What Iron Ore Do You Use for Ironmaking and Steelmaking? The quality of iron ore pellets is crucial to both ironmaking and steelmaking. The binder used in iron ore pelletization can be one of the key factors in producing high-quality pellets. Despite that bentonite is one of the most common binders used in iron ore pelletization, its drawbacks are obvious, too, such as adding silica to the pellets and lowering the iron grade. Today, we will discuss the process of producing iron ore pellets and a solution for you to increase the Fe grade. Let's dive in!

What are Iron Ore pellets?

Iron ore pellets are small balls indurated in a furnace using iron ore fines as the raw material, mixed with binders and other additives. Green pellets are pellets that haven't been dried, hardened, or heated in the furnace. The standard size of iron ore pellets is 6-16mm in diameter.

What is the Process of Producing Iron Ore Pellets?

The process of making iron ore pellets involves grinding, mixing, pelletizing, sifting, testing, induration (drying, preheating, indurating, cooling), and final testing.

↓↓Watch the process of producing iron ore pellets↓↓

1. Grinding: Grinding is the process of reducing iron ore into fine powders. The standard granularity for iron ore powders is such that more than 85% of the particles are smaller than 0.2mm.

2. Mixing: The iron ore fine powders are then mixed with a specific amount of binder and other additives.

3. Pelletizing: In pelletization, the mixed powders are rolled into small balls/pellets. Different manufacturers have different requirements for the sizes of the pellets. Normally, the size ranges from 6mm to 16mm.

4. Sifting: In this step, unqualified pellets are sifted out. Only qualified pellets will proceed to the next procedure.

5. Testing: Pellets are tested to ensure their strength and quality. Tests include moisture tests, strength tests, fall tests, etc.

6. Induration:

(1)Drying: Pellets are then sent to the furnace to dry out the moisture.

(2) Preheating: The pellets are heated to a temperature of 950-1050℃ where the binders start to activate, and the iron ore particles begin to sinter.

(3)Indurating: Pellets are hardened at a temperature of 1200-1250℃.

(4) Cooling: The hardened pellets are cooled down to a temperature suitable for handling andtransportation, ranging from 950-1050℃.

7. Final Testing: Pellets are now indurated and cooled. They will be tested through various tests for qualification, such as the reduction disintegration index (RDI), porosity, reduction index (RI), and more.

What Equipments Are Used in Making Iron Ore Pellets?

Disc granulators, traveling grates, rotary kilns, and straight grates are equipment used in iron ore pellet production. Straight grate work the same as travelling grate and rotary kiln, which can  deliver the pellets and indurate them in one equipment. Below are their roles explained in the production.

Disc Granulator: Used for iron ore pelletizing, a disc granulator is a type of granulator with a disc lined with high-strength glass fiber-reinforced plastic. It has the advantages of uniform granulation, a high granulation rate, stable operation, durable equipment, and a long service life. It is the ideal granulation equipment.

Travelling Grate: After the granulation is completed, the qualified green pellets are sent to the traveling grate for drying and preheating through the conveyor, and then enter the rotary kiln for roasting.

Rotary Kiln: In this equipment, the pellets are preheated, indurated, and cooled.

Straight Grate: After granulation is completed, the qualified green pellets are sent to the straight grate via a conveyor belt for drying, preheating, roasting, and cooling. The finished pellets are obtained after all processes are completed.

What are Iron Ore Pellet Binders?

Iron ore pellet binders are materials added to iron ore fines during the pelletizing process to help agglomerate the fine particles into larger, cohesive pellets. These binders play a crucial role in ensuring the green (unfired) pellets have sufficient strength to withstand handling and transportation before they are hardened in the induration process. The choice of binder affects the pellet's physical and metallurgical properties, as well as the efficiency of the pelletizing process.

Advantages of Using Jianjie Binders for Iron Ore Pellets

Jianjie organic binders provide a highly effective solution for increasing the iron content (Fe grade) in iron ore pellets. Jianjie binders are designed to minimize contamination to the finished products. By using these binders, iron ore pellets can maintain higher Fe content, enhancing overall smelting efficiency and the quality of the final product. This improvement in pellet quality contributes directly to more efficient ironmaking and steelmaking processes, reducing costs and improving productivity.

Enhanced Pellet Quality:

Organic binders for iron ore pellets ensure the pellets can withstand transportation and high-temperature processes in blast furnaces. Pellets using organic binders have consistent size, strength, and low impurity levels, greatly improving smelting efficiency.

Versatility:

Jianjie pellets are adaptable for use in various applications, including direct reduction plants and electric arc furnaces. This versatility allows Jianjie to meet diverse customer needs while maintaining competitiveness.

Sustainability:

Jianjie's organic binders reduce environmental impact by lowering emissions and minimizing residual waste. The eco-friendly approach aligns with the growing demand for greener technologies in the industry. By pioneering organic binder technology, Jianjie promotes cleaner and more efficient iron ore pellet production. The company contributes to a more sustainable future in metal production while addressing industry challenges.

Watch More Video of Pelletizing