Claims:WE CLAIM:
1. A sinter base mix composition comprising- iron ore fines, coke fines, sinter return fines, calcium oxide (burnt lime) and flux selected from a group comprising pyroxenite, limestone, dolomite and combinations thereof, wherein the flux has mean particle size ranging from about 2.0 mm to 2.6 mm.

2. The composition as claimed in claim 1, wherein the sinter base mix comprises- iron ore fines, coke fines, sinter return fines, calcium oxide (burnt lime), pyroxenite, limestone and dolomite, wherein the mean particle size of the pyroxenite, the limestone and the dolomite, individually is ranging from about 2.0 mm to 2.6 mm.

3. The composition as claimed in claim 1, wherein the iron ore fines is in an amount ranging from about 55 wt% to 65 wt%; wherein the coke fines is in an amount ranging from about 6 wt% to 7 wt%; wherein the sinter return fines is in an amount ranging from about 12 wt% to 13 wt%; wherein the calcium oxide (burnt lime) is in an amount ranging from about 2.4 wt% to 2.6 wt%; and the flux is in an amount ranging from about 17.5 wt% to 20 wt%.

4. The composition as claimed in claim 1, wherein the pyroxenite is in an amount ranging from about 0.5wt% to 1wt%; the limestone is in an amount ranging from about 13wt% to 14 wt%; and the dolomite is in an amount ranging from about 4 wt% to 5 wt%.

5. The composition as claimed in claim 1, wherein the iron ore fines comprises- Fe(T) ranging from about 61 wt% to 64 wt%, Al2O3 ranging from about 2.6 wt% to 3.6 wt%, SiO2 ranging from about 3.4 wt% to 3.9 wt%, P ranging from about 0.18 wt% to 0.19wt% and the iron ore fines has loss on ignition ranging from about 2 wt% to 3 wt%.

6. The composition as claimed in claim 1, wherein the coke fines comprises- Fe(T) ranging from about 1wt% to 1.15 wt%, Al2O3 ranging from about 4.5 wt% to 4.9 wt%, SiO2 ranging from about 10 wt% to 10.2 wt%, CaO ranging from about 1.5 wt% to 1.7 wt% MgO ranging from about 0.2 wt% to 3 wt%, P ranging from about 0.08 wt% to 0.1 wt%, TiO2 ranging from about 0.3 wt% to 0.4 wt%, and C ranging from about 79 wt% to 81wt%; and the coke fines has loss on ignition ranging from about 79 wt% to 81wt%.
7. The composition as claimed in claim 1, wherein the sinter return fines comprises- Fe(T) ranging from about 51 wt% to 51.5 wt%, Al2O3 ranging from about 2.8wt% to 2.9 wt%, SiO2 ranging from about 6.2 wt% to 6.4wt%, CaO ranging from about 13 wt% to 13.5 wt%, MgO ranging from about 2.8wt% to 3wt%, P ranging from about 0.08 wt% to 0.1wt% and TiO2 ranging from about 0.18 wt% to 0.2 wt%; and the sinter return fines has nil loss on ignition.

8. The composition as claimed in claim 1, wherein the calcium oxide (burnt lime) comprises SiO2 ranging from about 0.4 wt% to 0.5 wt%, CaO ranging from about 84 wt% to 86 wt% and MgO ranging from about 1.2 wt% to 1.3 wt%; and the calcium oxide (burnt lime) has loss on ignition ranging from about 22 wt% to 23wt%.

9. The composition as claimed in claim 1, wherein the pyroxenite comprises- Fe(T) ranging from about _5 wt% to 5.5 wt%, Al2O3 ranging from about 0.4 wt% to 0.5 wt%, SiO2 ranging from about 36 wt% to 38 wt%, CaO ranging from about 5.5 wt% to 6.5 wt%, MgO ranging from about 32 wt% to 34 wt% and TiO2 ranging from about 0.2 wt% to 0.4 wt%; and the pyroxenite has loss on ignition ranging from about 13 wt% to 14.5 wt%.

10. The composition as claimed in claim 1, wherein the limestone comprises- Fe(T) ranging from about 1wt% to 1.3 wt%, Al2O3 ranging from about 0.5 wt% to 0.6 wt%, SiO2 ranging from about 3 wt% to 4 wt%, CaO ranging from about 48 wt% to 50 wt% and MgO ranging from about 4 wt% to 4.5 wt%; and the limestone has loss on ignition ranging from about 40 wt% to 42 wt%.

11. The composition as claimed in claim 1, wherein the dolomite comprises- Al2O3 ranging from about 0.5 wt% to 0.8 wt%, SiO2 ranging from about 7 wt% to 8 wt%, CaO ranging from about 31wt% to 33 wt% and MgO ranging from about 13 wt% to 14.5 wt%; and the dolomite has loss on ignition ranging from about 42 wt% to 44 wt%.

12. The composition as claimed in claim 1, wherein the iron or fines has particle size of about -10mm+0.15mm; the coke fines has particle size of about -5mm+0.25mm; the calcium oxide (burnt lime) has particle size of about 0 to 0.15mm; and the sinter return fines has particle size of about -5mm+0.15mm.
13. A process of preparing the sinter base mix composition as claimed in claim 1, said process comprises- mixing the iron ore fines, the coke fines, the sinter return fines, the calcium oxide (burnt lime) and the flux selected from a group comprising pyroxenite, limestone, dolomite and any combinations thereof, wherein the flux has mean particle size ranging from about 2.0 mm to 2.6 mm.

14. The process as claimed in claim 13, wherein the mixing is carried out in such a manner that homogenous sinter base mix composition is obtained and wherein the mixing is dry mixing.

15. A sinter comprising the sinter base mix composition as claimed in claim 1.

16. The sinter as claimed in claim 15, wherein the sinter has size ranging from about 10 mm to 40 mm.

17. The sinter as claimed in claim 15, wherein the sinter has tumbler index (TI) ranging from about 73 to 75; has reduction degradation index (RDI) ranging from about 14 to 16; and has reducibility index (RI) ranging from about 73 to 80.

18. The sinter as claimed in claim 15, wherein the sinter comprises- Fe (T) ranging from about 52 wt% to 53 wt%, FeO ranging from about 11 wt% to 13 wt%, CaO ranging from about 14 wt% to 15 wt%, SiO2 ranging from about 5 wt% to 6 wt%, MgO ranging from about 1.8 wt% to 2.2 wt%, Al2O3 ranging from about 2.8 wt% to 3.4 wt%, TiO2 ranging from about 0.18 wt% to 0.19 wt%, P ranging from about 0.02 wt% to 0.08 wt%, K2O ranging from about 0.002 wt% to 0.06 wt% , Na2O ranging from about 0.012 wt% to 0.072 wt% and MnO ranging from about 0.03 wt% to 0.04 wt%.

19. A method of preparing the sinter as claimed in claim 15, said method comprises:
- mixing the base mix as claimed in claim 1 with water to obtain mixture; and
- granulating the mixture to obtain granules, followed by heating the granules and cooling to obtain the sinter.

20. The method as claimed in claim 19, wherein during the granulating, moisture content of the granules obtained is ranging from about 6% to 7%.

21. The method as claimed in claim 19, wherein the heating is carried out at a temperature ranging from about 950 ? to 1000 ?, for a duration ranging from about 2.3 minutes to 2.5 minutes. , Description:TECHNICAL FIELD
The present disclosure relates to field of material sciences and metallurgy. The disclosure particularly relates to sinter base mix composition including flux having mean particle size ranging from about 2.0 mm to 2.6 mm. The disclosure further relates to preparation of said base mix composition, a sinter and method of preparation thereof.

BACKGROUND OF THE DISCLOSURE
Lump ore from mines are used as it is in the blast furnace. The undersize -10 +0.15 mm is utilized in sinter making process. An improved iron ore sinter for use in a blast furnace is made from a raw sinter mix comprising: iron-bearing materials, basic fluxes including a source of CaO and a source of MgO, and solid carbon bearing material, such as coke breeze is used as heat-generating combustible. To produce the Sinter, the raw sinter mix is subjected to a sintering treatment at a high temperature in order to cause the iron bearing materials, fluxes and carbon-bearing material to agglomerate and sinter by incipient fusion, an air-cooling treatment in order to produce a hard lumpy substance having a porous cellular structure, and a mechanical treatment to break the lumpy substance into a specific size range.

However, it is noted that, there is a challenge in obtaining right sinter base mix which provides for improved sinter productivity and sinter quality. Sinter productivity and quality are dependent on the green permeability of the bed, which is determined by the particle size distribution of the raw materials, moisture content, the granulation effectiveness and sintering process.

In the present disclosure, an improved sinter base mix is described, which provides for improved sinter quality and sinter productivity.

STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure relates to a sinter base mix composition comprising- iron ore fines, coke fines, sinter return fines, calcium oxide and flux selected from a group comprising pyroxenite, limestone, dolomite and combinations thereof, wherein the flux has mean particle size ranging from about 2.0 mm to 2.6 mm. The inventors have particularly identified that maintaining the mean particle size of the flux in a range of from about 2.0 mm to 2.6 mm provides for improved sinter quality and improved sinter productivity.

The present disclosure relates to a process of preparing the sinter base mix, said method comprises- mixing the iron ore fines, the coke fines, the sinter return fines, the calcium oxide, and the flux selected from a group comprising pyroxenite, limestone, dolomite and any combinations thereof, wherein the flux has mean particle size ranging from about 2.0 mm to 2.6 mm.

The present disclosure further relates to a sinter comprising the sinter base mix composition. The sinter has improved sinter quality in terms of tumbler index (TI), abrasion index (AI), reduction degradation index (RDI) and reducibility index (RI).

The present disclosure further relates to a method of preparing the sinter described above, said method comprises: mixing the base mix composition described above with water to obtain mixture; and granulating the mixture to obtain granules, followed by heating the granules and cooling to obtain the sinter.

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 picture illustrating the apparatus employed for mixing of the sinter base mix composition.

Figure 2 depicts a picture illustrating a pot of 200 nm diameter employed for sintering of the sinter base mix composition.

Figure 3 depicts a plot illustrating influence of mean particle size of flux on tumbler index (TI) of the sinter.

Figure 4 depicts a plot illustrating influence of mean particle size of flux on RF of the sinter.

Figure 5 depicts a plot illustrating influence of mean particle size of flux on reduction degradation index (RDI) of the sinter.

Figure 6 depicts a plot illustrating influence of mean particle size of flux on reducibility index (RI) of the sinter.

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.

Reference throughout this specification to ‘some embodiments’, ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. thus, the appearances of the phrases ‘in some embodiments’, ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification may not necessarily all refer to the same embodiment. It is appreciated that certain features of the disclosure, which are for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the disclosure, which are, for brevity described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The present disclosure relates to a sinter base mix composition that provides for improved sinter quality and improved sinter productivity. The sinter base mix composition includes fluxes having specific mean particle size, whereby improved sinter quality and improved sinter productivity is achieved.

In some embodiments of the present disclosure, the sinter base mix composition comprises- iron ore fines, coke fines, sinter return fines, calcium oxide and flux selected from a group comprising pyroxenite, limestone, dolomite and combinations thereof.

In some embodiments of the present disclosure, the flux selected from a group comprising pyroxenite, limestone, dolomite and combinations thereof has mean particle size ranging from about 2.0 mm to 2.6 mm, including all the values in the range, for instance, 2.01 mm, 2.02 mm, 2.03 mm, 2.04 mm and so on and so forth.

In some embodiments of the present disclosure, the flux selected from a group comprising pyroxenite, limestone, dolomite and combinations thereof has mean particle size ranging from about 2.06 mm to 2.52 mm, including all the values in the range, for instance, 2.07 mm, 2.08 mm, 2.09 mm, 2.10 mm and so on and so forth.

In some embodiments of the present disclosure, the pyroxenite has mean particle size ranging from about 2.0 mm to 2.6 mm, preferably ranging from about 2.06 mm to 2.52 mm.

In some embodiments of the present disclosure, the limestone has mean particle size ranging from about 2.0 mm to 2.6 mm, preferably ranging from about 2.06 mm to 2.52 mm.

In some embodiments of the present disclosure, the dolomite has mean particle size ranging from about 2.0 mm to 2.6 mm, preferably ranging from about 2.06 mm to 2.52 mm.

In some embodiments of the present disclosure, the sinter base mix composition comprises- iron ore fines, coke fines, sinter return fines, calcium oxide, pyroxenite, limestone and dolomite, wherein the pyroxenite, limestone and dolomite, individually has mean particle size ranging from about 2.0 mm to 2.6 mm, including all the values in the range, for instance, 2.01 mm, 2.02 mm, 2.03 mm, 2.04 mm and so on and so forth.

In some embodiments of the present disclosure, the sinter base mix composition comprises- iron ore fines, coke fines, sinter return fines, calcium oxide, pyroxenite, limestone and dolomite, wherein the pyroxenite, limestone and dolomite, individually has mean particle size ranging from about 2.06 mm to 2.52 mm, including all the values in the range, for instance, 2.07 mm, 2.08 mm, 2.09 mm, 2.10 mm and so on and so forth.

In some embodiments of the present disclosure, the iron ore fines is in an amount ranging from about 55 wt% to 65 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instance, 56% wt%, 57% wt%, 58% wt%, 59 wt% and so on and so forth.

In some embodiments of the present disclosure, the coke fines is in an amount ranging from about 6 wt% to 7 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instance, 6.1 wt%, 6.2 wt%, 6.3 wt% and so on and so forth.

In some embodiments of the present disclosure, the sinter return fines is in an amount ranging from about 12 wt% to 13 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instant, 12.1 wt%, 12.2 wt%, 12.3 wt%, 12.4 wt% and so on and so forth.

In some embodiments of the present disclosure, the calcium oxide (burnt lime) is in an amount ranging from about 2.4 wt% to 2.6 wt% (inclusive in 100%) of sinter base mix. In an embodiment, the burnt lime is in an amount of about 2.4 wt% about 2.5 wt% or about 2.6 wt%.

In some embodiments of the present disclosure, the flux is in an amount ranging from about 17.5 wt% to 20 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instant, 17.6 wt%, 17.7 wt%, 17.8 wt%, 17.9 wt% and so on and so forth.

In some embodiments of the present disclosure, the pyroxenite is in an amount ranging from about 0.5 wt% to 1 wt% (inclusive in 100%) of sinter base mix, including the values in the range, for instance, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt% and so on and so forth.

In some embodiments of the present disclosure, the limestone is in an amount ranging from about 13 wt% to 14 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instance, 13.1 wt%, 13.2 wt%, 13.3 wt%, 13.4 wt% and so on and so forth.
In some embodiments of the present disclosure, the dolomite is in an amount ranging from about 4 wt% to 5 wt% (inclusive in 100%) of sinter base mix, including all the values in the range, for instance, 4.1 wt%, 4.2 wt%, 4.3 wt%, 4.4 wt% and so on and so forth.

In some embodiments of the present disclosure, wherein the iron ore fines comprises- Fe(T) ranging from about 61 wt% to 64 wt%, Al2O3 ranging from about 2.6 wt% to 3.6 wt%, SiO2 ranging from about 3.4 wt% to 3.9 wt%, P ranging from about 0.18 wt% to 0.19 wt%.

In some embodiments of the present disclosure, the iron ore fines has loss on ignition ranging from about 2 wt% to 3 wt%.

In some embodiments of the present disclosure the iron ore fines comprise non-traceable elements.

In some embodiments of the present disclosure, the iron ore fines has particle size of about -10mm+0.15mm.

In some embodiments of the present disclosure, the coke fines comprises- Fe(T) ranging from about 1 wt% to 1.15 wt%, Al2O3 ranging from about 4.5 wt% to 4.9 wt%, SiO2 ranging from about 10 wt% to 10.2 wt%, CaO ranging from about 1.5 wt% to 1.7 wt%, MgO ranging from about 0.2 wt% to 0.3 wt%, P ranging from about 0.08 wt% to 0.1 wt%, TiO2 ranging from about 0.3 wt% to 0.4 wt%, and C ranging from about 79 wt% to 81 wt%.

In some embodiments of the present disclosure, the coke fines has loss on ignition ranging from about 79 wt% to 81 wt%.

In some embodiments of the present disclosure, the coke fines has non-traceable elements.

In some embodiments of the present disclosure, the coke fines has particle size of about -5mm+0.25mm.

In some embodiments of the present disclosure, the sinter return fines comprises- Fe(T) ranging from about 51wt% to 51.5 wt%, Al2O3 ranging from about 2.8 wt% to 2.9 wt%, SiO2 ranging from about 6.2 wt% to 6.4 wt%, CaO ranging from about 13 wt% to 13.5 wt%, MgO ranging from about 2.8 wt% to 3 wt%, P ranging from about 0.08 wt% to 0.1 wt% and TiO2 ranging from about 0.18 wt% to 0.2 wt%.

In some embodiments of the present disclosure, the sinter return fines has nil loss on ignition.

In some embodiments of the present disclosure, the sinter return fines has non-traceable element.

In some embodiments of the present disclosure, the sinter return fines has particle size of about -5mm+0.15mm.

In some embodiments of the present disclosure, the calcium oxide (burnt lime) comprises SiO2 ranging from about 0.4 wt% to 0.5 wt%, CaO ranging from about 84 wt% to 86 wt% and MgO ranging from about 1.2 wt% to 1.3 wt%.

In some embodiments of the present disclosure, the calcium oxide has loss on ignition ranging from about 22 wt% to 23 wt%.

In some embodiments of the present disclosure, the calcium oxide has non-traceable elements.

In some embodiments of the present disclosure, the calcium oxide has particle size of about -0.15mm.

In some embodiments of the present disclosure, the pyroxenite comprises- Fe(T) ranging from about 5 wt% to 5.5 wt%, Al2O3 ranging from about 0.4 wt% to 0.5 wt%, SiO2 ranging from about 36 wt% to 38 wt%, CaO ranging from about 5.5 wt% to 6.5 wt%, MgO ranging from about 32 wt% to 34 wt% and TiO2 ranging from about 0.2 wt% to 0.4 wt%.

In some embodiments of the present disclosure, the pyroxenite has loss on ignition ranging from about 13 wt% to 14.5 wt%.

In some embodiments of the present disclosure, the pyroxenite has non-traceable elements.

In some embodiments of the present disclosure, the limestone comprises- Fe(T) ranging from about 1 wt% to 1.3 wt%, Al2O3 ranging from about 0.5 wt% to 0.6 wt%, SiO2 ranging from about 3 wt% to 4 wt%, CaO ranging from about 48 wt% to 50 wt% and MgO ranging from about 4 wt% to 4.5 wt%.

In some embodiments of the present disclosure, the limestone has loss on ignition ranging from about 40 wt% to 42 wt%.

In some embodiments of the present disclosure, the limestone has non-traceable elements.

In some embodiments of the present disclosure, the dolomite comprises- Al2O3 ranging from about 0.5 wt% to 0.8 wt%, SiO2 ranging from about 7 wt% to 8 wt%, CaO ranging from about 31 wt% to 33 wt% and MgO ranging from about 13 wt% to 14.5 wt%.

In some embodiments of the present disclosure, the dolomite has loss on ignition ranging from about 42 wt% to 44 wt%.

In some embodiments of the present disclosure, the dolomite has non-traceable elements.

The present disclosure further relates to a process of preparing the sinter base mix composition described above.

In some embodiments of the present disclosure, the process of preparing the sinter base mix composition comprises- mixing the iron ore fines, the cokes fines, the sinter return fines, the calcium oxide (burnt lime) and the flux selected from a group comprising the pyroxenite, the limestone, the dolomite and any combinations thereof, wherein the flux has mean particle size ranging from about 2.0 mm to 2.6 mm, including all the values in the range, for instance, 2.01 mm, 2.02 mm, 2.03 mm, 2.04 mm and so on and so forth.

In some embodiments of the present disclosure, the mixing is carried out in a manner that homogenous sinter base mix composition is obtained.
In some embodiments of the present disclosure, the mixing is carried out by technique including but not limited to dry mixing.

In some embodiments of the present disclosure, the mixing is carried out at a temperature ranging from about 25 ? to 40 ?, for a duration ranging from about 13 minutes to 15 minutes.

The disclosure further relates to a sinter.
In some embodiments of the present disclosure, the sinter comprises the sinter base mix composition described above.

In some embodiments of the present disclosure, the sinter has size ranging from about 10 mm to 40 mm, including all the values in the range, for instance, 11 mm, 12 mm, 13 mm, 14 mm and so on and so forth.

In some embodiments of the present disclosure, the sinter has tumbler index (TI) ranging from about 73 to 75.

In an embodiment, the figure 3 illustrates a plot describing the influence of mean particle size of the flux on the tumbler index (TI) of the sinter.

In some embodiments of the present disclosure, the sinter has reduction degradation index (RDI) ranging from about 14 to 16.

In an embodiment, the figure 5 illustrates a plot describing the influence of mean particle size of the flux on the reduction degradation index (RDI) of the sinter.

In some embodiments of the present disclosure, the sinter has reducibility index (RI) ranging from about 73 to 80.

In an embodiment, the figure 6 illustrates a plot describing the influence of mean particle size of the flux on the reducibility index (RI) of the sinter.

In some embodiments of the present disclosure, the sinter comprises - Fe (T) ranging from about 52 wt% to 54 wt%, FeO ranging from about 11 wt% to 13 wt%, CaO ranging from about 14 wt% to 15 wt%, SiO2 ranging from about 5 wt% to 6 wt%, MgO ranging from about 1.8 wt% to 2.2 wt%, Al2O3 ranging from about 2.8 wt% to 3.2 wt%, TiO2 ranging from about 0.18 wt% to 0.19 wt%, P ranging from about 0.02 wt% to 0.08 wt%, K2O ranging from about 0.002 wt% to 0.06, Na2O ranging from about 0.012 wt% to 0.072 wt% and MnO ranging from about 0.03 wt% to 0.04 wt%.

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

In some embodiments of the present disclosure, the method of preparing the sinter comprises:
- mixing the base mix composition described above with water to obtain mixture; and
- granulating the mixture to obtain granules, followed by heating the granules and cooling to obtain the sinter.

In some embodiments of the present disclosure, the water is in an amount ranging from about 6% to 7%.

In some embodiments of the present disclosure, mixing of the base mix composition and water comprises- adding half the total amount of water and mixing intensely for a duration ranging from about 10 minutes to 12 minutes, followed by adding remaining amount of the water and continuing mixing for a duration ranging from about 3 minutes to 5 minutes.

In some embodiments of the present disclosure, moisture content of the granules during granulating is ranging from about 6% to 7%.

In some embodiments of the present disclosure, the heating is carried out at a temperature ranging from about 950 ? to 1000 ?.

In some embodiments of the present disclosure, the heating is carried out for a duration ranging from about 2.3 minutes to 2.5 minutes.

In some embodiments of the present disclosure, the heating is carried out under suction pressure ranging from about 550 mmWC to 600mmWC.

In some embodiments of the present disclosure, the cooling is carried out for a duration ranging from about 10 minutes to 15 minutes.

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.

EXAMPLES
Example 1: Preparation of sinter base mix composition
About 61% of the iron ore fines, about 6.5% of the coke fines, about 12% sinter return fines, about 2.55% of the calcium oxide, about 0.75% of the pyroxenite having mean particle size of about 2.06%, about 14% of the limestone having mean particle size of about 2.06 mm and 4.2 mm of the dolomite having mean particle size of about 2.06 mm, were mixed for a duration of about 15 minutes to obtain homogenous sinter base mix composition.

Example 2: Preparation of sinter base mix composition
About 61% of the iron ore fines, about 6.5% of the coke fines, about 12% sinter return fines, about 2.55% of the calcium oxide, about 0.75% of the pyroxenite having mean particle size of about 2.52 mm, about 14%of the limestone having mean particle size of about 2.52 mm and about 4.2% of the dolomite having mean particle size of about 2.52 mm, were mixed for a duration of about 15 minutes to obtain homogenous sinter base mix composition.

Example 3: Preparation of sinter
The base mix composition having varied mean particle size were independently charged into the granulation drum which was inclined at about 45º and set into rotation at a constant speed of about 25 rpm. The composition was allowed to mix for about 15 minutes. The granules were allowed to grow without mixing during the last minute for granulation. The total amount of moisture used was about 6% of base mix. Further, the mixture was transferred to the sinter pot of about 200 mm diameter (illustrated in figure 2) and filled up to a height of about 600 mm. The top of the mixture was ignited using the movable ignition hood fuelled by coke oven gas while suction was applied across the bed. Ignition temperature was about 1000 ºC while suction during ignition was maintained at about 600 mmWC. Ignition was continued for about 2.3 minutes after which the ignition hood was removed, and the suction was increased. The increased suction was maintained until the desired sinters were formed. The obtained sinters were allowed to cool. Chemical analysis of the obtained sinters were carried out by Inductively coupled plasma atomic emission spectroscopy (ICP-AES). Further, the obtained sinters were subjected to analysis for assessing Tumbler index (TI), abrasion index (AI), reduction degradation index (RDI) and reducibility index (RI).

Table 1 describes the chemical constituents of the obtained sinter and the tumbler index, reducibility index and reduction degradation index, respectively.

Table 1: