Claims:WE CLAIM:
1. An agglomerate for iron making comprising- heat hardened material, sludge and binder.

2. The agglomerate as claimed in claim 1, wherein the heat hardened material has particle size ranging from about 0.1 mm to 6 mm and is in an amount ranging from about 50% to 80%.

3. The agglomerate as claimed in claim 1, wherein the heat hardened material is sinter return fines and the sludge is selected from a group comprising steel making sludge, ESP dust, mill sludge, flue dust, GCP sludge and any combination thereof.

4. The agglomerate as claimed in claim 1, wherein the sludge is in an amount ranging from about 10% to 40%.

5. The agglomerate as claimed in claim 1, wherein the binder is selected from a group comprising Portland cement, bentonite, molasses, slag cement, GGBS, LD slag, lime, organic binders, resins, and combinations thereof.

6. The agglomerate as claimed in claim 1, wherein the binder is in an amount ranging from about 1% to 10%.

7. The agglomerate as claimed in claim 5, wherein the cement is in an amount ranging from about 5% to 10%; and the bentonite is in an amount ranging from about 0.01% to 5%.

8. The agglomerate as claimed in any one of claims 1 to 7, wherein sinter return fines comprises total iron Fe (T) at about 45 wt.% to about 60 wt.%, ferrous oxide (FeO) at about 8 wt.% to about 12 wt.%, calcium oxides (CaO) at about 9 wt.% to about 14 wt.%, magnesium oxide (MgO) at about 1.50 wt.% to about 2.50 wt. %, Al2O3 at about 2.2 wt.% to about 3.0 wt. % and silicon dioxide (SiO2) at about 4.5 wt.% to about 5.5 wt. %, and Loss on ignition (LOI) the sinter return fines is zero; the steel making sludge comprises- Fe(t) at about 50 wt.% to about 75 wt.%, SiO2 at about 2 wt.% to about 4 wt.%, Al2O3 at about 0.2 wt.% to about 1 wt. %, CaO at about 10 wt.% to about 20 wt.%; the bentonite comprise- - Fe(t) at about 7 wt.% to about 15 wt.%, SiO2 at about 40 wt.% to about 50 wt.%, Al2O3 at about 10 wt.% to about 20 wt.%, CaO at about 1 wt.% to about 3 wt. %, MgO at about 2 wt.% to about 4 wt.%, the bentonite has loss on ignition of about 10% to 20% and moisture content of about 5% to about 15%; and the Portland cement comprise- Fe(t) at about 0.1 wt.% to about 0.5 wt.%, SiO2 at about 10 wt.% to about 20 wt.%, Al2O3 at about 4.0 wt.% to about 9.0 wt.%, CaO at about 50 wt.% to about 70 wt.%.

9. The agglomerate as claimed in claim 1, wherein the agglomerate has cold compressive strength ranging from about 105 kg/cm2 to 150 kg/cm2; shatter index ranging from about 70% to 95%; tumbler index ranging from about 55% to 60%; Decrepitation index ranging from about 1% to 3%; and thermal degradation index ranging from about 15% to 17%.

10. The agglomerate as claimed in claim 1, wherein the agglomerate is in a shape selected from a group comprising cylindrical, cuboid and spherical.

11. A method of preparing the agglomerate as claimed in claim 1, said method comprises-
- mixing the heat hardened material, the sludge, the binder with solvent to obtain a mixture; and
- moulding the mixture, followed by curing to obtain the agglomerate.

12. The method as claimed in claim 11, wherein the solvent is water; and the solvent is added to achieve moisture in the mixture ranging from about 4% to 8%.

13. The method as claimed in claim 11, wherein the moulding is carried out by applying pressure ranging from about 140 bar to 200 bar for a duration ranging from about 10 seconds to 20 seconds.

14. The method as claimed in claim 11, wherein the curing is carried with atmospheric air, steam or hot air.

15. A method for manufacturing metal from blast furnaces comprising charging the agglomerate as claimed in claim 1.

16. The method as claimed in claim 15, wherein the agglomerate is charged in an amount ranging from about 1 % to 10%.

17. The method as claimed in claim 15, wherein the industrial metal is iron.

18. The method as claimed in claim 15, wherein the charging of the agglomerate provides for reduction in carbon rate of about 1.9%, improvement in gas utilization of about 0.7% and maintains permeability during smelting in blast furnace.
, Description:TECHNICAL FIELD
The present disclosure relates to the field of metallurgy and material sciences. Particularly, the disclosure relates to an agglomerate for iron making comprising heat hardened material, sludge and binder, its preparation and applications thereof.

BACKGROUND OF THE DISCLOSURE
Sinter plants produce heat hardened materials, such as sinters for use in blast furnace. The heat hardened materials, such as sinters when being supplied to the blast furnaces is screened at 5 mm at the blast furnace stock house. The undersized heat hardened materials having particle size of less than 5 mm are not used in the furnaces as it causes hindrance to the flow of reducing gases, thus causing resistance to permeability in the upper stack of the blast furnace. So, the undersized heat hardened materials are taken out and is recirculated in the sintering process through raw material bedding and blending yards, where it constitutes 12% to 14% of the raw material mix for sintering. This results in loss of energy as the prepared yet undersized heat hardened materials are again routed through the sintering process instead of fresh feed.

Thus, there is a need for effective utilization of heat hardened materials, such as sinter fines which are returned/rejected from the blast furnace. The present disclosure achieves effective utilization of such heat hardened materials rejected/returned to sintering process.

STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure relates to agglomerate for making iron prepared from the rejected/returned undersized heated hardened material including but not limited to sinter return fines having enhanced properties and capable of being employed as feed in blast furnace.

In an embodiment of the present disclosure, the agglomerate comprises-heat hardened material, sludge and binder.

In an embodiment, the present disclosure relates to a method of preparing the agglomerate, comprising- mixing the heat hardened material, the sludge, the binder with solvent to obtain a mixture; and moulding the mixture, followed by curing to obtain the agglomerate.

In an embodiment, the present disclosure relates to a method of manufacturing industrial metal including but not limited to iron from blast furnaces, comprising- charging the agglomerate described above into the blast furnace for manufacturing the industrial metal.

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 figures. The figures 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: depicts a schematic representation of Conventional Route of usage of iron ore sinter fines.

Figure 2: depicts a schematic representation of production of the agglomerate according to the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE
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 disclosure belongs. By means of further guidance, term definitions are included for better understanding of the present disclosure.

As used herein, the 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. It is to be understood that the value to which the modifier ‘about’ refers is itself also specifically, and preferably disclosed.

The present disclosure relates to an agglomerate comprising heat hardened material, sludge and binder.

In some embodiments of the present disclosure, the agglomerate shows enhanced properties and is employed as feed material in blast furnace for producing industrial metal including but not limited to iron. In other words, the agglomerate can be used to produce industrial metal including but not limited to iron.

In some embodiments of the present disclosure, the heat hardened material includes but not limited to sinter return fines.

In some embodiments of the present disclosure, the heat hardened material is sinter return fines.

In some embodiments of the present disclosure, the heat hardened material has particle size ranging from about 0.1 mm to 6 mm, including all the values in the range, for instance, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 and so on and so forth.

In some embodiments of the present disclosure, the heat hardened material is in an amount ranging from about 50% to 80%, including all the values in the range, for instance, 50.1%, 50.2%, 50.3%, 50.4% and so on and so forth.

In an exemplary embodiment of the present disclosure, the sinter return fines has particle size ranging from about 0.1 mm to 6 mm, including all the values in the range, for instance, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 and so on and so forth; and the sinter return fines is in an amount ranging from about 50% to 80%, including all the values in the range, for instance, 50.1%, 50.2%, 50.3%, 50.4% and so on and so forth.

In some embodiments of the present disclosure, the sinter return fines is iron ore sinter fines.

In some embodiments of the present disclosure, the iron sinter fines comprises- total iron Fe (T) ranging from about 45 wt.% to about 60 wt.%, ferrous oxide (FeO) ranging from about 8 wt.% to about 12 wt.%, calcium oxides (CaO) ranging from about 9 wt.% to about 14 wt.%, magnesium oxide (MgO) ranging from about 1.50 wt.% to about 2.50 wt. %, Al2O3 ranging from about 2.2 wt.% to about 3.0 wt. % and silicon dioxide (SiO2) ranging from about 4.5 wt.% to about 5.5 wt. %.

In some embodiments of the present disclosure, the iron sinter fines has zero moisture content and has zero loss of ignition.

In some embodiments of the present disclosure, the sludge is selected from a group comprising steel making sludge, electrostatic precipitator (ESP) dust, mill sludge, flue dust, gas cleaning plant (GCP) sludge and any combination thereof.

In some embodiments of the present disclosure, the sludge is in an amount ranging from about 10% to 40%, including all the values in the range, for instance, 10.1%, 10.2%, 10.3%, 10.4% and so on and so forth.

In an exemplary embodiment of the present disclosure, the steel making sludge comprises- Fe(t) ranging from about 50 wt.% to about 75 wt.%, SiO2 ranging from about 2 wt.% to about 4 wt.%, Al2O3 ranging from about 0.2 wt.% to about 1 wt. % and CaO ranging from about 10 wt.% to about 20 wt.%.

In some embodiments of the present disclosure, the binder is selected from a group comprising Portland cement, bentonite, molasses, slag cement, Ground Granulated Blast-furnace Slag (GGBS), Linz-Donawitz (LD) slag, lime organic binders, resin and any combination thereof.
In some embodiments of the present disclosure, the binder is in an amount ranging from about 1% to 10%, including all the values in the range, for instance, 1.1%, 1.2%, 1.3%, 1.4% and so on and so forth.

In some embodiments of the present disclosure, the binder is cement, wherein the cement is in an amount ranging from about 5% to 10%, including all the values in the range, for instance, 5.1%, 5.2%, 5.3%, 5.4% and so on and so forth.

In some embodiments of the present disclosure, the binder is cement and bentonite, wherein the cement is in an amount ranging from about 5% to 10%, including all the values in the range, for instance, 5.1%, 5.2%, 5.3%, 5.4% and so on and so forth.; and the bentonite is in amount ranging from about 0.01% to 5%, including all the values in the range for instance, 0.02%, 0.03%, 0.04%, 0.05% and so on and so forth.

In an exemplary embodiment of the present disclosure, the bentonite comprises- Fe(t) ranging from about 7 wt.% to about 15 wt.%, SiO2 ranging from about 40 wt.% to about 50 wt.%, Al2O3 ranging from about 10 wt.% to about 20 wt.%, CaO ranging from about 1 wt.% to about 3 wt. % and MgO ranging from about 2 wt.% to about 4 wt.%.

In an exemplary embodiment of the present disclosure, the bentonite has loss on ignition ranging from about 10% to 20% and moisture content ranging from about 5% to about 15%.

In an exemplary embodiment of the present disclosure, the Portland cement comprises- Fe(t) ranging from about 0.1 wt.% to about 0.5 wt.%, SiO2 ranging from about 10 wt.% to about 20 wt.%, Al2O3 ranging from about 4.0 wt.% to about 9.0 wt.% and CaO ranging from about 50 wt.% to about 70 wt.%.

In an exemplary embodiment of the present disclosure, the agglomerate comprises- iron ore sinter fines in an amount of about 60%, steel making sludge in an amount of about 30%, Portland cement in an amount of about 8%, and bentonite in an amount of about 2%.

In an exemplary embodiment of the present disclosure, the agglomerate comprises- iron ore sinter fines in an amount of about 66%, steel making sludge in an amount of about 22%, Portland cement in an amount of about 10%, and bentonite in an amount of about 2%.

In some embodiments of the present disclosure, the agglomerate possesses enhanced properties including but not limited to cold compressive strength, shatter index, tumbler index, decrepitation index and thermal degradation.
In some embodiments of the present disclosure, the agglomerate has cold compressive strength ranging from about 105 kg/cm2 to 150 kg/cm2, including all the values in the range, for instance, 106 kg/cm2, 107 kg/cm2, 108 kg/cm2, 109 kg/cm2 and so on and so forth.

In some embodiments of the present disclosure, the agglomerate has shatter index ranging from about 70% to 95%, including all the values in the range, for instance, 71%, 72%, 73%, 74% and so on and so forth.

In some embodiments of the present disclosure, the agglomerate has decrepitation index ranging from about 1% to 3%, including all the values in the range, for instance, 1.1%, 1.2%, 1.3%, 1.4% and so on and so forth.

In some embodiments of the present disclosure, agglomerate has thermal degradation ranging from about 15% to 17%, including all the values in the range, for instance, 15.1%, 15.2%, 15.3%, 15.4% and so on and so forth.

In some embodiments of the present disclosure, the agglomerate is in a shape selected from a group comprising cylindrical, cuboid and spherical.

In some embodiments of the present disclosure, the agglomerate when used in blast furnace results in increase in the proportion of the prepared burden and thus helps in the reduction of reducing agent rate for metal production including but not limited to iron. Also, the agglomerate reduces the flux consumption in the metal making value chain.

In some embodiments of the present disclosure, the agglomerate when charged in the blast furnace for the production of iron provides for reduction in carbon rate by about 1.9% and provides improvement in gas utilization by about 0.7%, when compared to production of iron in the blast furnace in absence of the agglomerate.

Additionally, the agglomerate of the present disclosure maintains permeability during smelting in the blast furnace during production of iron.

In some embodiments of the present disclosure, the agglomerate when charged in the blast furnace for the production of iron reduces the consumption of reducing agent in the blast furnace which in turn reduces the carbon dioxide emission from the furnace. Therefore, employing the agglomerate makes the production of iron in blast furnace energy efficient and environmentally friendly.

In some embodiments of the present disclosure, the agglomerate described above is sinter return fines agglomerate comprising the heat hardened material, such as sinter return fines having particle size ranging from about 0.1 mm to 6 mm, the sludge and the binder.

The present disclosure further relates to a method of preparing the agglomerate described above.

In some embodiments of the present disclosure, the agglomerate can be prepared by employing techniques including but not limited to vibro pressing technique, stiff extrusion briquetting, roller pressing and pelletizing.

In some embodiments of the present disclosure, the method of preparing the agglomerate comprises:
- Mixing the heat hardened material, the sludge, the binder with solvent to obtain a mixture; and
- Moulding the mixture, followed by curing to obtain the agglomerate.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, the mixture is obtained by mixing- the heat hardened material in an amount ranging from about 50% to 80%, the sludge in an amount ranging from about 10% to 40% and the binder in an amount ranging from about 1% to 10%.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, the mixture is obtained by mixing- the heat hardened material in an amount ranging from about 50% to 80%, the sludge in an amount ranging from about 10% to 40% and the cement ranging from about 5% to 10%.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, the mixture is obtained by mixing- the heat hardened material in an amount ranging from about 50% to 80%, the sludge in an amount ranging from about 10% to 40%, the cement ranging from about 5% to 10% and the bentonite ranging from about 0.1% to 5%.

In some embodiments of the present disclosure, the binder in the mixture promotes mechanical strength during air curing of the mixture.
In some embodiments of the present disclosure, the solvent includes but not limited to water.

In some embodiments of the present disclosure, the solvent is added to achieve moisture in the mixture ranging from about 4% to 8%, including all the values in the range, for instance, 4.1%, 4.2%, 4.3%, 4.4% and so on and so forth.

In some embodiments of the present disclosure, the moulding of the mixture is carried out by applying pressure ranging from about 140 bar to 200 bar, including all the values in the range, for instance, 141 bar, 142 bar, 143 bar, 144 bar and so on and so forth, for a duration ranging from about 10 seconds to 20 seconds, including all the values in the range, for instance, 10.1 seconds, 10.2 seconds, 10.3 seconds, 10.4 seconds and so on and so forth.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, applying pressure inside the mould leads to formation of cold bonded agglomerates.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, curing is carried out by techniques including but not limited to atmospheric air, steam or hot air.

In some embodiments of the present disclosure, in the method of preparing the agglomerate, curing is carried out by techniques including but not limited to atmospheric air, steam in closed or open container or hot air in closed or open container.

In some embodiments of the present disclosure, the curing is carried out for a duration ranging from about 21 to 28 days, including all the values in the range, for instance 21.1 days, 21.2 days, 21. 3 days, 21.4 days and so on and so forth.

In some embodiments of the present disclosure, the curing is carried out for duration until the agglomerate (briquettes) reaches desired strength necessary for handling during subsequent applications including but not limited to application in blast furnace.

In an exemplary embodiment of the present disclosure, in the method of preparing the agglomerate, the mixture is prepared by mixing-
• About 66% of sinter return fines having particles size ranging from about 0.1 to 6 mm;
• About 22% of steel making sludge in dried condition;
• About 10% ordinary Portland cement; and
• About 2% bentonite.

In another exemplary embodiment of the present disclosure, in the method of preparing the agglomerate ASRF, the mixture is prepared by mixing-
• About 60% of sinter return fines having particles size ranging from about 0.1 to 6 mm;
• About 30% of steel making sludge in dried condition;
• About 10% ordinary Portland cement; and
• About 2% bentonite.

In an exemplary embodiment, the mixture comprising the sinter return fines, sludge and the binder is mixed with solvent in Muller mixer to prepare a homogenous mixture, followed by subjecting to compaction in a predetermined equipment to produce the agglomerates to be naturally cured for imparting handling strength necessary for charging to a blast furnace.

In an exemplary embodiment of the present disclosure, the method of preparing the agglomerate employs briquetting or agglomerating apparatus with cylindrical moulds in order to obtain agglomerates/briquettes of cylindrical geometry to minimize disintegration of the agglomerates during handling during subsequent applications including but not limited to use in the blast furnace.

The present disclosure further relates to a method of manufacturing industrial metals.

In some embodiments of the present disclosure, the method of manufacturing the industrial metals comprises- charging the agglomerate described above into the blast furnace along with other known components supplied to blast furnace to produce industrial metals.

In some embodiments of the present disclosure, in the method of manufacturing the industrial metals, the agglomerate described above is charged in an amount ranging from about 1% to 10% including all the values in the range, for instance, 1.1% ,1.2%, 1.3%, 1.4% and so on and so forth.

In some embodiments of the present disclosure, the industrial metals include but not limited to iron.

In some embodiments of the present disclosure, in the method of manufacturing the industrial metals, the charged agglomerate provides for reduction in carbon rate by about 1.9% and provides improvement in gas utilization by about 0.7%, when compared to production of the metals in the blast furnace in absence of the agglomerate of the present disclosure. Additionally, the agglomerate maintains permeability during smelting in the blast furnace during production of the metals.

In some embodiments of the present disclosure, in the method of manufacturing the industrial metals, the charged agglomerate reduces the consumption of reducing agent in the blast furnace which in turn reduces the carbon dioxide emission from the furnace. Therefore, method of manufacturing the industrial metals by employing the agglomerate makes the production of the metals in blast furnace energy efficient and environmentally friendly.

In the present disclosure, the expressions ‘agglomerate’ and ‘briquette’ are used interchangeably. Both the expressions relate to the agglomerate described above comprising heat hardened material, sludge and binder.

It is to be understood that the foregoing description is illustrative not a limitation. While considerable emphasis has been placed herein on particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred 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 may be practiced and to further enable those of skill in the art to practice the embodiments. Accordingly, following examples should not be construed as limiting the scope of the embodiments herein.

EXAMPLE

Example 1: Preparing the Agglomerate
Sinter return fines, steel making sludge, Portland cement (OPC) and bentonite were mixed with water in a lab scale setup in different proportions to get 4 different batches, i.e., Batch-A, Batch-B, Batch-C and Batch-D

Table 1 below describes the proportion of materials employed in mentioned 4 batches.
Raw Material, wt.% Batch- A Batch -B Batch- C Batch- D
Iron ore sinter fines 80 70 60 66
Steelmaking sludge 10 20 30 22
OPC 8 8 8 10
Bentonite 2 2 2 2
Table 1

Table 2 describes chemical characteristics of sinter return fines, bentonite, steel making sludge and Portland cement (OPC)
Constituents, wt.% Iron ore
Sinter Fines Bentonite Steelmaking Sludge Ordinary Portland Cement
Fe(t) 55.2 9.72 54.0 0.2
SiO2 4.8 45.97 2.6 20.0
Al2O3 2.3 14.49 0.27 5.0
CaO 12.5 1.78 15.0 63.0
MgO 1.8 2.24 - -
P 0.108 - - -
LOI - 15
Fixed carbon - - -
Moisture - 10

Table 2

The four batches were fed into a mould in an equipment, individually. The batches were levelled and rammed manually for about 30 times to impart pressure to the mixture, to obtain cylindrical agglomerates/briquettes. The obtained agglomerates/briquettes were naturally cured for about 28 days to get the strength necessary for handling during subsequent application.
The obtained agglomerates/briquettes from the Batch-C and Batch-D were subjected to physical and chemical analysis. Table 3 describes the chemical characteristics and cold compression strength (CCS) of the obtained agglomerates from Batch-C and Batch-D, wherein the agglomerates were prepared by manually ramming as described above.

Parameters UoM Batch C Batch D
Fe(t) % 49.6 48.6
CaO % 17.2 18.0
SiO2 % 6.1 6.6
MgO % 2.2 2.0
Al2O3 % 2.15 2.37
P % 0.06 0.07
CCS
After 28 days curing Kg/cm2 80.0 82.2
Table 3

Example 2: Preparing the Agglomerate
Sinter return fines, steel making sludge, Portland cement (OPC) and bentonite were mixed with water in different proportions to get 2 different batches, i.e., Batch-A and Batch-B.

Table 4 below describes the proportion of materials employed in mentioned 2 batches.
Raw Material, wt.% Batch A Batch B
Iron ore sinter fines 66 50
Steelmaking sludge 22 38
OPC 10 10
Bentonite 2 2

Table 4
The two batches were fed into a mould in an equipment and pressure of about 120 bar was applied for about 12 seconds (no manual ramming). The obtained agglomerates/briquettes were naturally cured for about 28 days to get the strength necessary for handling during necessary application.

The obtained agglomerates/briquettes from the Batch-A and Batch-B were subjected to physical and chemical analysis. Table 5 describes the chemical characteristics and physical characteristics such as cold compression strength (CCS) and shatter index of the obtained agglomerates from Batch-C and Batch-D, wherein the agglomerates were prepared by not manually ramming.
Parameters UoM Batch A Batch B
Fe(t) % 46.3 47.5
CaO % 15.9 15.0
SiO2 % 6.9 6.4
MgO % 2.9 2.8
Al2O3 % 3.6 3.1
P % 0.12 0.10
LOI % 3.2 3.5
CCS
After 21 days curing Kg/cm2 148 107
Shatter Index, +10 mm % 74 72

Table 5

Example 3: Preparing the Agglomerate
Preparation of the agglomerate were carried out in an equipment of capacity 35 tons/day. The materials according to Batch-A of Table 4 were mixed with water in Muller mixer for about 7 minutes. The mixture was then fed to a hopper, from which it was charged to moulds. A compaction pressure of about 170 bar was applied for about 18 seconds. Thereafter, the obtained agglomerates/briquettes were stacked for natural curing for about 28 days.

The obtained agglomerates were subjected to chemical and physical analysis. Table 6 describes the chemical characteristics and physical characteristic such as cold compression strength (CCS), shatter index, tumbler index, decrepitation index, thermal degradation index and particle size of the obtained agglomerates.

Parameters UoM Briquette
Fe(t) % 40.0
CaO % 18.5
SiO2 % 8.0
MgO % 3.5
Al2O3 % 2.7
FeO % 18.0
CCS Kg/cm2 140-150
Shatter Index, +10 mm % 95
Tumbler Index, +6.3 mm % 60
Decrepitation Index % 1.0
Thermal Degradation Index % 16.0
+50 mm % 0.0
+40 mm % 99.0
+30 mm % 0.04
+25 mm % 0.04
+10 mm % 0.0
-8 mm % 0.2

Table 6

Example 4: Method of manufacturing iron
The agglomerates obtained according to above obtained Example 3 were charged to the blast furnace at a rate of about 3% and 5% of the iron-bearing burden, respectively along with other known raw materials charged to the blast furnace for the production of iron.

It was observed that, charging of the agglomerate led to reduction in carbon rate, improvement in gas utilization with no significant change in furnace permeability. Table 7 describes the results achieved by charging the agglomerate in the blast furnace in comparison with the base condition (without the agglomerate).
PARAMETERS Units BASE Condition With 3% Agglomerate With 5% Agglomerate
PRODUCTION
(corrected with Moisture) TPD 1111 1037 1048
Coke Rate kg/thm 540 533 535
Tar Rate kg/thm 30 22 31
Normalized Carbon Rate kg/thm 480 465 471
Agglomerate Rate kg/thm 0 49 86
Slag Rate kg/thm 366 381 391
ETA CO (Gas Utilization) % 45.3 44.9 45.6
Hot Metal Temperature oC 1491 1499 1489
Sinter in burden % 60 55 54
Furnace Permeability - 16.3 16.9 17.0

Table 7
Data in Table 7 demonstrates that charging of the agglomerate of the present disclosure leads to reduction in the carbon rate by about 1.9% and improvement in gas utilization by about 0.7% with no significant change in the furnace permeability.

The foregoing description of the specific embodiments reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments in this disclosure have been described in terms of preferred embodiments, 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.

Throughout this specification, the term ‘combinations thereof’ or ‘any combination thereof’ or ‘any combinations thereof’ are used interchangeably and are intended to have the same meaning, as regularly known in the field of patents disclosures.

As regards the embodiments characterized in this specification, it is intended that each embodiment be read independently as well as in combination with another embodiment. For example, in case of an embodiment 1 reciting 3 alternatives A, B and C, an embodiment 2 reciting 3 alternatives D, E and F and an embodiment 3 reciting 3 alternatives G, H and I, it is to be understood that the specification unambiguously discloses embodiments corresponding to combinations A, D, G; A, D, H; A, D, I; A, E, G; A, E, H; A, E, I; A, F, G; A, F, H; A, F, I; B, D, G; B, D, H; B, D, I; B, E, G; B, E, H; B, E, I; B, F, G; B, F, H; B, F, I; C, D, G; C, D, H; C, D, I; C, E, G; C, E, H; C, E, I; C, F, G; C, F, H; C, F, I, unless specifically mentioned otherwise.

Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.