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Fe-C Composite Pellets for BOF: High-Efficiency & Cost-Saving

As the global steel industry seeks innovative solutions for environmental compliance, productivity, and cost-efficiency, Fe-C Composite Pellets for BOF are rapidly gaining traction. This in-depth analysis covers recent industry trends, technical specifications, manufacturing expertise, vendor comparisons, custom solutions, and proven application cases, all tailored to meet BOF (Basic Oxygen Furnace) operational excellence.

Industry Trends in Fe-C Composite Pellets for BOF

  • Market Growth: Global BOF-based steelmaking is projected to exceed 1.41 billion tons in 2024, with enhanced raw material efficiency as a strategic priority. Composite pellets are expected to achieve a 13% YoY adoption rate (source: Worldsteel, 2023).
  • Environmental Compliance: Composite pellets with optimized Fe-C content show a 25-35% reduction in NOx and particulate emissions due to improved combustion and faster reduction kinetics.
  • Digitization & Smart Manufacturing: Advanced tracking and quality monitoring (ISO 9001:2015/ISO 14001:2015) now enable batch certification and full traceability for Fe-C composite pellets.
Fe-C Composite Pellets for BOF: High-Efficiency & Cost-Saving

Definition and Role in Modern Steelmaking

Fe-C Composite Pellets for BOF are engineered agglomerates consisting of iron oxide concentrate, carbonaceous reductants (such as coke breeze or anthracite), and special binders. Used as charge materials for Basic Oxygen Furnaces, they provide a controlled Fe-C ratio to optimize oxygen usage and achieve targeted hot metal chemistry.

Key Technical Terms:
Direct Reduction Index (DRI), Apparent Density, Cold Crushing Strength (CCS), RDI (Reduction Degradation Index), Sinterability, ISO/ANSI Testing

Technical Parameters: Fe-C Composite Pellets for BOF

Property Specification Test Standard Typical Value
Fe Content (%) ≥ 70.0 ISO 2597:2015 71.3
C Content (%) 5.5 ~ 6.5 ISO 9556:2020 6.0
Cold Crushing Strength (CCS) ≥ 2500 N/pellet ISO 4700:2015 2650 N/pellet
Apparent Porosity (%) 16–18 ANSI 71 17.2
Bulk Density (t/m³) 2.23–2.35 ISO 11256:2015 2.31
Pellet Diameter (mm) 8–16 Company Spec 10.8
Reduction Degradation Index (RDI) ≤ 28% ISO 4696-1:2015 25.4%

Technical Data Comparison & Visualization

Manufacturing Process of Fe-C Composite Pellets for BOF

  1. Raw Material Preparation: Blending of high-purity iron ore fines (≥71% Fe), coke breeze (≤7% ash), and eco-binder.
  2. Mixing & Pre-granulation: Homogeneous mixing in high-shear granulators to ensure perfect Fe-C ratio.
  3. Pelletizing: Disc or drum pelletizer transforms the mixture into green balls (ISO 4701:2022 compliance).
  4. Drying: Controlled drying curve prevents microcracks, maximizes pellet strength pre-sintering.
  5. Thermal Hardening: Induration at 1250–1350°C yields a dense, metallurgically active structure.
  6. QA/QC Testing: Each batch analyzed for Fe/C content, crushing strength, porosity (ISO / ANSI / ROHS standards).
  7. Packing & Logistics: Bulk packaging in 1.5 ton bags, barcode traceability; end-to-end digital supply chain controls.
Fe-C Composite Pellets for BOF: High-Efficiency & Cost-Saving
Raw Materials Mixing & Granulating Pelletizing Drying Thermal Hardening Quality Control Bulk Bagging & Delivery

Material Focus: Strict selection of iron ore/concentrates (ISO 622:2012), coke breeze with consistent residue analysis, and non-toxic organic binders (FDA/EC1935 certified) ensure safety, sustainability, and product uniformity in Fe-C Composite Pellets for BOF.

Vendor Comparison: Market Leaders in Fe-C Composite Pellets

Vendor / Brand ISO Certified Typical Fe/C Ratio Custom Size Available After-Sales Support
Xingtai Luxi New Material ISO 9001, ISO 14001 11.9 :1 Yes (6–22 mm) 24/7 Tech, Field Engineer
Metinvest (Ukraine) ISO 9001, EN 197-1 10.8 :1 Limited (≈12mm) Online Only
Kobe Steel (Japan) ISO 14001, JIS 12.2 :1 Custom (10/16/20mm) Regional Team
Authoritative Reference: Xingtai Luxi’s Fe-C Composite Pellets for BOF are trusted by major metallurgical, petrochemical, and water treatment companies in Europe and Asia.
Annual shipments reached 120,000 tons in 2023, with zero non-conformance in customer audits (source: customer satisfaction surveys).

Customized Fe-C Composite Pellet Solutions

Recognizing the operational diversity of global customers, Fe-C Composite Pellets for BOF are available in fully customized specs:

  • Diameter Range: 6.0–22.0mm (±0.3mm)
  • C Content: Tuned between 4.5–8.0%, matching desired hot metal carbon input
  • Binder Formula: Ore-specific binders for high-temperature BOF, or corrosion-resistant for water treatment
  • Surface Coating: Optional anti-dust or corrosion-resistant layers for petrochemical/wastewater industries
  • Packing: Jumbo bags, paper sacks, or container111ized bulk
Fe-C Composite Pellets for BOF: High-Efficiency & Cost-Saving
Typical Customization Case: Petrochemical Plant, Oman (2023)
Customized 12mm Fe-C pellets, anti-corrosive coating, supplied for process water decarbonization. Result: 37% longer filter life (third party tested, SGS Oman).

Application Scenarios: Where Fe-C Composite Pellets for BOF Deliver Value

  • Steelmaking (BOF) Charging: Fast melting, optimized Fe/C ratio speeds up decarburization, and improves steel yield by 3-5% (source: Metal Bulletin, 2022)
  • Petrochemical Deoxidation: Used in process water to reduce O2 and control corrosion of reactors and pipelines
  • Municipal Water Treatment: Supports zero-discharge filtration systems by scavenging dissolved O2 and organic impurities.
  • Cement Kiln Additive: Serves as a secondary reducer, ensuring even heat transfer and clinker formation.
Field Case Example: 2023
Customer: Baosteel, PRC
Scenario: Replaced 30% of conventional sinter with Fe-C composite pellets in BOF
Results:
  • Slag Foaming improved by 15%
  • Yield increased by 3.9%
  • NOx emissions down 27% (confirmed by CERI)
  • Refractory life (below tuyere) increased by 20%
Key Performance Advantage: Uniform composition, low residual P/S, and high CCS enable reliable long-cycle operation—reducing unplanned BOF shutdowns by 8–11% based on annual TSG inspection reports (2023).

Fe-C Composite Pellets for BOF: FAQs & Applied Knowledge

1. What is the typical material composition?
Fe-C Composite Pellets for BOF usually contain:
  • Iron content: 70–72% (hematite or magnetite powder)
  • Carbon (as coke breeze or refined anthracite): 5–7%
  • Binding agent: 2–4% (organic/eco-binders)
  • Impurities (P, S): <0.032%
All incoming materials are tested via XRF and wet chemical analysis, certified to ISO 2597 and ISO 9556 standards.
2. What is the recommended pellet diameter and tolerance for BOF use?
Standard size is 8–16 mm diameter, ±0.3 mm tolerance (essential for even melting and flow in BOF charging). Custom sizes are available for special charge strategies.
3. What mechanical tests are applied to ensure pellet integrity?
Key tests include: Cold Crushing Strength (CCS, ≥2500 N/pellet, ISO 4700), Drop Number, Bulk Density, Degradation Index (RDI), and Taber abrasion. Random sampling per batch ensures consistency.
4. What standards must be met for export to EU/US markets?
Products must comply with REACH (EU), RoHS for hazardous content, and ISO 9001/14001 for production and environmental management—often supported by third-party audits (SGS, TÜV Nord).
5. How long is the typical service life and storage period?
In BOF operation, average turn cycle per pellet is 170–200 cycles. Indoor, dry storage shelf life: up to 14 months, based on humidity barrier packaging.
6. Can the pelletizing technology be adapted for other reduction systems (EAF, DRI)?
Yes, with formula and binder adjustments, these pellets can be adapted for Electric Arc Furnace (EAF) and direct reduction processes, offering similar energy and yield benefits.
7. Are installation/charging procedures different from other charge materials?
No significant difference. However, due to higher CCS and porosity, chute and conveyor dust emissions are reduced by 18–24% versus traditional sinter or fine ore.

Delivery Lead Time, Warranty & Customer Support

Order Lead Time:
Standard size: 7–14 working days
Custom specs: 17–20 working days (dependent on batch size & formula)

Warranty:
All Fe-C Composite Pellets for BOF include a 12-month defect-free warranty; product replacement or refund on non-conforming supply within the documented period.
Customer Service:
  • 24/7 technical hotline & online support
  • On-site commissioning and training for large-volume users
  • Batch traceability and certification available per shipment
  • Proactive recall/notice on any spec deviation found during post-shipment audits
Contact now: To discuss your BOF pellet specification, request a technical consultation & sample.

Conclusion & Authoritative References

The adoption of Fe-C Composite Pellets for BOF represents a significant leap in the optimization of metallurgical processes. With tailored technical parameters, ongoing innovation in binder chemistry, global certifications, and proven operational experience, these pellets are poised to become the market standard for next-generation steelmaking and industrial deoxidization. Their contribution to efficiency, emissions reduction, and process reliability is



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