Influence of several factors on synthesis of iron carbide from iron ore

Abstract

Iron carbides as alternative pure iron sources were synthesised by thermochemical reactions of iron ores with H2–CO gas mixtures having low sulphur pressures incapable of forming FeS. It was proved that high quality iron carbides without free carbon can be obtained more effectively at relatively high reaction rates. Some pressurisation was effective in eliminating the detrimental influence of oxidant components in the inlet gas mixtures. Ore type, reaction time, H2 /CO ratio, sulphur potential, and total gas pressure dependencies on the iron carburisation rates were examined and the rates were analysed using a first order rate model. Comparison shows that the productivity of the proposed process should be almost one order of magnitude greater than that of a conventional Iron Carbide process.