Luossavaara-Kiirunavaara AB (LKAB) produce pellets from magnetite iron ore. Pellets are formed by balling moist iron ore concentrate to green pellets, which are then burned to pellets. The green pellets are formed in balling circuits consisting of balling drums and roller decks for screening. In 2017 a pilot scale balling circuit with a drum was completed in LKAB's agglomeration laboratory in Malmberget. The purpose of the pilot balling circuit is to predict the dynamics in a full scale balling circuit under different conditions.
This master degree project is an initial attempt to study the response in LKAB's pilot circuit in terms of green pellet quality and dynamics in the circuit. The goal was to determine an effective way to run experiments and to investigate whether the pilot circuit can predict the dynamics of balling in large-scale circuits. Pelletizing production is within LKAB's core competence, and therefore the origin and character of the reagents, as well as the design of the pilot balling drum circuit, are confidential. Code names are used for both iron ore concentrates and reagents.
The work began by creating a test procedure with the aim of running as many different mixtures as possible in the pilot balling circuit during a normal working day. Five different mixtures could be run. Four different additives were tested: bentonite, a flotation reagent (FLOT), an organic binder (OB) and a new development product (UTV). The first experiment in the pilot balling circuit was run with varying doses of bentonite because its impact in balling is well known at LKAB. Experiment two and three, with FLOT and OB, could be compared to previous experience from large scale test runs. The fourth and last experiment was a test of how the pilot circuit predicted the behavior of a new development product UTV. Each type of experiment was performed twice.
The pilot balling circle predicted well both dynamics and green pellet quality in all three experiments where experience from large-scale runs was available. The new, unknown, UTV product showed improved green pellet quality, without affecting adversely on the dynamics of the circuit. UTV can therefore be an interesting option for a future large scale run at LKAB.
The developed working schedule worked very well. A "basic analysis package" has been created to facilitate planning of future experiments in the pilot balling circuit. The number of persons needed to run the circuit depends on the number of mixtures and analyzes. For smaller experiments, at least five people is required, in addition to the leader of the experiments. More advanced experiments will demand seven people.