Agglomeration process in agglomeration plants is quite sensitive to changes in input feed material characteristics. End-to-end optimization of the agglomerate process by combining all the units is difficult due to unique complexities and challenges associated with combining the individual process outputs. A method and system for optimizing the operation of an agglomeration plant has been provided. The system performs real time optimization on integrated wet agglomeration and thermal agglomeration process which subsequently increases the plant productivity and agglomerate quality and minimizes the operating cost and emissions from the plant. The optimization process involves various steps such as receiving data, pre-processing of data, prediction using physics-based and data-driven models of agglomeration plant, and optimization execution and configuration. The process also involves continuous monitoring of model performance and self-learning of the models in case of a performance drift. The system is also configured to estimate the key performance parameters of agglomeration plant.

Agglomeration process in agglomeration plants is quite sensitive to changes in input feed material characteristics. End-to-end optimization of the agglomerate process by combining all the units is difficult due to unique complexities and challenges associated with combining the individual process outputs. A method and system for optimizing the operation of an agglomeration plant has been provided. The system performs real time optimization on integrated wet agglomeration and thermal agglomeration process which subsequently increases the plant productivity and agglomerate quality and minimizes the operating cost and emissions from the plant. The optimization process involves various steps such as receiving data, pre-processing of data, prediction using physics-based and data-driven models of agglomeration plant, and optimization execution and configuration. The process also involves continuous monitoring of model performance and self-learning of the models in case of a performance drift. The system is also configured to estimate the key performance parameters of agglomeration plant.

Some variations provide a carbon-negative carbon product that is characterized by a carbon intensity less than 0 kg CO.sub.2e per metric ton of the carbon-negative carbon product, wherein the carbon-negative carbon product contains at least about 50 wt % carbon. In some embodiments, the carbon intensity is less than −500 kg CO.sub.2e per metric ton of the carbon-negative carbon product. Other variations provide a carbon-negative metal product (e.g., a steel product) that is characterized by a carbon intensity less than 0 kg CO.sub.2e per metric ton of the carbon-negative metal product, wherein the metal product contains from 50 wt % to 100 wt % of one or more metals and optionally one or more alloying elements. In some embodiments, the carbon-negative metal product is characterized by a carbon intensity less than −200 kg CO.sub.2e per metric ton of the carbon-negative metal product. The carbon-negative metal product can contain a wide variety of metals.

Some variations provide a carbon-negative carbon product that is characterized by a carbon intensity less than 0 kg CO.sub.2e per metric ton of the carbon-negative carbon product, wherein the carbon-negative carbon product contains at least about 50 wt % carbon. In some embodiments, the carbon intensity is less than −500 kg CO.sub.2e per metric ton of the carbon-negative carbon product. Other variations provide a carbon-negative metal product (e.g., a steel product) that is characterized by a carbon intensity less than 0 kg CO.sub.2e per metric ton of the carbon-negative metal product, wherein the metal product contains from 50 wt % to 100 wt % of one or more metals and optionally one or more alloying elements. In some embodiments, the carbon-negative metal product is characterized by a carbon intensity less than −200 kg CO.sub.2e per metric ton of the carbon-negative metal product. The carbon-negative metal product can contain a wide variety of metals.

A process for pelletizing particles of a fine mineral ore, the process comprises the steps of a) mixing the particles of a fine mineral ore with a binder composition to obtain a pellet feed, b) forming the pellet feed into balls, c) drying the balls to form dried balls, d) preheating the dried balls at 60 to 105° C. until constant weight to form preheated balls, e) subsequently heating the preheated balls to a temperature of 1200° C. to 1400° C. to obtain pellets,
wherein the binder composition comprises a) at least one colloid agent which exerts a cohesive force on the particles of a fine mineral ore forming the pellets, and b) at least one synthetic polymer which disperses the particles of a fine mineral ore in the pellets,
wherein the synthetic polymer is a maleic acid/acrylic acid or a maleic acid/methacrylic acid copolymer.

A process for pelletizing particles of a fine mineral ore, the process comprises the steps of a) mixing the particles of a fine mineral ore with a binder composition to obtain a pellet feed, b) forming the pellet feed into balls, c) drying the balls to form dried balls, d) preheating the dried balls at 60 to 105° C. until constant weight to form preheated balls, e) subsequently heating the preheated balls to a temperature of 1200° C. to 1400° C. to obtain pellets,
wherein the binder composition comprises a) at least one colloid agent which exerts a cohesive force on the particles of a fine mineral ore forming the pellets, and b) at least one synthetic polymer which disperses the particles of a fine mineral ore in the pellets,
wherein the synthetic polymer is a maleic acid/acrylic acid or a maleic acid/methacrylic acid copolymer.

The present invention relates to the use of hydrophobically associative copolymers as binders for pelletizing metal containing ores such as iron containing ores. The copolymers comprise monomer units derived from at least one hydrophobically as sociative monomer, preferably at least one unsaturated hydrophobically associating monomer.

The present invention relates to the use of hydrophobically associative copolymers as binders for pelletizing metal containing ores such as iron containing ores. The copolymers comprise monomer units derived from at least one hydrophobically as sociative monomer, preferably at least one unsaturated hydrophobically associating monomer.

The application describes pellets comprising particulate iron ore and between 0.05 and 1.0% by weight of an organic binder.

The use of such pellets in electric arc furnaces to produce steel is also described.

Binder compositions for agglomerating iron ore fines are provided, the compositions comprising: one or more types of modified starch and one or more types of synthetic dry polymers. A process for preparing iron ore pellets with the binder compositions is also provided, the process comprising: (i) adding a binder composition to particulate iron ore to form a mixture; and (ii) forming the mixture into pellets.