A novel iron ore pelletization for increased strength under ambient conditions

A novel ambient condition production of superior strength, non-abrasive, non-sticky iron ore pellets devoid of undesirable fines under the compression stress of 4 kN is presented. Interfacial bond between epoxy and iron oxide imparts high strength as opposed to physical bond in the conventional pellets. The pellets show high compression strength of 4 kN, without heat treatment compared to the industry requirement (2.5 kN) of an indurated pellet processed at 1200-1350 °C. Pelletization and iron ore reduction are accompanied by great reduction in energy and carbon dioxide emission. Enhanced rate and degree of iron ore reduction are due to secondary reactions involving carbon dioxide and the volatiles. Pellets reduced at 1550 °C show carbon dissolution up to 4 wt%, high porosity, low sulphur and slag levels. Silica fillers in the resin impart high mechanical strength to the crosslinked epoxy-iron oxide network facilitating mass transfer of off-gases at the interface enhancing the reduction rate and the degree of reduction. Utilising biorenewable or recycled resin, will make this process sustainable, cleaner and cost-effective reducing the landfill burden.