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Introduction
Sintering and pelletizing are examples of agglomeration processes which are used in manufacturing industries to convert fine powders and dusts into larger, more homogenous agglomerates. Sintering and pelletizing are most commonly used in the iron and steel industries, which convert finely ground ore into small pellets with a desirable size, shape, and mechanical strength for use as iron ore in iron and steelmaking. The final product yield (or pelletizing rate) is an important quality feature for iron and steel producers and influences several aspects of the production process.
Sintering Process
The sintering process utilizes a mixture of various iron ores, coke, and/or other additives which are mixed together and heated to high temperatures to bond the components into compacted chunks or sinter. The resulting product is a porous agglomerate with a strength of roughly 1/10th that of solid steel or iron. The size of the sinter produced depends on the size of the raw material and the temperature and atmosphere of sintering. Generally, higher temperatures result in higher yields, but the risk of oxidation, increased electric consumption, and higher cost of controlling sintering parameters are also increased.
Pelletizing Process
Pelletizing is a mechanical formation process for production of high-quality agglomerates of small particles. The process involves two steps: heating and compressing the mixture of iron ore, coke, and other additives at a predetermined temperature, and forming round pellets from the resulting mixture. Pelletizing yields high strength pellets with a uniform size for use in the production of iron and steel. Typical pellet sizes typically range from 4 to 8mm in diameter, though larger sizes (9 and 10mm) are also possible with certain combinations of materials.
Final Product Yield
The final product yield of sintering and pelletizing processes is an important factor in the overall efficiency of the operation. In general, the higher the yield, the lower the cost of operation and vice versa. Additionally, the final product yield is typically related to the initial composition of the raw material; sintering quality is often higher when materials with higher levels of mineral impurities are used. The final product yield can also be influenced by the design of the sintering furnace and pelletizing plant.
Conclusions
The sintering and pelletizing processes are widely used in the iron and steel industries to produce pellets with a desired size, shape, and mechanical strength for use as ore in iron and steelmaking. The final product yield is an important factor in the efficiency of the operation and can be affected by the initial composition of the raw material, the temperature, atmosphere, and design of the sintering furnace and pelletizing plant. Further research is needed to improve understanding and application of agglomeration processes for enhanced product yields and increased efficiency.
