Ilmenite coated pellet and process for reducing same

Claim 2

A coated pellet comprising a core consisting of a suitable mixture for a metallurgical reductive process and a coke matrix skin substantially surrounding the core, the core comprising an ilmenite ore, solid carbonaceous material capable of reducing the iron oxide in ilmenite to metallic iron and a flux chosen from the group consisting of alkali metal chlorides, alkaline earth metal chlorides and mixtures thereof; the weight ratio of ore to flux being in the range from about 5:1 to 1.2:1 the diameter of the core being in the range from 0.25 to 5 cms and the ratio of diameter of core to thickness of coke matrix skin being in the range from 10:1 to 10:3 said skin being in such a state that it does not crack or collapse under thermal stress thereby retaining its physical identity during reductive roasting, and the flux does not exude from the pellet.

Claim 3

A pellet according to claim 1 wherein the ilmenite and solid carbonaceous material are in the weight ratio between 1 : 01 to 1 : 03 and the weight ratio of flux to ilmenite is in the ratio 1 : 5 to 1 : 1.2.

Claim 4

A pellet according to claim 2 wherein the weight ratio of ilmenite to solid carbonaceous material is between 1 : 0.12 and 1 : 0.25 and the weight ratio of flux to ilmenite is between 1 : 2.5 and 1 : 1.4.

Claim 5

A pellet according to claim 2 wherein the flux is chosen from the group consisting of sodium chloride, potassium chloride and mixtures thereof.

Claim 6

In the process for reducing ilmenite ore by reductive heating of pellets containing the ore, the improvement which comprises utilizing, as the pellets, coated pellets comprising a core and a coke matrix skin substantially surrounding the core, said core comprising ore, solid carbonaceous material capable of reducing the iron oxide in ilmenite to metallic iron, and a flux chosen from the group consisting of alkali metal chlorides, alkaline earth metal chlorides and mixtures thereof; the weight ratio of ore to flux being in the range from about 5:1 to 1.2:1 the diameter of the core being in the range from 0.25 to 5 cms and the ratio of diameter of core to thickness of coke matrix skin being in the range from 10:1 to 10:3 said skin being in such a state that it does not crack or collapse under thermal stress thereby retaining its physical identity during reductive roasting, and the flux does not exude from the pellet, said pellets retaining their pellet form during said reductive heating and having a reduced tendency to be crushed or to coalesce.

Claim 7

In the process for reducing ilmenite ore by reductive heating of pellets containing the ore, the improvement which comprises utilizing, as the pellets, coated pellets comprising a core and a coke matrix skin substantially surrounding the core, said core comprising ore, solid carbonaceous material capable of reducing the iron oxide in ilmenite to metallic iron, and a flux chosen from the group consisting of alkali metal chlorides, alkaline earth metal chlorides and mixtures thereof; the weight ratio of ore to flux being in the range from about 5:1 to 1.2:1 the diameter of the core being in the range from 0.25 to 5 cms and the ratio of diameter of core to thickness of coke matrix skin being in the range from 10:1 to 10:3 said skin being in such a state that it does not crack or collapse under thermal stress thereby retaining its physical identity during reductive roasting, and the flux does not exude from the pellet, said pellets retaining their pellet form during said reductive heating and having a reduced tendency to be crushed or to coalesce.

Claim 8

A process of making the coated pellets according to claim 5 wherein a core material consisting ore, solid carbonaceous material and the flux is coated with coke precursor and the coated pellet is heated under coking conditions.

Claim 9

A process according to claim 6 wherein the coke precursor comprises a coking coal in admixture with inerts.

Claim 10

A process according to claim 7 wherein the inerts are chosen from the group consisting of coke, coal chars and graphite.

Claim 11

A process according to claim 7 wherein the weight ratio of coking coal to inerts is in the range from 1 : 2 w/w to 9 : 1 w/w.

Claim 12

A process according to claim 6 wherein the pellet is coked at a rate of heating between 50° to 200°C per minute and the coke precursor comprises a mixture consisting of from 50 to 60 w/w % coking coal and from 40 to 50 w/w % of inerts.

Claim 13

A process according to claim 6 wherein the pellet is coked at a slow rate of heating between 5° and 25°C per minute and the coke precursor comprises a mixture consisting of from 70 to 90 w/w % of coking coal and from 10 to 30 w/w % of inerts.