Development of iron ores sintering machine for blast furnace process

There must be proper means to sinter and, agglomerated iron ore concentrate before it can be further processed in the blast furnace. A Sintering machine of 5kg capacity of agglomerated ore was designed and fabricated using mild steel material, which was locally sourced. The machine was fabricated with a combustion chamber of 30 by 30 cm and with 15cm depth. It was also lined with refractory material to reduce the chamber to the volume of 3375 cm3. However, the sintering chamber was designed to have a truncated square pyramid shape to the volume of 2150 cm3 after lining with refractory material. The design was made to utilize coke and palm kernel shell char as fuel which will be ignited to produce heat into the sintered material by suction of the heat into the agglomerated sintered ore. Tests such as tumbler index, abrasion, and porosity test were carried out on the sintered products in agreement with ASTM E276 and E389 standards. The results from the test gave a tumbler index of 70.2% and 65.7% for coke and palm kernel shells respectively. Also, abrasion index of 5.1% and 4.6% for coke and palm kernel char, and porosity of 6.8% and 6.5% for coke and palm kernel char respectively. The results from the experimental test were in agreement with other research work. Therefore, the developed iron ore sintering machine has a better efficiency of producing sinter for blast furnace operation.

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Facile Hydrothermal and Solvothermal Synthesis and Characterization of Nitrogen-Doped Carbon Dots from Palm Kernel Shell Precursor

Applied Sciences ◽

10.3390/app11041630 ◽

2021 ◽

Vol 11 (4) ◽

pp. 1630

Author(s):

Yakubu Newman Monday ◽

Jaafar Abdullah ◽

Nor Azah Yusof ◽

Suraya Abdul Rashid ◽

Rafidah Hanim Shueb

Keyword(s):

Carbon Dots ◽

Batch Reactor ◽

Average Particle Size ◽

Research Work ◽

Palm Kernel ◽

Average Particle ◽

One Pot ◽

Palm Kernel Shell ◽

Doped Carbon Dots ◽

Nitrogen Doped Carbon

Carbon dots (CDs), a nanomaterial synthesized from organic precursors rich in carbon content with excellent fluorescent property, are in high demand for many purposes, including sensing and biosensing applications. This research focused on preparing CDs from natural and abundant waste, palm kernel shells (PKS) obtained from palm oil biomass, aiming for sensing and biosensing applications. Ethylenediamine and L-phenylalanine doped CDs were produced via the hydrothermal and solvothermal methods using one-pot synthesis techniques in an autoclave batch reactor. The as-prepared N-CDs shows excellent photoluminescence (PL) property and a quantum yield (QY) of 13.7% for ethylenediamine (EDA) doped N-CDs (CDs-EDA) and 8.6% for L-phenylalanine (L-Ph) doped N-CDs (CDs-LPh) with an excitation/emission wavelength of 360 nm/450 nm. The transmission electron microscopy (TEM) images show the N-CDs have an average particle size of 2 nm for both CDs. UV-Visible spectrophotometric results showed C=C and C=O transition. FTIR results show and confirm the presence of functional groups, such as -OH, -C=O, -NH2 on the N-CDs, and the X-ray diffraction pattern showed that the N-CDs were crystalline, depicted with sharp peaks. This research work demonstrated that palm kernel shell biomass often thrown away as waste can produce CDs with excellent physicochemical properties.

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Carbon Doped Iron Ore Using Palm Kernel Shell

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.701.28 ◽

2013 ◽

Vol 701 ◽

pp. 28-31 ◽

Cited By ~ 6

Author(s):

Rusila Zamani Abd Rashid ◽

Hadi Purwanto ◽

Hamzah Mohd Salleh ◽

Mohd Hanafi Ani ◽

Nurul Azhani Yunus ◽

...

Keyword(s):

Iron Ore ◽

Palm Kernel ◽

Reduction Process ◽

Attractive Alternative ◽

Low Grade ◽

Iron Ores ◽

Solid Carbon ◽

Green Composite ◽

Biomass Waste ◽

Palm Kernel Shell

This paper pertains to the reduction process of local low grade iron ore using palm kernel shell (PKS). It is well known that low grade iron ores contain high amount of gangue minerals and combined water. Biomass waste (aka agro-residues) from the palm oil industry is an attractive alternative fuel to replace coal as the source of energy in mineral processing, including for the treatment and processing of low grade iron ores. Both iron ore and PKS were mixed with minute addition of distilled water and then fabricated with average spherical diameter of 10-12mm. The green composite pellets were subjected to reduction test using an electric tube furnace. The rate of reduction increased as temperature increases up to 900 °C. The Fe content in the original ore increased almost 12% when 40 mass% of PKS was used. The reduction of 60:40 mass ratios of iron ore to PKS composite pellet produced almost 11.97 mass% of solid carbon which was dispersed uniformly on the surface of iron oxide. The aim of this work is to study carbon deposition of PKS in iron ore through reduction process. Utilization of carbon deposited in low grade iron ore is an interesting method for iron making process as this solid carbon can act as energy source in the reduction process.

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A Scale-up Approach to Produce Highly Reactive Iron Ore Catalyzed Coke for Blast Furnace Operation

Mineral Processing and Extractive Metallurgy Review ◽

10.1080/08827508.2019.1666124 ◽

2019 ◽

Vol 41 (6) ◽

pp. 370-380 ◽

Cited By ~ 3

Author(s):

Hammad Siddiqi ◽

V. K. Chandaliya ◽

A. Suresh ◽

P. S. Dash ◽

B. C. Meikap

Keyword(s):

Blast Furnace ◽

Iron Ore ◽

Scale Up ◽

Furnace Operation ◽

Blast Furnace Operation ◽

Reactive Iron

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Fabrication of Carbon-Copper Composites Using Local Carbon Material: Microstructure, Mechanical, Electrical and Wear Properties

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1133.171 ◽

2016 ◽

Vol 1133 ◽

pp. 171-174

Author(s):

Mohd Asri Selamat ◽

Ahmad Aswad Mahaidin ◽

Mohd Afiq Nurul Hadi ◽

Zaim Syazwan Sulaiman ◽

Mohd Idham Abdul Razak

Keyword(s):

Electrical Contact ◽

Research Work ◽

Palm Kernel ◽

Physical And Mechanical Properties ◽

Current Collector ◽

Wear Properties ◽

Palm Kernel Shell ◽

Low Thermal Expansion ◽

Contact Devices ◽

Carbon Brushes

The carbon-copper (C-Cu) composites combine the positive characteristics of thermal and electrical conductivity from Cu, low thermal expansion coefficient and lubricating properties from conventional graphite. For that particular application, C-Cu composites are widely used as electrical contact devices such as carbon brushes and current-collector for railway power collection system. Due to economic and environment concern, activated-carbon produced from MPOB’s oil palm kernel shell (OPKS) is studies as replacement for conventional graphite. The OPKS is crushed and mixed with copper and resin powder before it is compacted into shape. Then the green body undergoes warm-compaction (1140MPa;100-150°C) followed by post-baking (150-250°C) process to enhance its properties. The physical and mechanical properties of the C-Cu composite were analysed. The resulting microstructures, electrical and wear properties also are presented and discussed. The prototype of current-collector for PUTRA LRT and carbon brushes for electrical applications was produced from this research work.

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Lead Sorption by Carbon Nanofibers Grown on Powdered Activated Carbon — Kinetics and Equilibrium

NANO ◽

10.1142/s1793292015500174 ◽

2015 ◽

Vol 10 (02) ◽

pp. 1550017 ◽

Cited By ~ 8

Author(s):

Abdullah Al Mamun ◽

Yehya M. Ahmed ◽

Ma'an Fahmi R. AlKhatib ◽

Ahmad Tariq Jameel ◽

Mohammed Abdul Hakeem Abdul Rahman AlSaadi

Keyword(s):

Aqueous Solution ◽

Activated Carbon ◽

Carbon Nanofibers ◽

Research Work ◽

Palm Kernel ◽

Solid Substrate ◽

Second Order ◽

Powdered Activated Carbon ◽

Palm Kernel Shell ◽

Pseudo Second Order

Carbon nanofibers (CNFs) were synthesized by using a safe and less hazardous method, compared to using floating catalysts in chemical vapor deposition (CVD) process. This process used C 2 H 2 as carbon source and oil palm kernel shell-based powdered activated carbon (PAC) as cheap solid substrate. Use of nickel ( Ni 2+) impregnated PAC as fixed substrate for the synthesis of CNF is one of the novelties of the research work accomplished by the authors. The PAC–CNFs porous nanocomposite product was used for the sorption of lead ions ( Pb 2+) from synthetic aqueous solution. Kinetics of Pb 2+ adsorption and isotherms were investigated by varying initial concentration of lead and contact time. PAC–CNFs were found to remove Pb 2+ better at acidic pH of about 5.5. Langmuir and Freundlich isotherms were applied to the sorption equilibrium data to find the best fitted model. Langmuir isotherm model with R2 = 0.965 fitted the adsorption data better than the Freundlich isotherm. The kinetic processes of Pb 2+ adsorption on CNFs were investigated by applying different kinetic models, namely zero-order, pseudo-first-order and pseudo-second-order. The pseudo-second-order rate equation exhibited the best results with R2 = 0.999, qe = 74.79 (mg/g) and K2 = 0.029 (min ⋅ g/mg). The novel nanocomposite product seemed to have the potential to remove Pb 2+ ions from aqueous solution.

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Production of Low-SiO2 Iron Ore Sinter and Blast Furnace Operation at Kobe Works, Kobe Steel, Ltd.

Transactions of the Iron and Steel Institute of Japan ◽

10.2355/isijinternational1966.28.523 ◽

1988 ◽

Vol 28 (7) ◽

pp. 523-530 ◽

Cited By ~ 1

Author(s):

Kan AKETA ◽

Mitsunori TAKAMI ◽

Ichiro SHIGAKI ◽

Koichi HOSHINO ◽

Tasuku TAKAHASHI ◽

...

Keyword(s):

Blast Furnace ◽

Iron Ore ◽

Furnace Operation ◽

Blast Furnace Operation ◽

Iron Ore Sinter

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SHRINKAGE AND CREEP CHARACTERISTICS OF PALM KERNEL SHELL CONCRETE

Journal of Engineering Studies and Research ◽

10.29081/jesr.v26i1.8 ◽

2020 ◽

Vol 26 (1) ◽

pp. 47-56

Author(s):

ADETUKASI ADESOLA OLAYINKA ◽

IKPONMWOSA EFE EWAEN

Keyword(s):

Research Work ◽

Palm Kernel ◽

Shrinkage Strain ◽

Partial Replacement ◽

Normal Concrete ◽

Palm Kernel Shell ◽

Mix Proportion ◽

Creep Characteristics ◽

Shrinkage And Creep ◽

Creep And Shrinkage

This research work evaluates the shrinkage and creep characteristics of concrete containing Palm Kernel Shell (PKS) as partial replacement of natural coarse aggregate. Concrete was mixed at 0.55 water-cement ratio, mix proportion of 1:1:2 and percentage replacement of natural aggregate with PKS at 0%, 25 % and 50%. The creep and shrinkage results of Palm Kernel Shell Concrete (PKSC), increased as the percentage content of PKS increased in the concrete. The maximum creep strain observed for normal concrete, 25 % and 50 % PKS content were 0.00018 mm/m, 0.00057 mm/m and 0.00094 mm/m respectively. The maximum total shrinkage strain recorded for 0%, 25% and 50 % PKS content was 0.00102 mm/m, 0.00183 mm/m and 0.00247 mm/m respectively.

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Reduction Kinetics of Iron Ore Materials by Gases

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.283-286.45 ◽

2009 ◽

Vol 283-286 ◽

pp. 45-52 ◽

Cited By ~ 3

Author(s):

A.N. Dmitriev ◽

Yu.A. Chesnokov

Keyword(s):

Blast Furnace ◽

Mass Exchange ◽

Iron Ore ◽

Graphical Representation ◽

Furnace Operation ◽

Critical Parameters ◽

Blast Furnace Process ◽

Heat And Mass Exchange ◽

Model Calculations ◽

Furnace Process

The proposed balance logic-statistical model of the blast furnace process is based on the use of material and thermal balances along with calculations of heat- and mass exchange taking into account the non-uniformity of gas and burden distribution on the radius of the furnace and influence of the basic metallurgical characteristics of iron ore raw materials and coke on the indices of blast furnace operation. As a check of the applicability of the model, calculations on the most critical parameters of the blast furnace process – the smelting of ferromanganese and iron nickel with a graphical representation of heat- and mass exchange processes, dynamics of oxides reduction on the height and radius of the blast furnace have been carried out.

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Modeling a Compact Sintering Process Based on Biomass Fuels

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.902.33 ◽

2014 ◽

Vol 902 ◽

pp. 33-40 ◽

Cited By ~ 2

Author(s):

Jose Adilson de Castro ◽

Alexandre Furtado Ferreira ◽

Marcos Flavio de Camps ◽

Ivaldo Leão Ferreira

Keyword(s):

Blast Furnace ◽

Solid Fuel ◽

Chemical Species ◽

Coke Oven ◽

Reaction Rates ◽

Furnace Operation ◽

Base Case ◽

Fuel Gas ◽

Sintering Machine ◽

Gas Utilization

This paper is focused on the numerical simulation of a new technology of small size iron ore sintering machine using gaseous fuel and oxygen injections to produce high quality of sinter product for the blast furnace operation. The proposed methodology is to partially replace the solid fuel (coke breeze) by steelworks gases in a compact machine to enhance heat and mass transfer. A multiphase mathematical model based on transport equations of momentum, energy and chemical species coupled with chemical reaction rates and phase transformations is proposed to analyze the inner process parameters. A base case representing a possible actual industrial operation of the sintering machine is used in order to compare different scenarios of possible operations which represents advanced operations techniques. The model was used to predict four cases of fuel gas utilization: a) 3% of the wind boxes inflow from N01-N10 wind boxes of natural gas (NG) and oxygen, b) same condition with coke oven gas (COG) and c) mixture of 80% COG and 20% blast furnace gas (BFG). The model predictions indicated that for all cases, the sintering zone is enlarged and the solid fuel consumption is decreased about 12kg/t of sinter product for the best combination. In order to maximize the steelworks gas utilization it is recommended the use of mixture of COG and BFG with optimum inner temperature distribution within a compact sintering machine, which enhance the productivity and obviously, decrease the investment cost of the sintering facilities.

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