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Use of colemanite as an additive in iron ore pelletizing

Conference Paper · October 2008

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Osman Sivrikaya A. I. Arol

Adana Alparslan Türkeş Science and Technology University Middle East Technical University
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 Use of Colemanite as an Additive in Iron Ore Pelletizing

O. Sivrikaya, A. I. Arol

Middle East Technical University, Department of Mining Engineering

06531 Çankaya, Ankara, TURKEY

published in symposium proceeding of

11th. INTERNATIONAL MINERAL PROCESSING SYMPOSIUM

IMPS 2008

21-23 October 2009

Belek - ANTALYA - TURKEY

 PROCEEDINGS OF THE 11th INTERNATIONAL MINERAL PROCESSING SYMPOSIUM
21-23 October 2008, Belek-Antalya, Turkey

Use of Colemanite as an Additive in Iron Ore Pelletizing

O. Sivrikaya, A. I. Arol
Middle East Technical University, Department of Mining Engineering, 06531
Çankaya, Ankara, TURKEY

ABSTRACT:
Even though the use of bentonite in iron ore pelletizing is essential, it is also a
problem due to its adverse effects, caused by the impurities introduced with
bentonite, on iron-steel economy. There have been numerous studies to replace
bentonite with alternative binders to eliminate the adverse effects. Many of these
studies involve the use of organic binders which were found to fail to render the
required compressive strength of pre-heated and fired pellets. In this work, a new
generation binder for iron ore pelletizing consisting of an organic binder and
colemanite additive was investigated. The results showed that the use of colemanite
together with an organic binder yielded pellets with compressive strength
comparable with those of pellets produced with bentonite.

Keywords: Iron ore, pelletizing, binder, bentonite, organic binder, colemanite

1. INTRODUCTION:
Bentonite is the most common binder in iron ore pelletization and used at 0.5-1.5%
by weight. However, because of its acid constituents, bentonite is considered as an
impurity. The iron-steel production economy is adversely affected with increasing
SiO2 and Al2O3 contents. For instance, the addition of 1% bentonite decreases the
iron content by about 7 kg/ton of iron ore (Kater and Steeghs, 1984). An increase
in the silica content of iron product by 1% leads to an increase in the unit cost of
making the steel by $4-7 (U.S.)/ton (Chizhikova et.al, 2003).
Organic binders may offer a viable alternative to bentonite as they burn out at
high temperatures with virtually no residue. There have been laboratory, pilot and
industrial scale investigations on the use of organic binders in iron ore
pelletization. However, organic binders have not found widespread application in
the industry. Although they give good results for green pellets and dry pellets, they
fail to impart enough strength to the pre-heated and fired pellets as a result of
reduced slag bonding (Kater and Steeghs, 1984; de Souza et al., 1984; Goetzman et
al, 1988; Arol et al., 1989, Arol, 1997). If the pre-heated compressive strength of
pellets is insufficient, pellets will be disintegrated on the travelling grate and rotary
kiln and the process equipment will be harmed by pellet dust formed therein. As a
result, the operation of plant will be interrupted and the efficiency of plant will
decrease.

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 Colemanite is a Ca-borate salt with a melting point of 986 oC (Tektaş, 2003), it
forms boro-silicate glasses at relatively low temperatures in the presence of silica.
Formation of such structures is expected to contribute to the strength of the pellets
through slag bonding (Meyer, 1980). Absence of acidic impurities and alkalis in
colemanite combined with low melting temperature, good thermal and mechanical
properties of boro-silicate glasses favors the use of colemanite as a slag forming
constituent. When used together with an organic binder, while colemanite renders
the required properties for pre-heated and fired pellets, the organic binder fulfills
the tasks for green and dry pellets. The two together, then, can be used in place of
bentonite.

2. MATERIALS AND METHODS:

2.1. Materials
Magnetite concentrate was obtained from Divriği Concentration Plant, Sivas. The
as-received magnetite concentrate sample (Fe: 69.25%, SiO2: 0.95%, Al2O3:
1.40%, CaO: 0.53%, MgO: 0.90%, Na2O: 0.05%, K2O: 0.14% and S: 0.48%) was
washed repeatedly, filtered, dried at 105oC. The test samples of 500 g were taken
representatively and stored in plastic bags for pelletization experiments. The
concentrate had a particle size of 65.3% passing 45 microns (325 mesh), 1617
cm2/g Blaine specific surface area and 5.1 specific gravity.
The sodium-bentonite sample (SiO2: 67.76%, Al2O3: 16.86%, FeO: 4.17%,
Na2O: 1.38%, K2O: 0.73%, CaO: 2.19% and MgO: 3.62%) used in the pelletization
tests was obtained from Reşadiye, Tokat.
Colemanite concentrate (B2O3: 43%, SiO2: 6.50%, CaO: 26% and SO3: 0.50%)
was obtained from Eti Mine Bigadiç Concentration Plant. The sample was washed,
dried, crushed and screened from 1 mm screen. This sample was calcined at 550 oC
to remove water, and screened from 210 micron (65 mesh). Calcined colemanite
(CC) with a specific gravity of 1.95 was ground to 85% passing from 45 microns in
a centrifuge ball mill.
Technical grade Carboxyl Methyl Cellulose (CMC), food grade corn starch and
Ciba DPEP06-0007 were used as organic binders. The former two were obtained
from the local market; the latter was obtained from Ciba Specialty Chemicals
Holding Inc.

2.2. Equipments
Elemental analyses of magnetite and bentonite were determined with Spectro IQ
X-ray fluorescence (XRF) spectrometer. Specific surface area of iron ore was
determined with Blaine air permeability apparatus. A laboratory-scale balling disc
with 390 mm diameter, 100 mm depth and 11 rpm was used for pelletization.

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Laboratory drying oven and a muffle furnace were used to dry and fire the pellets.
A mechanical press with motorized drive with a 5000 kg maximum load capacity
with 1 kg of accuracy at a constant cross-head speed of 10 mm/min was used for
compressive strength testing.

2.3. Pelletization Tests

The predetermined amount of iron ore and binder (bentonite, CC, organic binders)
were weighed before the pelletization. They were mixed in a mechanical mixer for
5 minutes and predetermined amount of water was slowly added to this mixture
during mixing. The binder and water addition levels were dosed as percent by
weight of the dry iron ore.
The mixed material was screened from a 2 mm (10mesh) screen. A small
amount of material was put into the pelletizing disc to produce pellet seeds. During
the seed production, water mist was applied to the disc to stabilize the moisture
content. After the production of pellet seeds, the screened fine ore was fed to the
disc for the growth of the seeds. Enlarged pellets were removed from the disc and
screened through 12 and 10 mm screens to obtain -12+10 mm product pellets.
While pellets smaller than 10 mm were directly fed back to the disc and those
larger than 12 mm were crushed to -2 mm using a screen and were fed back to the
disc. This operation was continued until all feed was depleted.
The drop number and compressive strength of green pellets were determined.
Green pellets were dried at 105oC to determine the moisture content. Pellets were
dried at 400oC pre-heated at 1000oC and fired at 1300oC for 20 minutes. The
compressive strengths of dried, pre-heated and fired pellets determined. For each
value reported is the mean value of ten pellets selected from each group.

3. RESULTS AND DISCUSSION:

As bentonite is the common binder in iron ore pelletizing, any binder or
combination of binders must over-perform or at least equi-perform bentonite.
Therefore, a bench mark with bentonite must be established first. The study, for the
reasons explained above, was focused on the compressive strengths of indurated,
especially those of pre-heated (at 1000oC) and fired (at 1300oC) pellets. The drop
numbers and compressive strengths of green pellets produced with bentonite,
organic binders (CMC, Ciba DPEP06-0007 and corn starch) and organic
binders+CC were found to be larger than 3 and 1 kg/pellet which are acceptable.

3.1. Compressive Strengths of Pellets Produced with Bentonite

The first series of tests were conducted with 0%, 0.5% and 1% bentonite addition
in order to determine the performance of bentonite as a bench mark. The
compressive strengths of pellets produced with bentonite are given in the Figure 1.

1123
Compressive strengths were found 150.1 kg/pellet for 0.5% bentonite added pellets
pre-heated at 1000oC and 494.4 kg/pellet fired at 1300oC. These values were found
to be sufficient and compressive strengths of pre-heated and fired pellets produced
with alternative binders were compared to the values obtained with 0.5% bentonite
addition.

3.2. Compressive Strengths of Pellets Produced with Organic Binders

In order to see the effect of organic binders alone on the compressive strength of
pellets; CMC, Ciba DPEP06-0007 and corn starch were used. The compressive
strengths of pellets produced with organic binders are given in the Figures 2, 3 and
4. The maximum compressive strengths of pre-heated pellets produced with
organic binders were found 105.8, 89.4 and 80.8 kg/pellet for 0.2% CMC, 0.05%
Ciba DPEP06-0007 and 0.1% corn starch addition, respectively. These values are
lower when compared to the compressive strength of pellets produced with
bentonite.
700 700
0.05% CMC
600
Compressive Strength (kg/pellet)

600
Compressive Strength (kg/pellet)

0.1% CMC
Without Binder 0.15% CMC
500 500
0.5% Bentonite 0.2% CMC
400 0.5% Bentonite
400 1% Bentonite

300 300
(kg/pellet)

200 200

100 100

0
0
0 200 400 600 800 1000 1200 1400
0 200 400 600 800 1000 1200 1400
Temperature (oC) Temperature (oC)

Figure 1. Compressive strengths of pellets Figure 2. Compressive strengths of pellets

produced with bentonite produced with CMC
700 700
0.1% Corn Starch
600 0.05% Ciba DPEP06-0007 600 0.2% Corn Starch
Compressive Strength (kg/pellet)

Compressive Strength (kg/pellet)

0.1% Ciba DPEP06-0007 0.3% Corn Starch

500 500
0.5% Bentonite 0.4% Corn Starch
0.5% Bentonite
400 400

300 300

200 200

100 100

0 0
0 200 400 600 800 1000 1200 1400 0 200 400 600 800 1000 1200 1400

Temperature (oC) Temperature (oC)

Figure 3. Compressive strengths of pellets Figure 4. Compressive strengths of pellets

produced with Ciba DPEP06-0007 produced with corn starch

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3.3. Compressive Strengths of Pellets Produced with Calcined Colemanite
In order to determine the effect of CC on the compressive strength of pre-heated
pellets, different percentages of CC were tested. The compressive strengths of pre-
heated and fired pellets produced with CC are increasing by increasing the amount
of CC. The minimum and maximum compressive strengths of pre-heated pellets at
1000oC were found 123.6 and 183.6 kg/pellet. Figure 5 shows the compressive
strength of 0.5% CC and 0.5% bentonite added pre-heated pellets have almost the
same value (151.9 and 150.1 kg/pellet). The required pre-heated compressive
strength of pellets was obtained by using only CC instead of bentonite.
700 700
0.1% CMC + 0.25% CC
600 0.25% CC
600 0.1% CMC + 0.5% CC
0.5% CC
0.1% CMC + 0.75% CC

Compressive Strength (kg/pellet)

0.75% CC
Compressive strength (kg/pellet)

500 500 0.1% CMC + 1% CC

1% CC
400 0.5% Bentonite
0.5% Bentonite 400

300 300

200
200
100
100
0
0
0 200 400 600 800 1000 1200 1400
0 200 400 600 800 1000 1200 1400
Temperature (oC) Temperature (oC)

Figure 5. Compressive strengths of pellets Figure 6. Compressive strengths of pellets

produced with CC produced with CMC+CC

3.4. Compressive Strengths of Pellets Produced with Calcined Colemanite

Added Organic Binders
The compressive strengths of pre-heated pellets produced with organic binders
alone were found insufficient. On the other hand, the compressive strengths of pre-
heated pellets produced with CC were found sufficient. So the combination of
organic binders and CC (CMC+CC, Ciba DPEP06-0007+CC and corn starch+CC)
were used to obtain good green, pre-heated and fired pellet quality. The
compressive strengths of pellets produced with organic binders+CC are given in
the Figures 6, 7 and 8. The maximum compressive strengths of pre-heated pellets
were found 144.5, 168.8 and 178.6 kg/pellet with CMC+CC, Ciba DPEP06-
0007+CC and corn starch+CC, respectively. These compressive strengths are
comparable with the compressive strengths of pellets produced with bentonite.

1125
 700
700
600 0.05% Ciba DPEP06-0007+ 0.25% CC 0.1% Corn Starch + 0.25% CC
600 0.1% Corn Starch+ 0.5% CC
Compressive Strength (kg/pellet)

Compressive strength (kg/pellet)

0.05% Ciba DPEP06-0007+ 0.5% CC
500 500 0.1% Corn Starch+ 0.75% CC
0.05% Ciba DPEP06-0007+ 0.75% CC
0.1% Corn Starch+ 1% CC
400 0.05% Ciba DPEP06-0007+ 1% CC 400 0.5% Bentonite
0.5% Bentonite
300 300

200 200

100 100

0 0
0 200 400 600 800 1000 1200 1400 0 200 400 600 800 1000 1200 1400
Temperature (oC) Temperature (oC)

Figure 7. Compressive strengths of pellets Figure 8. Compressive strengths of pellets with

produced with Ciba DPEP06-0007+CC produced with corn starch+CC

4. CONCLUSIONS:
Bentonite is the most common binder in iron ore pelletizing, however it includes
impurities that adversely affect the iron-steel economy. Organic binders may be an
alternative to the bentonite. Pellets with good green quality could be produced with
organic binders alone. But the compressive strength of pre-heated and fired pellets
was found insufficient. In order to overcome this shortcoming of the organic
binders, calcined colemanite was used as an additive.
The results showed that the use of calcined colemanite together with an organic
binder yielded pellets with enough green, pre-heated and fired quality comparable
with those of pellets produced with bentonite.

5. REFERENCES:
Arol, A. I.; Özbayoglu, G.; Hiçyılmaz, C.; Akdemir, Ü.; Mamurekli, M., 1983,
Determination of an Alternative Binder to Bentonite in Iron Ore Pelletization,
11.Türkiye Madencilik Bilimsel ve Teknik Kongresi, p:393-405.
Arol, A. I., 1997, Unpublished study on the use of organic binders in iron
peletization.
ASTM C 204-07, Standard test methods for fineness of hydraulic cement by air-
permeability apparatus.
ASTM E 382-07, Standard test method for determination of crushing strength of
iron ore pellets.
ASTM E 877-03, Standard practice for sampling and sample preparation of iron
ores and related materials.
Ball, D. F.; Dartnell, J.; Davison, J.; Grieve, A.; Wild, R., 1973, Agglomeration of
Iron Ores, American Elsevier Publishing Company, Inc., New York.

1126
Chizhikova, V. M.; Vainshtein, R. M.; Zorin, S. N.; Zainetdinov, T. I.; Zinyagin,
G. A.; Shevchenko, A. A., 2003, Production of Iron Ore-Pellets with an
OrganicBinder, Metallurgist, Vol.47, Nos.3-4.
Eisele, T. C.; and Kawatra S. K.; 2003, A Review of Binders In Iron ore
Pelletization, Mineral Processing & Extractive Metall. Rev., 24, p:1-90.
De Souza R.P.; de Mendonca, C.F.; Kater T., 1984, Production of acid iron ore
pellet for direct reduction, using an organic binder, Mining Engineering
Magazine. p.1437.-1441.
Goetzman, H. E.; Bleifuss, R. L.; Engesser, J., 1988, Investigation of
Carboxymethylcellulose Binders for Taconite Pelletizing, Society of Mining
Engineers.
Kater, T.; Steeghs, R. G., 1984, Organic Binders for Iron Ore Pelletization, Mining
Symposium at Duluth-MN, USA.
Kawatra, S. K.; Ripke, S. J., 2002, Effects of bentonite fiber formation in iron ore
pelletization, International Journal of Mineral Processing, 65, p:141–149
Meyer, K., 1980, Pelletizing of Iron Ores, Springer-Verlag Berlin Heidelberg New
York .
Tektas E., 2003 Bigadiç ground colemanite health and safety data sheet, Eti
Holding A.Ş. Research & Development Department.

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