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1 A member of the Anglo American plc group Utilisation of the - 8+5mm Sishen iron ore fraction in the Sintering process September 2008 Andre Dippenaar
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1
A member of the Anglo American plc group
Utilisation of the -8+5mm Sishen iron ore fraction in the Sintering process
September 2008
Andre Dippenaar
2
Introduction
Sishen mine products:
• Lump ore: -25+8mm
• Fine ore: -5mm
• Intermediate fraction: -8+5mm
3
Pilot Plant Sinter Pot tests
Bc sinter – 50% fine Thaba, 50% fine Sishen
Coarse Sinter - Half of fine Sishen replaced with coarse Sishen50% fine Thaba, 25% fine Sishen, 25% coarse Sishen
Concentrate additions – 5, 10 and 15 %
4
Experimental Procedure
Sinter spesifications% SiO2 5.2
% MgO 0.77
% FeO 8.0
Basicity %CaO/SiO2 = 2.0
5
Experimental Procedure
Sinter working procedures
Sinter outputs
Tests on sinter product
6
Results – Ore fractions used
Ore Sieve analyses
mm
Thaba fine ore
Sishen fine ore
Sishen coarse ore
Concentrate
+8 1 0 15 0 +5 21 10 73 0 +3.35 20 30 10 0
+1 27 42 1 0 +0.106 25 18 1 10 +0.045 5 0 0 46 -0.045 1 0 0 44
D50 2.94 2.76 6.72 0.08
Ore fractional Sieve analyses
05
101520253035404550
16.0
00
12.5
00
10.0
00
8.00
0
6.30
0
5.00
0
4.00
0
3.35
0
2.00
0
1.00
0
0.50
0
0.25
0
0.12
5
0.10
6
0.07
5
0.05
3
0.04
5
0.00
0
Sieve size (mm)
% o
n s
ieve
Thaba fine Sishen f ine
Concentrate ore Sishen Coarse
7
Results
Identification of the different pot tests:
Fine Sishen sintersFS 0C - Base case sinter with 50% Fine Sishen and 0% ConcentrateFS 5C - Fine sinter with 45% Fine Sishen and 5% Conc.
Coarse Sishen sintersCS 0C - Coarse sinter with 25% Fine Sishen, 25% Coarse Sishen and 0% Conc.CS 5C - Coarse sinter with 20% Fine Sishen, 25% Coarse Sishen and 5% ConcCS 10C - Coarse sinter with 15% Fine Sishen, 25% Coarse Sishen and 10%
Conc.CS 15C - Coarse sinter with 10% Fine Sishen, 25% Coarse Sishen and 15%
Conc
8
Results
Raw material Mixture Sieve analyses
• FS 0C – 2.5 mm• CS 0C – 3.23 mm
Mixture fractional Sieve analyses
0
5
10
15
20
25
16.0
00
12.5
00
10.0
00
8.00
0
6.30
0
5.00
0
4.00
0
3.35
0
2.00
0
1.00
0
0.50
0
0.25
0
0.12
5
0.10
6
0.07
5
0.05
3
0.04
5
0.00
0
Sieve size (mm)
% o
n s
ieve
FS 0 FS 5 CS 0 CS 5 CS 10 CS 15
9
Results - Sinter Pot Tests
Sinter mixture with Thaba fines and: Fine Sishen Coarse Sishen
FS 0C (BC)
FS 5C CS 0C CS 5C CS 10C CS 15C
PRODUCTION: Prod. Rate [t/m2/24h] 39.4 39.0 43.3 42.7 41.7 39.5 Sintering rate (mm/min.) 24.9 24.6 26.4 26.0 26.4 25.0 Sinter fines ratio 1.02 1.02 0.99 1.04 1.02 1.04
Total Fuel [kg/ton sinter] 73.6 69.7 73.9 74.6 74.9 76.0
Yield 86.4 86.1 86.5 86.5 85.8 86.5 % Cake Shrinkage 12.8 10.5 10.4 9.94 9.8 10.5
SINTER SIEVE ANALYSES
+40 3.5 4.6 3.7 2.9 3.3 2.8 -40+25 3.9 5.7 4.8 5.0 4.7 4.3 -25+16 19.5 16.5 15.0 14.7 13.9 13.1 -16+12.5 14.9 14.5 14.5 14.7 13.6 14.0 -12.5+10 10.3 10.1 11.7 11.4 11.2 11.9 -10+5 23.1 22.8 26.0 26.5 27.2 27.1 -5 25.0 25.8 24.2 24.7 26.1 26.8 D50(excl. the -5mm frac.) 16.0 16.8 13.6 15.2 15.2 14.8
10
Results – Production Rate
39.4
39.0
43.3
42.7
41.7
39.5
38
39
40
41
42
43
44
0 5 10 15
% Concentrate ore
Pro
du
ctio
n [
t/m
2 /24h
rs]
Fine Sishen Coarse Sishen
11
Results – Fuel Consumption
73.6
69.7
73.974.6 74.9
76.0
68
70
72
74
76
78
0 5 10 15
% Concentrate ore
Fu
el r
ate
(kg
/to
n s
inte
r)
Fine Sishen Coarse Sishen
12
Results – Cake Shrinkage
12.8
10.510.409.94 9.8
10.5
8
9
10
11
12
13
14
0 5 10 15
% Concentrate ore
Sin
ter
cake
sh
rin
kag
e (%
) Fine Sishen Coarse Sishen
13
Results – Sinter Product size
16.0
16.8
13.6
15.2 15.214.8
13
14
15
16
17
18
0 5 10 15
% Concentrate ore
Sin
ter
pro
du
ct a
vera
ge
size
(m
m)
Fine Sishen Coarse Sishen
14
Results – Physical and Metallurgical properties
Sinter mixture with Thaba fines and: Fine Sishen Coarse Sishen
FS 0C (BC)
FS 5C CS 0C CS 5C CS 10C CS 15C
PHYSICAL PROPERTIES COLD STRENGTH (ISO 3271) % +6.3 mm (TI) 78.6 76.9 78.3 78.8 76.9 77.4 % -6.3+0.5mm 17.1 18.5 17.0 17.2 18.9 18.5 % -0.5mm (AI) 4.3 4.6 4.7 4.0 4.1 4.1
METALLURGICAL PROPERTIES: RDI7: (ISO 4696) % +6.3mm 12.3 14.3 29.9 32.5 30.2 34.8 % +3.15mm 52.4 55.5 66.9 70.1 69.8 70.9 % -0.5mm 7.5 6.9 5.5 4.7 4.9 4.9
RI: (ISO 4695) %/min. 1.23 1.47 1.39 1.20 1.21 1.23
High Temperature Properties (REAS) ST (°C) 1160 1192 1082 1203 1240 1193 MT (°C) 1289 1300 1213 1290 1324 1296 DT (°C) 1289 1300 1223 1299 1324 1296 Pmax (°C) 1210 1253 1130 1276 1274 1248 Pmax (mmH2O) 359 203 307 231 201 215 Cohesive zone 130 108 131 88 84 103 Viscosity (mmH2O.°C) 655 327 572 414 357 353 Relative drip mass (%) 73.9 77.0 70.7 73.7 72.8 72.8
15
Results – Cold Strength
78.6
76.9
78.3
78.8
76.9
77.4
75
76
77
78
79
80
0 5 10 15
% Concentrate ore
TI
(+6.
3mm
fra
ctio
n)
Fine Sishen Coarse Sishen
16
Results – Hot strength +3.15 mm
52.4
55.5
66.9
70.1 69.870.9
50
55
60
65
70
75
0 5 10 15
% Concentrate ore
RD
I (+
3.15
mm
fra
ctio
n)
Fine Sishen Coarse Sishen
17
Results – Hot strength -0.5mm
7.50
6.9
5.5
4.74.9 4.9
4
5
6
7
8
9
0 5 10 15
% Concentrate ore
RD
I (-
0.5
mm
fra
ctio
n)
Fine Sishen Coarse Sishen
18
Results – Reducibility
1.23
1.47
1.39
1.20 1.21 1.23
1.0
1.1
1.2
1.3
1.4
1.5
1.6
0 5 10 15
% Concentrate ore
RI
(%/m
in)
Fine Sishen Coarse Sishen
19
Results – High temperature properties
130
108
131
8884
103
50
60
70
80
90
100
110
120
130
140
0 5 10 15
% Concentrate ore
Co
hes
ive
zon
e (°
C)
Fine Sishen Coarse Sishen
20
Results – High temperature properties
73.9
77.0
70.7
73.772.8 72.8
65
70
75
80
85
0 5 10 15
% Concentrate ore
Dri
p m
ass
(%)
Fine Sishen Coarse Sishen
21
Results – Mineralogy
Sinter mixture with Thaba fines and:
Fine Sishen Coarse Sishen FS 0C (BC)
FS 5C CS 0C CS 5C CS 10C CS 15C
Mineral Morphology Hematite relict 19.8 19.1 23.8 21.9 24.8 27.2
Hematite rhombic 11.2 9.6 4.6 6.0 10.2 8.0
Spinel 23.5 19.5 30.9 32.8 30.8 32.2
SFCA acicular 9.6 11.4 3.9 10.0 8.4 10.2
SFCA tabular (columnar) 29.0 26.3 25.3 18.2 21.0 13.4
SFCA dendritic + eutectic 4.1 7.2 4.2 7.1 1.0 5.2
Calcium silicate (Ca2SiO4) 0.1 2.8 2.7 2.9 2.8 2.0
Periclase 0.0 0.0 0.0 0.0 0.0 0.0 Glass 5.7 4.1 4.6 0.8 1.0 1.8 Total bonding phases 48.4 49.0 38.0 36.1 31.4 30.6
22
Results – Mineralogy
19.819.1
23.8
21.9
24.8
27.2
15
20
25
30
35
0 5 10 15
% Concentrate ore
Re
lic
t H
em
ati
te (
%)
Fine Sishen Coarse Sishen
23
Results – Mineralogy
48.4 49.0
38.036.1
31.4 30.630
35
40
45
50
55
0 5 10 15
% Concentrate ore
Bo
nd
ing
ph
as
es
(%
)
Fine Sishen Coarse Sishen
24
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