Fundamental Analysis of Sinter Solid Structure: Implications of Mineral Associations for Understanding Industrial Iron Ore Sinter Formation

The solid structure of industrial sinter comprises seven mineral associations (A, B, C, D, Ds, E, N) which have different relative abundances of key minerals, textures and spatial relationships to micro-macropores and hematite nuclei. Among the key characteristics of the mineral associations: (MA), MA-A comprises abundant SFCA-I microplates with hematite; MA-B consists of disseminated fine-grained magnetite in a network of SFCA-III microplates; MA-C is similar to MA-B but contains patches of dendritic SFCA-III with larnite and minor glass; MA-D comprises magnetite surrounded by coarse prisms of SFCA within glass; MA-Ds, a subtype of MA-D, includes SFCA with secondary skeletal hematite; MA-E consists of anhedral to skeletal magnetite or hematite in a matrix of glass; and MA-N comprises unmelted hematite nuclei from iron ore feedstock. SFCA-III and SFCA-I are dominant in MA-B and MA-A, respectively, whilst magnetite is the most common mineral in MA-C, MA-D/Ds and MA-E. Low-temperature sintering samples are largely of MA-A to MA-D (62 area %), which contain higher combined levels of SFCA-SFCA-III and lower levels of magnetite-dominant MA-E (12.6 area %), whereas high-temperature/magnetite sintering examples had high levels of magnetite-dominant MA-E (31.6 area %) and MA-D/Ds (52.1 area %) and low levels of MA-A to MA-C (8.9 area %). It is proposed that the formation of each MA is controlled by the peak sintering temperature attained, the dwell time at higher temperature which adversely allows fractional crystallisation to tie up more Fe in magnetite rather than forming SFCA phases during cooling, and especially a slower rate of cooling which promotes the formation of more SFCA family phases at lower temperatures. However, local variations in chemistry inherited from raw material granulation and assimilation during sintering of Si-rich gangue or ore nuclei are also important.