Direct reduction of copper slag-carbon composite pellets by coal and biochar

Abstract

ABSTRACT As a renewable resource of reducer, biochar prepared by pine sawdust is proposed for direct reduction of copper slag in this paper. Combined with thermodynamic analysis, effects of reduction time, temperature and CaO addition ratio on solid copper slag reduction characteristics are discussed. The oxides of iron in copper slag are Fe3O4 and 2FeO·SiO2. The reduction processes were carried out step by step for Fe3O4 and 2FeO·SiO2, respectively: Fe3O4 → FeO → Fe and 2FeO·SiO2 → Fe. The porous structure of biochar exhibits higher reduction reactivity and reaction rate than that of coal. CaO reduced the Gibbs free energy of reduction reactions and facilitated the reduction of 2FeO·SiO2 with C and CO. When CaO was added, separation reaction of FeO and SiO2 took place and α-SiO2 and β-SiO2 were produced. When the addition ratio of CaO is above 0.3, CaO·SiO2 and 2CaO·SiO2 are produced. The reduction process of copper slag was established as follows: (a) dehydration and fast pyrolysis; (b) reduction of iron oxides by C and CO; and (c) sweating metallic iron outflows from cracks in pellet. Besides, direct reduction reaction mechanism and transport process of Cu are established based on reduction experiments, XRD and SEM-EDS analysis.