LAUSR

Abstract The alumina content of iron ores for sintering is gradually increasing with the growing depletion of high-grade iron ores, which is harmful to the sintering process. Therefore, it is essential to reveal the action mechanism of alumina on sinter quality. In this paper, the aluminum occurrence of various iron ores was determined by applying X-ray diffraction (XRD), optical microscopy, scanning electron microscopy and energy dispersive spectrum analysis (SEM-EDS). Then, the effects of iron ore type, aluminum occurrence (free alumina, gibbsite, diaspore, alumogoethite and kaolinite) and alumina content on formation characteristics of SFCA bonding phases as well as sinter matrix strength were investigated based on laboratory compact sintering tests. The results show that the discrepancy of aluminum occurrence contributes to different SFCA formation characteristics and then sinter matrix strength, due to different reactivity of various aluminum-containing minerals with iron oxides and fluxes. Increasing alumina content generally results in an increase in the porosity of sinters and deterioration of sinter matrix strength for all aluminum occurrence. Aluminum in the form of kaolinite is more conducive to form dendritic or acicular SFCA with superior sinter matrix strength compared with other aluminum occurrences. In contrast, aluminum occurring in free alumina presents greatest adverse impacts on sinter matrix strength due to its poor reactivity and high porosity of resultant sinters.