Dephosphorization study on hydrogen reduction-melting separation of high-phosphorus oolitic hematite

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In order to clarify the dephosphorization mechanism of DRI (Direct Reduced Iron) derived from hydrogen reduced high-phosphorus iron ore during the electric arc furnace melting process, slag was prepared using reagent-grade powder based on the gangue mineral composition of high-phosphorus oolitic hematite. By incorporating varying amounts of CaO, FeOx, and reduced iron powder, experiments simulating the dephosphorization of melting separation slag from DRI with different basicity and metallization rates were conducted at 1873 K. The results show that phosphorus in the iron primarily exists in the form of Fe–P–O spherical slag inclusions and FexP, while in the slag, phosphorus mainly resides within the silicate phases. As the amount of CaO added increases, there is a significant decrease in the phosphorus content within the slag inclusions, and the P-containing compounds in the iron gradually shift from FexP and Fe3(PO4)2 to FeO. As the dephosphorization capacity of the slag increases, the distribution of phosphorus-rich phases in the rapidly cooled slag becomes more extensive. When the basicity increases to 3, the phosphorus-rich phases in the slag transition to 2CaO·SiO2 and 3CaO·SiO2. When the basicity is fixed at 2.5, regulating the metallization rate can control the FeOx content in the molten slag, thereby enhancing the dephosphorization ability of slag. The results show that under conditions of a DRI basicity of 2.5 and a metallization rate of 85%, slag/metal separation can produce low-phosphorus iron with 0.022 wt% P, achieving a dephosphorization rate exceeding 95%.