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Rourkela, India

Dalmia Y.K.,Suraj Products Ltd. | Kurunov I.F.,Novolipetsk Metallurgical Combine | Steele R.B.,J. C. Steele and Sons Inc. | Bizhanov A.M.,J. C. Steele and Sons Inc.
Metallurgist | Year: 2012

An industrial line producing briquettes from metallurgical sludge and dust by the stiff-vacuum extrusion technology developed by J.C. Steele & Sons (U.S.) began operation in April 2011 at the metallurgical plant of Suraj Products Ltd. in Rourkel, India. The technology was first used at the Bethlehem Steel Corp. plant in 1993. The cement-bonded extrusion briquettes (brex) obtained by this method are a new-generation component of the blast-furnace charge, and their metallurgical properties allow them to be successfully used for blast-furnace smelting. The use of a charge composed of 80% brex on a small blast furnace has made it possible to eliminate the use of raw fluxes and reduced coke consumption by 150 kg/ton pig iron. © 2012 Springer Science+Business Media, Inc. Source


Dalmia Y.,Suraj Products Ltd. | Kurunov I.,Novolipetsk Steel | Steele R.,J. C. Steele and Sons Inc. | Bizhanov A.,J. C. Steele and Sons Inc.
6th Int. Congress on the Science and Technology of Ironmaking 2012, ICSTI 2012 - Including Proceedings from the 42nd Ironmaking and Raw Materials Seminar, and the 13th Brazilian Symp. on Iron Ore | Year: 2012

Self-reducing iron-carbon containing briquettes are perspective charge materials for Blast Furnaces (BF) making it possible to reduce considerably the coke consumption as well as the total emissions of the CO2 within the technological network "Sintering-Ironmaking-Steelmaking". Such cylindrical shape (diameter 30mm, length 50-70mm) briquettes (Fe content 37-44%, C content 12-15 %) have been produced by the "Stiff-extrusion" technology at the industrial extrusion line with productivity of 20 tonnes/hour. The briquettes were made from disperse metallurgical wastes (BOF dust -48 %, BF dust -25 %, fine iron-ore -20%, Portland cement -7 %). They have been used as a main component of the BF charge (briquettes 60-62 %, iron ore 38-40 %) for the production of the foundry iron (Si content 0,9-2,5 %) in a small BF (working volume 45 m3). The coke rate was 565-710 kg/r, the blast temperature - 750-900 oC and slag volume - 275-380 kg/t. Source


Bizhanov A.,J. C. Steele and Sons Inc. | Pavlov A.,National University of Science and Technology "MISIS" | Chadaeva O.,National University of Science and Technology "MISIS" | Dalmia Y.,Suraj Products Ltd. | Mishra B.,Suraj Products Ltd.
ISIJ International | Year: 2014

Stiff vacuum extrusion has been applied for the agglomeration of the iron ore concentrate and fine coal. The products of agglomeration-extrusion briquettes (BREX) were subjected to the high temperature reduction. Under the conditions similar to the ITmk3 process in general. It has been demonstrated that the iron ore and coal BREX could be considered as the alternative to the iron and coal pellets for the high temperature reduction in furnaces like Rotary Hearth Furnace (RHF). © 2014 ISIJ. Source


Bizhanov A.,J. C. Steele and Sons Inc. | Kurunov I.,Novolipetsk Steel NLMK | Dalmia Y.,Suraj Products Ltd. | Mishra B.,Suraj Products Ltd. | Mishra S.,IGIT
ISIJ International | Year: 2015

Industrial stiff vacuum extrusion briquettes (BREX) producing line can efficiently provide for the smallscale blast furnace (BF) operation with 100% briquetted charge. Physical and metallurgical properties of the BREX are being investigated. A new effect of the non-linear strengthening of the BREX bonded with the combined Portland cement and Bentonite binder is described. Application of this combined binder results in the local maximum of the cold compressive strength of the BREX on third day of strengthening. Hot strength mechanism of the BREX is explained and was found to be related with creation of the metallized shell on their surface, sintering of the iron-containing particles and further creation of the metallicc phase surrounded by the silicates and ferrites. The addition of the iron ore fines to the BREX composition can improve their sintering during reduction thus helping to keep the integrity of the agglomerates. Results of the industrial operation of the small-scale BF with BREX are analyzed. The consumption of coke in the BF at 100% of BREX does not exceed 500 kg/t compared with 680 kg/t for the smelting without BREX. © 2015 ISIJ. Source

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