RESEARCH & DEVELOPMENT

Microscopic analysis of DR Grade Pellet from Paradeep

Background: DR grade pellets samples were provided to understand the microstructure of the pellets.
The samples were first segregated based on strength (CCS) and the broken pellets were observed under
scanning electron microscope. Green balls were also provided to understand the distribution of fluxes
and coke, the pellets were fired at 1300 degrees in laboratory furnace and cold crushing strength was
measured. The lab fired pellets were also analyzed under scanning electron microscope to understand
the bonding phenomenon.

Work Done:

1. CCS results of the pellets as well as Lab fired pellets where green balls were provided from
paradeep pellet plant is shown below.

CCS Distribution Plant fired Pellets CCS Distribution Lab fired Pellets
15 15

No of Pellets
No of pellets

10 10

5 5

0 0
50.6 117.0 183.5 250.0 316.4 382.9 More 157.28 233.34 309.39 385.45 461.50 More
Cold Crushing Strength Cold Crushing Strength

From the above graphs it is clearly observed that Plant fired pellets showed lower CCS compared to
same green balls fired in laboratory furnace. The Average CCS of plant fired pellets were 178 against lab
fired pellets having CCS of 318.

2. The green balls were observed under Stereo zoom microscope and the distribution of coke and
fluxes were found uniform. Some pellets showed large sized flux as shown below.

3. The plant fired pellets during CCS test were collected from three strength ranges 0 to 100 CCS,
100-200 CCS and more than 200 CCS. The samples were observed under scanning electron
microscope both under normal conditions and under BSC mode where compositional difference
is observed in shades of grey.

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a) Low CCS pellets in the range of 0-100 kg.

Above images are of same location observed in the core of the below 100 CCS pellets observed in
scanning mode and back scattered mode. The white shining particles in first image can be seen as grey
in the second image. They are lime particles and they have not taken part in pelletization due to
exposure to lower temperature. This was confirmed by taking a spot using EDS on the selected particles
as shown below.

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Element Weight% Atomic% Compd% Formula

Ca K 68.32 48.26 95.59 CaO

Fe K 3.43 1.74 4.41 FeO

O 28.25 50.00

Totals 100.00

The particles showed presence of free lime which has seized to melt and form bond with iron due to
exposure to insufficient temperature.

b) Medium CCS pellets in the range of 100-200 kg

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These pellets showed no-presence of free lime but the gangue minerals like silica and alumina have only
partially formed melt phases(grey color in BSC mode). The gangue minerals are generally in the ore and
also contributed from bentonite addition. EDS spot was taken to confirm the same as shown below.

Element Weight% Atomic% Compd% Formula

Al K 20.08 17.54 37.95 Al2O3

Si K 13.41 11.25 28.68 SiO2

Fe K 23.05 9.72 29.65 FeO

O 40.59 59.78

Totals 100.00

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c) Good CCS more than 200 kg pellets

Above 200 CCS the pellet bond formation is uniform with distinct slag bond(grey area surrounding each
particles) present throughout the pellet. The composition of slag bond was analyzed by taking an EDS
spot at the bonding phase. The slag phase composition is as shown below.

Element Weight% Atomic% Compd% Formula

Al K 1.64 1.83 3.09 Al2O3

Si K 5.07 5.43 10.84 SiO2

Ca K 21.31 16.00 29.81 CaO

Fe K 43.73 23.57 56.26 FeO

O 28.26 53.17

Totals 100.00

As per ternary phase diagram, these phases are formed at a temperature range of 1100-1200 degrees.

In other pellets large silica particles were found un-dissolved in the matrix, along with few clusters of large
ore particles not participating in the matrix. Their surfaces are separated from the matrix with a large void
leading to reduction in CCS. The images are shown below.

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The white particle in the first image is an impurity of quartz originating from limestone, it is confirmed from
the EDS spot analysis as shown below.

Element Weight% Atomic% Compd% Formula

Mg K 2.67 2.23 4.43 MgO

Si K 42.67 30.90 91.28 SiO2

Ca K 1.78 0.90 2.48 CaO

Fe K 1.41 0.51 1.81 FeO

O 51.48 65.45

Totals 100.00

Comments:

1. We need to study the temperature profile in the pellet bed, it is clearly understood that lower CCS
in the DR grade pellet produced in plant scale is due to insufficient temperature during firing at
the middle/lower part of the pellet bed.
2. Same pellets fired in lab showed good CCS and microstructure.
3. Lower bed permeability may be due to poor green strength or lower size of green balls. Pellets
becoming more plastic in absence of Pyroxinite can lead to poor heat transfer in the lower part of
the pellet bed. (subject to investigation)
4. Presence of coarse particles of coke and flux is still visible in the green balls that needs to be
under control, though the mixing is more uniform.

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