Why Binder Ratio are Critical for Efficient Briquetting and Pelletizing

In briquetting, pelletizing and other metallurgical agglomeration processes, binders are more than just a “glue.” They play a vital role in product quality, production efficiency, and cost control. The proper binder ratio, such as in iron ore pellet binder applications or as a briquette binder, determining the strength, stability, and metallurgical performance of briquettes or pellets. Improper ratios, on the other hand, can lead to high breakage rates, increased ash content, and even production interruptions.

This article will highlight the importance of industrial binder ratios, explain how to identify the right proportion based on different raw materials and process conditions, and share Jianjie’s recommended binder ratios from practical applications.

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Binder ratio are never one-size-fits-all in agglomeration processes. The right dosage depends on a careful balance between material properties, production conditions, and performance requirements. Let’s look at some key factors through real-world scenarios and data.

Raw Material Characteristics

In a steel plant recycling, EAF dust with particle sizes are mostly below 75 µm. Since finer particles have a higher surface area, they demand more binder to achieve sufficient bonding. Research from the Journal of Sustainable Metallurgy (2021) shows that reducing particle size from 150 µm to 75 µm can increase industrial binder demand by up to 20%. For mill scale, which has coarser particles, the ratio can be lower, usually 2–3% briquette binder by weight, while ultra-fine dust may need 4–5% to maintain strength.

Moisture Content and Drying Conditions

Consider a coal briquette producer operating in a humid environment. If the raw coal fines already contain a notable amount of moisture, the binder behaves differently compared to a dry setting. Industrial experience and trials have shown that even small changes in moisture can noticeably affect compressive strength, making precise water control critical when setting binder ratios. In practice, when the moisture content exceeds about 13%, cold briquetting becomes very difficult and the binder cannot function effectively, making raw material pre-treatment necessary. 

End-Use Performance Requirements

RHF dezincification briquettes: Must withstand rapid high-temperature conditions. Binder content is often adjusted slightly to enhance thermal stability during RHF operations.

Household coal briquettes: Mainly require steady combustion, where binder selection ensures consistent burning performance.

Excessive binder addition: May increase ash content, thereby lowering the calorific value of the briquettes.

Equipment and Pressure Conditions

In the cold briquetting process, the type of equipment and briquetting pressure conditions directly affect the binder dosage. High-pressure briquetting machines can achieve higher particle density, which generally allows for a reduction in binder addition. Under low-pressure forming conditions, however, a higher binder proportion is required to ensure sufficient strength. Adjusting the binder ratio flexibly according to different briquetting press conditions not only guarantees briquette strength but also helps reduce overall binder consumption.

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Consequences of Misapplied Binder Ratio in Agglomeration

When industrial binder ratios are misapplied—either excessively or insufficiently—the consequences can go beyond simple inconvenience. Let’s explore these issues with concrete examples and research-backed data.

Excess Binder

Higher production cost and ash content
Using excess industrial binder often results in increased ash formation. For example, studies on inorganic binder like bentonite show that while they enhance briquette strength through silicate bonding mechanisms, they also elevate silica and ash content, which can diminish metallurgical reducibility and increase downstream energy consumption (Accroding to IspatGuru.) 

Mechanical weakness due to binder aggregation

Optical microscopy studies reveal that high binder concentrations tend to form aggregated clusters rather than a uniform dispersion. These aggregated binders impair mechanical integrity, reducing compressive strength of briquettes.

Insufficient Binder

Poor strength and high breakage rates
Research on charcoal briquettes indicates a clear correlation between low binder ratios and structural fragility. Briquettes with minimal binder content display noticeably lower compressive strengths—just 0.12 N/mm²—whereas higher ratios yield significantly improved durability. (Accroding to ResearchGate)

Compromised combustion and densification
When binders are inadequately applied, briquette porosity remains high, weakening particle bonds and reducing density. This leads to higher rates of disintegration under thermal or mechanical stress.

In industrial agglomeration, such as agglomerating steel mill dust or EAF dust, excessive industrial binder content may raise production costs and introduce ash-related inefficiencies. Conversely, insufficient binder often leads to high fines generation—posing challenges during material handling and compromising furnace feed quality .

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From Lab to Production: Jianjie’s Scientific Approach to Binder Ratio

At Jianjie, we believe that the key to high-performance briquettes and pellets lies in scientifically determined binder ratios. Our approach integrates three essential steps:

Laboratory Testing

We conduct comprehensive laboratory evaluations to determine suitable binder ratio before scaling up to production. These tests include:

Compressive Strength Test 

assessing the briquettes’ ability to withstand static pressure during handling and storage.

Drop Test 

Measuring briquettes or pellets resistance to impact and breakage during transport.

Reduction Index (RI)

evaluating the reducibility of briquettes or pellets in simulated furnace conditions.

Reduction Degradation Index (RDI) 

determining how much the briquettes disintegrate during reduction.

Swelling Index

monitoring expansion behavior during reduction, which can affect furnace permeability.

Porosity Analysis

analyzing pore structure and distribution, directly influencing gas permeability and reduction kinetics.

By combining these tests, we establish reliable binder ratio ranges that balance mechanical strength, reduction performance, and operational efficiency.

Optimized Solutions 

By combining the right binder type with raw material properties and process conditions, Jianjie’s technical team provides on-site services to analyze actual production needs. We develop customized binder ratio plans and solve binder proportioning challenges directly at the client’s facility, ensuring stable briquetting or pelletizing performance.

 Thanks to this systematic method, Jianjie binders enable our customers to:

• High strength with low dosage
• Patented technology
• Environmentally friendly
• Suitable for multiple agglomeration applications
• Improve agglomerate products quality
• Customized formulation according to your real situations

Optimized Binder Ratio Guidelines by Jianjie for Diverse Applications

Based on extensive application experience, Jianjie suggests the following typical binder ratios as a reference for different raw materials. The actual dosage may vary depending on particle size, surface area, and moisture content of the material.

Anti-oxidation Ca-based Binder for Steel Dust Briquettes

Dry addition; binder-to-material ratio: 100:3. Adjust according to particle size and surface area.

Mineral Powder Briquette Binder

Dry addition; binder-to-material ratio: 100:3. Adjust depending on particle size and surface area.

Органическое связующее вещество for Iron Ore Pellets

Bentonite to binder ratio: 100: 3–5

Iron ore concentrate to binder ratio: 100:0.04–0.1

Mix bentonite, iron ore concentrate, and binder together before feeding into the pelletizing disc. Spray appropriate water during pelletizing depending on material moisture.

Редуктор фильтрата for Petroleum Drilling

Dry addition; binder-to-material ratio: 100:1.5–3. Adjust depending on particle size and surface area.

Note: These ratios are provided as general guidance. For best results, Jianjie recommends conducting small-scale trials and adjusting according to specific raw material properties and production conditions.

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 Conclusion