IRON SULPHIDE COMPOSITIONS

Abstract: A composition comprising iron disulphide for metallurgical purposes, characterised in that the iron disulphide is in the form of compacted aggregates. A range of sulphur contents is provided for by the presence of ferrous sulphide or sulphur. The composition may contain one or more binders such as an organic binder, or an inorganic binder comprising for example a hydraulic material, a silicate, an aluminate, a synthetic or mineral clay, calcium hydroxide or gypsum and is preferably pressure-formed at a pressure greater than 10<3> N/cm<2>. Briquettes or pellets according to the invention may be added directly to a ferrous metal melt.

Description: Iron sulphide compositions This invention relates to iron sulphide compositions for metallurgical use and to a process for their production. Raw pig iron used in the production of steel may contain sulphur which may have been introduced into the blast furnace charge as a contaminant of coke. Some of this sulphur may form hydrogen sulphide and carbonyl sulphide gases which may come off from the charge or may react with calcium oxide and ferrous oxide to form the corresponding sulphides. The ferrous sulphide so formed may react with further calcium oxide to form further calcium sulphide which may be removed with the slag. The extent and balance of these mechanisms depends on the temperature and precise composition of the furnace charge but in at least some pig iron products there may be a relatively low content of sulphur. In the production of steel from pig iron the oxidising stage, designed mainly to reduce the carbon content of the iron, also acts to remove other minor constituents and, at this stage sulphur may come off as sulphur dioxide. The effect of a content of sulphur on steel may be detrimental in reducing the strength and impact resistance of the product. The sulphur tends to separate out in combined form at grain boundaries and this may lead to the formation of zones or lines of weakness in the steel. However, a limited content of sulphur may be beneficial in that it tends to improve the machmability of the steel. Commercial steels, therefore, generally have a low and carefully controlled content of sulphur of at least obout 0.005% and within a normal maximum content of about 0.06% or, more usually, about 0.04% by weight. Where a relatively pure pig iron is used as the raw material for steel production there may be a reguirement for the precisely controlled addition of a small proportion of sulphur to the molten steel . Iron disulphide, commonly available as iron pyrites, may be used as a source of sulphur in metallurgical processes. Some grades of iron pyrites, such as the finely divided flotation grade of this material, or fines of other grades, may be difficult to handle or to process. Irrespective of grade, iron pyrites is electrically conductive and slightly magnetic and may be subject to severe problems of dusting. It may be difficult to distribute homogeneously in throughout a charge of molten metal. The present invention has as an object to facilite the use of iron disulphide as a sulphur carrier in metallurgy. According to a first aspect the invention provides an iron disulphide composition suitable for addition to molten ferrous metals or for other uses. According to a second aspect the invention provides sulphur-containing compositions suitable for a similar range of uses comprising iron disulphide having a sulphur contents departing from that of the iron disulphide and determmable in a range of from about 30% to 90% by weight, calculated as S. According to further aspects the present invention provides a means of including elemental sulphur satisfactorily into a molten ferrous metal and also a low energy process for the production of the aforesaid compositions. The composition provided by the first aspect of the invention comprises iron disulphide for metallurgical purposes, for example for addition to a melt of a ferrous metal, characterised in that the iron disulphide is in the form of compacted aggregates, i.e. agglomerates, such as, without limitation thereto, briquettes or pellets. Such aggregates suitably have a largest dimension of from about 1 to about 12 centimeters, more usually from about 2 to about 8 centimeters and may be of approximately spherical, ovoid, rhomb-shaped or other convenient shape or may be formed into a sheet which may be cut or broken to the desired size. The iron disulphide particles of which these aggregates are made, or other particles included therein, may comprise at least 80%, or up to 100%, by weight of particles of at least 0.001 mm, preferably at least 0.01 mm in diameter. Preferably the iron disulphide or other particles comprise at least 80% by weight smaller than 0.1 mm. The iron disulphide or other particles may comprise larger particles, for example preferably below 5 mm in diameter subject, of course, to being sufficiently smaller m diameter than the required aggregates to enable those aggregates to be formed, as a practical matter, by compaction. The iron disulphide may have zinc as a main impurity but this metal is preferably present in less than 0.2% calculated as Zn. The compacted aggregates of the present invention may be readily metered into a steelmakmg ladle and mixed into the melt and their density of about 4.0 to 5.5 g/cc makes them compatible with the melt. They are also susceptible to selection of size, or size distribution, to facilitate dosage control. The process provided by the further aspect of the invention comprises forming an aggregation mixture of the iron disulphide particles and a binder or binders and shaping the mixture under conditions such that the binder is effective. Aggregation can m theory be achieved m the case of some finely divided materials without the addition of a binder or binders by the utilisation of van der Waals or electrostatic forces or, in the case of some ferromagnetic substances, magnetic forces. In the case of iron disulphide the use of a binder is necessary to enable the compacted aggregates to mix homogeneously with the steel melt and to retain their form during storage or use. Inorganic binders are particularly suitable for use according to the invention. Such binders may be inorganic salts such as the sulphates of the alkaline earth metals, of aluminium or of iron, the alkaline earth metal alummates, particularly but without limitation calcium aluminate, calcium oxide or hydroxide, or silicates such as alkali metal silicates or naturally occurring or synthetic aluminium or magnesium silicates such as clay minerals or synthetic analogues thereof. Calcium aluminate in the form of ciment fondu is particularly suitable. This material has a contant of calcium silicate and of iron oxide and it is particularly compatible with pyrites as a binder/lubricant in pressure-briquetting or pelleting processes. Many of the other inorganic binders, for example the silicates, alummates or clays, also have a lubricating action, which makes them suitable for use in a pressure-forming process, as well as a binding action and may very suitably be used in combination with other binders identified herein. Hydraulic inorganic binders such as cements of various kinds may also be used. Gypsum is a further example of a suitable binder. Organic binders are also suitable for use in the practice of the invention. Examples of such binders are the naturally occurring, processed or synthesised and preferably colloidal polysaccharides. Such materials give immediate or fast acting binding effect and support to the aggregates and may be introduced as finely divided solids and show binding properties under the influence of pressure, temperature and/or moisture. The polysaccharide is preferably a gum for example a seaweed extract, such as an agar or algin, a plant extract, for example tragacanth or karaya, but is, particularly preferably, a seed gum for example guar or a microbial gum for example xanthan and/or a galactomannan. Another particularly preferred polysaccharide binder is starch. Saccharide materials such as molasses may very preferably be used. Other organic binders suitable for use according to the invention are resin binders capable of curing at the temperatures used m the production of the aggregates of the present invention such as ambient or low super- ambient temperatures or, for example, at from 10°C to 60°C. Formaldehyde resins or other aldehyde resins capable of cure at a temperature of from about 15°C to about 40°C are particularly suitable for use according to the invention. Alternatively, a "hot-cure" resin or hardener may be used, curing at up to 200°C provided the duration of cure is sufficiently short to avoid adverse effects, for example a lignosulphonate. Resin binders tend to have a somewhat delayed effect and may preferably be used in conjunction with a binder having a more immediate effect as identified above. Other suitable binders in any of the above categories, or mixtures of any of the above binders or other suitable binders, may be used according to the invention. A binder or binders is preferably present in at least 0.3% by weight of the aggregation mixture or of the final aggregates if different. While the binder may be present in up to 10% or more it is preferred to limit to some extent the organic content of the composition and it is therefore generally preferred that the binder is present in less than 10%, particularly preferably no more than 5% by weight of the composition. If it is nevertheless desired to produce a low sulphur content product from the iron disulphide the above quantities may be exceeded and a binder may be present in up to 20% or more by weight. Without a suitable binder or binder system, or other material having a similar affect, the agglomerates according to the invention may, at least initially, be subject to fracture and may, in some cases, never achieve the required mechanical strength for use in the metallurgical industry. The aggregates according to the invention may be produced by mixing the iron sulphide with the binder or binders and forming the mixture under the influence of pressure. Non-pressure aggregating processes, such as of a balling plate or drum, may be feasable according to the invention but may not give final products having a sufficiently high density. Pressure-forming may suitably be conducted using moulding or roller presses, such as briquetting presses, or extrusion devices such as auger mills. The pressure employed is preferably at least 10^ N/cm^ and up to 10-> N/cm^ or 10" N/cm^ or equivalent linear pressures, for example from 10^ N/cm to 10^ N/cm when using roller presses. There may be some degree of generation of heat due to shear of the particles during compression and this may be beneficial to the binding action of those binders which require certain alterations of their chemical or physical structure such as by cross¬ linking or curing in the case of the resin binders or by melting or dissolving in the case of polysaccharide binders. In the case of iron disulphide heat evolution due to shear does not provide sufficient assistance to the binder and it is desirable to add heat. The aggregates according to the invention preferably include ferrous sulphide, or elemental sulphur, or both. If ferrous sulphide is included in the iron disulphide aggregation mix there may be a degree of increased heat evolution and more effective binding of the final product. This may reduce or eliminate the need to provide an external source of heat. The inclusion of ferrous sulphide in the aggregates of the present invention has the further advantage that, having a lower sulphur content than iron disulphide, it enables aggregates having a high sulphide content but a lower content of sulphur to be produced. A source of sulphur having a content of sulphur of from 40% to 53%, preferably from 40% to 50%, for example very suitably from 40% to 45% by weight, is of interest in steelmaking and is advantageously produced according to this aspect of the invention for example by the use of iron disulphide and ferrous sulphide in a weight ratio of from about 40:60 to about 60:40. Generally, the weight ratio of iron disulphide:ferrous sulphide may be 5:95 to 95:5 or, very suitably, 10:90 to 90:10. The spontaneous heating effect in the presence of ferrous sulphide, or of iron disulphide, is apparently encouraged by the presence of some water or moisture in the mix. Preferably therefore, the aggregation mix of the present invention contains a quantity of water in liquid or vapour form. Preferably the quantity of water is at least 0.1% by weight, for example at least 0.5% by weight of the aggregation mix and/or sufficient to achieve an appreciable heating effect. Preferably the quantity of water is below 10% on the same basis. A suitable quantity of water may be at least 0.75% by weight, and/or up to 8%, of the aggregation mixture. There may in certain circumstances, for example when the material has been stored in contact with damp air, be a proportion of water present absorbed in the iron disulphide or ferrous sulphide. Such water may be present in up to 10% of more, for example in at least 2%. Such water is taken into account in determining the amount of water to be added, if any. Water also plays a part in making the iron disulphide more readily handleable. The quantity of water should preferably be such that a flowable paste is not formed. The formed agglomerates do not normally require to be dried of residual moisture but this is not excluded if required. If elemental sulphur, for example granular or powdered sulphur, is included in the iron disulphide aggregation mix the aggregates have a correspondingly higher content of sulphur. Elemental sulphur is not preferred as a direct additive to a ferrous metal melt because its low density makes it difficult to incorporate. Elemental sulphur-containing iron disulphide compacted aggregates may be suitable for metallurgical use up to a high overall sulphur content. Such aggregates are therefore also provided according to the present invention. Generally, the weight ratio of iron disulphide:sulphur may be from 5:95 to 95:5 or, very suitably, 10:90 to 90:10. The overall content of sulphur in the aggregates is preferably greater than 54%, particularly preferably at least 60% by weight and, to achieve suitable binding and density, is preferably less than 90%, for example less than 85%, by weight. The present invention also provides compacted aggregates of iron disulphide containing both ferrous sulphide and elemental sulphur to produce a product having a density and overall sulphur content nearer to that of iron disulphide than in the cases where only one of these additives may be used. This gives valuable flexibility in materials usage. In the case of either a content of ferrous sulphide or of elemental sulphur the ratio of iron disulphide: ferrous sulphide or elemental sulphur is preferably <75%:>25%, for example, very suitably, <73%:>27%. The ratio of iron disulphide: ferrous sulphide or elemental sulphur is preferably at least 10%:90%. Preferably iron disulphide, ferrous sulphide and/or sulphur is present in the aggregates of the invention in at least 80%, particularly preferably at least 90%, and up to 99% or more, by weight of the final aggregates. The need to use binders may be reduced or eliminated in the presence in the aggregates of ferrous sulphide and/or sulphur. Additives or diluents or other materials may be present in addition to the binder and may be selected according to practice in the art. The pressure-formed iron sulphide articles of the invention may be fed into the steel ladle and due to the relatively smaller density difference between them and the steel melt, in comparison with particulate forms of iron pyrites, ferrous sulphide and/or sulphur, and mix in easily to give accurate and even dosing of sulphur. The invention will now be more specifically described by reference to the following non-limiting Example. Example 1 The composition of the aggregation mix was as follows: Iron pyrites 60.6% by weight Water (by wt of pyrites) 6% to 8% Guar gum 6.1% " Molasses 15.1% " Lignosulphonate 18.2% " The mixing and pressure-forming steps were carried out as follows. The iron pyrites, consisting of particles in the 0 to 2 mm diameter range, were placed in a mixer bowl and the water was added and mixed in to give a damp mixture. The guar, and the molasses, were then added and mixed in and, lastly, the lignosulphonate was mixed in. The mixture was passed to a press in which pressure- formed aggregates of about the size of a domestic soap bar were produced at a pressure above 10-^ N/cm^. The pressure formed-aggregates were oven heated at 180°C to cause crosslinking. The products of these Examples had a density of 4 - 5 g/cπH and were physically strong and breakage resistant and suitable for use as sulphur sources in steel production.

Claims: Cl aims : 1. A composition comprising iron disulphide for metallurgical purposes, characterised in that the iron disulphide is in the form of compacted aggregates. 2. A composition as claimed in claim 1 wherein the aggregates have a largest dimension of from 1 to 12 centimeters and the smaller iron sulphide particles of which these articles are made have a largest dimension, to the extent of at least 50% by weight, of from 0.001 mm to 0.5 cm. 3. A composition as claimed in claim 1 or 2 comprising one or more binders. 4. A composition as claimed in any preceding claim wherein the binder is an organic binder comprising a resin curing at from 10°C to 60°C, a lignosulphonate, a polysaccharide colloidal material, a seed or microbial gum, molasses or a starch. 5. A composition as claimed in any preceding claim wherein the binder is an inorganic binder comprising a hydraulic material, a silicate, an aluminate, a synthetic or mineral clay, calcium hydroxide or gypsum. 6. A composition as claimed in any preceding claim wherein the binder is an alkaline earth metal aluminate or mixture thereof with an alkaline earth metal silicate. 7. A composition as claimed in any one of claims 3 to 6 wherein the binder or binders are present in from 0.3% to 20% of the aggregates. 8. A composition as claimed in any preceding claim comprising ferrous sulphide and having a content of sulphur of at least 40% by weight. 9. A composition as claimed in any preceding claim comprising elemental sulphur and having a content of sulphur of less than 90% by weight. 10. A process for the production of compacted aggregates for metallurgical use and having a composition as claimed in any one of claims 1 to 9 wherein iron disulphide particles, optionally in admixture with ferrous sulphide and/or sulphur, are mixed with a binder and the mixture is pressure-formed at a pressure of at least IO 3 N/cm 2 . 11. A process as claimed in claim 10 wherein the mixture contains from 0.5% to 10% of water. 12. A metallurgical process wherein a composition as claimed in any one of claims 1 to 9 is included in a melt of a ferrous metal to give a content of sulphur in the metal of 0.005% to 0.06% by weight.

Inventors: CARDWELL PAUL ALYN, GRIFFIN PATRICK ALPHONSUS, MOBBS DAVID BARRY, SWANN KEVIN, CARDWELL, PAUL, ALYN, GRIFFIN, PATRICK, ALPHONSUS, MOBBS, DAVID, BARRY, SWANN, KEVIN
Applicants: CARDWELL PAUL ALYN, GRIFFIN PATRICK ALPHONSUS, LAPORTE INDUSTRIES LTD, MOBBS DAVID BARRY, SWANN KEVIN, CARDWELL, PAUL, ALYN, GRIFFIN, PATRICK, ALPHONSUS, LAPORTE INDUSTRIES LIMITED, MOBBS, DAVID, BARRY, SWANN, KEVIN
Application year: 1996
Main classification: C01G49
IPC codes: B01J2, C21C7, C22B1