Binding iron ore pellets with fluidized-bed combustor fly ash

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A high calcium fluidized-bed combustor ash was shown to be an effective binder for iron ore pellets at dosages of 1% to 2% of the magnetite concentrate weight. Magnetite pellets that were between 1.1 and 12.7 mm (7/16 and 1/2 in.) in diameter were produced with dry crushing strengths greater than 22.3 N (5.0 lb-force) per pellet, which is comparable to the results produced using conventional bentonite binder. The effectiveness of fly-ash-based binders was considerably improved when calcium chloride was added as an accelerator. The addition of calcium chloride at a rate of 0.1% to 0.2% of the total powder weight increased the strength of the dried pellets by as much as 22% compared to the strength of pellets made using fly-ash without accelerators.

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Minerals and Metallurgical Processing