Abstract
In this paper, an effective method was developed to remove phosphorus and upgrade iron from high phosphorus oolitic hematite ore by high temperature flash reduction—a wet magnetic separation process. A thermodynamic analysis of iron and phosphorus mineral reactions and experiments with Fe-P separation process were performed, and the mechanism of phosphorus removal and beneficiation of iron is discussed as well. The results show that under the proper conditions, a final metallic iron powder assaying over 91% Fe and 0.25% P was obtained with iron recovery of 90% and phosphorus removal rate of 91.79% using the new process, indicating that the high temperature flash reduction process is a feasible and efficient way to process this kind of complex and refractory iron ore. Moreover, sodium sulfate is found to be capable of improving the removal of phosphorus and the upgrading of iron, as well as enhancing the growth of metallic iron grains significantly for higher recovery of iron.
Highlights
Oolitic hematite ore, one type of the most refractory iron ores, is characterized by low total iron grade (Fetotal 35%–50%), high phosphorus and aluminum content (0.4%–1.8% P and 2.5%–9.0% Al2 O3, respectively), as well as poor liberation of iron minerals due to fine dissemination [1,2]
The results showed that a magnetic concentrate with total iron grade of 92.7% and phosphorus content of 0.09% was produced from an oolitic hematite ore containing 48.96% iron and 1.61% phosphorus, where reduction of the iron ore blended with excessive coal at 1050 ̋ C for 120 min with 9.0% sodium sulfate was conducted
The characterization of the sample in mineralogy indicates that phosphorus appears mainly in calcium phosphate, and the main iron-bearing mineral, hematite, is superfinely disseminated and combined closely with other gangue minerals, resulting in poor beneficiation of iron and phosphorus removal by traditional dressing process
Summary
One type of the most refractory iron ores, is characterized by low total iron grade (Fetotal 35%–50%), high phosphorus and aluminum content (0.4%–1.8% P and 2.5%–9.0% Al2 O3 , respectively), as well as poor liberation of iron minerals due to fine dissemination [1,2]. If oolitic hematite ore were properly processed with effective technologies, the increasing pressure of an iron resource shortage would be reduced. Many efforts have been focused on improving the beneficiation of iron and the removal of phosphorus from oolitic hematite ore, such as chemical leaching [3,4,5], bio-leaching [6,7,8], magnetic roasting [9], selective agglomeration-reverse flotation [10], physical separation and direct reduction-magnetic separation [11,12]. Ba et al noted that an iron concentrate with 76.47% Fe and 0.25% P was obtained under following conditions: pelletizing the mixture of oolitic hematite ore with 10% Na2 CO3 , reducing the pellets at
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