Optimization of Roasting Process and Thermal Parameter Adaptability for Guisha Limonite Pelletizing

Driven by the urgent demand of the steel industry for utilizing low-grade, high-crystal-water iron ores, this study focuses on the thermal decrepitation problem in Guisha limonite pellet preparation caused by goethite dehydroxylation. Different from previous studies that mainly focused on single factors or single performance indicators, this work establishes a multi-factor experimental framework that simultaneously considers bentonite dosage, preheating temperature, and pellet size. This framework enables the strength–decrepitation trade-off of Guisha limonite pellets to be evaluated quantitatively rather than empirically. This work systematically investigated bentonite addition (0.8–1.6 wt%), preheating temperature (600–800 °C), and pellet diameter (9–13 mm). These factors were evaluated in terms of thermal cracking mass ratio and compressive strength. Their interactive effects on thermal cracking behavior and mechanical properties were quantitatively revealed. A target-oriented dual-window process control strategy was then proposed. The results show that thermal cracking intensifies with increasing preheating temperature and decreases with increasing bentonite content; compressive strength peaks at 1.2 wt% bentonite (approx. 1456 N). On this basis, a Min–Max normalization and weighted scoring method was adopted. A quantitative decision-making model was established for strength-prioritized and safety-prioritized objectives. The model identified two optimal process control windows at 1.2 wt% and 1.4 wt% bentonite. An optimized thermal regime—preheating at 700 °C, roasting at 1250 °C, and slow furnace cooling—was established. This regime provides directly referable process parameters. It also offers a decision-making framework for pellet production of similar ores.