Synchronous Upgrading Iron and Phosphorus Removal from High Phosphorus Oolitic Hematite Ore by High Temperature Flash Reduction
Abstract
:1. Introduction
2. Experimental
2.1. Raw Materials
2.1.1. Oolitic Hematite Ore
2.1.2. Reducing Coal
2.1.3. Additive
2.1.4. Flux
2.2. Experimental Methods
2.2.1. High Temperature Flash Reduction
2.2.2. Magnetic Separation
2.2.3. Analytic Tests
2.3. Evaluation Indexes
3. Results and Discussion
3.1. Thermodynamic Analysis
3.1.1. Thermodynamic Analysis of Iron Mineral Reactions in the Reduction
3.1.2. Thermodynamic Analysis of Phosphorus Mineral Reactions in the Reduction
3.2. High Temperature Quick Reduction
3.2.1. Effects of C/Fe (Mass Ratio)
3.2.2. Effects of Reduction Temperature
3.2.3. Effects of Reduction Duration
3.2.4. Effects of Basicity
3.2.5. Effects of Sodium Sulfate Dosage
3.3. Magnetic Separation of Reduced Products
3.4. Analysis of Final Product
3.5. Mechanism of Removal of Phosphorus and Beneficiation of Iron
3.5.1. Phase Transformation of Oolitic Hematite Ore During Reduction Process
3.5.2. Growth of Metallic Iron Grains in Reduction
4. Conclusions
- Oolitic hematite ore, assaying 41.50% Fetotal, 1.24% P, 17.04%Al2O3 and 4.68% SiO2, was used as a raw material to produce metal iron powder. The characterization of the sample in mineralogy indicates that phosphorus appears mainly in calcium phosphate, and the main iron-bearing mineral, hematite, is superfinely disseminated and combined closely with other gangue minerals, resulting in poor beneficiation of iron and phosphorus removal by traditional dressing process.
- The quick high-temperature reduction process was conducted to improve the separation of Fe and P with the optimized conditions briquetting the ore mixture with 15% sodium sulphate and 2.4 basicity, and reducing at 1350 °C for 10 min with C/Fe of 0.48. The reduced briquettes obtained were then subjected to wet magnetic separation under the conditions of grinding at 95.72% over 0.074 mm, and magnetically separating the ground product in a Davi Tube at 0.10 T, and the final product (metallic iron powder), assaying 91.12% Fetotal and 0.25% P, was produced at overall iron recoveries of 90.08%, which can be used as the burden for steel-making.
- CaO and Na2SO4 can preferentially participate in the reactions with SiO2 and Al2O3, suppressing the reduction of calcium phosphate and intensifying the phosphorus removal. Meanwhile, sodium sulfate is suited to promoting the aggregation and growth of metallic iron grains, resulting in the elevation of the iron grade and recovery in the magnetic separation process.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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TFe | P | SiO2 | Al2O3 | CaO | MgO | K2O | S | LOI * |
---|---|---|---|---|---|---|---|---|
41.50 | 1.24 | 17.04 | 4.68 | 7.82 | 1.54 | 0.9 | 0.09 | 5.72 |
Mineral | Apatite | Iron Phosphate | Others | Total Phosphorus |
---|---|---|---|---|
Content | 1.175 | 0.041 | 0.024 | 1.24 |
Fraction | 94.76 | 3.31 | 1.94 | 100 |
Fe2O3 | SiO2 | Al2O3 | CaO | MgO | P | S |
---|---|---|---|---|---|---|
16.70 | 27.62 | 8.02 | 24.94 | 1.34 | 0.01 | 5.17 |
Proximate Analysis/% | Ash Fusibility Analysis/°C | ||||||
---|---|---|---|---|---|---|---|
Mad | Aad | Vad | FCad | DT | ST | HT | FT |
12.98 | 4.49 | 30.41 | 52.12 | 1332 | 1376 | 1450 | 1469 |
Reduction Duration/min | Metallization Degree/% | Magnetic Product | Iron Recovery/% | Phosphorus Removal Rate/% | |
---|---|---|---|---|---|
TFe/% | P/% | ||||
5 | 76.32 | 77.32 | 0.33 | 72.23 | 83.76 |
10 | 86.92 | 86.02 | 0.29 | 89.69 | 89.03 |
15 | 76.54 | 84.24 | 0.27 | 75.25 | 91.51 |
20 | 69.59 | 83.56 | 0.25 | 63.57 | 93.02 |
TFe | SiO2 | Al2O3 | CaO | MgO | Na2O | P | S |
---|---|---|---|---|---|---|---|
91.12 | 2.13 | 0.27 | 0.79 | 0.54 | 0.35 | 0.25 | 0.10 |
Grinding Fineness (–0.074 mm/%) | Magnetic Field Intensity/T | Magnetic Product | Iron Recovery/% | Phosphorus Removal Rate/% | |
---|---|---|---|---|---|
TFe/% | P/% | ||||
88.49 | 0.06 | 89.45 | 0.26 | 82.30 | 91.91 |
0.08 | 83.75 | 0.32 | 86.29 | 88.85 | |
0.10 | 85.70 | 0.29 | 83.51 | 90.44 | |
95.72 | 0.06 | 89.36 | 0.23 | 89.20 | 93.11 |
0.08 | 88.78 | 0.24 | 88.26 | 92.48 | |
0.10 | 91.12 | 0.25 | 90.08 | 91.79 | |
97.86 | 0.06 | 89.37 | 0.27 | 79.30 | 91.90 |
0.08 | 90.16 | 0.23 | 77.40 | 93.32 | |
0.10 | 88.01 | 0.25 | 88.63 | 91.49 |
Element | OK | MgK | AlK | SiK | PK | SK | KK | CaK | FeK | NaK | |
---|---|---|---|---|---|---|---|---|---|---|---|
A1 | Wt% | 28.72 | 0.28 | 1.63 | 13.60 | 0.88 | 0.18 | 0.53 | 40.94 | 13.25 | / |
At% | 49.08 | 0.31 | 1.65 | 13.24 | 0.78 | 0.15 | 0.37 | 27.93 | 6.49 | / | |
B1 | Wt% | 24.83 | 0.93 | 2.44 | 10.80 | 5.21 | 3.93 | 1.15 | 44.67 | 1.81 | 4.23 |
At% | 41.76 | 1.03 | 2.43 | 10.35 | 4.53 | 3.30 | 0.79 | 29.99 | 0.87 | 4.96 | |
A2 | Wt% | / | / | / | / | 0.78 | / | / | / | 99.22 | / |
At% | / | / | / | / | 1.39 | / | / | / | 98.61 | / | |
B2 | / | / | / | / | / | / | / | / | 0.45 | 99.55 | / |
/ | / | / | / | / | / | / | / | 0.63 | 99.37 | / |
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Zhu, D.; Guo, Z.; Pan, J.; Zhang, F. Synchronous Upgrading Iron and Phosphorus Removal from High Phosphorus Oolitic Hematite Ore by High Temperature Flash Reduction. Metals 2016, 6, 123. https://doi.org/10.3390/met6060123
Zhu D, Guo Z, Pan J, Zhang F. Synchronous Upgrading Iron and Phosphorus Removal from High Phosphorus Oolitic Hematite Ore by High Temperature Flash Reduction. Metals. 2016; 6(6):123. https://doi.org/10.3390/met6060123
Chicago/Turabian StyleZhu, Deqing, Zhengqi Guo, Jian Pan, and Feng Zhang. 2016. "Synchronous Upgrading Iron and Phosphorus Removal from High Phosphorus Oolitic Hematite Ore by High Temperature Flash Reduction" Metals 6, no. 6: 123. https://doi.org/10.3390/met6060123