Sintering mechanism of Western Australian pisolitic limonite

Australia has large reserves of pisolitic limonite. Mining recently commenced on the Yandicoogina deposit to produce a high-grade sintering ore. The ore contains about 10 wt% combined water and simulated sintering temperature profiles indicate that progressive dehydration of ore particles occurs in the temperature range 300-700 degrees C. Studies by optical microscopy show that although the dehyrdrated ore particles contain numerous cracks, there is no change in the microstructure of the ore because topotactic transformation to haematite results in the formation of compact masses of very fine-grained haematite microcrysts. When the ore is held at around 1 200 degrees C for 1 min significant recrystallisation of these microcrysts occurs, resulting in the formation of optically visible, micrometre sized haematite crystallites. Studies to simulate the behaviour of ore particles during sintering (as nuclear particles surrounded by a standard adhering fines mixture) show that the recrystallisation process occurs much earlier at temperatures of about 900 degrees C. Further studies indicate that CaO in the adhering fines mixture enhances the recrystallisation of the ore nuclei. The results of the investigation indicate that the pseudo-relict haematite in sinters produced from ore blends that contain significant levels of pisolitic limonite consists of dehydrated goethite that has undergone significant recrystallisation and grain growth, a phenomenon that is facilitated by the presence of lime derived from the sintering melt.