Solid Agglomerate of Fine Metal Particles Using Liquid Oily Lubricant
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Solution Overview
Problem
Existing methods for recycling steel mill wastes and producing charge materials for steel plants are inefficient, expensive, and limited in terms of the type and purity of iron-based powders they can handle, often requiring additional steps like sintering or using expensive binders, which can lead to oxidation and reduced resistance to crumbling and high temperatures.
Innovation Solution
A solid agglomerate of fine metal particles compacted with a liquid oily lubricant, such as canola oil, which provides a desirable density, resistance to crumbling and dusting, and maintains integrity at high temperatures, using a process that involves mixing the particles with the lubricant and compacting them under pressure to form a solid shape like a briquette or brick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing binding materials (lime, molasses, starch) are used to agglomerate fine metal particles, then the particles can be bound together, but the resulting agglomerates have high humidity index, poor resistance to crumbling and dusting, and degraded metal quality
Solution Approach 1:
The invention changes the chemical and physical parameters of the binding agent from traditional organic materials (lime, molasses, starch) to a liquid oily lubricant. This parameter change transforms the binding mechanism while eliminating the harmful effects of high humidity and organic degradation, achieving both strong binding and low humidity index
Solution Approach 2:
The invention replaces expensive and problematic traditional binders with a simple, inexpensive liquid oily lubricant that can be easily applied and removed. The lubricant serves its binding function temporarily during handling and storage, then does not interfere with subsequent metallurgical processes
2Strength
If sintering step is used to strengthen agglomerates, then resistance to crumbling improves, but oxidation occurs requiring additional reduction steps
Solution Approach 1:
The invention extracts the sintering step from the process sequence by achieving sufficient binding strength through mechanical compaction with liquid oily lubricant alone. This eliminates the need for thermal sintering and the associated oxidation problem, while still providing adequate resistance to crumbling and dusting
3Strength
If expensive binders are used to improve agglomerate strength, then handling resistance improves, but manufacturing cost increases
Solution Approach 1:
The invention substitutes expensive traditional binders with a cheap liquid oily lubricant that can be readily obtained and applied. The lubricant provides sufficient binding strength for handling and storage requirements without adding significant manufacturing cost
4Shape
If fine metal particles are compacted with traditional binders, then agglomerates can be formed, but resistance to high temperature is reduced
Solution Approach 1:
The invention changes the thermal stability parameter by selecting a liquid oily lubricant with high temperature tolerance. Unlike organic binders that decompose at elevated temperatures, the oily lubricant maintains structural integrity and binding function throughout the temperature ranges encountered in handling, storage, and initial furnace operations
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 method produces agglomerates with improved density, handling resistance, and high-temperature stability, reducing the need for additional processing steps and expensive binders, while allowing for the use of a wider range of iron-based powders, and exhibits a lower humidity index for better storage and handling.
Implementation Method 1
fine metal particles and a liquid oily lubricant, wherein the fine metal particles and liquid oily lubricant are compacted together to form the solid agglomerate
Data Source
AI summary
Described are solid agglomerates of fine metal particles and methods for manufacturing same. A liquid oily lubricant is used in the manufacture of the solid agglomerates. The manufacturing comprises blending fine metal particles with the liquid oily lubricant and compacting the oily metallic mixture obtained to desired solid form. Advantageously, the solid agglomerates possess a desirable density, a suitable resistance to crumbling and dusting during handling, and they can resist to high temperature and to humidity. Solid agglomerated metal products, according to the invention, may be useful for different purposes such as quality charge material for steel plants, blast furnaces and foundries.