Non-Fired Pellet Composition for Reduction Furnace Anti-Clustering
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Solution Overview
Problem
Conventional methods for preventing clustering in solid reduction furnaces using non-fired pellets are inadequate, requiring costly covering steps and additional facilities, and do not effectively address the issue of slag fusion and clustering.
Innovation Solution
Non-fired pellets with a specific ratio of high-viscosity slag components (Al2O3+MgO+SiO2) to total Fe, formulated with a high LOI of 5% or more, and pretreated to remove crystal water, are produced to prevent slag fusion and clustering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional covering methods (Ca(OH)2, Mg(OH)2, or other non-metallic components) are applied to prevent clustering, then clustering prevention is improved, but manufacturing cost increases and additional facilities are required
Solution Approach 1:
The invention changes the chemical composition parameters of the pellet surface by controlling the ratio of high-viscosity slag components (Al2O3+MgO+SiO2) to total Fe within 3-15%, and controlling FeO content at 2-10%. This compositional parameter change inherently prevents clustering without requiring external covering materials or additional facilities
Solution Approach 2:
The pellet formulation itself provides the clustering prevention function through its inherent chemical composition. The high-viscosity slag components and controlled FeO content create a self-protecting mechanism that prevents metallic iron contact during reduction, eliminating the need for separate covering steps or additional equipment
2Object-generated harmful factors
If non-fired pellets are used in solid reduction furnaces, then CO2 emissions are reduced, but slag fusion and clustering occur in high-temperature zones
Solution Approach 1:
The invention modifies the chemical parameters of the pellet composition by controlling high-viscosity slag components (Al2O3+MgO+SiO2) at 3-15% of total Fe and FeO at 2-10%. These parameter changes alter the slag behavior in high-temperature zones, preventing fusion and clustering while maintaining the CO2 reduction benefit of non-fired pellets
Solution Approach 2:
The invention creates a composite pellet structure combining iron ore powder, high-viscosity slag components (Al2O3, MgO, SiO2), and controlled FeO content. This composite formulation provides both the CO2 reduction advantage of non-fired pellets and the clustering prevention through the high-viscosity slag matrix that prevents metallic iron contact
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 solution effectively prevents slag fusion and clustering in solid reduction furnaces, reducing CO2 emissions and enhancing operational efficiency without additional costs or facilities.
Implementation Method 1
a ratio of high-viscosity slag components (Al2O3+MgO+SiO2) to total Fe (T.Fe) satisfies the following Expression (1)
Implementation Method 2
an iron-containing raw material formulated to achieve an average LOI (Loss on Ignition) of 5% or more
Data Source
AI summary
Non-fired pellets are used in a solid reduction furnace and are effective in preventing clustering by reducing the possibility of contact between low-melting-temperature slags and thus preventing the fusion therebetween. A method produces such non-fired pellets. Non-fired pellets for reduction, in which the proportion of high-viscosity slag components (Al2O3+MgO+SiO2) to the total Fe (T.Fe) satisfies an expression: (Al2O3+MgO+SiO2)/T.Fe≥0.12, and a method for producing the same. In the expression, Al2O3 represents the concentration (mass %) of Al2O3 in the non-fired pellets, MgO represents the concentration (mass %) of MgO in the non-fired pellets, SiO2 represents the concentration (mass %) of SiO2 in the non-fired pellets, and T.Fe represents the concentration (mass %) of T.Fe in the non-fired pellets.