Abstract
Mill scale is one of the byproducts which produced during the processing of steel. It is rich in iron (≥70%), has lower impurities and a stable chemical composition. The present research studies the effects of partial replacement of iron ore with different proportions of mill scale on the sinter charge. The results in this study showed that with an increase in iron ore substitution by mill scale at 3%, the rate of production increases from 21.94 to 25.50 ton/m2/day (16.2%), the vertical velocity increases from 0.0192 to 0.0217 m/min (13%) and the strength of the produced sinter increases from 88% to 90% (2%). Thus, the bulk density increases, but this negatively affects the reducibility degrees and apparent porosity of the produced sinter. At 2% mill scale, both reducibility and apparent porosity reach their highest values (66.42, 20.53%), respectively. On the other hand, the bulk density and softening interval decrease to the lowest values (2.3gm/cm3, 70%) , respectively.
Highlights
The Egyptian Iron and Steel Company (EISCO) as a first integrated steel plant in Egypt based on blast furnace and converter technology with a designed capacity of 30000 ton liquid steel /Year
In an expansion plant two larger (BFs) having 1033m3 useful volume each were added in order to produce 1.5 million tons of liquid steel /year
It is clear that the FeO%in the produced sinter increases as mill scale
Summary
The Egyptian Iron and Steel Company (EISCO) as a first integrated steel plant in Egypt based on blast furnace and converter technology with a designed capacity of 30000 ton liquid steel /Year. It had two blast furnaces (BFs) having 575 m3 useful volume each. Aswan iron ore was used to feed both blast furnaces This ore is poor in iron and has high silica and phosphorous contents. Bahariya iron ore was discovered and used in the form of self-fluxing sinter as BF feed This ore is characterized by having relatively high iron content. The produced sinter is low quality due to the relatively high content of alkalis which causes corrosion and failure of the equipment's in the sinter machine and the poor mechanical properties which are likely to cause operational problems in the blast furnaces such as pillaring, chammying, cold run of the furnace, hot run of the furnace, scaffolding and blocking of the hearth [1]
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