Decoding organic binders: three hidden advantages for improving pellet production efficiency

In pellet production,composite organic binders have attracted much attention due to their properties of replacing bentonite and improving cold compression strength (CCS). However, their core function of reducing powder in the furnace is creating more "invisible benefits" for steel companies. This article will deeply analyze how this feature optimizes production processes, extends equipment life, and brings considerable economic returns.

I. Reduction of powder in the furnace: the core breakthrough of process optimization

Traditional bentonite binders are prone to dust residue during high-temperature roasting, while organic binders use molecular chain reconstruction technology to make pellets form a denser structure at high temperatures, reducing powder generation by 30%-50%. This change not only directly improves the yield rate, but also brings multiple added value to downstream links.

II. Three practical scenarios for doubling economic benefits

1. Traveling grate-rotary kiln system: ring formation cycle extended by 60%

Pain point solution: Powder deposition is the main cause of ring formation in rotary kilns, and traditional processes require shutdown and cleaning every 3 months

Solution: Organic adhesives reduce the amount of powder in the kiln by more than 40%, and the cleaning cycle is extended to 4-5 months

Benefit calculation: Single cleaning cost savings of 120,000-180,000 yuan/time (including shutdown losses), and annual maintenance costs reduced by 25%

2. Revolution in the life of key equipment: The service life of fan bearings is increased by 2 times

Wear mechanism: Powder particles carried by high-speed airflow cause micro-cutting of the bearing surface

Experimental data: After using organic adhesives, the vibration value of the main exhaust fan is reduced by 26%, and the bearing replacement cycle is extended from 8 months to 18 months

Cost optimization: The annual maintenance cost of a single fan is reduced by 400,000 yuan (including spare parts + labor)

3. Precise control of roasting atmosphere: The qualified rate of finished products is increased by 3 percentage points

Process guarantee: Stable airflow environment narrows the temperature fluctuation range of the roasting zone to ±15℃

Quality improvement: FeO content fluctuation rate is reduced to less than 0.5%, and the standard deviation of compressive strength is reduced by 28%

Premium space: High-quality pellets can obtain a purchase premium of 5-8 US dollars/ton

III. Comprehensive benefit calculation model (taking a pellet plant with an annual output of 2 million tons as an example)

| Benefit dimension | Traditional process | Organic binder process | Annual income growth |

|----------------|------------------|------------------|------------------|

| Bentonite cost | 10 million yuan | 6 million yuan | 4 million yuan |

| Equipment maintenance cost | 3.2 million yuan | 1.9 million yuan | 1.3 million yuan |

| Quality premium income | - | 8 million yuan | 8 million yuan |

| Total benefit | | | 13.3 million yuan |

IV. Suggestions on the implementation path of technology upgrade

1. Transition plan: Use 30% organic binder replacement ratio to gradually verify process adaptability

2. Parameter optimization focus: adjust the wind speed in the drying section (recommend a reduction of 0.5-0.8m/s) to control powder escape

3. Detection system upgrade: increase online monitoring of dust content in kiln tail gas (target value <15mg/Nm3)

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The value of organic binders is far more than formula replacement. The systematic process optimization it brings is reconstructing the production cost model of pellet ore. For steel companies pursuing long-term competitiveness, seizing this window of technology upgrade will achieve a strategic transformation from "cost control" to "value creation". Consult our technical team now to get a customized process transformation plan!

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