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<p>Iron ore pelletization is becoming increasingly critical to ironmaking as global crude steel production exceeded 1.85  billion tons in 2024, while the availability of high-grade lump ore and sinter feed continues to decline. Current pellet feedstocks are increasingly derived from low-grade and complex ores, typically containing less than 62 pct Fe, (Al<sub>2</sub>O<sub>3</sub>&#xa0;+SiO<sub>2</sub>) levels above 6 to 8 wt pct, high loss on ignition (LOI), or multimineral ores such as Ti-, V-, and Cr-bearing magnetites. These characteristics impose significant constraints on pellet strength development, reducibility, and high-temperature stability. This review critically examines advances in iron ore pelletization reported over the last decade, with emphasis on raw material beneficiation and blending strategies, binder–flux–additive design, and process innovations directed toward decarbonization. Reported quantitative relationships are synthesized to clarify governing mechanisms and limitations, including reductions in blast furnace productivity of up to ~&#xa0;4 pct per 1 wt pct increase in Al<sub>2</sub>O<sub>3</sub>, basicity-controlled improvements in reduction degree from ~&#xa0;60  to ~&#xa0;85 pct in Ti-bearing magnetite pellets, and strength–porosity trade-offs influencing hydrogen reduction behavior. Recent process developments are assessed, including cold-bonded pelletization achieving compressive strengths above 200 kg/pellet without high-temperature induration, electrified and hydrogen-fired induration routes that reduce peak firing temperatures by 50&#xa0;°C to 75&#xa0;°C, and digital twin-assisted control of oxidation and sintering profiles. Their associated challenges related to scalability, durability, and industrial robustness are discussed. Particular attention is given to hydrogen-ready pellets, where accelerated reduction kinetics are increasingly offset by sticking, dense iron shell formation, and the absence of well-defined specification frameworks. The review maps how ore quality degradation, decarbonization pressures, and data-driven process control are collectively reshaping pelletization practice and identifies the technical uncertainties relevant to deployment across blast furnace and direct-reduction-based steelmaking routes.</p>

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Iron Ore Pelletization in Transition: A Critical Review of Raw Material Constraints, Technological Innovations, and Pathways Toward Low‑Carbon Steelmaking

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Biswajit Mishra,
  • Shaik Mahaboob Basha,
  • Srinivas Dwarapudi,
  • Siddhartha Misra

摘要

Iron ore pelletization is becoming increasingly critical to ironmaking as global crude steel production exceeded 1.85  billion tons in 2024, while the availability of high-grade lump ore and sinter feed continues to decline. Current pellet feedstocks are increasingly derived from low-grade and complex ores, typically containing less than 62 pct Fe, (Al2O3 +SiO2) levels above 6 to 8 wt pct, high loss on ignition (LOI), or multimineral ores such as Ti-, V-, and Cr-bearing magnetites. These characteristics impose significant constraints on pellet strength development, reducibility, and high-temperature stability. This review critically examines advances in iron ore pelletization reported over the last decade, with emphasis on raw material beneficiation and blending strategies, binder–flux–additive design, and process innovations directed toward decarbonization. Reported quantitative relationships are synthesized to clarify governing mechanisms and limitations, including reductions in blast furnace productivity of up to ~ 4 pct per 1 wt pct increase in Al2O3, basicity-controlled improvements in reduction degree from ~ 60  to ~ 85 pct in Ti-bearing magnetite pellets, and strength–porosity trade-offs influencing hydrogen reduction behavior. Recent process developments are assessed, including cold-bonded pelletization achieving compressive strengths above 200 kg/pellet without high-temperature induration, electrified and hydrogen-fired induration routes that reduce peak firing temperatures by 50 °C to 75 °C, and digital twin-assisted control of oxidation and sintering profiles. Their associated challenges related to scalability, durability, and industrial robustness are discussed. Particular attention is given to hydrogen-ready pellets, where accelerated reduction kinetics are increasingly offset by sticking, dense iron shell formation, and the absence of well-defined specification frameworks. The review maps how ore quality degradation, decarbonization pressures, and data-driven process control are collectively reshaping pelletization practice and identifies the technical uncertainties relevant to deployment across blast furnace and direct-reduction-based steelmaking routes.