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Sponge iron, also name as direct reduced iron (DRI), is the resulting product (with a metallization degree greater than 82 percent) of solid state reduction of iron ores or agglomerates (generally of high grade), the principal constituents of which are Metallic iron, residual iron oxides carbon and impurities such as phosphorus, sulphur and gangue (principally silica and alumina).
Sponge iron/DRI has gained great prominence in some countries as a substitute of steel scrap (partially) in steel making in electric arc furnace and in induction furnace. Direct Reduction is a metallurgical process of producing sponge iron from iron oxides (mainly from lump iron ores or pellets) directly in the solid phase. The product of this solid state route has a honey comb structure with minute pores. Hence this product is most commonly known as sponge iron/direct reduced iron (DRI). In addition to the metallic iron content sponge iron contains some unreduced iron oxides and gangue. Since there is no separation of impurities in DR process, all the gangue present in the original oxide (silica, alumina, oxides of phosphorous) goes in to the product sponge iron. In fact concentration of these oxides increases due to the removal of oxygen to a level of plus 90%.
Hot DRI in the form of pellets, lumps, fines at a temperature of 650-850 deg C is passed through hot briquetting machine where the product is pressed between the rolls at extremely high pressure to produce highly compacted pillow shaped material called hot briquetted iron (HBI).
While producing sponge iron some amount of sponge fines of minus 4mm is also generated. This sponge fines is briquetted in cold condition using binders in the cold roller press to produce highly compacted pillow shaped material called as cold briquetted iron. (CBI)
Iron ore powder (hematite, magnetite, limonite, etc.), Manganese Ore, Chromium ore (chromite massive Isometric, chrompicotite, etc.), Silica ( quartz, tridymite,cristobalite, etc.),Bauxite,Fluorite,Magnesite, Dolomite, Limestone, Quicklime,Bentonite, Copper ore ( sulphide copper ore,oxidized copper ore, etc. ), Nickel ( sulphide ore,oxidized ore ),Lead ore concentrate,Zink ore concentrate,Tin ore concentrate, etc.
Get a material with the small particle is the first thing we need to ensure in mineral briquette process. Forms a solid and homogeneous product (briquettes or flakes) out of various size fractions and a further crushing/sieving step is required to obtain granules of various size ranges.
By choosing the different briquette presses with different pressure and briquette size, you will need to find the most suitable moisture for making your briquette.Generally located between 3 and 15%. Normally, low pressure should be with high moisture, and also, high pressure with low moisture.
Minerals are hard to briquette as its oflow plasticity, we need high pressure and a well-distributed binder to do this work. Mix the mineral powder with binder will help you to make high quality briquette, note, different mineral powders need to use different mixers to get a better mix effect.