Compressive Strength Behavior of Briquettes Produced from Manganese Ore Fines and Metal Dust: Optimization Using Response Surface Methodology

Electric reduction furnaces cannot be fed fines in the production of manganese ferroalloy as they hinder gas permeability. Thus, agglomeration techniques can be used to minimize the environmental and economic impacts of storing fines. Among these techniques, briquetting is advantageous because it allows for cold agglomeration of the particles and is flexible in terms of particle sizes. Therefore, this work aimed to develop self-reductor briquettes composed of ore manganese fines, dust ferromanganese, charcoal fines, and three different binders. The compaction pressure, curing time, and % binder were optimized to enhance briquette strength through a multivariate experimental design consisting of a screening study using a 2(3) full factorial design followed by response surface methodology with a spherical central composite design. The results were assessed by analysis of variance, and a regression model was established. The study found that briquettes elaborated with bentonite exhibited an optimized compressive strength of 4.02 MPa, achieved with a compaction pressure of 67.55 MPa and 12.71% bentonite. For briquettes elaborated with pregelatinized starch, a compressive strength of 7.04 MPa was obtained with a compaction pressure of 67.52 MPa, a curing time of 19.51 days, and 8.07% pregelatinized starch. For briquettes agglomerated using slaked lime and molasses, an optimized compaction pressure of 27.09 MPa and a curing time of 23.27 days resulted in a compressive strength of 1.63 MPa. These results suggest that briquettes containing bentonite and pregelatinized starch are feasible substitutes for lump ore in electric furnaces.