WO2006073347A1

WO2006073347A1 - Arrangement and method for the optical analysis of a test specimen of reducible material that contains iron.

Info

Publication number: WO2006073347A1
Application number: PCT/SE2005/001991
Authority: WO
Inventors: Anders Apelqvist; Kjell-Ove Mickelsson; Seija Forsmo; Urban Holmdahl
Original assignee: Luossavaara-Kiirunavaara Ab
Priority date: 2005-01-04
Filing date: 2005-12-21
Publication date: 2006-07-13
Also published as: SE0500017D0; SE528158C2; SE0500017L

Abstract

An arrangement for the optical analysis of a test specimen (A) of reducible material that contains iron. It comprises a frame (2) with a first device and a second device that can be displaced relative to each other and that demonstrate contact surfaces (8, 13) between which it is intended that the test specimen (A) is to be compressed during the recording of measurement data until the test specimen disintegrates, and an image-recording means (21) directed towards the test specimen for recording the change of shape and the disintegration of the test specimen during the compression.

Description

Arrangement and Method for the Optical Analysis of a Test Specimen of Reducible

Material that Contains Iron

The present invention concerns an arrangement and a method for the optical analysis of a test specimen of reducible material that contains iron according to the introduction to claim 1.

Extraction of metallic iron normally takes place through the reduction of iron oxide in a blast furnace or through its direct reduction in a direct reduction furnace. The iron oxide in the form of pellets comes into contact with a reducing gas, whereby the iron oxide is reduced to metallic iron in the form of molten iron, or what is known as sponge iron. The temperature of the reducing gas in the direct reduction process is approximately 800-950 ⁰C. If the pellets disintegrate during the reduction process, the contact of the reducing gas with the iron oxide is made more difficult, resulting in uneven operation and reduced productivity. For this reason, it is desired to obtain pellets of an even and high strength. The term "pellets" is here used to denote bodies composed of a reducible material containing iron that are in the form of agglomerates of finely divided material. Chemically pure iron ore concentrate that has been milled to a suitable size is mixed during the manufacture of pellets with an additive, and the mixture is then filtered to give a moist fibre cake. The moisture content of the fibre cake normally lies in the interval from 8 to 9% by weight. The moist filtered material is mixed with a binding agent and is rolled by known methods, for example, using rolling drums or rolling disks to give raw balls, known as green pellets, having a diameter of approximately 10-15 mm. The raw pellets are further processed by drying at an elevated temperature, in order subsequently to be sintered at high temperature to hardened pellets.

Moist raw pellets are weak and normally demonstrate a compressive strength of approximately 10 N/pellet. The low strength means that the pellets break easily. Broken pellets are separated out by sieving before the raw pellets are fed into the pelletizing machine, but raw pellets may break also after the sieving. The means that the penetrating ability of the gas in the bed of raw pellets during the process of forming pellets is reduced, and this in turn means that the drying, and the oxidation (if the iron ore concentrate is magnetite), cannot take place in an efficient and homogeneous manner. Furthermore, raw pellets are plastic, i.e. they can be deformed by pressure, and this further reduces the penetrability of the bed, since deformed pellets will close the spaces that form between pellets that have a high strength, and through which spaces the gas is to pass.

When moist raw pellets are dried, binding agent and any other dissolved or finely divided material present collects at the points of contact between the particles that are components of the raw pellets. This creates new bonds, whereby a dry raw pellet demonstrates an increased strength when binding agent is used, typically in the interval 20-60 N/pellet. If the iron ore concentrate is magnetite, the raw pellets are oxidised to hematite during the peptization process. Further points of contact are formed between the particles that are components of the raw pellets, whereby the compressive strength typically amounts to approximately 500-800 N/pellet, although also other values may arise. After the sintering, which normally takes place at approximately 1 ,300^° C, the sintered pellet obtains a compressive strength greater than 2,000 N/pellet. It is important for several reasons to obtain a high and even strength of the pellets. In addition to the effects during the reduction process described above, also the strength during handling during transport is important. The final strength of the pellets is determined to a major extent by the strength of the raw pellets at the beginning of the peptization process.

Different moisture contents, the fineness of the starting material, the amount of binding agent and the conditions during the mixing process are examples of parameters that give different strengths. A higher strength of the raw pellets and the pellets means that the peptization process can be carried out at a higher capacity. Lower amounts of fines are created during the transport, and the productivity of the reduction process will be higher. The requirements for an even and high quality of the pellets is increasing, and this means that feedback between the quality of the pellets and the properties of the raw pellets is becoming ever more important. Random samples from the pellet production are taken in order to determine the strength of the final pellets used in the extraction of iron. The random samples are subjected to different types of test. Test methods for non-sintered pellets and for moist and dry raw pellets, however, have not been reliable, and there is for this reason a need for an efficient and reliable test method.

Arrangements for testing the hardness of test specimens are previously known. A common method of testing moist raw pellets is to drop the raw pellet a number of times from a pre-determined height. The number of times that the raw pellets can be dropped from that height without breaking gives the result of the test. The disadvantage of this method is that the result depends of the person conducting the test, i.e. the result can be unconsciously influenced by the person who carries out the test.

An arrangement for testing moist and dried raw pellets and pellets has been designed in such a manner that it can press the raw pellet or pellet to breakage through the application of a piston with increasing force until the raw pellet or pellet breaks. Reading takes place at the moment of breakage, either manually on a meter or automatically, as a maximum value before the diameter has been reduced by a certain percentage. The value of the force read is entered into a table. The disadvantage of this is that the applied force is not recorded during the complete pressure application process, and for this reason only information about the maximum force that was applied during the complete pressure application process can be obtained. It has proven to be the case that the maximum force can arise once the formation of cracks has begun in the raw pellet or pellets and thus in this manner give an erroneous image of the strength. Visual reading is imprecise and depends on the person who performs it. A further disadvantage of this arrangement is that it is designed in such a manner that the weak moist and dried raw pellets must be manually inserted one at a time.

If the moist, filtered material can be given an optimal moisture content, it demonstrates a sufficiently rapid growth during the rolling procedure, i.e. during the formation of raw pellets, maximal strength of the raw pellets formed, and sufficiently high plasticity such that it can survive the handling, and this is of major significance for the subsequent peptization process.

One aim of the present invention is thus to provide an arrangement and a method for the optical analysis of the disintegration of test specimens in the form of raw pellets and pellets.

This aim is achieved through an arrangement and a method with the properties and characteristics that are defined in the subsequent claims.

An embodiment selected as an example will be described below, with reference to the attached drawings, of which

Figure 1A shows a press according to the invention,

Figure 1 B shows the press from Figure 1 with its cover removed, Figure 2A shows the width measurement function before the compression of the test specimen, and

Figure 2B shows the width measurement function after the shape of the test specimen has been changed.

The arrangement shown in Figure 1 comprises a press 1 for test specimens A of reducible material that contains iron, in the form of green pellets, i.e. moist or dried raw pellets, or sintered pellets. The press 1 comprises a frame 2 with a base 3 in the form of a bottom part. A cover 4 is arranged over the frame 2 in the form of a pair of essentially vertical walls 5 at a distance from each other and a back piece 6. The cover 4 is provided with openings 7 for the connection of the press 1 with control and recording apparatus in the form of, for example, a computer, PLC or similar (not shown in the drawings).

A first device is arranged between the vertical walls 5, as is shown in Figure 2, with a contact surface in the form of a pressure device 8 that can be displaced under control between a first withdrawn end position and a second extended position. The pressure device comprises, for example, a piston or a punch with a force that has been adapted for the current field of application. A force in the interval 0-100 N is used when testing raw pellets, while the measurement area is selected when testing sintered pellets such that the maximal force lies between 100-3,30O N. The speed of the pressure device 8 is set at between 2-50 mm/min in the preferred embodiment, and the distance of displacement of the pressure device 8 is set to 100 mm. The said speed and distance are regulated via an electric, hydraulic or pneumatic motor 9 and they are controlled by the said computer through a sensor. A contact sensor 11 is arranged at the free end of the pressure device 8, at its surface 10 of contact, and it is intended that the contact sensor record the contact of the pressure device 8 with the surface of the pellet A. The pressure device may be driven with two or more different speeds in sequence, in order to minimise the time taken for pressure to be applied. The pressure device is fed forwards rapidly from its upper end position in a direction towards the test specimen. Rapid feed is ended before the contact sensor makes contact with the test specimen, at a distance from the end position that has been pre-determined. The contact sensor is used to measure the diameter of the test specimen, which diameter is read when the contact sensor makes contact with the test specimen. The cover 4 is furthermore provided with an opening 12 for access to a second device, arranged on the base 3, with a contact surface 13 in the form of an element having the shape of a platform, a disk, for example. This element can be rotated, preferably in the horizontal plane.

The disk 13 demonstrates on its surface 14 that faces the pressure device 8 a number of depressions or cavities 15, in which it is intended that test specimens A are placed in a manner that keeps them in place. The depressions 15 are symmetrically located at mutual distances from each other around the outer edge of the disk 13. The number of depressions 15 is 20 in this embodiment, but it must be realised that the number of depressions may be larger or smaller. The depressions 15 have a size that can accommodate a test specimen having a diameter in the interval 1-30 mm, a suggested interval is 5-15 mm. It is an advantage if the depressions have the form of bowls, whereby the test specimens can be displaced towards the centre of the depression in a simple manner during deployment. The disk in another embodiment has been designed with continuous walls or collars that surround the depressions. The task of the collars is to prevent dust and fragments from being spread inside the equipment when the test specimens are broken. The depressions in a further embodiment are only partially surrounded by collars in order to make possible an optical study of the breakage of the test specimens during the pressurisation procedure.

The disk 13 is arranged with a turning mechanism 16, such as a motor, a disc driven by a drive belt or a toothed wheel that is driven by a motor, and it may be disassembled to allow the depressions 15 of the disk 13 to be cleaned and to allow new test specimens to be placed into the depressions. The turning mechanism 16 is provided with an angle sensor in order to locate the depression of the disc at the correct location relative to the direction of motion of the pressure device 8. Furthermore, a rotation coupling 17 is arranged between the turning mechanism 16 and the disk 13. The rotation coupling 17 is constructed with a loose structure or with play. The function of the looseness or play is to free the disk 13 from the turning mechanism 16 when the depression 15 of the disk is positioned in the correct manner, and in this way to free the mechanical contact between the disk 13 and the turning mechanism 16. This is necessary in order to avoid errors in the collection of data. The rotation of the disk 13 is coupled to the motion of the pressure device 8 in such a manner that when the pressure device 8 moves away from the disk 13, this disk is moved forward one step in order to position a new test specimen A in line with the direction of motion of the pressure device 8. The contact surface 13 of the second device comprises in another embodiment an extended element with the form of a platform intended to receive a number of test specimens and to be moved forward, in its longitudinal direction, one step during the pressing operation.

When the disk 13 has been rotated such that it has the correct position, the disk 13 is released from mechanical contact with the turning mechanism 16 by the turning mechanism being turned backwards somewhat in the opposite direction, whereby the rotation coupling 17 releases the disk 13 from the turning mechanism 16. When the pressure device 8 is displaced in a direction towards the disk 13, the disk 13 is placed in a manner that holds it in place with a depression 15 in line with the direction of motion of the pressure device 8. It should be realised that both of the contact surfaces may in another embodiment be displaceable in a direction towards and away from each other, or that only the contact surface having the form of a platform may be displaceable in a direction towards the first contact surface.

At least one loading cell 18 is arranged in line with the pressure device 8 and the disk 13 that can be displaced in a direction along the direction of motion of the pressure device 8. The measurement region of the loading cell is selected in order to correspond to the putative loads that may arise and it is coupled to the motion of the pressure device 8 and the disk 13 whereby the value of the load that is applied to the test specimen A is transferred to the computer. The disk 13 is supported at three points distributed over the surface 14 of the disk that faces away from the pressure device 8, distributed as, for example, a triangle, in which one point comprises the loading cell 18 and the two other points comprise mechanical supports 19. The loading cell 18 is located in a line with the direction of motion of the pressure device 8 at the position at which the depressions 15 of the disk 13 are placed before each test. Loading cells 18 are arranged in another embodiment at two or at all of the support points. Sources of error during the collection of data are avoided if a loading cell is arranged at each support point, which error may arise if the test specimen is located obliquely in the depression, i.e. if the test specimen is not located centrally in the depression. The loading cell 18 is in another embodiment arranged at the pressure device 8. The pressing procedure can in such an embodiment be the same as that described above, but it should be realised that the pressure device 8 may be arranged also as a fixed device whereby the surface of contact 13 is first moved forward one step in order to position a test specimen A at the correct position, after which the surface of contact 13 is displaced in a direction towards the pressure device 8 for the compression of the test specimen A.

A frame 20 is arranged at a distance from the disk for at least one image-recording means, which in this embodiment is a high-speed camera 21 with its optical system 22 directed towards the test specimen. It must be realised that it is possible to use also other types of camera, such as a video camera or another image-recording arrangement. The camera is adapted to take monochrome images, but it can be adapted in another embodiment to take colour images. The frame has been designed in such a manner that it stabilises the camera when the camera is placed in association with the press at a distance from the pressure device. Furthermore, the frame comprises adjustable guides (not shown in the drawings) in which the camera is placed in order to ensure that the camera records images from the same position relative to the pressure device every time, even if the camera has been removed for repair, exchange of optical system, or similar. The frame 20 comprises also an adjustable guide for a light source arranged in association with the pressure device. The light source comprises at least one point source 23 of light appropriately in the form of a light-emitting diode, something that is known as an "LED-spot". This point source 23 of light illuminates the side of the test specimen A that is directed towards the camera 21. At least one source 24 of background illumination, appropriately in the form of an LED-spot, is arranged at one wall of the press. It is intended that the background illumination give sharp edge contrast when recording images, and it illuminates the side of the test specimen that faces away from the camera.

The advantage of using diodes as sources of illumination is that the illumination will be concentrated at the point that it is intended to image, in this case the test specimen. The illumination is controlled by an illumination controller, which controls and limits the power supply. The diodes are illuminated in pulses, and the pulsation is synchronised with the camera, in order to obtain a maximal intensity of illumination when the image is recorded. The recording of the image is synchronised by the computer to the location of the pressure device during the compression of the pellet. A preview of the images given in real time provides the operator with the possibility of checking the adjustment of the camera and the sources of illumination, i.e. to check that the image of the test specimen is recorded in the manner that is intended. The loading cell 18, the disk 13, the pressure device 8 and the camera 21 are, as has been described above, connected to a computer (not shown in the drawings). A test specimen A is placed during testing in each depression after which the testing is sequentially carried out on all test specimens. The computer collects the measured values through the loading cell, the contact sensors of the pressure device and the camera, and stores these values in a storage medium in the form of a memory, for example a hard disk of the computer, in a manner that is previously known, after which a measurement file is generated. The measured values that are collected are, for example, sequence number of the test specimen A that is being tested, continuous measurement of the force that is applied by the pressure device 8 from the moment at which the pressure device makes contact with the test specimen until the test specimen disintegrates, i.e. until the pressure device has reached a specified reversal position, the magnitude of the distance between the pressure device 8 and the disk 13 when the pressure device makes contact with the pellet, the voltage across the contact sensor 11 , and images of the disintegration of the pellet. It should be realised that also other values may be collected, depending of the aim and nature of the analysis. The rate at which the values are collected in this embodiment is 1 ,000 per second, but it may be 200,000 per second. Furthermore, images of the compression process are recorded. In this embodiment 200 images are recorded each second, but it should be realised that the number of images recorded per second can be increased or decreased, depending on the aim of the analysis.

The measured values that are collected are used to create a numerical report and a graphical report. The numerical report is automatically created after each compression. Examples of the values that are presented in tabular form are diameter, force, classification as defined by the manner in which it disintegrates, deformation and any deviation from linearity.

The graphical report illustrates the force process during the pressure procedure and the crushing of each test specimen with respect to the motion of the pressure device. The values that have been collected are plotted in a graph whereby, for example, the force is displayed as a function of time. Pellets may be constructed according to a principle of shells, i.e. the pellet is built up in shells during the rolling of the raw material in the roller drum or roller disk, in such a manner that one shell is laid down outside of the second or through the combination of raw pellets or fragments of raw pellets of different sizes. Both mechanisms take place at the same time in a roller drum. Which of the mechanisms dominates depends in a complex manner on several process parameters and on the properties, such as the moisture content, of the raw material. Thus, force curves with similar appearances can arise from different pellet properties, and it is necessary to analyse these properties by feedback to the production of pellets. The images that are synchronised with the force curve provide information not only about the growth mechanism during the rolling operation, but also about the strengths of the bonds at different phases.

The diameter of the specimen is recorded when the pressure device makes contact with the surface of the test specimen; as described above. The force from the pressure device is recorded during the compression while images that show how the test specimen disintegrates are at the same time collected and stored. Thus it is possible for the operator to analyse individual samples based on diagrams and images after the compression of all test specimens. The images are stored at those time points that form the curve in the diagram, at every fifth point in the embodiment here, whereby the process of disintegration of each test specimen is recorded as images and to allow the process to be correlated with the diagram in the graphical report. The operator can, with the aid of this, study the curve in the diagram together with the images, and in this way determine the way in which the sample has disintegrated and draw conclusions about the structure of the test specimen. Furthermore, the computer programme that controls the camera and the illumination is provided with a function for the measurement of width. The plasticity of the test specimen A is checked with the aid of this function through a frame 25 being inserted into each image based at the centre of the test specimen A that forms the image. The outer edge of the frame 25 is limited by lines 26 that coincide with the periphery of the test specimen. The size of the test specimen in the vertical direction decreases when it is compressed, while its size in the horizontal direction increases. Up to 200 images may be recorded each second, and for each image the limiting lines 26 are displaced away from the centre of the test specimen A, whereby the relationship between the decrease in height and the increase in width of the test specimen can be used to determine the degree of plastic deformation. The present invention is not limited to what has been described above and shown in the drawings: it can be changed and modified in a number of different ways within the scope of the innovative concept specified by the attached claims.

Claims

I . An arrangement for the optical analysis of a test specimen (A) of reducible material that contains iron, c h a r a c t e r i s e d in that it comprises a frame (2) with a first device and a second device that can be displaced relative to each other and that demonstrate contact surfaces (8, 13) between which it is intended that the test specimen (A) is to be compressed during the recording of measurement data until the test specimen disintegrates, and an image-recording means (21 ) directed towards the test specimen (A) for recording the change of shape and the disintegration of the test specimen during the compression.

2. The arrangement according to claim 1 , whereby each image recording corresponds to one point in a diagram plotted of the values of the measured data.

3. The arrangement according to either of the preceding claims, whereby the test specimen is illuminated during the recording of the images.

4. The arrangement according to any one of the preceding claims, whereby a source (23) of illumination is arranged in association with the contact surfaces (8, 13) and is directed towards that part of the test specimen (A) that faces the image-recording means (21 ).

5. The arrangement according to any one of the preceding claims, whereby a source (24) of illumination is arranged in association with the contact surfaces (8, 13) and directed towards the side of the test specimen (A) that faces away from the image-recording means (21).

6. The arrangement according to any one of the preceding claims, whereby the sources (23, 24) of illumination, the contact surfaces (8, 13) and the image-recording means (21 ) are connected to and controlled by a computer in which the recorded images are stored together with the collected measurement data.

7. The arrangement according to any one of the preceding claims, whereby the image-recording means (21 ) and the sources (23,24) of illumination are arranged on the frame (2) of the contact surfaces (8, 13).

8. The arrangement according to any one of the preceding claims, whereby two or more image-recording means (21 ) are arranged evenly distributed around the test specimen (A) for the simultaneous recording of the compression.

9. The arrangement according to any one of the preceding claims, whereby the image-recording means comprises a camera (21 ) for recording monochrome images.

10. The arrangement according to any one of claims 1-8, whereby the image-recording means comprises a camera (21 ) for recording colour images.

I I . The arrangement according to any one of claims 1-8, whereby the camera comprises a high-speed camera (21).

12. The arrangement according to any one of claims 1-8, whereby the camera comprises a camera (21 ) designed for taking still images.

13. The arrangement according to any one of claims 1-8, whereby the camera comprises a video camera (21).

14. A method for the optical analysis of a test specimen (A) of reducible material that contains iron, which method is c h a r a c t e r i s e d by the steps:

- the test specimen (A) is arranged between a first device and a second device that can be displaced relative to each other and that demonstrate contact surfaces (8, 13) that face each other; - the test specimen (A) is compressed until the test specimen disintegrates while measurement data is collected;

- the test specimen (A) is imaged during the compression process by an image-recording means (21 );

- that an extended frame (25), essentially horizontal, is inserted into the image of the test specimen (A) during its recording;

- the frame (25) is outwardly limited by lines (26) that coincide with the periphery of the imaged test specimen (A);

- the outwardly limiting lines (26) follow the change of shape of the test specimen (A); - the change of shape of the test specimen (A) is measured.