Effect of alumina on microstructures of iron ore sinters from the perspective of the phase equilibria of the CaO-SiO2-Fe2O3-Al2O3 system

Owing to the deterioration of iron ore, the Al2O3 concentration in iron ore increases, and thus it is important to investigate the effect of increment in Al2O3 concentration on the microstructures of iron ore sinters. During the sintering process, a melt is present in the sinter for only a few minutes, and therefore the microstructure of the sinter doesn’t reach thermodynamic equilibrium. Nevertheless, the formation process of the microstructures can be interpreted and predicted to some extent from the equilibrium phase diagram. This study investigated the liquidus isotherm in the CaO-SiO2-Fe2O3- 5 mass% Al2O3 system at 1240°C in air and the phase equilibria of silico-ferrite of calcium and aluminium (denoted by SFCA) and SFCA-I by XRD (X-ray diffraction analysis) and electron probe micro analyzer (EPMA). The following results were obtained: 1. The ferrite melt region with a high Fe2O3 concentration shifts to the lower Fe2O3 side than the liquidus isotherm in the CaO-SiO2-Fe2O3 system. 2. The compositional region of SFCA extends in the CaOꞏ3Fe2O3-4CaOꞏ3SiO2 direction than the silico-ferrite of calcium (denoted by SFC) composition region with a 0 mass% Al2O3. 3. SFCA-I is observed in the present system, which suggests that the increment in the Al2O3 concentration contributes to the stability of SFCA-I. These results imply that an increment in Al2O3 concentration in iron ore leads to a decrement in the volume fraction of the bonding phase and that the fraction of the SFCA phase increases, and those of 2CaOꞏSiO2 and slag phases decrease in the bonging phase. The SFCA-I phase is also precipitated from the slag with an Al2O3 concentration around 5 mass%.