The purpose of this study was to comprehensively analyze the effects of the carbon powder coating mass fraction, pressure, reduction temperature, reduction time, gas linear velocity, and particle size on fluidization reduction. Brazilian fine iron ore particles were the experimental object, and reduction experiments were performed under added carbon powder coating and pressure conditions. A six-factor, three-level orthogonal experiment method was used to obtain the optimal operating conditions and investigate the adhesion and inhibition mechanisms of fine iron ore during reduction. The experimental results show that with the addition of a carbon powder coating, an appropriate increase in pressure can increase the metallization rate, improve the fluidization state, and reduce the sticking ratio. The optimal operating conditions for pure hydrogen to reduce Brazilian fine iron ore was found to be a reduction temperature of 923–1023 K, the linear velocity of the reducing gas was 0.6 m/s, the reducing time was 30–50 min, the reducing pressure was 0.25 MPa, the mass content of the coated carbon powder was 2–6% (accounting for the mass of the mineral powder), and the particle size of the carbon powder was 4–7 µm. Iron whiskers cohesion and agglomeration were the main reasons for the adhesion of ore powder particles. It was found that carbon powder coating can effectively change the morphology of metal iron, as metal iron generates spherical particles around the carbon powder to improve the fluidization state.
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