The present invention concerns the use of a magnesium-including compound as binder for producing metallic ore fluxed pellets, in particular iron ore fluxed pellets, said magnesium-including compound comprising semi-hydrated dolime fitting the general formula aCa(OH).sub.2.Math.bMg(OH).sub.2.Math.cMgO, a, b, and c being weight fractions wherein the weight fraction b of Mg(OH).sub.2 is between 0.5 and 19.5 % by weight with respect to the total weight of said semi-hydrated dolime.

Composite particles are used in combination with ore particles in an ore-refining or purification process, such as in a steel- or iron-making process. The composite particles comprise a core, which may be an aggregate of limestone, dolomite, or another ore particle. The core is surrounded by a coating layer of a metal dust and a binder. The metal dust may be iron oxide dust, which, along with limestone, is prevalent in the iron smelting process anyway. In this way, the composite particles help to recycle otherwise wasted and hazardous iron dust. The binder may be mineral clay such as bentonite, montmorillonite or kaolinite, and may comprise about 2-10% by weight of the particle.

Composite particles are used in combination with ore particles in an ore-refining or purification process, such as in a steel- or iron-making process. The composite particles comprise a core, which may be an aggregate of limestone, dolomite, or another ore particle. The core is surrounded by a coating layer of a metal dust and a binder. The metal dust may be iron oxide dust, which, along with limestone, is prevalent in the iron smelting process anyway. In this way, the composite particles help to recycle otherwise wasted and hazardous iron dust. The binder may be mineral clay such as bentonite, montmorillonite or kaolinite, and may comprise about 2-10% by weight of the particle.

A method for producing briquettes from pellet fines, DRI sludge, DRI fines and dust from DRI dedusting systems and, in this way, reincorporating same into steel production processes, thereby contributing to the re-use of the by-products of these processes, as well as minimizing the stocks of these types of materials and, consequently, helping to improve the environment. The invention comprises: grinding and sieving the pellet fines and the DRI sludge; sieving the DRI fines; storing the dust from DRI dedusting systems; briquetting with roller presses, using liquid sodium silicate and bentonite or composite Portland cement as binders; sieving the briquettes; shredding the edges and waste of the fresh briquettes; and curing in order to improve the physical properties thereof, such as strength. Once cured, the fresh briquette can be stored or sent directly to direct-reduced iron production processes for use as part of the feedstock for reduction ovens or reactors.

A method for producing briquettes from pellet fines, DRI sludge, DRI fines and dust from DRI dedusting systems and, in this way, reincorporating same into steel production processes, thereby contributing to the re-use of the by-products of these processes, as well as minimizing the stocks of these types of materials and, consequently, helping to improve the environment. The invention comprises: grinding and sieving the pellet fines and the DRI sludge; sieving the DRI fines; storing the dust from DRI dedusting systems; briquetting with roller presses, using liquid sodium silicate and bentonite or composite Portland cement as binders; sieving the briquettes; shredding the edges and waste of the fresh briquettes; and curing in order to improve the physical properties thereof, such as strength. Once cured, the fresh briquette can be stored or sent directly to direct-reduced iron production processes for use as part of the feedstock for reduction ovens or reactors.

A process for upgrading waste powders of the mining industry containing iron oxides is described, which includes preparing a mixture containing powder based on iron oxides, an aqueous dispersion of a thermosetting resin and optionally carbon powder, and a catalyst of acidic nature; kneading the mixture at a temperature between 5 and 100° C. to form a homogeneous paste, and granulating such homogeneous paste at a temperature between 100 and 300° C., thus obtaining granules of powder based on iron oxides and optionally carbon powder bound by the resin that has been polymerized.

A process for upgrading waste powders of the mining industry containing iron oxides is described, which includes preparing a mixture containing powder based on iron oxides, an aqueous dispersion of a thermosetting resin and optionally carbon powder, and a catalyst of acidic nature; kneading the mixture at a temperature between 5 and 100° C. to form a homogeneous paste, and granulating such homogeneous paste at a temperature between 100 and 300° C., thus obtaining granules of powder based on iron oxides and optionally carbon powder bound by the resin that has been polymerized.

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.

The present invention relates to a process for the production of iron ore fines agglomerate, resistant to handling, transport, and contact with water. The process consists of mixing iron ore fines with sodium silicate, nanomaterials, catalyst, fluxes and plasticizer; adjusting the moisture of the mixture; agglomerating the mixture by pelletizing, briquetting or extrusion; performing curing at room temperature. The process does not require energy input for heat treatment and allows obtaining an agglomerated product with high physical and metallurgical performance to replace metallic load, including sinter, in reduction furnaces, without the emission of harmful gases such as CO.sub.2, dioxins, furans, and SO.sub.x.