Interactions between magnetite oxidation and flux calcination during iron ore pellet induration

Many chemical reactions take place simultaneously during the induration of iron ore pellets produced from magnetite concentrates. Two of the most important are magnetite oxidation and calcination of carbonate fluxes. The first reaction consumes oxygen diffusing into the pellet, while the second reaction produces carbon dioxide that must diffuse out of the pellet. A mathematical model combining the two reactions and gaseous diffusion within the pellet has been developed to quantify the interaction between the two reactions. This combined mathematical model showed that current induration plant mathematical models for the mass and energy balance around a pellet furnace are inaccurate in treating magnetite oxidation and flux calcination as separate reactions. Assuming separate reactions can lead to an error of up to 20 pct conversion of magnetite at the end of the preheat stage. This combined mathematical model, confirmed by experiments with single pellets, also demonstrated that calcination of fluxes also tends to follow a "shrinking core" model rather than reacting simultaneously across the pellet, as existing whole plant models assume. Modifying induration plant mathematical models in accordance with the findings of this article could lead to further savings in energy costs for pellet plants.