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Beneficiation of ESP dust in sponge iron production: Efficient recovery of iron and carbon for waste reduction and resource cycling.

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Title: Beneficiation of ESP dust in sponge iron production: Efficient recovery of iron and carbon for waste reduction and resource cycling.
Authors: K, Ashok1 (AUTHOR) ashok.k@jsw.in, Kumar, Ravindra1 (AUTHOR), T, Umadevi1 (AUTHOR)
Source: Mineral Processing & Extractive Metallurgy. Dec2025, Vol. 134 Issue 4, p251-261. 11p.
Subject Terms: *WASTE minimization, *MAGNETIC separation, *WASTE recycling, *COMPRESSIVE strength, *IRON, *HEMATITE
Abstract: The BMM Ispat sponge iron plant in Hospet, Karnataka, produces 30 to 40 tons/day of electrostatic precipitator (ESP) dust containing 19.37% Fe, 25.32% SiO2, 14.20% carbon and 0.338% sulphur, with 99.83% passing 150 microns. Magnetic separation yielded an iron concentrate with 50.55% Fe and 0.30% carbon (33.48% weight recovery), while flotation of the non-magnetic fraction produced a carbon concentrate with 52.5% carbon and 1.50% Fe, achieving an overall recovery of 59.46%. Partial substitution of hematite ore with 5% to 15% ESP concentrate in pellets improved green crushing strength (1.47–1.51 kg/pellet) but reduced cold compressive strength from 275 to 237 kg/pellet and increased porosity from 24.0% to 27.39% at 15% substitution, due to silica and alumina effects. Up to 10% substitution maintained acceptable strength. Process optimizations – adjusting basicity, increasing induration temperature and limiting ESP to ≤10% – are recommended for sustainable recycling and waste reduction. [ABSTRACT FROM AUTHOR]
Database: Academic Search Index
Description
Abstract:The BMM Ispat sponge iron plant in Hospet, Karnataka, produces 30 to 40 tons/day of electrostatic precipitator (ESP) dust containing 19.37% Fe, 25.32% SiO2, 14.20% carbon and 0.338% sulphur, with 99.83% passing 150 microns. Magnetic separation yielded an iron concentrate with 50.55% Fe and 0.30% carbon (33.48% weight recovery), while flotation of the non-magnetic fraction produced a carbon concentrate with 52.5% carbon and 1.50% Fe, achieving an overall recovery of 59.46%. Partial substitution of hematite ore with 5% to 15% ESP concentrate in pellets improved green crushing strength (1.47–1.51 kg/pellet) but reduced cold compressive strength from 275 to 237 kg/pellet and increased porosity from 24.0% to 27.39% at 15% substitution, due to silica and alumina effects. Up to 10% substitution maintained acceptable strength. Process optimizations – adjusting basicity, increasing induration temperature and limiting ESP to ≤10% – are recommended for sustainable recycling and waste reduction. [ABSTRACT FROM AUTHOR]
ISSN:25726641
DOI:10.1177/25726641251379027