Microwave Sintering of Magnetite Ore for High Reducibility
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Solution Overview
Problem
Magnetite ore, with its low reducibility index, limits its usability in iron-making processes, and existing methods for using it in sintered iron ore production either result in low cold strength or require additional carbonaceous materials and additives that increase environmental impact and coke ratios.
Innovation Solution
Manufacturing magnetite-based sintered iron ore by compacting magnetite ore powder under pressure and then sintering it using microwave irradiation at temperatures above 1100°C, which enhances cold strength and reducibility index without the need for excessive carbonaceous materials or additives, thereby reducing environmental emissions and coke ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetite ore is used as main material for sintered iron ore, then reducibility index is improved, but cold strength deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution of magnetite ore (D10: 0.01-0.05mm, D50: 0.08-0.15mm, D90: 0.20-0.30mm) and sintering temperature (1100-1300°C) to achieve both high reducibility index and cold strength without adding carbonaceous materials or fluxes
Solution Approach 2:
The patent uses composite material approach by combining magnetite ore with iron-containing by-products (mill scale, dust, sludge) in specific proportions to create sintered iron ore that maintains high reducibility while improving cold strength through the synergistic effect of different materials
2Strength
If carbonaceous materials and additives are added to sintered iron ore production, then cold strength is improved, but environmental impact and coke ratio increase
Solution Approach 1:
The patent extracts and eliminates carbonaceous materials (coke, coal) and flux additives from the sintering process by using magnetite ore with specific particle size distribution and sintering under controlled atmosphere, thereby improving cold strength without increasing environmental emissions or coke ratio
Solution Approach 2:
The magnetite ore itself serves multiple functions: it provides the iron content, maintains structural integrity through its magnetic properties, and enables high reducibility without requiring external carbonaceous materials or fluxes, making the system self-sufficient and environmentally friendly
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in magnetite-based sintered iron ore with high compressive strength and rapid reduction capabilities, increasing energy efficiency and reducing environmental impact and costs compared to conventional methods.
Implementation Method 1
sintering it using microwave irradiation at temperatures above 1100°C
Data Source
AI summary
This invention relates to magnetite-based sintered iron ore wherein a magnetite ore powder, which is not currently utilized owing to its low reducibility index among iron ore materials serving as a main material in iron-making processes, is improved so as to have a high reducibility index, and to a method of manufacturing the same.