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The iron ore pelletizing process consists of three main steps:

Pelletizing feed preparation and mixing: the raw material (iron ore concentrate, additives—anthracite, dolomite—and binders are prepared in terms of particle size and chemical specifications, dosed, and mixed together to feed the pelletizing process;

Balling process: the green pellet is the rolled pellet without any thermal process. It is obtained under strict control of moisture and has a spherical shape and diameter of 8–16 mm;

Induration process: the green pellets are hardened in a high temperature processing at controlled heating rates, and aiming to achieve the physical and metallurgical requirements for handling, transportation, and final application.

This chapter aims to provide an overview and the evolution of iron ore pelletizing process including:

Pelletizing process and raw materials

Balling technologies

Bonding mechanisms

Evolution of binders for iron ore pelletizing

Induration technologies

Challenges and innovations in iron ore pelletizing
A rotary kiln is a pyro-processing device that raises materials to very high temperatures in a continuous process.
Rotary kilns work by processing material in a rotating drum at high temperatures for a specified retention time to cause a physical change or chemical reaction in the material being processed. The kiln is set at a slight slope to assist in moving material through the drum.