Abstract
In this study, high-purity iron with purity of 99.987 wt.% was prepared employing a process of direct reduction–melting separation–slag refining. The iron ore after pelletizing and roasting was reduced by hydrogen to obtain direct reduced iron (DRI). Carbon and sulfur were removed in this step and other impurities such as silicon, manganese, titanium and aluminum were excluded from metallic iron. Dephosphorization was implemented simultaneously during the melting separation step by making use of the ferrous oxide (FeO) contained in DRI. The problem of deoxidization for pure iron was solved, and the oxygen content of pure iron was reduced to 10 ppm by refining with a high basicity slag. Compared with electrolytic iron, the pure iron prepared by this method has tremendous advantages in cost and scale and has more outstanding quality than technically pure iron, making it possible to produce high-purity iron in a short-flow, large-scale, low-cost and environmentally friendly way.
Highlights
Pure iron, which refers to iron with very few impurities, has excellent properties such as low coercivity, high ductility, soft texture as well as good performance in thermal conductivity and electrical conductivity
Similar to the process investigated in this study, researchers [9,10,11] have studied the process of smelting pure iron with direct reduced iron (DRI) in an induction furnace, which has delivered good results
This study presents the research results of preparation of high-purity iron with purity of 99.987 wt.%
Summary
Pure iron, which refers to iron with very few impurities, has excellent properties such as low coercivity, high ductility, soft texture as well as good performance in thermal conductivity and electrical conductivity. Similar to the process investigated in this study, researchers [9,10,11] have studied the process of smelting pure iron with DRI in an induction furnace, which has delivered good results These results still have the capacity to improve the impurities removal in pure iron, especially in solving the problem of deoxidation of pure iron, so the purity has not reached a high grade. The pure iron obtained by this method has tremendous advantages in cost and scale compared with electrolytic iron and has more outstanding quality than technically pure iron This is because this process takes full advantage of the purity advantage of DRI and solves the problem of deoxidization of pure iron in the context of large-scale production. This paper mainly expounds upon the experimental process and related mechanism of producing high-purity iron by this method, as well as the feasibility of industrialization
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