A laboratory hydraulic press serves a critical function in the preparation of charge materials by transforming loose mixtures of ilmenite slag, coal powder, and fluxes into dense, durable briquettes. By applying massive pressure—ranging from several to dozens of tons—this equipment overcomes the physical limitations of fine powders to create a feed material optimized for electric furnaces.
The core objective of using a hydraulic press is to maximize the efficiency of the carbothermic reduction reaction. Compressing reactants into pellets drastically increases the contact area between the ore and the fuel while shortening the diffusion path required for the chemical reaction to occur.
The Physics of Densification
Increasing Reactant Contact
The primary challenge in reducing ilmenite is ensuring the reducing agent (coal) is physically close to the oxide being reduced.
The hydraulic press forces these distinct particles into intimate contact. This proximity significantly shortens the reduction diffusion path, allowing the chemical reaction to proceed more rapidly and completely.
Preventing Material Loss
Fine fuel powders and mineral dust are susceptible to being blown out of the furnace or lost to thermal updrafts before reacting.
Briquetting locks these fine particles into a solid mass. This structure minimizes the loss of fine fuel powders at high temperatures, ensuring the stoichiometry of the mix remains consistent throughout the process.
The Role of Binders and Structural Integrity
Utilizing Viscoelastic Properties
Pressure alone is often insufficient to hold dry powders together; a binder is required to maintain the shape created by the press.
Molasses is frequently used as an organic binder due to its viscoelastic and film-forming properties. It securely bonds the loose mineral and coal powders together during the compression phase.
Ensuring Green Strength
The briquettes must survive physical handling and transport before they even reach the furnace.
The combination of hydraulic pressure and the binder ensures adequate mechanical strength. This allows the "green" (unfired) pellets to withstand drying and loading without crumbling back into dust.
Common Pitfalls to Avoid
Premature Fragmentation
If the pressure applied is inconsistent or the binder is insufficient, briquettes may suffer from premature fragmentation.
This disintegration inside the furnace leads to non-uniform reactions. When the pellet breaks apart early, the intimate contact between reactants is lost, and the efficiency gains of the process are negated.
Reactant Segregation
Without proper briquetting, the heavier ore and lighter coal particles tend to separate (segregate) during handling.
The press freezes the mixture in a homogenous state. Failing to achieve sufficient compaction density allows this segregation to reoccur, resulting in zones of unreacted ore and wasted fuel.
Making the Right Choice for Your Goal
To optimize your ilmenite reduction process, consider the following parameters when setting up your hydraulic press operations:
- If your primary focus is Reaction Speed: Prioritize higher pressure settings to maximize density and minimize the diffusion distance between the coal and ilmenite.
- If your primary focus is Material Handling: Focus on the ratio of binder (molasses) to ensure the green pellets possess high mechanical strength for transport and drying.
By mechanically forcing reactants together, the hydraulic press transforms a chaotic mixture into a controlled, high-efficiency chemical system.
Summary Table:
| Feature | Benefit for Ilmenite Reduction |
|---|---|
| High Compaction Pressure | Shortens diffusion paths and maximizes reactant contact area |
| Binder Integration | Increases green strength using molasses for structural integrity |
| Material Consolidation | Prevents loss of fine fuel powders and dust in high-temp updrafts |
| Homogenization | Eliminates reactant segregation for uniform chemical reactions |
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References
- Kuralai Akhmetova, А.К. Касымжанова. Efficiency of Soda-Technology Carbothermal Smelting of Thermoactivated Ilmenite Concentrate with Aluminosilicate Mineralization. DOI: 10.3390/min15090906
This article is also based on technical information from Kintek Press Knowledge Base .
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