Overcoming Consistency Challenges in the Iron Making Sector

Caleva's International Sales Manager Steve Mate visited the Department of Chemical Engineering at Osaka Metropolitan University to find out how the Mixer Torque Rheometer (MTR) is being used.

Associate Professor, Dr Nakamura, and Ph.D. candidates, Motoshi Iwao and Otsu Tomotaka, have been using the Mixer Torque Rheometer to overcome challenges in the production of crude iron (also known as pig iron), where the consistency of raw materials can vary greatly.

Mixer Torque Rheometer with Laptop

Consistency Challenges During Production

During any production process it is crucial to ensure that product quality is consistently maintained. This becomes particularly challenging when raw materials or ingredients are sourced from different suppliers, who in turn may be sourcing their products from different places, and stored and transported under different environmental conditions. While this may help to avoid supply chain issues, it can unintentionally lead to problems with product quality and useable yield.


Monitoring and Maintaining Product Quality 

Maintaining product quality can be difficult to manage when raw materials vary. However, if the formula (or recipe) could be monitored for consistency throughout production, potential issues can be mitigated before they arise.

This is where the Mixer Torque Rheometer (MTR) comes in.

The MTR can monitor consistency across production lines and between batches. This can help ensure product quality and yield remain consistent, or even improve.

When asked to comment on the MTR’s application in pig iron manufacturing, Dr Nakamura said the following:


"We have proposed to utilize the MTR in the iron making sectors. In pig iron manufacturing, the physicochemical properties, such as particle-size distribution, wettability, and porosity, of raw powders often vary because ironmaking industries blend various types of iron ore powders imported from different regions and use them as raw materials. This results in a large variation in the optimum water content for wet granulation of fine iron ore powders. To address this issue, we have employed the MTR with support from Higuchi Inc. and Caleva Ltd. We have demonstrated that the optimum water content for wet granulation of fine ore powders can be determined using the MTR, even when the raw ore powders varied."


Characterise Wet Granulations with the Mixer Torque Rheometer

The Mixer Torque Rheometer is a powerful instrument for characterising wet granulations both in development and production. When applied as a line side tool during production it can ensure consistency is maintained and has the potential to identify issues before they result in costly mistakes. 


Monitor Quality Control with Caleva Bench Top Equipment

Caleva bench top equipment is used every day across the world to perform cutting edge research, and to improve production line processes and monitor quality control. The Mixer Torque Rheometer is used in a wide range of different settings and sectors, from food development to pig iron production.


View the Mixer Torque Rheometer to find out more, or request a free online demonstration. 



Dawn Philips
By Dawn Philips
24 Apr 2023 in Mixer Torque Rheometer, Product Yield

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