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Mineralogy of Iron Ore Sinters, Volume II
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Mineralogy of Iron Ore Sinters, Volume II

A special issue of Minerals (ISSN 2075-163X). This special issue belongs to the section "Mineral Processing and Extractive Metallurgy".

Deadline for manuscript submissions: closed (31 August 2022) | Viewed by 15680

Special Issue Editors

Dr. Mark I. Pownceby

E-Mail Website
Guest Editor
CSIRO Mineral Resources, Private Bag 10, Clayton South, VIC 3169, Australia
Interests: applied/process mineralogy; experimental petrology and phase equilibria; geometallurgy; iron ore characterization and processing (beneficiation, agglomeration, sintering); ore mineralogy; materials characterization (SEM, EPMA, in situ XRD); heavy mineral sand deposits; uranium deposits; hydrometallurgy
Special Issues, Collections and Topics in MDPI journals
Dr. Nathan A.S. Webster

E-Mail Website
Guest Editor
CSIRO Mineral Resources, Private Bag 10, Clayton South, VIC 3169, Australia
Interests: X-ray diffraction; quantitative mineral analysis; in-situ analysis; technique development; iron ore sinter mineralogy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Iron ore sintering is an important stage in the production of steel from iron ore. Sinter can constitute more than 60% of ferrous burden in modern blast furnaces in Japan and most blast furnaces in Europe. Iron ore sintering is a high temperature process which converts iron ore fines (<6–8 mm in size, too small for direct feed into the blast furnace) into larger agglomerates containing bonding phases, unmelted nuclei and pores. The sinter must possess the chemical, physical, metallurgical and gas permeability characteristics required for efficient blast furnace operation and these are controlled in part by the sinter mineralogy. Although a mature field of research, the progressive decline in iron ore grades requires that innovative research into all aspects of the mineralogy of iron ore sinter, including its effect on the physical and mechanical properties, continues. For this Special Issue (Volume II), a follow-up to a 2019 Special Issue, we welcome contributions detailing fundamental physical chemical studies, experimental as well as theoretical, on the mineralogy or iron ore sinters. This includes detailed characterization of the formation mechanisms of sinter mineral phases. We also solicit methodological studies employing cutting-edge analytics. The intention of this Special Issue is that it will contribute to a better understanding of how iron ore sinter mineralogy impacts sinter quality.

Dr. Mark I. Pownceby
Dr. Nathan A.S. Webster
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Minerals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • sinter mineralogy
  • crystal structures
  • phase equilibria
  • characterisation
  • formation mechanisms
  • mineralogy/property relationships

Related Special Issue

Published Papers (6 papers)

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Research

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14 pages, 3893 KiB  
Article
Porosity, Mineralogy, Strength, and Reducibility of Sinter Analogues from the Fe2O3 (Fe3O4)-CaO-SiO2 (FCS) Ternary System
by Isis R. Ignácio, Geoffrey Brooks, Mark I. Pownceby, M. Akbar Rhamdhani, Willian John Rankin and Nathan A. S. Webster
Minerals 2022, 12(10), 1253; https://0-doi-org.brum.beds.ac.uk/10.3390/min12101253 - 30 Sep 2022
Cited by 2 | Viewed by 1683
Abstract
The presence of Ca-ferrite and silico-ferrite-of-calcium-and-aluminium (SFCA) bonding phases is thought to be crucial to maintain sinter quality due to their high reducibility and strength levels. However, new evidence suggests that porosity might be an equally important factor controlling reducibility, in addition to [...] Read more.
The presence of Ca-ferrite and silico-ferrite-of-calcium-and-aluminium (SFCA) bonding phases is thought to be crucial to maintain sinter quality due to their high reducibility and strength levels. However, new evidence suggests that porosity might be an equally important factor controlling reducibility, in addition to mineralogy. This work aims to fundamentally understand the development of porosity in simple sinter analogues from the Fe2O3-(Fe3O4)-CaO-SiO2 (FCS) ternary system (with no SFCA), and to connect results back to overall sinter mineralogy, strength, and reducibility properties. Laboratory-scale experiments were conducted to simulate the sintering process by firing tablets of magnetite, hematite, lime and silica mixtures under tightly controlled temperature, holding time and atmosphere conditions. Mineralogy of the fired samples was observed using microscopy techniques, porosity was measured by Mercury Intrusion Porosimetry (MIP), strength was determined using laboratory-scale tumble index equipment and reducibility was measured by the weight loss obtained after reaction of the tablets in a reducing atmosphere of CO/N2. The results confirmed that reducibility is strongly influenced by porosity, and highly reducible sinters can be produced without forming SFCA-like phases. Magnetite-containing samples had similar reducibility to hematite-containing samples, suggesting that magnetite-based sinters could potentially be used in the blast furnace. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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15 pages, 5332 KiB  
Article
Variation in Iron Ore Sinter Mineralogy with Changes in Basicity
by Tom Honeyands, Thi Bang Tuyen Nguyen, David Pinson, Paul R. J. Connolly, Mark I. Pownceby, James Manuel, Leanne Matthews, John Leedham, Tejbir Singh and Damien P. O’Dea
Minerals 2022, 12(10), 1249; https://0-doi-org.brum.beds.ac.uk/10.3390/min12101249 - 30 Sep 2022
Cited by 3 | Viewed by 2025
Abstract
The target basicity of iron ore sinter is set by blast furnace slag composition requirements, and therefore varies with the proportion of acid burden such as lump iron ore and pellets. Increasing the lump proportion of the burden will increase the target sinter [...] Read more.
The target basicity of iron ore sinter is set by blast furnace slag composition requirements, and therefore varies with the proportion of acid burden such as lump iron ore and pellets. Increasing the lump proportion of the burden will increase the target sinter basicity. The mineralogy of sinter produced with a range of basicity between 1.0 and 3.0 was analysed using optical point counting under reflected light microscopy. Sinter from BlueScope Steel’s industrial sinter strand was analysed over a 30-year period, during which time a wide range of iron ore fines blends were utilised and several significant process modifications made. These data were compared with the mineralogy of sinters produced in a pilot-scale sinter pot, a laboratory-scale milli-pot, and small-scale sinter analogues. The mineralogy of the sinters from all scales followed a predictable trend with basicity, generally following the diagram proposed by Bagnall. At a basicity of 1.0, high temperatures were required to produce sinter with adequate strength, resulting in bonding phases dominated by magnetite and glass. Increasing basicity to 2.0 decreased the required sintering temperature and changed the mineralogy to a majority of hematite and SFCA. Further increases in basicity to 3.0 further decreased the required sintering temperature and increased the SFCA and dicalcium silicate content. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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20 pages, 14210 KiB  
Article
Iron Ore Sinter Macro- and Micro-Structures, and Their Relationships to Breakage Characteristics
by Siyu Cheng, Peter Charles Hayes and Evgueni Jak
Minerals 2022, 12(5), 631; https://0-doi-org.brum.beds.ac.uk/10.3390/min12050631 - 16 May 2022
Cited by 2 | Viewed by 4311
Abstract
A systematic analysis of industrial iron ore sinter product and associated sinter returns was undertaken. The samples were characterised through identification of the major macro- and micro-structural types present in these materials. Examination of the breakage surfaces of the particles indicates a strong [...] Read more.
A systematic analysis of industrial iron ore sinter product and associated sinter returns was undertaken. The samples were characterised through identification of the major macro- and micro-structural types present in these materials. Examination of the breakage surfaces of the particles indicates a strong correlation between mechanical sinter strength and sinter microstructure. Preferential breakage was observed to occur in sinter materials having high porosity and those microstructures consisting of isolated hematite grains in a glass matrix. The bulk of the sinter product consisted of material with a microstructure of magnetite and silico-ferrite of calcium and aluminium (SFCA). The phases formed and the reaction sequences responsible for the formation of the principal microstructure types are explained by the non-equilibrium solidification of melts in the “Fe2O3”-Al2O3-CaO-SiO2 system. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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13 pages, 6964 KiB  
Article
Quantitative Investigation of MgO, Al2O3 and SiO2 Effects on Solid-State Formation of Secondary Hematite in Sintering Process of Iron Ore Fines
by Yan-Bo Chen, Yu Du, Yu-Feng Guo and Xing-Min Guo
Minerals 2022, 12(3), 282; https://0-doi-org.brum.beds.ac.uk/10.3390/min12030282 - 24 Feb 2022
Cited by 1 | Viewed by 1836
Abstract
Secondary hematite (SH) is a serious factor resulting in reduction degradation of iron ore sinter in a blast furnace; however, until now, a quantitative study for SH formation had not been reported. In this work, the effects of gangue composition, including MgO, Al [...] Read more.
Secondary hematite (SH) is a serious factor resulting in reduction degradation of iron ore sinter in a blast furnace; however, until now, a quantitative study for SH formation had not been reported. In this work, the effects of gangue composition, including MgO, Al2O3 and SiO2, on the solid-state formation in the sintering process of iron ore fines were investigated quantitatively. It shows that the SH formation decreased from 67.84% to 46.11%, 35.44% and 22.37% after adding 1.0%, 3.0% and 5.0% MgO, respectively, while for Al2O3, the amount increased to 69.38%, 69.98% and 70.56%, respectively. For SiO2, the amount changed to 68.14%, 61.59% and 47.96%, respectively. Simultaneously, the magnetite (magnesioferrite) formation increased from 8.24% to 34.79%, 50.26% and 70.45% after adding 1.0%, 3.0% and 5.0% MgO, respectively. For Al2O3 and SiO2, the amount changed to 8.95%, 8.37%, 7.62% and 7.62%, 11.10%, 18.77%, respectively, compared with no gangue. This indicates that the SH formation increased with decrease in magnesioferrite. It was found that the decrease in SH formation relates to the diffusion of Mg2+ in magnesioferrite, which inhibits the solid-state formation of SH kinetically. A supposition was suggested that a maghemite existed at a high temperature, and decreased with an increase in MgO addition. This would be another reason to improve the degradation performance of iron ore sinter. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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14 pages, 4339 KiB  
Article
Research on the Preparation of Sinter for COREX Reduction Process by Varying Basicity and MgO Content
by Benjing Shi, Deqing Zhu, Jian Pan and Zhaocai Wang
Minerals 2022, 12(2), 207; https://0-doi-org.brum.beds.ac.uk/10.3390/min12020207 - 06 Feb 2022
Cited by 2 | Viewed by 1155
Abstract
Sinter has been introduced into the composite burden of the COREX ironmaking process in China to lower the material cost, but the proportion is limited due to its poor low-temperature reduction degradation performance in the shaft furnace. This work dealt with the preparation [...] Read more.
Sinter has been introduced into the composite burden of the COREX ironmaking process in China to lower the material cost, but the proportion is limited due to its poor low-temperature reduction degradation performance in the shaft furnace. This work dealt with the preparation of sinter for the COREX process by varying the MgO content and basicity. Their effects on the sintering and reduction properties under reducing condition simulating COREX shaft furnace were investigated, and the changes in the mineralogy of sinter with different MgO content and basicity were explored. The results showed that increasing MgO content affected the sinter strength and solid fuel consumption but restrained reduction degradation of sinter in the shaft furnace. In the basicity range of 0.8–2.6, the strength, RDI+6.3 and RDI+3.15 of sinter all presented a V-shaped curve and the minimum value occurred at a basicity of approximately 1.6. By comprehensive consideration, sinter with 2.35%+ MgO and 2.2+ basicity for COREX process was proposed and verified in industrial tests. Sinter with higher MgO content contained less SFCA and hematite, while glass and SFCA were dominant in the binding phase in sinter with low basicity (0.8) and high basicity (2.6) respectively and were associated with the relatively higher sinter strength. The changes in the mineralogy of sinter determined the variations of RDI of sinter with different MgO content and basicity, by affecting the sinter strength and the probable reduction of inner stress. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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Review

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15 pages, 4270 KiB  
Review
A Short Review of the Effect of Iron Ore Selection on Mineral Phases of Iron Ore Sinter
by Junwoo Park, Eunju Kim, In-kook Suh and Joonho Lee
Minerals 2022, 12(1), 35; https://0-doi-org.brum.beds.ac.uk/10.3390/min12010035 - 25 Dec 2021
Cited by 8 | Viewed by 3700
Abstract
The sintering process is a thermal agglomeration process, and it is accompanied by chemical reactions. In this process, a mixture of iron ore fines, flux, and coal particles is heated to about 1300 °C–1480 °C in a sinter bed. The strength and reducibility [...] Read more.
The sintering process is a thermal agglomeration process, and it is accompanied by chemical reactions. In this process, a mixture of iron ore fines, flux, and coal particles is heated to about 1300 °C–1480 °C in a sinter bed. The strength and reducibility properties of iron ore sinter are obtained by liquid phase sintering. The silico-ferrite of calcium and aluminum (SFCA) is the main bonding phase found in modern iron ore sinters. Since the physicochemical and crystallographic properties of the SFCA are affected by the chemical composition and mineral phases of iron ores, a crystallographic understanding of iron ores and sintered ore is important to enhance the quality of iron ore sinter. Scrap and by-products from steel mills are expected to be used in the iron ore sintering process as recyclable resources, and in such a case, the crystallographic properties of iron ore sinter will be affected using these materials. The objective of this paper is to present a short review on research related to mineral phases and structural properties of iron ore and sintered ore. Full article
(This article belongs to the Special Issue Mineralogy of Iron Ore Sinters, Volume II)
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