The deposit-forming problem is one of the main bottlenecks restricting the yield and production benefit of iron ore pellets produced by coal-fired rotary kilns. In order to implement measures to ensure the efficient production of pellets by coal-fired rotary kilns, the mechanism and influencing factors on the deposit formation were reviewed. The pellet powder and coal ash come together to form the material base of the deposit. Meanwhile, the local reducing atmosphere caused by the continued combustion of residual carbon increases the FeO content, resulting in the formation of low-melting-point silicates. Moreover, alkali metal elements in coal ash can also promote liquid phase formation to cause serious deposit aggregation problems. During high-temperature roasting, the liquid phase corrodes the surface of the refractory brick to form the initial deposit, whereafter, it binds the pellet powder and coal ash from the material layer, which causes the deposit to accumulate continuously. The deposit formation of coal-fired rotary kilns is the result of interaction between many factors, which includes the quality of the green pellets, the composition of coal ash, the combustion efficiency of pulverized coal, roasting temperature, FeO content and alkali metal input. Finally, it is recommended that some measures to mitigate deposit formation can be adopted, such as increasing the compression strength of preheated pellets, choosing high-quality raw materials with low alkali metals, improving the combustion of pulverized coal.
The Deposit Formation Mechanism in Coal-Fired Rotary Kiln for Iron Ore Pellet Production: A Review