BREX (EXTRUSION BRIQUETTES) (FOR PRODUCTION OF FERRO ALLOYS

Bizhanov Aytber Makhachevich1; Richard Binion Steele1, Podgorodetskyi Gennady

Stanislavovich2, Ph.D., Kurunov Ivan Filippovich4, ScD, Tech. Sc., prof., PhD.,Tech.Sc.,
Dashevskyi Victor Yakovlevich3, ScD. Tech.Sc., prof., Korovushkin Vladimir Vassilyevich2,
ScD. Geol. & Mineral. Sc., prof.
1
. J.C. Steele & Sons, Inc. USA, Statesville, NC. E-mail: abizhanov@jcsteele.com,
2
. National University of Science and Technology "MISA", Moscow, Russia
3
. A.A.Baikov Institute of Metallurgy and Materials Science, Russian Academy of Sciences,
Moscow, Russia
4
. JSC "Novolipetsk Iron and Steel Works", Lipetsk, Russia

The results of laboratory studies, full-scale pilot and industrial trials, and industrial use of Brex
(extrusion briquettes) made of anthropogenic and natural materials, and fuels for ferro alloy
production have been documented. The opportunity to reduce power and coke consumption
together, with increased recovery of the main component based on the briquetted charge, has
been demonstrated.

Keywords: Brex, extrusion briquettes, stiff extrusion vacuum; Steele Extruder, ferro alloys,
ferronickel, laterite nickel ore, ferro silico manganese, aspiration dust, electric ore smelting
furnace.

The stiff extrusion with vacuum process developed by J.C. Steele & Sons, Inc. allows for
efficient agglomeration of various anthropogenic and natural materials and fuel, conferring
metallurgical properties to Brex (extrusion briquettes) that make them an attractive component of
the charge for most metallurgical furnaces [1-3]. The article reviews issues related to the
application of this technology for ferro alloy production.

Steele’s first successful implementation in this sector involved the use of Brex in the charge for
ferronickel smelting. At the BHP-Billiton company enterprise in Cerro Matoso (Monte Libano,
Colombia), resources identified in 2006 amounted to 99 million tons containing 1.54% nickel.
Three Steele high-production 90 Series Extruders (Fig. 1) agglomerated lateritic nickel ore fines
(dust) subsequent Brex metallization in rotary kilns and their use as components of the charge for
ferronickel smelting in electric furnaces. Dust accumulates during lump ore grinding in the
rotary kilns and in furnace gas de-dusting systems. Total Brex production amounts to
approximately700,000 tons annually.

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Fig. 1. Lateritic nickel ore dust agglomeration in a Steele 90 Series Extruder in Colombia.
The extrusion line at Cerro Matoso consists of a mixer based on a clay mill with a single shaft,
vacuum mixer and extruder with a vacuum system. A characteristic feature of lateritic nickel ore
sintering by stiff extrusion is its binder-free operation. A single extruder’s average performance
is 70 tons per hour. According to the results of operation of industrial extrusion lines in 2004 -
2010, the total cost of Brex production equaled 2.1 USD/ton. The service life of the main
equipment is 30-plus years.
Originally, the Cerro Matoso operation used on pelletizing and roller briquetting to agglomerate
laterite ore dust. In 1996, after a series of comparative tests involving various methods of laterite
ore fines agglomeration and processing (pelletizing, sintering, plasma furnace and extrusion),
BHP Billiton chose Steele stiff extrusion. This was the only technology that produced an
agglomerated product with technical specifications required for size, shape, heat and cold
exposure endurance (both in rotary kiln and electric furnaces), while providing high performance
at low cost. The production of nickel as a ferronickel component by BHP Billiton in Cerro
Matoso amounts to 50,000 tons per year, with 10,000 tons produced from Brex. The nickel
content in production is 35% [5]
Successful results shown in Cerro Matoso attracted VALE, another leading mining enterprise.
The company’s plant in Onça Puma (Brazil, identified resources - 423.3 million tons, nickel
content - 1%) has also been equipped with three extrusion lines for lateritic nickel ore fines
agglomeration (Fig. 2) with annual Brex production at 700,000 tons.

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Fig. 2 Installation of JC Steele equipment at the VALE plant in Mineração Onça Puma (Brazil)
Systematic studies of stiff extrusion agglomeration in the ferro alloy industry were first made by
the authors of this article in 2010, when we studies the metallurgical properties of Brex using
natural and man-made raw materials for ferrochrome and manganese ferro alloy smelting.

At the request of one of the largest producers of ferrochrome, the Steele laboratory in the United
States manufactured formulations based on chrome ore concentrate and coal, along with dust-
based formulations derived from the aspiration systems used by ferrochrome manufacturing
industry (the NITU MISA in Moscow tested these formulations).

Table 1 Composition of brex based on chrome ore

Brex components No.1 No.2 No.3

Chromite ore concentrate 76.2 71.5 15.0
Aspiration dust ferrochrome 67.0
Coal 19.1 23.8 15.0
Portland 4.7 4.7 3.0

The materials above, after mixing and adding of the required amount of water for extrusion
(15.7%, 14.7% and 16.1%, respectively), showed high plasticity and extruded easily with the
formation of strong green Brex. After a 24-hours natural condition test hardening, we measured
mechanical strength for compression and splitting resistance. The results are shown in Table 2.
As can be seen, even for laboratory brex, adding less than 5% of Portland cement produces the
strength values required by specifications. If Steele’s expertise is any guide, the proportion of
binder used in industrial extruders operation is much lower than in laboratory produced Brex.

Table 2 Mechanical strength test results for brex composition 1

Brex No. Splitting, N/mm2 Compression, N/mm2

1 4.78 8.46

2 2.88 8.06

3 3.33 5.86

Studies of the behavior of these Brex in ore-smelting furnaces and metallization ovens continues
in the U.S. and the results will be presented in a separate paper.

In 2010-2011, at the request of one of the largest producers of manganese ferroalloys, the authors
of this article carried out complex scientific research, prompting a pilot program highlighting the
use of a furnace charge, with a high content of Brex based on manganese concentrate and dust
derived from industrial aspiration systems, for silicomanganese smelting.

Based on the analysis of the available natural and man-made materials and fuel, we studied the
following Brex compositions in accordance with the terms of reference (Table 3).

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Table 3 Composition of Brex based on manganese concentrate and aspiration dust derived from
the silicomanganese production process

Brex components Brex No.

No.1 No.2 No.3 No.4 No.5
Manganese ore concentrate 70 50 56 - -
Aspiration dust derived from silicomanganese 30 50 24 15 -
production
Silicomanganese breakage fines breeze - - - 85 -
Coke screenings - - 15 - 94.5
Portland 3* 5* 5 5* 5
Bentonite - - - - 0.5
* Over 100%.

We tested Brex No. 1 and No. 2, based on a mixture of manganese concentrate and dust derived
from the aspiration systems used in silicomanganese production, in the laboratory, along with
Brex No. 3, with added coke fines, in the lab, using Portland cement as a binder (None of the
Brex included Bentonite.)
We noted distinctive features of manganese oxides dissociation consideration while testing Brex
No. 3 (see: Table 4).

Table 4: Dissociation of manganese oxides

Chemical reaction lg pO 2 (Па) = A T + B Т, K

4MnO2(т) = 2Mn2O3(т)+O2 lg pO 2 = − 9,860 T + 15.98 560–640
6Mn2O3(т) = 4Mn3O4(т)+O2 p 810–910
lg O 2 = -11,740/T+ 13.92
2Mn3O4(т) = 6MnO + O2 lg pO 2 = -23,910/T+ 17.73 1,270–1,350
2MnO (т) = 2Mn(г) + O2 lg pO 2 = -24,739/T+ 14.00 1,602–1,747

In the presence of carbon, oxides MnO2, Mn2O3 and Mn3O4 are known to interact both with solid
carbon and carbon monoxide. Manganese oxide (Mn interacts with solid carbon [5]. Manganese
ore pellets containing coal or coke breeze, when subjected to heat, would have their manganese
oxides restored. However, this process will take place only at the expense of solid carbon. At the
same time, there is a process of oxides dissociation and recovery of higher oxides of manganese
with carbon monoxide.

In the real melting temperature, dissociation proceeds to the oxide MnO, which is then reduced
by reacting with solid carbon:
MnO + (1 + x) C = МnСх + CO

ΔGT = 196,293 – 1,23T, J / mol.

In case of close contact of manganese materials in the charge with the carbon contained in brex,
recovery of higher oxides may involve carbon:

2MnO2 + C = Mn2O3 + CO,

3Mn2O3 + C = 2Mn3O4 + CO,
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Mn3O4 + C = MnO + CO.
Two factors determine the amount of reducing agent (carbon) contained in Brex. On the one
hand, close contact with the burden constituents has impact on recovery kinetics. In this case, it
would be reasonable to introduce the required amount of reducing agent to the Brex during the
reducing process. Furthermore, the presence of carbon in Brex enhances conductivity of this
part of the charge. On the other hand, increasing the reducing agent in Brex reduces its
mechanical strength. Potential increased flow of the reducing agent can be offset with technical
and economic measures, particularly increasing extraction of manganese to metal and decreasing
power consumption. A detailed study of the interaction of these factors and the search for the
optimal quantities of carbon in Brex will be the subject of further investigation.

We used thermal analysis to identify the transformation that can take place in Brex when heated.
Our studies used the STA 449 C instrument (Germany) in argon ambience, heating powdered
samples weighing 50-70 mg in the temperature range 20 - 1400oC at 20o/ min. The
corresponding thermal image is shown in Fig. 3-5.

Figure 3 Brex sample No.1 material thermogram.*

* Diagram symbols: left hand vertical - TG /%; right hand vertical - DSK/(MWt/mg) ↑ exo;
Maximum peak and inflection values are marked by “+”: 803.0oC, 0.5005 MWt/mg; 936.2 oC,
0,3773 MWt/mg; 1,274.4 oC, 0.207 MWt/mg; 1,093.9 oC, 0, 1833 MWt/mg; 1,165.3 oC, 0,1833
MWt/mg; 1,213.6 oC, 0.1433 MWt/mg; horizontal line - remaining mass; 88.62% (1,299.9 oC);
bottom line – temperature.

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Figure 4 Brex sample No. 2 material thermogram.*

* Diagram symbols: left hand vertical TG/%; right hand vertical - DSK/(MWt/mg) ↑ exo;
Maximum peak and inflection values are marked by “+”: topmost blue horizontal line 790,8oC,
0,62755 MWt/mg; second topmost horizontal line (green) - remaining mass -7,89%; horizontal
lines in the center (blue): 1,100.8oC, 0.2522 MWt/mg; 1,137.1oC, 0.2228 MWt/mg; 1,186.7oC,
0.1882 MWt/mg; botton green horizontal line - mass variation -0.85%; (1,299.9 oC); bottom
horizontal line (green) - remaining mass -87.30% (1,399.8 oC); bottom line – temperature.
The above figures show that the mineral composition of briquettes 1 and 2 is similar. Mass loss
of the samples 1 and 2 has been registered at 12.7 - 11.38%. These mass losses are primarily
associated with the removal of constituent water and moisture hydrates. In general, the water
content range in samples 1 and 2 has been 6 - 8%. At temperatures above 1,000°C carbonate
decomposition begins, which ends at 1,400oC. At temperatures close to 800°C the pronounced
exothermic effect is, probably, due to the beginning of the solid-phase interaction in the system
FeO - SiO2 - CaO.
Fig. 5 shows an endothermic peak in the range 150 - 200oC accompanied by the mass loss of
1.69%. This is due to the removal of moisture sorption from the sample. In the range of 300-
500oC, no pronounced endothermic peaks were observed, but there has been a loss of mass. This
can be attributed to the stretched reduction of MnO2 to Mn2O3. In the same range, a phased
transformation of manganite (MnOOH) into kurnakit (Mn2O3) occurs by the reaction:
2MnOOH = Mn2O3 + H2O
At 594.8oC, the DSC curve shows an inflection accompanied by a loss of mass. This
endothermic effect can be attributed to the effect of restoration of lower oxides of manganese to
Mn3O4. The exothermic peaked at 742.8oC unaccompanied by weight loss and its effects can be
explained byre

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crystallization or crystallization of amorphous phases. Excesses at 783.7 and 867.9oC are also
not accompanied by weight loss, so they cannot be associated with the restoration of manganese
in this range. According to [6], there should be no evident thermal effects. Apparently, there are
also effects of a structural change at play. The endothermic effect with a maximum value
reached at 1,031.7 oC is associated with the reduction of Mn3O4 to MnO, because it is
accompanied by weight loss, and the effect at 1,056.1oC is associated with the phase change in
the ferric phase. Endothermic peak with a maximum at 1,122.7oC result from the formation of
manganese carbide Mn3C, which recovers carbon manganese from MnO.

Fig. 5 Brex sample № 3 thermograms*

* Diagram symbols: left hand vertical TG/%; right hand vertical - DSK/(MWt/mg) ↑ exo;
Maximum peak and inflection values are marked by “+”: topmost blue horizontal lines 783,7oC,
867.9 oC,742.8 oC; topmost horizontal line (green) - mass variation -1,69%; horizontal lines in the
center (blue): 594.8oC, 1,031.7 oC, 1,056.1oC; horizontal line (green) - mass variation – 1.86%;
horizontal line in the center (blue): 1,213.2oC; horizontal line (green) - mass variation – 1.86%; -
0.13%, -0.18%; horizontal line (green) – remaining mass – 96.05% (1,399.8oC); bottom line –
temperature.

Consequently, the thermal effects observed at 1,122.7 oC and 1,213.2oC have been associated
with the phase changes of manganese component of Brex.

Thermal stability is an important indicator of the metallurgical properties in Brex. This

parameter determines the behavior of Brex in subsequent metallurgical processing (fusion,
restoration). High thermal stability in Brex supports improved performance of metallurgical
units.

We tested the thermal stability of Brex by feeding samples into a furnace pre-heated to 1,200°C
and 1,500°C, followed by aging in the furnace for five minutes. We cut Brex into samples of 50
mm, placed them in a tungsten wire basket and then melted them in a Tamman furnace. We
weighed the specimens before and after thermal aging specimens and maintained the furnace at
ambient air. Pictures of samples No.1 and No. 3, before and after thermal treatment, are shown in
Fig. 6-7.

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Fig.6 Sample No.1 before and after thermal treatment at t = 1,200оС

Fig. 7 Sample No.3 before and after thermal treatment at t = 1200oC.

Thermal test results showed a high thermal stability of all Brex samples.

Brex Samples No. 4 (Table 1) made of silicomanganese breeze also endured a 15-minute stay in
the furnace at 1,200°C without destruction or loss of form. When submerged into the molten slag
at 1,580°C, samples melted. It took ten minutes to complete melting of the sample (length and
diameter of 25 mm). The test results for Brex sample No. 5, based on coke fines, are provided in
[3]. It has been shown, in particular, that binder content (5%) as well as the CSR (20%) and CRI
(45.6%) parameters are significantly higher in such samples than in roller coke pellets made by a
well-known manufacturer (binder content - 15%, CSR - 1.1%, and CRI - 54.9%). Comparative
tumbler-test analysis of hot and cold samples of such pellets and Brex showed the following
results: in cold test - brex 75%, pellets - 63.6%; in hot test - Brex 74%, pellets - 71%.

Based on these results, it is apparent that all of the Brex samples have sufficiently high
temperature resistance. The mineralogical composition of Brex facilitates the formation of low-
melting eutectics, which determines their high melt rate. All Brex samples are positively
characterized by a high thermal strength without pre-drying. To conduct the previously noted
pilot program, we selected Brex No. 1 samples, with a minimum consumption of cement (3%),
in the first phase. Before manufacturing 2,000 tons of this sample, an independent laboratory (L.
Robert Kimball & Associates in Ebensburg, Pennsylvania) tested the Brex. To determine the
strength characteristics of manganese-based Brex, two samples of this type of charge material
were selected. The strength of Brex from the first sample group amounted to 120 kg/cm2, while
for the second sample group of Brex was 211 kg/cm2.
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Brex were manufactured in the United States at a plant equipped with a Steele 75 Series
Extruder, (average capacity of 53 tons per hour) and then shipped about 1600 KM by barge to
the SiMn smelter. Trucks handled transport from the dock to the open warehouse at batch plant,
with subsequent conveyor feeding into the furnace hopper. The total number of reloading and
handling operations from the date of manufacture to Brex melting in an industrial ore-smelting
furnace totaled about 20. Even with all this handling, the Brex attrition rate was less than 10%,
as measured by particles less than 6mm.

Fig.8 Barge unloading. Brex handling (approx. 20): extruder>conveyors, dumper> stacks>
loader> truck> stack> loader> bunker> grapple> barge> grapple> bunker> conveyor
belts>dumper> stack> loader> storage plant> furnace.

Brex were melted in industrial ore-smelting furnaces at the ferro alloy plant in the U.S. A
detailed account of that pilot program will be presented in a separate publication. The main
results are summarized in [7].

Conclusion

Laboratory findings and pilot program results offer convincing evidence of the value of stiff
extrusion agglomeration of natural and man-made materials and fuel, combined with subsequent
use of Brex as an essential charge component (up to 50% of the ore) for industrial ore-smelting
furnaces. Findings obtained in a large-scale industrial initiative are unique and have no
precedent in previous conventional methods of pelletizing. On all important parameters , the use
of Brex in the furnace charge in the process of silicomanganese smelting permits considerable
savings in energy and coke consumption, and increased extraction of the main component of the
furnace at no expense to furnace performance. Given the low cost of Brex production (less than
10 USD per ton, including the binder) and smaller binder consumption (3%) than other
agglomeration methods, we conclude that significant improvement is possible, in general, in the
technical and economic performance of the ferro alloy smelting process.
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Bibliographical list

1. Dalmia J.C., Kurunov I.F., Steele R.B., Bizhanov A.M. New generation of briquettes:
Production and smelting of new generation briquettes in a blast furnace. / / “Металлург”
(Metallurgist), 2012, No. 3, Pp. 39-41.

2. Bizhanov A.M., Kurunov I.F., Durov N.M., Nushtaev D.S., Ryzhov S.V. Mechanical
strength of brex. Part 1 / / “Металлург” (Metallurgist), 2012, No. 7, Pp. 32-35.

3. Kurunov I.F., Bizhanov A.M., Tikhonov D.N., Mansurova N.R. Metallurgical properties of
brex / / “Металлург” (Metallurgist), 2012, No. 6, Pp. 44-48.

4. L.V. Igrevskaya. Trends in the nickel industry. Russia and the world. // M: “Научный мир”
(Scientific World}, 2009, 268 P.

5. M.I. Gasik. Manganese. //M.: “Металлургия” (Metallurgical Engineering), 1992, 608P.

6. V.P.Ivanova et al. Thermal analysis. // L.: "Недра" (Mineral Resources), 1974, 400.

7. R.B.Steele, A.M.Bizhanov, I.F.Kurunov, G.A.Farnasov Brex for the Ferro alloys

production (Full-scale trial results). Submitted to INFACON XIII, Kazakhstan, Almaty, June 9-
12 2013.

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