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风化煤制备胶体型黏结剂及其在白云鄂博铁矿造块中的应用

Preparation of coal-based colloidal composite binder derived from weathered coal and its application in agglomeration of Bayan Obo iron ore

  • 摘要: 黏结剂对铁矿造块产品的产质量具有重要影响。为开发适用于白云鄂博铁矿造块的低用量、高效黏结剂,本研究选用了中南大学自主研发的胶体型黏结剂。该黏结剂以新疆高腐殖酸风化煤为主要原料,系统研究其制备工艺及在白云鄂博铁矿造块中的应用性能。结果表明,适宜的制备条件为水煤比为5.5~6.0、碱腐比为27%~30%、碱预活化时间为4~24 h,制得的黏结剂能够在6~10 d内保持良好的流动性和稳定性。胶体型黏结剂对白云鄂博铁矿具有良好的适配性,将胶体型黏结剂替代膨润土用于球团制备,在适宜的制备参数下,胶体型黏结剂用量为1.5%(干基用量0.21%,质量分数)时,即可获得优于添加2.0%膨润土时生球的质量。模拟链箅机-回转窑扩大化试验表明,胶体型黏结剂球团矿在预热温度为950 ℃、预热时间为12 min,焙烧温度为1 200~1 225 ℃、焙烧时间为20 min的条件下,预热球团矿的抗压强度大于440 N/P,焙烧球团矿的抗压强度大于2 600 N/P。相比于2.5%膨润土氧化球团矿,采用干基用量0.21%胶体型黏结剂制备的球团矿铁品位提高了1.39个百分点,还原度提高了4.1个百分点。在高比例配加白云鄂博铁精矿的烧结过程中,胶体型黏结剂可以明显改善制粒效果,显著提升烧结的产质量指标。烧结原料二次混合过程中配加0.3%(干基用量0.04%,质量分数)的胶体型黏结剂替代部分制粒水,可提高混合料大于3 mm粒级比例并优化粒度分布,烧结利用系数提升了0.19 t/(m2·h),烧结矿的转鼓强度提升了1.73个百分点。胶体型黏结剂的核心优势在于用量低,通过有效改善铁矿颗粒间的相互作用强化制粒与黏结过程,可实现造块产品的产质量协同提升。

     

    Abstract: Binders play critical role in determining the quality and performance of iron ore agglomerates. To develop a low-dosage and highly efficient binder suitable for the agglomeration of Bayan Obo iron ore, a novel coal-based colloidal composite binder (3Co-binder) independently developed by Central South University was investigated. The binder was prepared using high-humic-acid weathered coal from Xinjiang as the main raw material, and its preparation process and application performance in the agglomeration of Bayan Obo iron ore were systematically studied. The results indicate that the optimal preparation conditions are water-to-coal ratio of 5.5-6.0, alkali-to-humic-acid ratio of 27%-30%(mass fraction), and alkali pre-activation time of 4-24 h. Under these conditions, 3Co-binder exhibits stable rheological behavior and maintains good flowability and stability for up to 6-10 d. 3Co-binder shows excellent compatibility with Bayan Obo iron ore. When used as replacement for bentonite in pelletizing, a dosage of only 1.5% (corresponding to 0.21% on a dry basis,mass fraction) is sufficient to achieve superior green pellet quality compared with that obtained using 2.0%(mass fraction) bentonite under comparable conditions. Scale-up simulation tests of the grate-rotary kiln process demonstrated that, under conditions of preheating temperature of 950 ℃, preheating time of 12 min, roasting temperature of 1 200-1 225 ℃, and roasting time of 20 min, the compressive strength of preheated pellets exceeds 440 N per pellet, while that of roasted pellets exceeds 2 600 N per pellet. Compared with oxidized pellets produced with 2.5% bentonite, pellets prepared with 0.21% (dry basis,mass fraction) 3Co-binder exhibit an increase in iron grade by 1.39 percentage points and an improvement in reducibility index by 4.1 percentage points. In sintering applications with high proportions of Bayan Obo iron ore, the addition of 3Co-binder significantly improves granulation behavior and enhances product quality and productivity. During secondary mixing, adding 0.3% binder (0.04% on dry basis,mass fraction) in place of part of the granulation water increases the proportion of more than 3 mm granules and optimizes the particle size distribution. As a result, the sintering productivity increases by 0.19 t/(m2·h), and the tumbler index increased by 1.73 percentage points. Overall, 3Co-binder enables significant dosage reduction through enhanced interparticle interaction among iron ore particles, thereby strengthening granulation and bonding processes, ultimately achieving coordinated enhancement of agglomeration product quality and productivity.

     

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