Enhancing the Reduction of High-Aluminum Iron Ore by Synergistic Reducing with High-Manganese Iron Ore

Abstract

How to utilize low grade complex iron resources is an issue that has attracted much attention due to the continuous and huge consumption of iron ores in China. High-aluminum iron ore is a refractory resource and is difficult to upgrade by separating iron and alumina. An innovative technology involving synergistic reducing and synergistic smelting a high-aluminum iron ore containing 41.92% Fetotal, 13.74% Al2O3, and 13.96% SiO2 with a high-manganese iron ore assaying 9.24% Mntotal is proposed. The synergistic reduction process is presented and its enhancing mechanism is discussed. The results show that the generation of hercynite (FeAl2O4) and fayalite (Fe2SiO4) leads to a low metallization degree of 66.49% of the high-aluminum iron ore. Over 90% of the metallization degree is obtained by synergistic reducing with 60% of the high-manganese iron ore. The mechanism of synergistic reduction can be described as follows: MnO from the high-manganese ore chemically combines with Fe2SiO4 and FeAl2O4 to generate Mn2SiO4, MnAl2O4 and FeO, resulting in higher activity of FeO, which can be reduced to Fe in a CO atmosphere. The main products of the synergistic reduction process consist of Fe, Mn2SiO4, and MnAl2O4.

On the Direct Reduction Phenomena of Bauxite Ore Using H2 Gas in a Fixed Bed Reactor

“…The rate of reduction is faster for higher reduction temperatures. The reduction to metallic iron seems to increase with increasing the temperature; however, the formation of hercynite seems to retard the complete reduction to metallic iron [24] according to XRD and EPMA results and the literature. The fraction of conversion seems to be more than 1 for the sample treated at 1060 °C and this is possible due to some inhomogeneities among the samples used and thus the slightly higher iron content than the one measured in the bauxite sample.…”

“…The resulting ferrous iron is partly dissolved into the matrix and partly forms hercynite [22]. According to [23,24], the formation of wustite is the reason for the hercynite formation in the presence of alumina in the samples. The formation of the above phase seems to retard the complete reduction of iron oxides [24,25].…”

Ironmaking and Steelmaking

“…Naseri Seftejani and Schenk [31] analysed the thermodynamics of the hydrogen plasma smelting reduction of iron ore in the process of using hydrogen in a plasma state to reduce iron oxides. The other nine papers covered experimental studies (El-Tawil et al [26], Fukushima, and Takizawa [23], Wu et al [5], Zhou et al [6], Zhang et al [7]), modelling predictions (Gao et al [8], Tang et al [9]), and kinetic analysis (Wang et al [10], Chen et al [11]).…”

Roles of MgO and Al2O3 on the Viscous and Structural Behavior of Blast Furnace Primary Slag, Part 1: C/S = 1.3 Containing TiO2

“…The variables represent the MgO and Al 2 O 3 content, which change from 8 to 12 mass% and 10 to 18 mass% at a fixed CaO/SiO 2 of 1.3 (binary basicity, abbreviated as C/S), with a FeO content of 5 mass% and a TiO 2 content of 10 mass%, respectively. The starting materials for the viscosity experiments consist of FeC 2…”

“…In the last few years, the steel industry has faced significant challenges from iron resources and environment-energy saving restrictions [1]. High alumina iron ore has been considered due to its low cost [2]. The reasonable combination of high aluminum ore and titanium magnetite ore is an economical choice for Ti-bearing iron ore smelting.…”