Effect of magnesia on the compressive strength of pellets

The compressive strength of MgO-fluxed pellets was investigated before and after they were reduced. The porosity and pore size of green pellets, product pellets, and reduced pellets were analyzed to clarify how MgO affects the strength of the pellets. Experimental resuits show that when the MgO-bearing flux content in the pellets increases from 0.0wt% to 2.0wt%, the compressive strength of the pellets at ambient temperature decreases, but the compressive strength of the pellets after reduction increases. Therefore, the compressive strength of the pellets after reduction exhibits no certain positive correlation with that before reduction. The porosity and pore size of all the pellets （with different MgO contents） increase when the pellets are reduced. However, the increase in porosity of the MgO-fluxed pellets is relatively smaller than that of the traditional non-MgO-fluxed pellets, and the pore size range of the MgO-fluxed pellets is relatively narrower. The reduction swelling index （RSI） is a key factor for governing the compressive strength of the reduced pellets. An approximately reversed linear relation can be concluded that the lower the RSI, the greater the compressive strength of the reduced pellets is.

Gas-solid reduction kinetic model of MgO-fluxed pellets

The reduction process of MgO-fluxed pellets was investigated and compared with traditional acidic pellets in this paper. Based on the piston flow concept and experimental data, a kinetic model fitting for the gas-solid phase reduction of pellets in tubular reactors （blast furnace, BF） was built up, and the equations of reduction reaction rate were given for pellets. A series of reduction experiments of pellets were carried out to verify the model. As a result, the experimental data and calculated result were fitted well. Therefore, this model can well describe the gas-solid phase reduction process and calculate the reduction reaction rate of pellets. Besides, it can give a better explanation that the reduction reaction rate （reducibility） of MgO-fluxed pellets is better than that of traditional acidic pellets in BF.

Combustion characteristics of unburned pulverized coal and its reaction kinetics with CO2

The combustion characteristics of two kinds of unburned pulverized coal (UPC) made from bituminous coal and anthracite were investigated by thermogravimetric analysis under air. The reaction kinetics mechanisms between UPC and CO2 in an isothermal experiment in the temperature range 1000–1100°C were investigated. The combustion performance of unburned pulverized coal made from bituminous coal (BUPC) was better than that of unburned pulverized coal made from anthracite (AUPC). The combustion characteristic indexes (S) of BUPC and AUPC are 0.47 × 10^-6 and 0.34 × 10^-6 %2·min^-2·°C^-3, respectively, and the combustion reaction apparent activation energies are 91.94 and 102.63 kJ·mol^-1, respectively. The reaction mechanism of BUPC with CO2 is random nucleation and growth, and the apparent activation energy is 96.24 kJ·mol^-1. By contrast, the reaction mechanism of AUPC with CO2 follows the shrinkage spherical function model and the apparent activation energy is 133.55 kJ·mol^-1.

Diffusion behavior and distribution regulation of MgO in MgO-bearing pellets

In this paper, the diffusion behavior between MgO and Fe2O3（the main iron oxide in pellets） is investigated using a diffusion couple method. In addition, the distribution regulation of MgO in MgO-bearing pellets is analyzed via pelletizing experiments. The results illustrate that MgO is prone to diffuse into Fe2O3 in the form of solid solution; the diffusion rate considered here is 13.64 μm·min^（-1）. Most MgO content distributes in the iron phase instead of the slag phase. The MF phase {（Mg（1-x）Fex）O·Fe2O3, x ≤ 1} is generated in the MgO-bearing pellets. However, the distribution of MgO in the radial direction of the pellets is inconsistent. The solid solution portion of MgO in the MF phase is larger in the outer layer of the pellets than in the inner layer. In this work, the approximate chemical composition of the MF phase in the outer layer of the pellets is {（Mg（0.35-0.77）·Fe（0.65-0.23）） O·Fe2O3} and in the inner layer is {（Mg（0.13-0.45）·Fe（0.87-0.55））O·Fe2O3}.

Characteristics of Calcined Magnesite and Its Application in Oxidized Pellet Production

Calcined magnesite is a binding additive and an MgO-bearing flux for pellets production. The effects of cal- cination temperature and time on the characteristics of calcined magnesite were investigated. Experimental results in dicated that the best calcination condition was 850℃ and 1h. Under this condition, the hydration activity of the eal cined magnesite was 80.56%, and the average diameter of crystal grain D, specific surface area S and the medium particle size D50 were 25.4 nm, 45.40 m2/g and 3.41μm, respectively. This kind of calcined magnesite was a good binding additive for pellets production. At the same proportion of calcined magnesite, the effects of activities of cal cined magnesite on metallurgical properties of green pellet and indurated pellet showed that calcined magnesite with high activity could improve the dropping strength and compressive strength of green pellet and enhance the burst temperature of green pellet; however, the effects of activity on compressive strength, low-temperature reduction degradation index, reduction swelling index and reduction index of indurated pellet were not obvious.

Fundamental mechanism of effects of MgO on sinter strength

MgO-containing flux may have a series of effects on the quality of sinter and performances of the blast furnace.Thus,the fundamental mechanism of the effects of MgO on the sinter strength was investigated.Both the chemical reagent and industrial flux were used for preparing the specimens.The experimental results show that the sinter strength decreases with MgO addition.There are three reasons for it.The first reason is diffusion rate.Almost all of the CaO may react with Fe2O3 and generate CaO Fe2O3,but most of MgO cannot react with Fe2O3,and it still remains in the state of original minerals.The diffusion rate of MgO in iron oxide is only 17.51μm/min in 30 min.The second reason is the fluidity and ability to generate liquid phase.In the case of Fe2O3 mixed with CaO,there is some liquid phase formed above 1200℃,while in the case of Fe2O3 mixed with MgO,even at 1200 and 1220℃,there is still no liquid phase.The third reason is self-strength.In the case of industrial flux,the compression strength of the specimens made of Fe2O3 and limestone is 0.52 and 0.71 kN at 1150 and 1180℃,respectively,while that of the specimens made of Fe2O3 and magnesite is 0.48 and 0.56 kN,respectively.Therefore,the fundamental mechanism of the effects of MgO additive on sinter strength can be better understood based on the diffusion rate of MgO in iron oxides,the fluidity of liquid phase,and the self-strength of bonding phase.

Three-segment control theory of MgO/Al2O3 ratio based on viscosity experiments and phase diagram analyses at 1500℃

In recent years, more and more high Al2O3 iron ores were used in East Asia, especially in China, which increased the Al2O3 content in blast furnace (BF) slag and resulted in poor metallurgical properties of slag. Adding MgO-bearing flux is one of the methods to improve the metallurgical properties of slag with high Al2O3. However, there is lack of theoretical basis for the proper MgO/Al2O3 ratio. Therefore, the properties of slag in SiO2-CaO-MgO-Al2O3 system were investigated based on viscosity experiments and phase diagram analyses at 1500℃, and the proper MgO/Al2O3 ratio was explored according to the Al2O3 content in slag. The experimental results show that: (1) in the case of Al2O3 content less than 14mass%, there is no limitation of the MgO/Al2O3 ratio, and the amount of MgO in slag can be determined according to the hearth tempera-ture and desulfurization;(2) in the case of Al2O3 content between 15 and 17mass%, the proper MgO/Al2O3 ratio should be 0.40-0.50;(3) in the case of Al2O3 content between 18 and 20mass%, the proper MgO/Al2O3 ratio should be 0.45-0.55. Consequently, the three-segment control theory of MgO/Al2O3 for BF slag was built, and the actual BF performances proved the validity and applicability of this theory. The research contents and results can give theoretical guidelines for stable BF operation in a wide range of Al2O3 content of 12-20mass%.

Effect of MgO on Oxidation Process of Fe_3O_4 in Pellets

Induration process of oxidized pellets involves the oxidation of Fe3O4 and re-crystallization of Fe2O3.The oxidation process of Fe3O4 is significant for pellets to obtain better ambient strength.Thus,the effect of MgO on oxidation process of Fe3O4 was investigated.The unreacted core model was applied to analyze the oxidizing induration process of pellets.The experimental results show that MgO plays a negative role in the oxidation process of Fe3O4.The oxidation rate of Fe3O4 in MgO-fluxed pellets（95.0% Fe3O4 ＋5.0% MgO）is slower than that in standard acid pellets（100% Fe3O4）.The relation between oxidation ratio of Fe3O4 and time was calculated based on the unreacted core model for both MgO-fluxed pellets and standard acid pellets.According to verification experiments,the values calculated by model coincide well with the experimental values.Therefore,the unreacted core model could be applied to describe the oxidizing induration process of pellets.

Thermodynamic Analysis and Experimental Study on Reaction of CO_2 Gas with Hot Metal

The reaction of CO2 gas with hot metal was investigated based on the thermodynamic analysis and experi- mental results. It shows that both silicon and carbon in hot metal can be oxidized by CO2 gas in the temperature range of 1300-1 500 ℃. When using graphite crucible, temperature has little influence on final mass percent of car bon w[c] because of the carburization effect. Decarburization degree rises significantly with increasing gas injection rate and w[c] can be reduced to 3.2% at most when using MgO crucible. I.ower temperature or higher gas injection rate is propitious to promote desilication reaction, but only 5%- 10% of desilication ratio could be obtained in 20 rain. The final mass percent of silicon W[si] when using MgO crucible is lower than that when using graphite crucible. Ex- perimental results also demonstrate that CO2 injection has no effect on the concentration of manganese, sulfur and phosphorus in hot metal. In view of the weak oxidation ability and temperature drop of hot metal, CO2 gas is sugges- ted to be used as carrier gas in desilication process rather than oxidizing agent.

Distribution of reformed coke oven gas in a shaft furnace

In recent years, the reformed coke oven gas (COG) was proposed to be used as reducing gas in a shaft furnace. A mathematical model of gas flow based on the reformed COG was built. The effects of the pressure ratio of reducing gas to cooling gas (k) on the gas distribution in the shaft furnace were investigated. The calculation results show that k is an important operation parameter, which can obviously affect the gas distribution in the shaft furnace. The value of k should be compromised. Both too big and too small k values are not appropriate, and the most reasonable value for k is 1:1.33.Under this condition, the utilization coefficient of reducing gas, the utilization coefficient of cooling gas and the coefficient of upward gas are 0.94, 0.92 and 1.03, respectively. Based on the validation of physical experiments, the calculated values of the model agreed well with the physical experimental data. Thus, the established model can properly describe the reformed COG distribution in an actual shaft furnace.