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Chrome ore concentrate consists of high-temperature melting oxides such as Cr2O3, MgO, and Al2O3. The presence of these refractory constituents makes the ore a very high melting mineral. Hence, it is difficult to produce sinter from chrome ore by a pyrometallurgical route. Currently, chrome ore is ground to below 75m, pelletized, heat hardened through carbothermic reaction at 1300C to 1400C, and then charged into a submerged electric arc furnace (EAF), along with lumpy ore for ferrochrome/charge-chrome production. Electricity is a major cost element in this extraction process. This work explores the sinterability of chrome ore. The objective of this study was to: (1) determine whether chrome ore is sinterable and, if so, (2) ascertain ways of achieving satisfactory properties at a low temperature of sintering. Sintering of the raw material feed could be a way to reduce electricity consumption, because during sintering a partial reduction of minerals is expected along with agglomeration. Studies carried out by the authors show that it is possible to agglomerate chrome ore fines through sintering. The chrome ore sinter thus produced was found to be inferior in strength, comparable to that of an iron ore sinter, but strength requirements may not be the same for both. Because the heat generation during chrome ore sintering is high owing to some exothermic reactions, compared with iron ore, and because chrome ore contains a high amount of fines, shallow-bed-depth sinter cake production was attempted in the laboratory-scale pot-sintering machine. The sintered product was found to be a good conductor of electricity because of the presence of phases such as magnetite and maghemite. This characteristic of the chrome ore sinter will subsequently have a favorable impact in terms of power consumption during the production of ferrochrome in a submerged EAF. The sinter made was melted in the arc furnace and it was found that the specific melting energy is comparable to that of heat-hardened chrome ore pellets but lower than briquettes and lump ore.
The authors gratefully acknowledge the help rendered by Messrs. S.S.N. Chand and P.K. Mishra for their useful consultations. The authors also acknowledge Messrs. S.K. Bakshi, Kishore, and S. Tiwary for their help in carrying out the tests.
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Steele stiff extrusion powers sustainable, scalable by-product management solutions for iron & steel mills around the world. These solutions deliver more metal recovery, improved sinter and lower carbon costs.
Our process converts fine, wet materials into engineered, high-quality feedstock for the consistent durability and reducibility you need in your melt recipe. Your sinter performance and productivity improve, while you recover the captive value in your by-products and shorten your supply chain.
Stiff extrusion eliminates your mountains of accumulated by-products, unlocking the high-Fe material and carbon units in the form of cold-bonded briquettes or pellets for feedstock, which you can produce on- or off-site. A complementary stiff extrusion line to sinter strands can also improve their performance, removing the fine materials that cause problems with sintering.
Our process uses high-shear mixing and vacuum de-airing to shape your bulk raw materials into durable units (Steele extruded pellets and briquettes are strong enough for rough handling in their green state).
Vacuum improves both the green and cured product strength and binder effect. The lower levels of binder and moisture required permit more metal recovery from slag and other steel production residues with individual waste streams converted into homogenous feedstock for your melt recipe.
The mill had ready access to fines from its DRI process, plus wet, carbon-rich LD sludge and blast furnace dust imported from Australia. Steel provided key process equipment and start-up support, to produce roughly 60,000 tons of engineered feedstock annually.
The homogenous blend of iron oxide fines and fine carbon particles have driven a 20%-plus reduction in coke rates. The briquettes carbon content has reduced the need for imported carbon from Australia for both the mill and its customers mill, while improving the performance of sinter strands (stiff extrusion removes the fine materials that cause problems with sintering).
Steele extruders deliver the reliability you need for a simple process. Theyre heavier and more durable than competitive machines built with fabricated frame components and augers we cast primary frame components from ductile iron and wearing parts from our wear-resistant high chrome alloy.
Weve been repurposing and adding value to bulk raw materials since 1889, so we have the material preparation experience and skills to engineer an optimal agglomerated product. We can evaluate stiff extrusion for your feedstock requirements, working with up to 5 kg of your raw materials in our lab and up to 20TPH in our test plant.
Once weve qualified your materials, well recommend specific machines and a process for a homogenous mix and consistent performance in the furnace. You can read more about our engineering and lab services here.
We started working with TMS International, a global leader in on-site mill services, in 2014. TMS International opened its Extruded Product Services (EPS) pilot plant in Middletown, Ohio in 2016, to stage feedstock trials for mills looking for sustainable, scalable by-product management and metal recovery.
Steele stiff extrusion powers the EPS process, converting fines, dust and sludge into standardized, consistent feedstock for customer melt recipes. To learn more, visit TMS International or contact Steele.