Clean recycle and utilization of hazardous iron-bearing waste in iron ore sintering process

Applying recycled iron-bearing waste materials (RIM) into iron ore sintering process is the general disposal approach worldwide, while its use is still a thorny problem. Results showed that adding RIM increased contents of hazardous elements (K, Na, Pb, Zn, and Cl) in sinter product, and also enhanced emission concentration of PM2.5 in flue gas; increasing reaction temperature, and contents of CaO & coke breeze in raw mixtures improved hazardous elements removal. Based on these features, a novel method through granulating natural iron ores and RIM separately and distributing granulated RIM in bottom sintering layers was proposed for clean RIM cycle. When recycling 5% RIM, granulating RIM separately with higher contents of CaO and coke breeze removed hazardous elements effectively, the contents of which in sinter were reduced to comparable level of the case without RIM. Moreover, distributing RIM in bottom sintering layer reached intensive release of hazardous elements and PM2.5 during sintering, which reduced the flue gas volume needing purification by about 2/3. Through activated carbon purification, about 60% of PM2.5 comprised high contents of hazardous elements was removed. Novel technique eliminated the negative impact of RIM and has the prospect to reach clean recycle in sinter-making plants.