New Binders for Iron Ore Pelletization: Step Change for a Sustainable Future

"INTRODUCTION Iron ore beneficiation needs advances in areas such as process control, automation, burner and furnace designs, silica-free binders, and even alternative iron making routes. While some – like new binders – are only step-changes, all are tools that can help make the ironmaking industry more sustainable. This paper focuses on binders. Binders are added to iron ore fines before they are agglomerated. Binders are used to control the balling process and increase the mechanical quality (e.g. strength) of green-balls and pellets. Agglomeration usually follows thickening and filtration. Good-grade ores, which don't require upgrading, are wet ground to decrease particle size and increase specific surface area. Low-grade ores are often extensively upgraded through wet operations (flotation, dispersion and selective flocculation, magnetic separation, etc.). For both types of ores, thickening and filtration conclude the circuits so that moisture contents are lowered and the ores can be agglomerated. It's been known for a long time that thickening and filtration behaviors are influenced by zeta potential (Sandvik, 1979). Highly-negative zeta potential is good for dispersion while low zeta potential is good for filtration. So, the zeta potentials of iron ore particles are lowered with additions of acid or carbon dioxide, for example, to increase filtration rates and throughputs (Eisele et al., 2005). What happens to particles as their zeta potentials are lowered? Particles aggregate together, effectively forming larger particles. How stable then, are those aggregates during mixing and balling? Are they easily broken up during mixing (if mixers are even used)? Are they broken up during balling? Or, do the aggregates resist breakage so that the availability of ultra-fines, which are so beneficial for agglomeration (Stone, 1968), is decreased? For plants where high doses of bentonite are used as binder, the above questions may be of no concern. The bentonite adds the necessary amount of fines; however, even at those plants, the calcium and magnesium contents in the water affect bentonite's effectiveness (more magnesium and calcium means less effective bentonite). (Engesser, 2003) For plants where new silica-free organic binders are being developed and used, the above questions may need to be considered. The binder is only amongst the iron ore particles for a short period of time – until it burns away or thermally decomposes in the induration furnace – so the liberation, availability and distribution of fine particulates is very critical for the quality of balls and pellets. It was hypothesized that high zeta potential conditions would lead to good pellets, while low zeta potential conditions would lead to relatively bad pellets."