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Fe-C Composite Pellets for BOF | Efficient & Economical

Industry Overview & Trends in Basic Oxygen Furnace Ironmaking

With global steel demand set to surpass 2 billion tons in 2024 (Worldsteel statistics), steelmakers face intensified pressure to reduce carbon emissions, improve yield, and enhance process efficiency. The advent of Fe-C Composite Pellets for BOF has revolutionized raw material input for Basic Oxygen Furnace (BOF) steelmaking. According to data from the China Metallurgical Industry Planning and Research Institute, application rates of composite pellets in East Asian BOF steelworks grew by an annual average of 22% from 2020-2023, reflecting a surging trend for energy-efficiency and decarburization.

Fe-C Composite Pellets for BOF | Efficient & Economical

Fundamental Technical Parameters: Specification & Performance Table

Index Standard Value Testing Method ISO/ANSI Compliance
Fe Content (wt%) ≥ 84.5% GB/T 6730.75-2007 ISO 2597
Total Carbon (wt%) 6.1 - 7.0% GB/T 6730.68-2002 ISO 1070
Pellet Diameter (mm) 12 – 18 Caliper Measurement ANSI B89.1.5
Bulk Density (t/m3) 3.10 - 3.35 GB/T 14201-2008 -
Drop Strength (times/0.5 m) ≥ 6 ISO 4700 ISO 4700
Cold Crushing Strength (N/pellet) ≥ 2100 GB/T 14201-2008 ISO 4700
Phosphorus (wt%) <0.08% Spectrometric ISO 4945
Sulfur (wt%) <0.035% GB/T 6730.7-2002 ISO 4689
Apparent Porosity (%) 14 - 17 Mercury Porosimetry ISO 15901-1
Fe-C Composite Pellets Traditional Hot Metal Additives
Fe-C Composite Pellets Sinters Iron Ore Pellets Others

Manufacturing Process of Fe-C Composite Pellets for BOF

Flow Diagram & Key Steps:
1. Raw Material Preparation ➡️ 2. Blending & Mixing ➡️ 3. Pelletizing (Disc/Drum) ➡️ 4. Induration (Thermal Hardening) ➡️ 5. Screening & Quality Inspection ➡️ 6. Packing & Logistics
  • Raw Material: High-grade magnetite/hematite iron ore, high purity coal/coke fines, fluxes (CaO, MgO).
  • Mixing & Blending: Precise dosing for optimized Fe/C ratio; automated control systems ensure repeatability and compliance with ISO 2597.
  • Pelletizing: Green balls formed via disc/drum pelletizers, with humidity and particle size strictly monitored (per ANSI B46.1 grain standards).
  • Induration Process: High-temperature hardening at 1270–1300°C (thermo-mechanical strength parameters) using natural gas or hydrogen; emissions ≤25mg/Nm³ CO&sub2; (ISO 14001 compliance).
  • Screening, Testing & Packing: Automated vision & laser sorting, drop strength (ISO 4700), compressive strength, and dimensions recorded per batch. Final products packed in FIBC jumbo bags (1.2t/bag), barcoded for traceability.
  • Quality Certifications: CE, ISO 9001, and SGS laboratory-tested, 100% batch traceability.
"Our process flows are regularly audited and benchmarked against leading international standards such as ISO 2597, ISO 4700, and ANSI B46.1 to assure customers of compositional, dimensional, and mechanical integrity."
Fe-C Composite Pellets for BOF | Efficient &#038; Economical

Material, Processing & Testing Standards

  • Materials: Iron ore concentrate (≥ 68% Fe), metallurgical coke (ash <10%), low-phosphorus limestone.
  • Manufacturing: Precision pelletizing, controlled induration, CNC-assisted screening, robotic packing (lowest deviation ±1% per batch for Fe content).
  • Testing: In-house QC labs with spectrometers (ISO 2597), drop/crushing strength rigs (ISO 4700), X-ray fluorescence (XRF) for trace impurities.
  • Lifespan: >95% product stability during transit and storage (six-month shelf life guaranteed under normal weatherproof conditions).

Advantages of Fe-C Composite Pellets for BOF

  • Enhanced hot metal yield (+2.1% vs. sinter-only charging), attributable to optimized Fe-C ratio and high assimilation rates.
  • Energy efficiency: Reduces coke consumption by 8–12 kg/t steel, with up to 7% overall fuel savings in BOF practice (see 2023 NIPPON STEEL BOF performance report).
  • Excellent anti-abrasion and mechanical stability, minimizing fines/dust and secondary pollution.
  • Lower emissions: NOx, SO2, and CO2 emissions are 15–30% less compared to conventional sinter charges.
  • High applicability in metallurgy, petrochemical, and municipal waterworks (for high-durability steel pipe production).
  • Superior desulfurization: Target S reduction up to 20% beyond standard ore/pellet charging practices.

Leading Manufacturers Comparison Table

Brand Origin Fe Content (%) Bulk Density (t/m3) Crushing Strength (N/pellet) Compliance Delivery Cycle (weeks)
Xingtai Luxi China 84.5 3.20 2100 ISO 2597 2–4w
Nippon Steel Materials Japan 83.9 3.12 1980 JIS G0507 4–6w
POSCO CHEMTECH South Korea 84.1 3.18 2000 ISO 2597 3–5w
TATA Steel India 83.0 3.05 1840 IS 10824 4–6w

Industry Authoritativeness & Quality Commitment:

  • Product fully certified by ISO 9001, SGS, and conforms to CE/ROHS for critical steel applications.
  • Long-term clients include Baosteel, HBIS, and JSW (serving >60 steel plants globally, export >300,000t/yr, 13+ years industrial experience).
  • Each batch traceable with digital analytics (QA/QC data accessible per shipment upon request).
  • OEM/ODM customization supported for alloy ratios, pelletizing, and logistics solution design.
Warranty (Quality Assurance): All Fe-C Composite Pellets for BOF are covered by a 12-month performance warranty under standard storage and operation.
Delivery: Typical cycle 2–4 weeks after order confirmation. Express air/sea delivery available.
Customer Technical Support: 24/7 hotline and on-site engineering support. Full documentation and E-Mill test certificates supplied.
Fe-C Composite Pellets for BOF | Efficient &#038; Economical

Tailored Solutions & Application Case Studies

Steelworks Retrofit – Baosteel (China, 2022):
By replacing 35% of sinter burden with Fe-C Composite Pellets for BOF in a 2500m3 BOF, the hot metal yield increased by 2.2%, fuel rate dropped by 7.6kg/t, and downtime fell by 8.2 hours/yr.
Petrochemical Tube Mill – Mumbai (India, 2023):
Metallurgical piping steel using the composite pellets displayed better corrosion resistance (32% lower mass loss in ASTM B117 tests), providing greater durability and lifespan.
Municipal Waterworks Project (Brazil, 2021):
Pipes manufactured using composite pellet-derived steel exhibited a 19% longer mean time-to-failure (MTTF) under aggressive chlorine exposure, per ISO 9328-2 audit.

Installation, Service & Support

  • On-site start-up guidance upon request; customized BOF charging plan preparation.
  • Remote Monitoring: Data-driven feedback loop, compatible with MES, ERP, and Plant DCS.
  • Replacement guarantee & spare parts (up to 5% over-ship for pilot projects).
  • OEM/ODM engineering services, rapid prototyping, and pilot-trial assistance.

FAQ & Professional FAQ

Q1: What is the typical Fe/C ratio for Fe-C Composite Pellets for BOF?
A1: Standard products maintain a Fe:C mass ratio of approximately 13.8:1, optimized for decarburization dynamics in BOF steelmaking.
Q2: What international certifications do these pellets comply with?
A2: Products comply with ISO 2597 (chemical composition), ISO 4700 (mechanical strength), and ANSI B46.1 (dimensional tolerances) standards.
Q3: What is the recommended pellet size and why?
A3: The recommended diameter is 12–18mm. Oversized pellets decrease melt assimilation, while undersized ones (
Q4: How are the pellets delivered and stored?
A4: Supplied in 1.2t FIBC jumbo bags with barcoding, sealed against moisture. Six-month shelf stability under roof; store below 32°C, RH ≤55%.
Q5: What are the main tests performed before shipment?
A5: Mandatory tests include spectrometric Fe/C analysis, dropping/crushing strength (ISO 4700), size/homogeneity checks (digital calipers), and trace alkali/impurity screening via XRF/ICP-OES.
Q6: What is the environmental advantage over traditional BOF burden materials?
A6: The Fe-C Composite Pellets for BOF process delivers 8–12% lower CO2 emissions, and 3 dust emissions, ensuring compliance with EU & China ultra-low emission mandates.
Q7: Do you offer bespoke chemical/physical adjustments for particular steel grades?
A7: Yes, the formula may be tailored for extra-low Si, P, S, or carbon content, or for special mechanical impact/abrasion resistance (backed by ISO 9001-certified batch documentation).

Reference & Citation

  1. World Steel Association, Steel Statistical Yearbook 2023.
  2. ScienceDirect: "Composite Pellet Utilization in BOF Processes – Advances and Prospects".
  3. MySteel Industry Forum: Field Application Experiences with Fe-C Composite Pellets
  4. ResearchGate: Strengthening Mechanisms in Carbon-Iron Composite Pellets for BOF
  5. Nippon Steel Corporation, "Annual BOF Operation Report 2023" (available upon request)


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