FIELD OF THE INVENTION
The present invention relates to a process for manufacturing of briquettes from ferro
manganese and silico manganese fines. More particularly, the present invention is
directed to a process for producing briquettes from ferro manganese and silico
manganese fines by using selectively resol type Phenol formaldehyde as binder for
the first time for making such briquettes wherein Quantity of resin and mixing
sequence had been suitably formulated to have good quality briquettes. In this
process 0-10 mm of fines preferably 0-3mm is used to make briquettes of size
50x25x15mm3. Advantageously, plastic clay is also used as an additive in the
process of briquette making to impart plasticity/ workability to the mix of FeMn/
SiMn fines (0-3mm) with binder which is very much non-plastic in nature, in order to
form briquettes by applying pressure in briquetting machine. The maximum strength
obtained after oven drying at 150°C for 8 hrs for the briquettes made with resin
binder, indicated many fold increase in strength that is from green briquette
(49kg/cm2) to oven dried (102kg/cm2) with maximum retention under drop test
obtained for resin-bonded briquettes produced according to the process of the
invention making it suitable for advantageous application in iron and steel making.
BACKGROUND OF THE INVENTION
In is well known and widely reported that briquetting and palletisation are processes
used for agglomeration of fines. It is also reported that agglomeration of iron ore,
coal, chrome ore and lime fines are being done for various industrial processes.
Binder for agglomeration of these fines is generally controlled quantity of moisture.
Applicants' Ferro Alloy Plant is the largest producer of Manganese based ferro-alloy in
India with average annual production of 1.1 lakh ton of ferro alloy. Ferro manganese
and silico manganese fines are the finished product of smelting process done in Sub
Merged Arc Furnace. Liquid ferro alloy is tapped from tap hole of the furnace and
poured in the sand mould. It is allowed to cool till it solidifies and forms cake. These
cakes are fed to double toggle jaw crusher for crushing to the sizes of >60mm, 25-
60mm, 12-25mm and 3-12mm. During crushing, fines (0-10mm) fractions are
generated and they are screened out. The market value of these fines is low and the
demand is small. These fines are very hard and cannot be briquetted using water as
the binder.

In view of the above, development of a process for agglomeration of Ferro
manganese (FeMn) & Silico manganese (SiMn) fines (0-10mm) by briquetting has
been attempted by way of the present invention. Experimental study on the prospect
of converting ferro alloys fines (Size < 3mm) into agglomerates by briquette making
was taken up. Ferro manganese (FeMn) & Silico manganese (SiMn) fines (0-3mm)
were mixed with different binders and additives in a mixer and briquettes were made
using briquetting machine and resulting strength of briquettes were tested after
controlled curing to decide on the selection and optimum use of ingredients and
determining the process parameters to achieve desired best quality of briquettes.
OBJECTS OF THE INVENTION
The basic object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines which can be sold at the
same rates at which other sized ferro manganese alloys are being sold favouring
higher revenue earning of Ferro Alloy Plant.
A further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines so as to avoid
environmental problem for storage of fines.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines to provide technological
solution for using these fines in the metallurgical furnaces as these briquettes will
participate more effectively in any metallurgical process.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines wherein selective binder
and additives are used with fines for briquetting such that the briquettes get some
plasticity which will bear the stress during and after manufacturing of briquettes
avoiding appearance of cracks and scratches.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines wherein quantity of

resin/binder and mixing sequence had been suitably formulated to have good quality
briquettes.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines wherein after controlled
curing and heat treatment meet the requirement of desired crushing test and
drop/shatter test to suit their end application in metallurgical process.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines which will have
sufficient strength so as to maintain its shape and size during transportation.
A still further object of the present invention is directed to a process for producing
briquettes from ferro manganese and silico manganese fines which when charged in
metallurgical furnaces like sub merged arc furnace, arc furnace, basic oxygen
furnace or steel ladle, it easily melts with the steel due to higher density of these
briquettes and contributes in deciding the chemistry of liquid steel.
SUMMARY OF THE INVENTION
The basic aspect of the present invention is thus directed to a process for
manufacturing of briquettes from ferro manganese and/or silico manganese fines,
comprising
providing Ferro manganese (FeMn) and/or Silico manganese (SiMn) fines in the size
range of 0-10mm preferably 0-3mm in a mixer;
adding plastic clay in amount of 1-2 % by weight to the mix for dry mixing;
adding resol type phenol formaldehyde liquid resin in amount of 2-3 % by weight to
the dry mix and mixing continued till attaining homogeneity;
allowing the prepared mix to undergo ageing for 4-5 hours; and
obtaining cured briquettes of desired strength and hardness.

A further aspect of the present invention is directed to said process wherein said
ferromanganese and silico manganese fines of the size range of 0 to 10mm
preferably 0 to 3mm are mixed with plastic clay in a high intensive mixer for
specified time of 10 to 15 minutes and then further mixing is done by slow addition
of phenol formaldehyde liquid resin for specified time of 10 to 15minutes.
A still further aspect of the present invention is directed to said process wherein said
aging of the mix is done by keeping it in a covered area for specified duration
preferably for 4 to 8 hours.
A still further aspect of the present invention is directed to said process wherein said
briquettes are produced involving a briquetting machine by pressing the ready mix
between the rollers moving in opposite direction to each other, said rollers having
tires mounted thereon and having grooves such that when the mix is fed in between
the rollers a pressure of 30-40KN/cm2 is generated and briquettes are thus obtained.
A still further aspect of the present invention is directed to said process wherein self
curing of briquettes is carried out in specified temperature preferably at room
temperature for about 16 hours.
Yet another aspect of the present invention is directed to said process wherein cured
briquettes are subjected to said heat treatment at specified temperature preferably
150°C to 200°C for specified time preferably 8 to 16hours to get the required quality
of the briquettes.
A still further aspect of the present invention is directed to said process wherein said
ferro manganese fines provided comprises: Mn:60-70 wt%, Si:l-2wt%, C: 5-10wt%,
P:0.1-0.5wt%, S:0.01-0.05wt%.
A still further aspect of the present invention is directed to said process wherein said
silico manganese fines provided comprises: Mn:50-60 wt%, Si: 10-20wt%, C: 1-
2wt%, P:0.1-0.5wt%, S:0.01-0.05wt%.

A still further aspect of the present invention is directed to said process wherein said
resol type Phenol Formaldehyde liquid Resin provided comprises:
Non-volatile matter: 68-72wt%,
Fixed carbon: 35-40wt%,
Viscosity (cp), at 25°C: 250-300,
Sp. Gravity at 20°C: 1.17-1.19,
PH at 20°C: 6.5-7,
Moisture Content: 8-10wt%;
Free Phenol: 14 (± 2) wt%.
Free Formaldehyde :0.8 (± 0.2) wt%,
Shelf life (days) min:45,
Water miscibility at 25°C (Resin: water): 100:50 min,
Ash content :0.2wt % (max) ,
Gel forming: At 80°C:9hrs, At 100°C:1.5hrs, At 120°C:0.5hrs; At 150°C: 9 minutes.
A still further aspect of the present invention is directed to said process wherein said
plastic clay provided comprises
Al2O3 (min): 35-40wt% ;
Fe2O3 (max): 1.5-2.0wt%;
PCE(Orton):30-35;
LOI (max):10-15%;
with good plasticity and sintering properties.
The various other objects and advantages of the present invention are described in
greater details with reference to the following accompanying non limiting illustrative
drawings and example.
BRIEF DECSRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1: is the graphical plot of Shatter index of briquettes formed comparing with
resin vs other binders at different temperatures.
Figure 2: is the photograph showing the arrangements of briquetting machine which
is used for making briquettes following the process according to the present
invention.

EXAMPLE I:
For manufacturing of briquettes four batch compositions were formulated and
briquettes were made using different combination of binders and additives. As the
fines of Ferro manganese (FeMn) & Silico manganese (SiMn) were having no
plasticity; the additives were selected so as to get some plasticity which will bear the
stress during and after manufacturing of briquettes otherwise cracks and scratches
could appear. The quantity of binders and additives were optimized to get stable size
briquettes.
Ferro manganese (FeMn) & Silico manganese (SiMn) fines were taken in a laboratory
mixer. Dry mixing of ferro alloy fines and plastic clay was done. Phenol formaldehyde
liquid resin was added and mixing was done till homogeneity. Prepared mix was left
aside for aging for 4-5 hours. After aging briquettes were made in a laboratory
briquetting machine. Briquettes were self cured for 16 hours.
Thus according to the exemplary illustration of the process according to the present
invention following steps are followed:
(i) providing ferromanganese and silico manganese fines of the size range of
0 to 10mm preferably 0 to 3mm in a high intensive mixer for mixing with
plastic clay for specified time (10 to 15 minutes);
(ii) further mixing carried out in the mixer with slow addition of phenol
formaldehyde liquid resin for specified time (10 to 15minutes);
(iii) Keeping the mix thus obtained thereafter in a covered area for specified
duration preferably 4 to 8 hours for aging; and
(iv) pressing the mix in briquetting machine at specified pressure of 30 to 40
KN/cm2 to form desired briquette of size 50x25x15mm3;
(v) self curing of briquettes thus produced in specified temperature preferably
at room temperature,
(vi) heat treating the cured briquettes thereafter at specified temperature
preferably in the range of 150°C to 200°C for specified time preferably 8
to 16hours to get the required quality of the briquettes.

In the above example, Ferro manganese and silico manganese fines, Phenol
formaldehyde liquid resin and plastic clay comprised



According to a preferred aspect of the present invention resol type phenol
formaldehyde liquid resin is added binder in amount of 2-3 % by weight and plastic
clay is used as additive in amount of 1-2 % by weight.
Testing of Briquettes:
After curing briquettes were tested for crushing strength and drop test. Initial
strength was found low. To increase the strength briquettes were heated for different
temperatures i.e 110°C, 150°C, 200°C, 300°C and 600°C for different holding time of
2hrs, 3hrs, 6hrs, 8hrs & 16hours. These heated samples were tested for crushing
strength and drop test. Strength increased drastically when the green briquettes
were heated at 150°C for 8 hours.
From the test results it was found that for green briquettes maximum strength (CCS)
was obtained with cement and molasses (52kg/cm2), and for the same binder
combination strength was 59kg/cm2 after oven drying at 110°C . The maximum
strength obtained after oven drying at 150°C was the briquettes made with resin,
which indicated many fold increase in strength that is from green briquette
(49kg/cm2) to oven dried (102kg/cm2).
Similarly after shatter test i.e. dropping the briquette (2kg) from a height of 2 meter
and retention on 10 mm screen up to 4 drops. Maximum retention obtained was for

resin-bonded briquette (97.5% after 1st drop and 76% after 4th drop). For cement-
bonded briquettes it was 95% for 1st drop and 50% for 4th drop.
These briquettes are stored in the briquetting plant and later on it will be fed to
series of belt conveyors before charging it to metallurgical furnaces. During this
process of transportation of briquettes there will be number of falls for the
briquettes. To check the ability of the briquettes to retain its size during
transportation Shatter test was conducted. Accompanying Figure 1 illustrates the
result and comparison of shatter test of briquettes made with different combination
of binders.
Figure 2 illustrates the arrangement of briquetting machine. Briquettes are
produced by pressing the ready mix between the rollers moving in opposite direction
to each other. These rollers have tires mounted on it having groves. When the mix is
fed in between the rollers a pressure of 30-40KN/cm2 is generated and briquettes are
made.
Strength is the combined effect of binder and specific pressure during briquetting.
Briquettes produced tries to release the pressure applied on them as normal
phenomena of material. During this process slight expansion is there on the
briquettes and due to this cracks and lamination occurs. Clay provides plasticity to
the mix which accommodates the stress and later on expansion and saves the
briquettes from cracks or lamination. With the use of phenol formaldehyde liquid
resin as a binder and clay as an additive crushing strength was found to be highest
when the briquettes were heat treated at 150°C to 200°C for 8 to 16 hours as can be
seen in Figure 3.
It is thus possible by way of the present invention to providing a process for
producing briquettes from ferro manganese and silico manganese fines using
selective binder and additives so that superior quality of cured and heat treated
briquettes is ensured in terms of strength and maximum retention under drop test
making these briquettes fit for economic industrial utilization in iron and steel
making, maintaining the shapes during transit.

We Claim:
1. A process for manufacturing of briquettes from ferro manganese and/or silico
manganese fines, comprising
providing Ferro manganese (FeMn) and/or Silico manganese (SiMn) fines in the size
range of 0-10mm preferably 0-3mm in a mixer;
adding plastic clay in amount of 1-2 % by weight to the mix for dry mixing;
adding resol type phenol formaldehyde liquid resin in amount of 2-3 % by weight to
the dry mix and mixing continued till attaining homogeneity;
allowing the prepared mix to undergo ageing for 4-5 hours; and
obtaining cured briquettes of desired strength and hardness.
2. A process as claimed in claim 1, wherein said ferromanganese and silico
manganese fines of the size range of 0 to 10mm preferably 0 to 3mm are mixed with
plastic clay in a high intensive mixer for specified time of 10 to 15 minutes and then
further mixing is done by slow addition of phenol formaldehyde liquid resin for
specified time of 10 to 15minutes.
3. A process as claimed in anyone of claims 1 or 2 wherein said aging of the mix is
done by keeping in a covered area for specified duration preferably for 4 to 8 hours.
4. A process as claimed in anyone of claims 1 to 3, wherein said briquettes are
produced involving a briquetting machine by pressing the ready mix between the
rollers moving in opposite direction to each other, said rollers having tires mounted
thereon and having grooves such that when the mix is fed in between the rollers a
pressure of 30-40KN/cm2 is generated and briquettes are thus obtained.

5. A process as claimed in anyone of claims 1 to 4, wherein self curing of briquettes
is carried out in specified temperature preferably at room temperature for about 16
hours.
6. A process as claimed in anyone of claims 1 to 5, wherein cured briquettes are
subjected to said heat treatment at specified temperature preferably 150°C to 200°C
for specified time preferably 8 to 16hours to get the required quality of the
briquettes.
7. A process as claimed in anyone of claims 1 to 6 wherein said ferro manganese
fines provided comprises: Mn:60-70 wt%, Si: l-2wt%, C: 5-10wt%,P:0.1-
0.5wt%,S:0.01-0.05wt%.
8. A process as claimed in anyone of claims 1 to 7 wherein said silico manganese
fines provided comprises: Mn:50-60 wt%, Si: 10-20wt%, C: l-2wt%, P:0.1-0.5wt%,
S:0.01-0.05wt%.
9. A process as claimed in anyone of claims 1 to 8 wherein said resol type Phenol
Formaldehyde liquid Resin provided comprises :
Non-volatile matter: 68-72wt%,
Fixed carbon: 35-40wt%,
Viscosity (cp), at 25°C: 250-300,
Sp. Gravity at 20°C: 1.17-1.19,
PH at 20°C: 6.5-7,
Moisture Content: 8-10wt%;
Free Phenol: 14 (± 2) wt%,
Free Formaldehyde :0.8 (± 0.2) wt%,
Shelf life (days) min:45,
Water miscibility at 25°C (Resin: water): 100:50 min,
Ash content :0.2wt % (max),
Gel forming: At 80°C:9hrs, At 100°C:1.5hrs, At 120°C:0.5hrs; At 150°C: 9 minutes.

10. A process as claimed in anyone of claims 1 to 8 wherein said plastic clay
provided comprises
Al2O3 (min): 35-40wt% ;
Fe2O3 (max): 1.5-2.0wt%;
PCE (Orton):30-35;
LOI (max):10-15%;
with good plasticity and sintering properties.

ABSTRACT

The present invention relates to a process for manufacturing of briquettes from ferro manganese and silico manganese fines of 0-10 mm preferably 0-3mm size, by using selectively resol type Phenol formaldehyde as binder for the first time for making briquettes wherein Quantity of resin and mixing sequence had been suitably formulated to have good quality briquettes. Advantageously, plastic clay is also used as an additive in the process of briquette making to impart plasticity/ workability to the mix of FeMn/SiMn fines with binder which is very much non-plastic in nature, in order to form briquettes by applying pressure in briquetting machine. The maximum strength obtained after oven drying for the briquettes made with resin binder,
indicated many fold increase in strength from 49kg/cm2 for green briquette to 102kg/cm2 for oven dried briquettes with maximum retention under drop test obtained for resin-bonded briquettes making it suitable for advantageous application in iron and steel making.