 2.91 55.4% 3.1m
48.0 91.8 13.3 21.7
m%

Table.4: Indices of Sintering with Joda ore fines I and Noamundi fines
(Basicity ratio 2.1, Moisture in mix 5%, Bed height 550 mm)

Ore fines Sinter. TI % RDI RI % Sinter Prod. Coke

Type + 6.3mm LOI Time % FeO % T/m2/d %
Noa. 26.0 2.91 32 min. 55.4 48.0 91.8 13.3 21.7 4
Noa. 26.0 2.91 23 min. 51.7 29.0 81.3 13.9 34.1 5
Joda I# 0.3 3.82 25 min. 51.7 35.4 83.9 13.0 30.7 4
Joda I# 0.3 3.82 18 min. 51.9 23.3 80.6 15.7 43.0 5
# : +6.3 mm size fraction crushed to 6.3 mm size fraction and mixed

Table.5: Indices of Sintering with Joda ore fines of varied size

(Basicity ratio 2.1, Bed height 550 mm)

Ore fines Coke Sinter Tumbler RDI RI Sinter Prod.

Type + 6.3mm % Time index,% % % FeO T/m2/d
Joda I 17.3% %4 22 min. 49.6 -39 88.4 12.3 27.7
mix 3.1m
Joda I# 0.3% 4 25 min. 51.7 m35% 83.9 13.0 30.7
Joda I# 0.3% 5 18 min. 51.9 23.3 80.6 15.7 43.0

# : +6.3 mm size fraction crushed to 6.3 mm size fraction and mixed