Synergistic conversion of iron ore sintering dust and waste biochar to produce direct reduction iron and syngas: Gasification, reduction behavior and thermodynamic analysis

Abstract

Waste biochar from biomass power generation and sintering dust from ferrous metallurgy were skillfully used to produce direct reduced iron (DRI) and syngas via a synergetic conversion in this study. The thermodynamic analysis of their related reactions, biochar conversion and reduction behavior of sintering dust were investigated. The biochar gasification and reduction of sintering dust were coupled and promoted by each other at 1000 °C for 60 min with 1.2 mol (C/Fe). For biochar conversion, adding sintering dust deepened the pyrolysis of the volatiles in the waste biochar to generate more CH4, and it provided more oxygen atoms, gasifying carbon atoms in the fixed carbon to generate more CO. The CO and CH4 yield from biochar conversion with iron oxides of sintering dust increased by 633.8% and 41.5% to its pyrolysis alone. For the reduction of sintering dust, the whole conversion process of sintering dust was the generation, aggregation and growth of the iron grains, including the generation of metallic iron grains, forming curved bars and composite flocculent metallic iron, and its larger lumps particles finally. A DRI with a 92.4% metallization ratio, meeting the requirements of the subsequent electric arc furnaces, was obtained at 1000 °C for 60 min with 1.2 mol (C/Fe). This study achieves an efficient and reciprocal conversion of these two solid waste resources. It offers an essential research reference for fuel gasification and DRI processes.