Search Results (13)

High-phosphorus oolitic iron ores (HPOIOs) possess abundant reserves but are incompatible with conventional blast furnace ironmaking, as phosphorus migrates into hot metals during carbothermic reduction, preventing the production of low-phosphorus clean steel. To overcome this limitation, an innovative approach integrating alkaline briquette direct reduction and smelting separation was proposed. Briquettes were prepared from oolitic magnetite concentrate (52.01 wt% Fe, 0.29 wt% P, 0.11 wt% S) with a basicity (R) of 2.0 and 5 wt% MgO added as a desulfurizer. After direct reduction and smelting separation, the resulting metallic iron exhibited a content of 98.56 wt% Fe, with 0.036 wt% P and 0.046 wt% S, achieving an Fe recovery of 87.63%. The dephosphorization and desulfurization efficiencies reached 94.67% and 90.56%, respectively, meeting the clean steel requirements. Phosphorus was effectively stabilized within the gehlenite and merwinite phases as a solid solution of Ca₃(PO₄)₂, inhibiting its transfer to iron. Thermodynamic analyses confirmed that high basicity (R ≥ 2.0) significantly suppressed P₂O₅ activity, preventing phosphate reduction. The formation of a Ca₃(PO₄)₂–Ca₂SiO₄ solid solution further obstructed phosphorus migration. This dual mechanism of “chemical fixation and thermodynamic stabilization” enables efficient dephosphorization, offering a sustainable pathway for utilizing HPOIOs. Full article

Conventional separation methods often prove ineffective for complex, refractory high-phosphorus iron ores. Recent advances propose a coal-based direct reduction dephosphorization-magnetic separation process, achieving significant dephosphorization efficiency. This review systematically analyzes phosphorus occurrence states in high-phosphorus oolitic iron ores across global deposits, particularly within iron minerals. We categorize contemporary research and elucidate dephosphorization mechanisms during coal-based direct reduction. Key factors influencing iron mineral phase transformation, iron enrichment, and phosphorus removal are comprehensively evaluated. Phosphorus primarily exists as apatite and collophane gangue m horization agents function by: (1) inhibiting phosphorus-bearing mineral reactions or binding phosphorus into soluble salts to prevent incorporation into metallic iron; (2) enhancing iron oxide reduction and coal gasification; (3) disrupting oolitic structures, promoting metallic iron particle growth, and improving the intergrowth relationship between metallic iron and gangue. Iron mineral phase transformations follow the sequence: Fe₂O₃ → Fe₃O₄ → FeO (FeAl₂O₄, Fe₂SiO₄) → Fe. Critical parameters for effective dephosphorization under non-reductive phosphorus conditions include reduction temperature, duration, reductant/dephosphorization agent types/dosages. Future research should focus on: (1) investigating phosphorus forms in iron minerals for targeted ore utilization; (2) reducing dephosphorization agent consumption and developing sustainable alternatives; (3) refining models for metallic iron growth and improving energy efficiency; (4) optimizing reduction atmosphere control; (5) implementing low-carbon emission strategies. Full article

Diverging from conventional dephosphorization approaches, this study employs a novel pre-reduction and smelting separation (PR-SS) to efficiently co-recover iron and phosphorus from high-phosphorus oolitic iron ore, directly yielding Fe–P alloy, and the Fe–P alloy shows potential as feedstock for high-phosphorus weathering steel or wear-resistant cast iron, indicating promising application prospects. Using oolitic magnetite concentrate (52.06% Fe, 0.37% P) as feedstock, optimized conditions including pre-reduction at 1050 °C for 2 h with C/Fe mass ratio of 2, followed by smelting separation at 1550 °C for 20 min with 5% coke, produced a metallic phase containing 99.24% Fe and 0.73% P. Iron and phosphorus recoveries reached 99.73% and 99.15%, respectively. EPMA microanalysis confirmed spatial correlation between iron and phosphorus in the metallic phase, with undetectable phosphorus signals in vitreous slag. This evidence suggests preferential phosphorus enrichment through interfacial mass transfer along the pathway of the slag phase to the metal interface and finally the iron matrix, forming homogeneous Fe–P solid solutions. The phosphorus migration mechanism involves sequential stages: apatite lattice decomposition liberates reactive P₂O₅ under SiO₂/Al₂O₃ influence; slag–iron interfacial co-reduction generates Fe₃P intermediates; Fe₃P incorporation into the iron matrix establishes stable solid solutions. Full article

Acid leaching is an effective method for dephosphorization; however, it is time-consuming and requires a high amount of acid consumption, resulting in increased production costs and environmental risks. This work aims to remove silicon, aluminum, and phosphorus from high-phosphorus oolitic magnetite concentrate through high-pressure alkaline leaching and ultrasonic acid leaching. Compared with traditional acid leaching processes, the sulfuric acid dosage can be significantly reduced from 200 kg/t to 100 kg/t, and the pickling time is shortened from 60 min to 10 min. Thermodynamic and kinetic studies have demonstrated that acid leaching facilitates apatite dissolution at low temperatures, whereas the dephosphorization reaction is controlled mainly by diffusion. The application of ultrasonic waves leads to finer particle sizes and greatly increased specific surface areas, thereby accelerating the diffusion rate of the leaching agent. Furthermore, microscopic analysis revealed that under the influence of ultrasonic waves, numerous micro-fragments and pores form on particle surfaces due to cavitation effects and mechanical forces generated by ultrasonic waves. These factors promote both the reaction rates and diffusion processes of the leaching agent while enhancing the overall leaching efficiency. Full article

Calcium carbonate, renowned for its affordability and potent dephosphorization capabilities, finds widespread use as a dephosphorization agent in the direct reduction roasting of high-phosphorus oolitic hematite (HPOIO). However, its precise impact on iron recovery and the dephosphorization of iron minerals with phosphorus within HPOIO, particularly the mineral transformation rule and dephosphorization mechanism, remains inadequately understood. This study delves into the nuanced effects of calcium carbonate on iron recovery and dephosphorization through direct reduction roasting and magnetic separation. A direct reduction iron (DRI) boasting 95.57% iron content, 93.94% iron recovery, 0.08% phosphorus content, and an impressive 92.08% dephosphorization is achieved. This study underscores how the addition of calcium carbonate facilitates the generation of apatite from phosphorus in iron minerals and catalyzes the formation of gehlenite by reacting with silicon dioxide and alumina, inhibiting apatite reduction. Furthermore, it increases the liquid phase, enhancing the dissociation of metallic iron monomers during the grinding procedure, thus facilitating efficient dephosphorization. Full article

The feasibility of dephosphorization using the flotation process and its mechanism of high-phosphorus oolitic hematite were discussed in this paper. The results showed that phosphorus minerals mainly exist in the form of collophane, which can be divided into three types. Block collophane and band collophane could be effectively removed through flotation, while the third type could not be eliminated through physical concentration alone. A lab-made fatty acid was identified as an effective collector for high-phosphorus oolitic hematite, resulting in a product containing 57.67% iron and 0.14% phosphorus with a flotation recovery rate of 82.43%. The study of the flotation mechanism revealed that, in the presence of starch and the lab-made fatty acid, there was both physical absorption and chemisorption occurring on the surfaces of apatite. However, only very weak physical absorption was observed on the surface of hematite. Full article

Oxygen is an important energy medium in the steelmaking process. The accurate dynamic prediction of oxygen demand is needed to guarantee molten steel quality, improve the production rhythm, and promote the collaborative optimization of production and energy. In this work, a analysis of the mechanism and of industrial big data was undertaken, and we found that the characteristic factors of Basic Oxygen Furnace (BOF) oxygen consumption were different in different modes, such as duplex dephosphorization, duplex decarbonization, and the traditional mode. Based on this, a dynamic-prediction modeling method for BOF oxygen demand considering mode classification is proposed. According to the characteristics of BOF production organization, a control module based on dynamic adaptions of the production plan was researched to realize the recalculation of the model predictions. A simulation test on industrial data revealed that the average relative error of the model in each BOF mode was less than 5% and the mean absolute error was about 450 m³. Moreover, an accurate 30-minute-in-advance prediction of dynamic oxygen demand was realized. This paper provides the method support and basis for the long-term demand planning of the static balance and the short-term real-time scheduling of the dynamic balance of oxygen. Full article

As an effective flux, CaF₂ is beneficial in improving the fluidity of slag in the steel-making process, which is crucial for dephosphorization. To reveal the existence form and functional mechanism of CaF₂ in phosphosilicate systems, the microstructures and transport properties of CaO-SiO₂-CaF₂-P₂O₅ quaternary slag systems are investigated by molecular dynamics simulations (MD) combined with experiments. The results demonstrate that the Si-O coordination number does not vary significantly with the increasing CaF₂ content, but the P-O coordination number dramatically decreases. CaF₂ has a minor effect on the single [SiO₄] but makes the structure of the silicate system simple. On the contrary, F⁻ ions could reduce the stability of P-O bonds and promoted the transformation of [PO₄] to [PO₃F], which is beneficial for making the P element-enriched phosphate network structure more aggregated. However, the introduction of CaF₂ does not alter the tetrahedral character of the original fundamental structural unit. In addition, the results of the investigation of the transport properties show that the self-diffusion coefficients of each ion are positively correlated with CaF₂ content and arranged in the order of F⁻ > Ca²⁺ > O²⁻ ≈ P⁵⁺ > Si⁴⁺. Due to CaF₂ reducing the degree of polymerization of the whole melts, the viscosity decreases from 0.39 to 0.13 Pa·s as the CaF₂ content increases from 0% to 20%. Moreover, the viscosity of the melt shows an excellent linear dependence on the structural parameters. Full article

In order to better understand and develop the technology of integrating dephosphorization and decarburization in a single converter (abbreviated as IDDSC), the relevant thermodynamic issues were discussed by calculation. Based on the thermodynamic calculation, the bridges between the phosphorus distribution ratio, temperature, and slag composition were constructed. Besides, the connections between the dephosphorization behavior and the microstructure of slag were also established by investigating four heats of hot metal smelt using IDDSC technology. As a result, the mechanism of phosphorus enrichment in the dephosphorization slag was revealed. Also, the results show that the dephosphorization efficiency increases gradually with increasing slag basicity. While the dephosphorization efficiency increases first and then decreases with the increase of FeO content in slag. There is a competition relationship between P₂O₅ and FeO in reacting with CaO and SiO₂. When CaO/FeO is relatively high, not enough FeO is provided. Thus P₂O₅ is in priority to react with CaO and SiO₂ through [3n + 2](CaO) + 2SiO₂ + n(P₂O₅) = n(3CaO·P₂O₅)-2CaO·SiO₂(s), generating P₂O₅-rich nC₂S-C₃P solid solution which promotes the removal of [P] from the hot metal. When CaO/FeO is relatively low, FeO competes over P₂O₅ in reacting with CaO and SiO₂ through a(CaO) + b(SiO₂) + c(FeO) = aCaO·bSiO₂·cFeO(s), generating CaFeSiO₄ instead of P₂O₅-rich solid solution. As a consequence, the slag with low CaO/FeO shows a poor dephosphorization ability. Full article

According to the mineral composition characteristics of high-phosphorus iron ore, the reaction mechanism of fluorapatite was investigated using pure substance and gangue under vacuum carbon thermal reduction (VCTR) conditions. The effects of reduction temperature, basicity, and C/O ratio on the metallization ratio, dephosphorization ratio, and phosphorus content of pellets were studied. The reaction process of fluorapatite in high-phosphorus iron ore was investigated. The results showed that when the metallization ratio of pellets reached maximum (95%), the dephosphorization ratio was only 5.6%, thus indicating adverse result. The reduction processes of high-phosphorus iron ore under vacuum and nitrogen environment were, respectively, compared under the optimal condition. It was found that the metallization ratio of pellets in the vacuum condition was higher than that under the nitrogen condition, while the dephosphorization ratio showed an opposite result. This indicated that in the process of vacuum reduction, fluorapatite not only reacted with carbon to form gaseous phosphide, but also with iron to form compounds containing the Fe–P bond. Therefore, a new mechanism of reduction of fluorapatite was proposed as follows: 2Ca₅(PO₄)₃F + 12Fe + 9SiO₂ + 15C = 9CaSiO₃ + 6Fe₂P + 15CO + CaF₂. Full article

In this paper, the process of direct reduction roasting using magnetic separation to produce direct reduction iron (DRI) from high-phosphorus oolitic hematite, using coal slime and blast furnace dust as reductant, is investigated. The possible use of slime coal and blast furnace dust as reductant and the dephosphorization behavior during the process of direct reduction was studied. Experimental results showed that both blast furnace dust and coal slime can be used as reductant under certain conditions in the process. The dephosphorization mechanism of blast furnace dust and coal slime were investigated by X-ray diffraction (XRD) and scanning electron microscope (SEM)-energy dispersive X-ray spectroscopy (EDS). A DRI with 91.88 wt. % iron grade, 88.38% iron recovery and 0.072 wt. % P can be obtained with 30 wt. % blast furnace dust as reductant. The program not only used blast furnace dust but also recovered iron from blast furnace dust and high-phosphorus oolitic hematite. The analysis results revealed that phosphorus is distributed in gangue mineral and fluorapatite when blast furnace dust is used as reductant. Phosphorus-bearing minerals were not reduced to phosphorus element when the blast furnace dust was the reductant, but part of the fluorapatite reduced to phosphorus which smelt into metallic iron with coal slime as reductant. This led to a high phosphorus content of DRI. This research could provide support to the idea concept for recycling of carbon-containing solid waste and to assist the effective recovery of refractory iron ore by direct reduction–magnetic separation. Full article

The release of valuable minerals from the associated gangues is called liberation. Good liberation is essential to the subsequent separation stage. Selective liberation is advantageous to improve the degree of liberation. Oolitic hematite is one of the typical refractory iron ores in China, and its resources are abundant. However, owing to its fine dissemination and complex mineralogical texture, the conventional grinding processes are inefficient in improving the selective liberation of oolitic hematite. In this study, microwave processing and acid leaching were used to assist the liberation of oolitic hematite. The assisted liberation of the oolitic hematite mechanisms of microwave processing and acid leaching were studied by using scanning electron microscope (SEM), X-ray diffraction (XRD), BET specific surface area detection method (BET) and the transflective microscope method. The results indicated that microwave processing can reduce the mechanical strength of oolitic hematite and improve the liberation of hematite, and acid leaching can improve the microwave-assisted liberation efficiency and reduce the content of phosphorus in the grinding product. Compared to direct grinding, the liberation of hematite increased by 54.80% in the grinding product, and especially, the fractions of −0.038-mm and 0.05–0.074 mm increased significantly; however, there was no obvious change in other grain sizes, and the dephosphorization ratio reached 47.20% after microwave processing and acid leaching. After the two stages, the iron grade and recovery of the magnetic separation product increased by 14.26% and 34.62%, respectively, and the dephosphorization ratio reached 88.59%. It is demonstrated that microwave processing and acid leaching comprise an efficient method to improve the liberation of hematite and the dephosphorization ratio of oolitic hematite. The two-stage treatment can achieve selective liberation of oolitic hematite, which is beneficial to the following magnetic separation. Full article

A novel staged leaching process has been reported in this paper to selectively extract vanadium from roasted stone coal and the mechanisms have been clarified. Results showed that the leaching efficiency of V, Al, P and Fe was 80.46%, 12.24%, 0.67% and 3.12%, respectively, under the optimum dilute sulfuric acid dephosphorization (DSAD)-two-stage pressure acid leaching (PAL) conditions. The efficient separation of V from Fe, Al and P was realized. As apatite could be leached more easily than mica, the apatite could completely react with sulfuric acid, while the mica had almost no change in the DSAD process, which was the key aspect in realizing the effective separation of V from P. Similarly, the hydrolyzation of Fe and Al could be initiated more easily than that of V by decreasing the residual acid of leachate. The alunite and iron-sulphate compound generated in the first-stage PAL process resulted in the effective separation of V from Fe and Al. Full article