Purpose. This research aims to promote the assay of iron and reduce the phosphorus grade of the final DRI. Methodology. A high-phosphorus oolitic iron ore from Gara Djebilet deposit underwent the procedure of coal-based direct reduction (coal-based DR) followed by wet low-intensity magnetic separation (WLIMS). The effects of temperature, periods of time and Na2SO4 dosage on phosphorus removal, metallisation degree and iron recovery rate were tried and optimised. Furthermore, phase changes in iron oxides and the distributing features of phosphorus in both reduced and magnetic materials were investigated as well. Findings. The appropriate addition of sodium sulfate improves the Fe-P separation during the coal-based DR of Gara Djebilet mixed pellets. Originality. Using additives of CaO and sodium sulfate during the coal-based DR-magnetic separation of mixed pellets sourced from Gara Djebilet deposit. Practical value. The results reveal that a final direct reduced powder (DRI) assaying 96 wt% Fe and 0.16 wt% P at a recovery rate of 97.72% was obtained when the ore-coal-CaO mixed pellets were reduced in the presence of 5 wt% Na2SO4 at 1250 C for 30 min. Thus, the coal-based DR could be used as an alternative to the blast furnace (BF) route in the steelmaking industry from refractory iron ores.
A process involving coal-based direct reduction followed by wet low-intensity magnetic separation is presented in this paper with the objective of promoting the Fe content and reducing the P assay of phosphorus-rich oolitic iron ore. A final direct reduced iron powder assaying 92.5 wt% Fe and 0.2wt % P at a recovery rate of 95.9% was obtained when a mixture of ore-coal-CaO was reduced at 1200°C during 60 min in the presence of 7.5% sodium sulfate. In addition, microscopic analyses reported that the oolitic texture was completely destroyed, and most of the iron occurred in the metallic state. These findings suggest the ease utilisation of the ore mined from Gara Djebilet in the steelmaking industry as a substitute to scrap steel in electric arc furnace.
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