Degree of reduction and swelling values of fired BPJ haematite iron ore pellets reduced in Basundhara non-coking coal: A comparison for the

effect of firing temperature

-100#

(% )

-25+36#

(% )

Binder (wt% )

Firing Te mper ature (^oC)

Firing time (min)

Re duc tion temperature (^oC)

Re duc tion Ti me (min)

Degree of reduction (% )

Swelling (% )

100 0 3 1000 60 950 0 77.36 -1.26

5 90.76 -20.96

10 93.42 -16.86

15 97.61 -13.86

20 93.10 0.71

25 94.55 4.05

100 0 3 1100 60 950 0 81.88 20.14

5 96.21 19.64

10 95.77 11.74

15 96.35 18.11

20 94.47 19.58

25 94.44 28.84

90 10 3 1300 60 950 0 75.76 4.74

5 78.19 3.54

10 90.39 6.17

15 84.73 2.13

20 80.55 9.32

25 72.29 3.7

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0 10 20 30 40 50 60 70 80 90

0 10 20 30 40 50 60 70 80 90 100

Time(min.)

Degree of reduction(%)

RT 850^oC RT 900^oC

Fig4.1: Degree of reduction vs time plots for fired BPJ hae matite iron ore pellets [3% binde r, firing te mperature-1300^oC, firing time-1hour, {-100#(80%),- 25+36#(20%) }]

0 5 10 15 20 25

0 10 20 30 40 50 60 70 80 90 100

Time(min.)

Degree of reduction(%)

RT 950^oC RT 1000^oC

Fig4.2: Degree of reduction vs time plots for fired BPJ haematite iron ore pellets, [3% binde r, firing te mperature-1300^oC, firing time-1hour, {-100#(80%),- 25+36#(20%) }]

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0 5 10 15 20 25

0 10 20 30 40 50 60 70 80 90 100

Time(min.)

Degree of reduction(%)

RT 950^oC RT 1000^oC

Fig4.3: Degree of reduction vs time plots for fired BPJ haematite iron ore pellet, [3% binde r, firing te mperature-1300^oC, firing time-1hour, {-100#(90%),- 25+36#(10%) }]

0 20 40 60 80 100

10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

RT-850^oC RT-900^oC

Degree of reduction(%)

Time in(min)

Fig4.5: Degree of reduction vs time plots for fired DR Pattnaik hae matite iron ore pellets [3% binder, firing te mpe rature-1300^oC, firing time-1hour, {-100#(80%),- 25+36#(20%) }]

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0 10 20 30

0 10 20 30 40 50 60 70 80 90 100

RT 950^oC RT 1000^oC

Degree of reduction(%)

Time in(min)

Fig4.6: Degree of reduction vs time plots for fired DR Pattnaik hae matite iron ore pellet [3% binder, firing te mperature-1300^oC, firing time-1hour, {-100#(80%),- 25+36#(20%) }]

0 5 10 15 20 25 30

0 10 20 30 40 50 60 70 80 90 100 110

RT 950^oC RT 1000^oC

Degree of reduction(%)

Time in(min)

Fig4.7: Degree of reduction vs time plots for fired DR Pattnaik hae matite ironore pellets [3% binde r, firing temperature-1300^oC, firing time-1hour,{-100#(90%),- 25+36#(10%) }]

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0 10 20 30 40 50 60 70 80 90 100

0 10 20 30 40 50 60 70 80 90 100 110

BPJ RT-900^oC DRP RT-900^oC

Degree of reduction(%)

Time in(min)

Fig4.8: Degree of reduction vs time plots for fired BPJ and DR Pattnaik haematite ironore pellets [3% binder, firing te mperature-1300^oC, firing time-1hour,{- 100#(90%),-25+36#(10%) }]

0 5 10 15 20 25 30

0 10 20 30 40 50 60 70 80 90 100 110

FT 1000^oC FT 1100^oC FT 1300^oC

Degree of reduction(%)

Reduction time in (min)

Fig4.9: Degree of reduction vs time plots for fired BPJ hae matite ironore pellets [3%binde r, effect of firing temperature, reduction temperature-950^oC firing time- 1hour, {-100#(90%),-25+36#(10%) }]

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1000 1050 1100 1150 1200 1250 1300

5 10 15 20 25 30 35 40 45

BPJ3% binder BPJ6% binder BPJ10% binder

Porosity(%)

Firing temperature(^oC)

Fig 4.10: Porosity vs firing te mpe rature plots for fired BPJ hae matite ironore pellets [firing time-1 hour,{-100#(100%)}]

1000 1050 1100 1150 1200 1250 1300

8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

DRP3% binder DRP6% binder DRP10% binder

Porosity(%)

Firing temperature(^oC)

Fig 4.11:Porosity vs firing temperature plots for fired DR Pattnaik haematite ironore pellets [firing time-1 hour,{-100#(100%)}]

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1000 1050 1100 1150 1200 1250 1300

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

BPJ DRP

Crushing strength(kg/pellet)

Firing temperature(^oC)

Fig 4.12 :Crushing strength vs firing temperature plots for fired BPJ and DR Pattnaik haematite ironore pellets [3% binder, firing tempe rature-1300^oC, firing time -1hour,{-100#(100%)}]

1000 1050 1100 1150 1200 1250 1300

50 100 150 200 250 300 350 400 450 500 550 600 650

BPJ DRP

Crushing Strength(kg/pellet)

Firing temperature(^oC)

Fig 4.13 : Crushing strength vs firing temperature plots for fire d BPJ and DR Pattnaik haematite ironore pellets [6% binder, firing tempe rature-1300^oC, firing time -1hour,{-100#(100%)}]

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1000 1050 1100 1150 1200 1250 1300

50 100 150 200 250 300 350 400 450 500 550 600

BPJ DRP

Crushing strength(kg/pellet)

Firing Temperature(^oC)

Fig 4.14 : Crushing strength vs firing temperature plots for fire d BPJ and DR Pattnaik haematite ironore pellets [10% binder, firing tempe rature-1300^oC, firing time -1hour,{-100#(100%)}

900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 0

500 1000 1500 2000 2500

BPJ DRP

Drop No.

Firing Temperature(^oC)

Fig 4.15: Drop No. vs firing temperature plots for fired BPJ and DR Pattnaik haematite ironore pellets [3% binde r, firing time -1hour, {-100#(100%)}]

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1000 1050 1100 1150 1200 1250 1300

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

BPJ DRP

Drop No.

Firing Temperature(^oC)

Fig 4.16: Drop No. vs firing temperature plots for fired BPJ and DR Pattnaik haematite ironore pellets [6% binde r, firing time -1hour, {-100#(100%)}]

1000 1050 1100 1150 1200 1250 1300

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

BPJ DRP

Drop No.

Firing Temperature in(^oC)

Fig 4.17: Drop No. vs firing temperature plots for fired BPJ and DR Pattnaik haematite ironore pellets [10% binder, firing time -1hour, {-100#(100%)}]

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1100 1150 1200 1250 1300

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Red. time 0 min 5 min 10 min 15 min 20 min 25 min

Swelling(%)

Firing Temperature(^oC) RT-950^oC

Fig 4.18: Percentage swelling vs firing te mperature plots for fired BPJ haematite ironore pellets [3% binder, firing time -1hour, {-100#(100%), reduction temperature-950^oC}]

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30 35 40 45 50 55 60 65 70 75

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-850^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.19: Percentage swelling vs degree of reduction plots for fired BPJ haematite

ironore pellets [3%binder, firing te mperature-1300^oCfor 1hour, {-100#(80%), -25+36#(20%)}]

50 60 70 80 90 100

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-900^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.20: Percentage swelling vs degree of reduction plots for fired BPJ haematite

ironore pellets [3%binder, firing te mperature-1300^oCfor 1hour, {-100#(80%), -25+36#(20%)}]

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84 86 88 90 92 94 96 98 100

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-950^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.21: Percentage swelling vs degree of reduction plots for fired BPJ haematite ironore pellets [3%binder, firing temperature-1300^oC for 1hour, {-100#(80%), -25+36#(20%) }]

76 78 80 82 84 86 88 90

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-1000^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.22: Percentage swelling vs degree of reduction plots for fired BPJ haematite

ironore pellets [3%binder, firing temperature-1300^oC for 1hour, {-100#(80%), -25+36#(20%) }]

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55 60 65 70 75 80 85 90

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-900^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.23: Percentage swelling vs degree of reduction plots for fired BPJ haematite ironore pellets [3%binder, firing temperature-1300^oC for 1hour, {-100#(90%), -25+36#(10%) }]

70 72 74 76 78 80 82 84 86 88 90 92

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-950^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.24: Percentage swelling vs degree of reduction plots for fired BPJ haematite ironore pellets [3%binde r, firing temperature-1300^oC for 1hour,{-100#(90%),- 25+36#(10%) }]

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75 80 85 90 95 100

-50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

RT-1000^oC

Swelling(%)

Degree of Reduction(%)

Fig 4.25: Percentage swelling vs degree of reduction plots for fired BPJ haematite ironore pellets [3%binder, firing temperature-1300^oC for 1hour, {-100#(90%), -25+36#(10%) }]

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Fig 4.26: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [reduction tempe rature-900^oC, 3% binder, reduction time-75 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.27: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [reduction tempe rature-900^oC, 3% binder, reduction time-75 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.28: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature-900^oC, 3% binde r, reduction time-75 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.29: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature-900^oC, 3% binde r, reduction time-75 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.30: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature-850^oC, 3% binde r, reduction time-90 min, {-100#(80%),-25+36#(20%)}]

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Fig 4.31: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature-900^oC, 3% binde r, reduction time-30 min, {-100#(80%),-25+36#(20%)}]

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Fig 4.32: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour[ reduction tempe rature-950^oC, 3% binder, reduction time-25 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.33: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mperature-1000^oC, 3% binder, reduction time-25 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.34: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature -850^oC, 3% binde r, reduction time-90 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.35: SEM photograph of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mpe rature-900^oC, 3% binde r, reduction time-90 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.36: SEM photographs of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mperature -950^oC, 3% binder, reduction time-25 min,{-100#(80%),-25+36#(20%)}]

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Fig 4.37: SEM photographs of reduced DR Pattnaik haematite iron ore pellet fired at 1300^oC for 1 hour [ reduction te mperature -1000^oC, 3% binde r, reduction time-25 min,{-100#(80%),-25+36#(20%)}]

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