Abstract
The problem of properly utilizing non-coking coals in alternative iron making processes dates back to long ago. Lean grade coals with higher ash and volatile matter content (e.g. boiler grade coals) have always challenged the metallurgists to develop a suitable process for their utilization. The aim of this work is to achieve an energy efficient method for the reduction of briquetted iron ore fines using ‘SYNGAS’—which is the gaseous product (enriched with reducing agents) generated by pyrolysis of coal along with fine sized carbon particles produced during pyrolysis. A laboratory scale reduction furnace with pyrolysis facility has been designed and fabricated after in depth thermo-gravimetric analysis (TGA), differential thermal analysis (DTA), and gas chromatograph (GC) studies. A particular temperature profile has been maintained inside the furnace to achieve the optimum reduction temperature. The briquettes are reduced in the pyrolysis furnace and the extent of reduction has been calculated from the weight loss. The reduced specimens are characterized using X-ray diffractometer (XRD), scanning electron microscope (SEM), energy dispersive X-ray spectrometer (EDX), field emission scanning electron microscope (FESEM), and chemical analysis method. It is observed that iron ore can be significantly reduced to metallic iron by using the devolatilization product of lean grade coal.
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