Claims:WE CLAIM:
1. A method for reducing yield stress of bulk solids, said method comprises-
- mixing bulk solids with stearate to obtain a blend; and
- activating the stearate in the blend to obtain the bulk solids having reduced yield stress.
2. The method as claimed in claim 1, wherein ratio of the bulk solids to the stearate is ranging from about 1000:1 to 10000:1.
3. The method as claimed in claim 1, wherein the stearate is activated by addition of activator, wherein ratio of the stearate to the activator is ranging from about 1:1 to 1:2
4. The method as claimed in claim 1, wherein the stearate has particle size ranging from about 100 nm to 5000 nm; and the stearate has surface area ranging from about 5 m2/g to 40 m2/g.
5. The method as claimed in claim 1, wherein the stearate is present in an amount ranging from about 10 ppm to 1000 ppm.
6. The method as claimed in claim 1, wherein the bulk solids have particle size ranging from about 0.1 mm to 10mm.
7. The method as claimed in claim 1, wherein the blend is allowed for conditioning before activating the stearate, for a duration ranging from about 60 seconds to 600 seconds.
8. The method as claimed in claim 1, wherein the blend is allowed for conditioning after activating the stearate, for a duration ranging from about 60 seconds to 600 seconds.
9. The method as claimed in claim 8, wherein the blend is subjected to holding time for a duration ranging from about 60 seconds to 600 seconds.
10. The method as claimed in claim 1, wherein the bulk solids is iron ore fines; the stearate is selected from a group comprising magnesium stearate, calcium stearate, sodium stearate and any combination thereof.
11. The method as claimed in claim 3, wherein the activator is selected from a group comprising nano silica, fumed silica, fluffy silica and any combination thereof.
12. The method as claimed in claim 1, wherein stearate treated bulk solids has cohesive strength ranging from about 367 Pascal to 1403 Pascal; has flowability index (FFC) ranging from about 7.20 to 10.83; has yield strength (Fc) ranging from about 1700 pascal to 7000 Pascal; has density weighed flow (FFRHO) ranging from about 12.77to 18.54; and has compressive stress (SIGMA1) ranging from about _18414 pascal to 50419 Pascal.
13. A stearate treated bulk solids prepared according to the method as claimed in claim 1.
14. The stearate treated bulk solids as claimed in claim 13, wherein the stearate treated bulk solids has cohesive strength ranging from about 367 Pascal to 1403 Pascal; has flowability index (FFC) ranging from about 7.20 to 10.83; has yield strength (Fc) ranging from about 1700 pascal to 7000 pascal; has density weighed flow (FFRHO) ranging from about 12.77 to 18.54; and has compressive stress (SIGMA1) ranging from about 18414 Pascal to 50419 Pascal.
15. A composition comprising iron ore fines and stearate.
16. The composition as claimed in claim 15, wherein ratio of stearate and iron ore fines is ranging from about 1:1000 to 1:10000.
17. The composition as claimed in claim 15, wherein the stearate is selected from a group comprising magnesium stearate, Sodium stearate, Calcium stearate and any combination thereof.
18. The composition as claimed in claim 15, wherein the iron ore fines have particle size ranging from about 0.1 mm to 10mm; and wherein the stearate has particle size ranging from about 100 nm to 5000 nm; the stearate has surface area ranging from about 5 m2/gto 40 m2/g.
, Description:TECHNICAL FIELD
The present disclosure relates to the field of metallurgy. The present disclosure particularly relates to reducing yield stress in bulk solids, wherein the yield stress of the bulk solids is reduced by mixing the bulk solids with stearate. The disclosure further relates to stearate treated bulk solids having reduced yield stress and improved flowability. The disclosure also relates to a composition comprising iron ore pellets and stearate and to the process of preparing the composition.

BACKGROUND OF THE DISCLOSURE
The iron ore fines are processed in a mining industry across several unit operations that include crushers, screens, drum scrubbers, classifiers, hydrocyclone etc. The iron ore fines processing is normally carried out either in wet operation or in dry process. The dry process consists of stages of crushing followed by screening in dry screens. The iron ore fines processing plants operating in dry mode usually are fed with run of mine (ROM) ore which contains particles of different size range. The material handling of iron ore is carried out in conveyors, hoppers, silos, chutes etc. The run of mine ore is often moist and contains varying level of moisture in different weather conditions. During hot and arid weather, the moisture level of run of mine is in the range of 3 % to 4 %, however, during moist and humid weather the moisture level goes to as high as 12%. The material handling of moisture laden run of mine ore is very difficult since moisture forms a layer of water on the solid particles resulting in liquid bridging. This liquid bridging results in increase in cohesiveness of the bulk solids including but not limited to iron ores which ultimately increases the yield stress of bulk solids. The increase in yield stress corresponds to a decrease in flowability across the material handling equipment like silos, hoppers and chutes.

The yield stress of bulk solids is a major factor which affects the flow behaviour. A higher yield stress also means a higher consolidation of material under compressive loading conditions. Thus, when the same bulk solid is transported in rail wagons over long distance, it encounters a compressive stress due to vibrations of the rail wagons. This compressive loading over a period of time develops a very high yield stress in bulk solids. This is called time consolidation. The time consolidation of the bulk solids, such as iron ore results in a packed bed of particles which requires a very high force to yield. Thus, the railway wagons often require an aid such as high external force (vibrators etc) to unload the bulk solids.

The problems associated with high yield stress of bulk solids are not efficiently addressed. For instance- In US6055781A, the bulk solids are made to flow more easily by suitably altering the design of hopper. The hopper in conventional designs are uniformly made with a slope such that the material with certain characteristics flows easily. However, with change in material (bulk solids) characteristics, the same hopper design does not work and often arching or ratholing is seen in hoppers. In US4886097A, the material flow properties are enhanced using specially designed container, wherein the container is constructed to hold particulate solids, comprising a cone like wall converging downwardly from at least a top inlet located at the widest diameter portion of the vessel to at least one outlet located at the narrowest diameter portion of the vessel. In WO1990015757A1A, bin adapted for storing and dispensing particulate materials is formed by joining two or more bin modules of similar shape, wherein the linear dimensions of the modules increase in geometric series, with the smallest module being at the bottom. The modules are designed to prevent arching of the particulate material to assure mass flow. A bin constructed of these modules requires appreciably less head room than does a conical bin.

In the above mentioned documents, to improve the flowability of the bulk solids, the silo, the hopper or the bin dimensions are modified. However, there was no disclosure about improving flowability or reducing yield stress of the bulk solids which can lead to a permanent solution without altering the apparatus/equipment or that can be applicable to all types of bulk solids.

Thus, there appears to be a need for efficient manner of improving flowability or reducing yield stress of the bulk solids. The present application aims to improve flowability and reduce yield stress of bulk solids efficiently.

STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure provides for simple, efficient, economical and environmentally friendly method for reducing yield stress of bulk solids.

According to the present disclosure, the method of reducing yield stress of the bulk solids comprises: mixing the bulk solids with stearate to obtain a blend; and activating the stearate in the blend to obtain the bulk solids having reduced yield stress and improved flowability.

The present disclosure further relates to stearate treated bulk solids prepared by said method.

The present disclosure further relates to a composition comprising iron ore fines and stearate.

The present disclosure further relates to a process for preparing the composition, said process comprises- mixing iron ore fines with stearate to obtain a blend; and activating the stearate in the blend to obtain the composition.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
In order that the present disclosure may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figure. The figure together with detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, where:

Figure 1: illustrates the indicative pattern of Yield locus of a bulk solid tested with Shear tester.

DETAILED DESCRIPTION OF THE DISCLOSURE
Definitions:
Unless otherwise defined, all terms used in the disclosure, including technical and scientific terms, have meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included for better understanding of the present disclosure.

As used herein, singular forms ‘a’, ‘an’ and ‘the’ include both singular and plural referents unless the context clearly dictates otherwise.

The term ‘comprising’, ‘comprises’ or ‘comprised of’ as used herein are synonymous with ‘including’, ‘includes’, ‘containing’ or ‘contains’ and are inclusive or open-ended and do not exclude additional, non-recited members, elements or method steps.

The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within the respective ranges, as well as the recited endpoints.

The term ‘about’ as used herein when referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of ±10% or less, preferably ±5% or less, more preferably ±1% or less and still more preferably ±0.1% or less of and from the specified value, insofar such variations are appropriate to perform the present disclosure.

The term ‘cohesive strength’ as used herein refers to the strength of bonding between the particles or surfaces that make up the solids or the material.

The term ‘flowability index’ or ‘flowability’ as used herein refers to ratio of compressive stress to unconfined yield stress.

The term ‘yield strength’ or ‘yield stress’ as used herein refers to the stress at which a predetermined amount of permanent deformation occurs. The graphical portion of the early stages of a tension test is used to evaluate yield strength/yield stress. Yield stress of bulk solid is dependent on the inter particle cohesive forces and the adhesive forces between the particles and the surrounding environment. Any element/factor that reduces these forces will directly result in reduction in total forces acting on the bulk solid.

The term ‘density weight flow’ as used herein refers to the density-weighed flowability ffr taking into account the influence of the bulk density on gravity flow. ffrho can be useful if powders are to be compared for an application where gravity plays a role (e.g. when the bulk solid must flow out of a hopper).

The term ‘compressive stress’ as used herein refers to the force that is responsible for the deformation of the material such that the volume of the material reduces. It is the stress experienced by a material which leads to a smaller volume. High compressive stress leads to failure of the material due to tension.

The present disclosure relates to a method of reducing yield stress of bulk solids.

In some embodiments of the present disclosure, the method of reducing yield stress of the bulk solids comprises:
- mixing the bulk solids with stearate to obtain a blend; and
- activating the stearate in the blend to obtain the bulk solids having reduced yield stress.

In some embodiments of the present disclosure, the method of reducing yield stress of the bulk solids improves flowability of the bulk solids.

In some embodiments of the present disclosure, the method reduces the yield stress of the bulk solids by at least 70%.

In some embodiments of the present disclosure, the method reduces the yield stress of the bulk solids by at least 70% when compared to the bulk solids which are not combined or treated with stearate.

In some embodiments of the present disclosure, the bulk solids include, but it is not limited to iron ore fines.

In some embodiments of the present disclosure, the bulk solids have particle size ranging from about 0.1 mm to 10 mm.

In some embodiments of the present disclosure, the bulk solids have particle size of about 0.1 mm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm or about 10 mm.

In some embodiments of the present disclosure, the bulk solids have moisture content ranging from about 2% to 12%.

In some embodiments of the present disclosure, the bulk solids have moisture content of about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11% or about 12%.

In some embodiments of the present disclosure, ratio of bulk solids to the stearate is ranging from about 1000:1 to 10000:1.

In some embodiments of the present disclosure, the stearate is selected from a group comprising magnesium stearate, calcium stearate, sodium stearate and any combinations thereof.

In some embodiments of the present disclosure, the stearate has particle size ranging from about 100 nm to 5000 nm.

In some embodiments of the present disclosure, the stearate has particle size of about 100 nm 200 nm, 300 nm, about 400 nm, about 500 nm, about 600 nm, about 700 nm, about 800 nm, about 900 nm, about 1000 nm, about 1100 nm, about 1200 nm, about 1300 nm, about 1400 nm, about 1500 nm, about 1600 nm, about 1700 nm, about 1800 nm, about 1900 nm, about 2000 nm, about 2100 nm, about 2200 nm, about 2300 nm, about 2400 nm, about 2500 nm, about 2600 nm, about 2700 nm, about 2800 nm, about 2900 nm, about 3000 nm, about 3100 nm, about 3200 nm, about 3300 nm, about 3400 nm, about 3500 nm, about 3600 nm, about 3700 nm, about 3800 nm, about 3900 nm, about 4000 nm, about 4100 nm, about 4200 nm, about 4300 nm, about 4400 nm, about 4500 nm, about 4600 nm, about 4700 nm, about 4800 nm, about 4900 nm or about 5000 nm.

In some embodiments of the present disclosure, the stearate has surface area ranging from about 5 m2/g to 40 m2/g.

In some embodiments of the present disclosure, the stearate has surface area of about 5 m2/g, about 10 m2/g, about 15 m2/g, about 20 m2/g, about 25 m2/g, about 30 m2/g, about 35 m2/g or about 40 m2/g.

In some embodiments of the present disclosure, the stearate is in an amount ranging from about 10 ppm to 1000 ppm.

In some embodiments of the present disclosure, the stearate is in an amount of about 10 ppm, about 20 ppm, about 30 ppm, about 40 ppm, about 50 ppm, about 60 ppm, about 70 ppm, about 80 ppm, about 90 ppm, about 100 ppm, about 120 ppm, about 140 ppm, about 160 ppm, about 180 ppm, about 200 ppm, about 220 ppm, about 240 ppm, about 260 ppm, about 280 ppm, about 300 ppm, about 320 ppm, about 340 ppm, about 360 ppm, about 380 ppm, about 400 ppm, about 420 ppm, about 440 ppm, about 460 ppm, about 480 ppm, about 500 ppm, about 520 ppm, about 540 ppm, about 560 ppm, about 580 ppm, about 600 ppm, about 620 ppm, about 640 ppm, about 660 ppm, about 680 ppm, about 700 ppm, about 720 ppm, about 740 ppm, about 760 ppm, about 780 ppm, about 800 ppm, about 820 ppm, about 840 ppm, about 860 ppm, about 880 ppm, about 900 ppm, about 920 ppm, about 940 ppm, about 960 ppm, about 980 ppm or about 1000 ppm.

In some embodiments of the present disclosure, the blend in the method is allowed for conditioning for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, the blend is allowed for conditioning for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.

In some embodiments of the present disclosure, the stearate in the blend is activated by addition of activator.

In some embodiments of the present disclosure, the activator is selected from a group comprising nano silica, fumed silica, fluffy silica, and any combinations thereof.

In some embodiments of the present disclosure, amount of the activator is ranging from about 1 g/g to 2 g/g.

In some embodiments of the present disclosure, ratio of the activator to the stearate is ranging from about 1:1 to 2:1.

In some embodiments of the present disclosure, the activator is added at a rate of half the weight of the stearate.

In some embodiments of the present disclosure, upon activating the stearate in the blend, the blend is allowed for conditioning for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, upon activating the stearate in the blend, the blend is allowed for condition for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.

In some embodiments of the present disclosure, upon conditioning the blend post activation of the stearate, the blend is subjected to holding time for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, upon conditioning the blend post activation of the stearate, the blend is subjected to holding time for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.

In some embodiments of the present disclosure, the method of reducing yield stress of bulk solids comprises:
- mixing bulk solids and stearate to obtain a blend, followed by conditioning the blend;
- activating the stearate in the blend by adding the activator;
- conditioning the blend, followed by holding the blend to obtain bulk solids having reduced yield stress.

In some embodiments of the present disclosure, the method of reducing yield stress of bulk solids comprises:
- mixing bulk solids and stearate in a ratio of about 1000:1 to 10000:1 to obtain a blend, followed by conditioning the blend for a duration ranging from about 60 seconds to 600 seconds;
- activating the stearate in the blend by adding the activator in a ratio of about 0.5:1 by weight of the stearate;
- conditioning the blend for a duration ranging from about 60 seconds to 600 seconds; and
- holding the blend for a duration ranging from about 60 seconds to 600 seconds to obtain bulk solids having reduced yield stress.

In some embodiments of the present disclosure, the bulk solids obtained from the above described method have cohesive strength ranging from about 360 pascal to 1410 pascal. The mentioned cohesive strength of the stearate treated bulk solids is decreased by at least 70% when compared to bulk solids not treated/combined with stearate.

In some embodiments of the present disclosure, the bulk solids obtained from the above described method have flowability index (FFC) ranging from about 7.20 to 11.

In some embodiments of the present disclosure, the bulk solids obtained from the above described method have yield strength (Fc) ranging from about 700 pascal to 1700 pascal.

In some embodiments of the present disclosure, the bulk solids obtained from the above described method have density weight flow (FFRHO) ranging from about 12 to 19.

In some embodiments of the present disclosure, the bulk solids obtained from the above described method have compressive stress (SIGMA1) ranging from about 18410 pascal to 50420 pascal.

The present disclosure further relates to stearate treated bulk solids.

In some embodiments of the present disclosure, the stearate treated bulk solids have at least 70% reduced yield stress when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the stearate treated bulk solids have at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 100% reduced yield stress when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the stearate treated bulk solids have at least 70% reduced cohesive strength when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the stearate treated bulk solids have at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 100% reduced cohesive strength when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the stearate treated bulk solids have at least 70% improved flowability/flowability index when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, stearate treated bulk solids have cohesive strength ranging from 360 pascal to 1410 pascal. The mentioned cohesive strength of the stearate treated bulk solids is decreased by at least 70% when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the stearate treated bulk solids have flowability index (FFC) ranging from about 7.20 to 11.

In some embodiments of the present disclosure, the stearate treated bulk solids have yield strength (Fc) ranging from about 700 pascal to 1700 pascal.

In some embodiments of the present disclosure, the stearate treated bulk solids have density weight flow (FFRHO) ranging from about 12 to 19.

In some embodiments of the present disclosure, the stearate treated bulk solids have compressive stress (SIGMA1) ranging from about 18410 pascal to 50420 pascal.

The present disclosure further relates to a composition comprising iron ore fines and stearate.

In some embodiments of the present disclosure, ratio of stearate to iron ore fine is ranging from about 1:1000 to 1:10000.

In some embodiments of the present disclosure, the iron ore fines have particle size ranging from about 0.1 mm to 10 mm.

In some embodiments of the present disclosure, the iron ore fines have particle size of about 0.1 mm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm or about 10 mm.

In some embodiments of the present disclosure, the iron ore fines have moisture content ranging from about 2% to 12%.

In some embodiments of the present disclsorue, the iron ore fines have moisture content of about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11% or about 12%.

In some embodiments of the present disclosure, the stearate is selected from a group comprising magnesium stearate, sodium stearate, calcium stearate and any combination thereof.

In some embodiments of the present disclosure, the stearate has particle size ranging from about 100 nm to 5000 nm.

In some embodiments of the present disclosure, the stearate has particle size of about 100 nm 200 nm, 300 nm, about 400 nm, about 500 nm, about 600 nm, about 700 nm, about 800 nm, about 900 nm, about 1000 nm, about 1100 nm, about 1200 nm, about 1300 nm, about 1400 nm, about 1500 nm, about 1600 nm, about 1700 nm, about 1800 nm, about 1900 nm, about 2000 nm, about 2100 nm, about 2200 nm, about 2300 nm, about 2400 nm, about 2500 nm, about 2600 nm, about 2700 nm, about 2800 nm, about 2900 nm, about 3000 nm, about 3100 nm, about 3200 nm, about 3300 nm, about 3400 nm, about 3500 nm, about 3600 nm, about 3700 nm, about 3800 nm, about 3900 nm, about 4000 nm, about 4100 nm, about 4200 nm, about 4300 nm, about 4400 nm, about 4500 nm, about 4600 nm, about 4700 nm, about 4800 nm, about 4900 nm or about 5000 nm.

In some embodiments of the present disclosure, the stearate has surface area ranging from about 5 m2/g to 40 m2/g.

In some embodiments of the present disclosure, the stearate has surface area of about 5 m2/g, about 10 m2/g, about 15 m2/g, about 20 m2/g, about 25 m2/g, about 30 m2/g, about 35 m2/g or about 40 m2/g.
In some embodiments of the present disclosure, the stearate is in an amount ranging from about 10 ppm to 1000 ppm.

In some embodiments of the present disclosure, the stearate is in an amount of about 10 ppm, about 20 ppm, about 30 ppm, about 40 ppm, about 50 ppm, about 60 ppm, about 70 ppm, about 80 ppm, about 90 ppm, about 100 ppm, about 120 ppm, about 140 ppm, about 160 ppm, about 180 ppm, about 200 ppm, about 220 ppm, about 240 ppm, about 260 ppm, about 280 ppm, about 300 ppm, about 320 ppm, about 340 ppm, about 360 ppm, about 380 ppm, about 400 ppm, about 420 ppm, about 440 ppm, about 460 ppm, about 480 ppm, about 500 ppm, about 520 ppm, about 540 ppm, about 560 ppm, about 580 ppm, about 600 ppm, about 620 ppm, about 640 ppm, about 660 ppm, about 680 ppm, about 700 ppm, about 720 ppm, about 740 ppm, about 760 ppm, about 780 ppm, about 800 ppm, about 820 ppm, about 840 ppm, about 860 ppm, about 880 ppm, about 900 ppm, about 920 ppm, about 940 ppm, about 960 ppm, about 980 ppm or about 1000 ppm.

In some embodiments of the present disclosure, the composition has cohesive strength ranging from about 360 pascal to 1410 pascal.

In some embodiments of the present disclosure, the composition has flowability index (FFC) ranging from about 7.20 to 11.

In some embodiments of the present disclosure, the composition has yield strength (Fc) ranging from about 700 pascal to 1700 pascal.

In some embodiments of the present disclosure, the composition has density weight flow (FFRHO) ranging from about 12 to 19.

In some embodiments of the present disclosure, the composition has compressive stress (SIGMA1) ranging from about 18410 pascal to 50420 pascal.

In some embodiments of the present disclosure, the composition has at least 70% reduced yield stress when compared to bulk solids not treated with stearate.

In some embodiments of the present disclosure, the composition has at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95% or at least 100% reduced yield stress.

In some embodiments of the present disclosure, the composition has at least 70% reduced cohesive strength.

In some embodiments of the present disclosure, the composition has at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 100% reduced cohesive strength.

The present disclosure further relates to process of preparing the composition described above.

In some embodiments of the present disclosure, the process of preparing the composition comprises-
o mixing the iron ore fines with the stearate to obtain a blend; and
o activating the stearate in the blend to obtain the composition.

In some embodiments of the present disclosure, the process of preparing the composition comprises-
o mixing the iron ore fines with the stearate to obtain a blend, followed by conditioning the blend;
o activating the stearate in the blend by adding activator; and
o conditioning the blend, followed by holding the blend to obtain the composition.

In some embodiments of the present disclosure, the blend is allowed for conditioning for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, the blend is allowed for conditioning for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.
In some embodiments of the present disclosure, the activator is selected from a group comprising nano silica, fumed silica, fluffy silica, and any combinations thereof.

In some embodiments of the present disclosure, amount of the activator is ranging from about 1 g/g to 2 g/g.

In some embodiments of the present disclosure, amount of the activator is about 1 g/g, about 1.2 g/g, about 1.3 g/g, about 1.4 g/g, about 1.5 g/g, about 1.6 g/g, about 1.7 g/g, about 1.8 g/g, about 1.9 g/g or about 2 g/g.

In some embodiments of the present disclosure, upon activating the stearate in the blend, the blend is allowed for conditioning for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, upon activating the stearate in the blend, the blend is allowed for condition for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.

In some embodiments of the present disclosure, upon conditioning the blend post activation of the stearate, the blend is subjected to holding time for a duration ranging from about 60 seconds to 600 seconds at atmospheric temperature and pressure.

In some embodiments of the present disclosure, upon conditioning the blend post activation of the stearate, the blend is subjected to holding time for a duration of about 60 seconds, about 70 seconds, about 80 seconds, about 90 seconds, about 100 seconds, about 120 seconds, about 140 seconds, about 160 seconds, about 180 seconds, about 200 seconds, about 220 seconds, about 240 seconds, about 260 seconds, about 280 seconds, about 300 seconds, about 320 seconds, about 340 seconds, about 360 seconds, about 380 seconds, about 400 seconds, about 420 seconds, about 440 seconds, about 460 seconds, about 480 seconds, about 500 seconds, about 520 seconds, about 540 seconds, about 560 seconds, about 580 seconds or about 600 seconds.
In some embodiments of the present disclosure, the process of preparing the composition comprises:
- mixing iron ore fines and stearate in a ratio of about 1000:1 to 10000:1 obtain a blend, followed by conditioning the blend for a duration ranging from about 60 seconds to 600 seconds;
- activating the stearate in the blend by adding the activator in a ratio of about 0.5:1 by weight of the stearate;
- conditioning the blend for a duration ranging from about 60 seconds to 600 seconds; and
- holding the blend for a duration ranging from about 60 seconds to 600 seconds to obtain the composition.

The present disclosure provides for the following advantages-
- The bulk solids with reduced yield stress provide for window of opportunity to design material handling equipment.
- The structural requirement of manufacturing of silos and hoppers will be reduced thereby reducing the structural load and cost.
- The productivity measured in terms of production rate of bulk solids, such as iron ore or unit time will be improved due to ease of flowability in material handling units.
- The penalty costs associated with iron ore wagon unloading like demurrage and detention will be eliminated in view of better unloading characteristics of bulk solids such as iron ore.

It is to be understood that the foregoing descriptive matter is illustrative of the disclosure and not a limitation. While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the embodiments without departing from the principles of the disclosure. Those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. Similarly, additional embodiments and features of the present disclosure will be apparent to one of ordinary skill in art based upon description provided herein.

Descriptions of well-known/conventional methods/steps and techniques are omitted so as to not unnecessarily obscure the embodiments herein. Further, the disclosure herein provides for examples illustrating the above-described embodiments, and in order to illustrate the embodiments of the present disclosure, certain aspects have been employed. The examples used herein for such illustration are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, following examples should not be construed as limiting the scope of the embodiments herein.

EXAMPLES

Example 1: Method of reducing yield stress of bulk solids
The iron ore fines were mixed with about 50 ppm to 1000 ppm of stearate to obtain a blend. The blend was conditioned for a duration of about 600 seconds at atmospheric temperature and pressure. Further, about 25 ppm to 500 ppm nano silica was added to the blend to activate the stearate in the blend, followed by conditioning for a duration of about 600 seconds at atmospheric temperature and pressure. Further, the blend was subjected to holding for a duration of about 600 seconds at atmospheric temperature and pressure to obtain bulk solids having reduced yield stress.

Table 1 describes the yield stress values of the Iron ore fines before mixing with stearate and Table 2 describes yield stress values of the iron ore fine upon treating with stearate according to the method described above.
Sample No. (Iron ore fines) SIGMA1 [Pa] FC [Pa] FFC FFRHO TAU,C [Pa]
1 22321 10037 2.22 3.36 2057
2 17953 7706 2.33 3.45 1545
3 27055 12013 2.25 3.47 2450
4 32328 18099 1.79 2.82 3741
Table 1: Yield stress values of iron ore fines without treatment with stearate.

Sample No. (Iron ore fines) SIGMA1 [Pa] FC [Pa] FFC FFRHO TAU,C [Pa]
1 50419 7000 7.20 12.77 1403
2 38737 4705 8.23 14.45 983
3 28557 3258 8.77 15.19 668
4 18414 1700 10.83 18.54 367
Table 2: Yield stress values of iron ore fines upon treatment with stearate.

The Sigma 1 values are dependent on the compressive stress that is put on the bulk solids. The sigma1 values are chosen from minimum to maximum for ensuring consistency in yield locus. The data in Table 2 demonstrates that the iron ore fines treated with stearate shows about 70% decrease in the yield stress. Further, the data demonstrates that the cohesive strength of the iron ore fines treated with stearate is reduced by about 70%.

Example 2: Process of Preparing the composition
The iron ore fines were mixed with about 50 ppm to 1000 ppm of stearate to obtain a blend. The blend was conditioned for a duration of about 600 seconds at atmospheric temperature and pressures. Further, about 25 ppm to 500 ppm nano silica was added to the blend to activate the stearate in the blend, followed by conditioning for a duration of about 600 seconds at atmospheric temperature and pressures. Further, the blend was subjected to holding for a duration of about 600 seconds at atmospheric temperature and pressure to obtain bulk solids having reduced yield stress.
Table 3 demonstrates the yield stress values of the composition.
Sample No. (Iron ore fines) SIGMA1 [Pa] FC [Pa] FFC FFRHO TAU,C [Pa]
1 50419 7000 7.20 12.77 1403
2 38737 4705 8.23 14.45 983
3 28557 3258 8.77 15.19 668
4 18414 1700 10.83 18.54 367
Table 3: Yield stress values of the composition