Reduction Of Iron Ore Research Articles

Iron-Ore Reduction in Fluidized Beds: Review of Commercial Technologies, Status, and Challenges

Iron-Ore Reduction in Fluidized Beds: Review of Commercial Technologies, Status, and Challenges

Sensitization and Mechanical Response of Cu‐Containing Steel Rods

The iron and steel manufacturing sector significantly adds to global greenhouse gas emissions, caused primarily by the carbothermic reduction of iron ore. Recycling scrap steel offers an effective decarbonization strategy but introduces impurities like copper (Cu) that can negatively impact mechanical properties. This study investigates the effects of Cu content and heat treatment on the mechanical performance and sensitization of steel wire rods for tire manufacturing. Steel rods with 0.04 and 0.21 wt% Cu are heated to 1050 or 1200 °C, then air quenched, or furnace cooled. Tensile testing coupled with microscopic analysis is used to evaluate mechanical properties and assess the sensitization effects. Higher Cu content leads to larger sensitized zones with increased Cu precipitation along grain boundaries. Ductility and toughness, crucial for wire drawability, are found to be reduced, despite higher ultimate strength. Slower furnace cooling is seen to result in smaller sensitized zones compared to air quenching, suggesting a pivotal role of cooling rate in sensitization control. The findings provide insights into optimize heat treatment parameters and Cu content limits, balancing mechanical performance and maintaining drawability for enhanced scrap steel recycling in tire production.

A zero-carbon emission approach for the reduction of refractory iron ores: Mineral phase, magnetic property and surface transformation in hydrogen system

In this study, a feasible strategy, named hydrogen mineral phase transformation (HMPT) technology, is proposed and employed to achieve efficient and clean recovery of Hainan Shilu refractory iron ore (HSRIO). The influences of HMPT roasting temperature, roasting time, and H2 concentration on the separation index of HSRIO are investigated. Under the optimal experimental conditions, the iron concentrate grade increases from 62.5% to 67.9%, and the iron recovery increases from 65.0% to 94.7% compared with the original beneficiation process. In addition, the evolution of mineral phases, magnetic properties, and mineral microstructures is analyzed using XRD, VSM, SEM, and high-temperature hot-stage microscopy. It is revealed that the transformation of hematite to magnetite occurs during the HMPT process, with the newly formed magnetite exhibiting a loose and porous reticulation structure. This study is of guiding significance for the development of Hainan Shilu refractory iron ore with high efficiency and zero-carbon emission.

Factors influencing physical and mechanical properties of direct reduced iron ore pellets

Direct Reduction processes for iron ore employing natural gas or hydrogen are becoming more important. Correspondingly, properties of outgoing products are of importance. Degradation of Direct Reduced Iron (DRI) feedstock greatly influences storage, handling, risk of reoxidation, and following melting operations. The focus of this work has been on the physical properties of DRI, and their effect on mechanical properties. Four types of industrially produced DRI having varying metallization, carbon content, structure and apparent porosity have been studied. Three of the selected DRI types have been reduced using natural gas, and one DRI type has been reduced using pure hydrogen. Cold compression strength and tumbling tests are performed. Qualitative analysis of samples before and after mechanical testing is made using SEM and LOM. Results show that total carbon content has a significant influence on overall mechanical strength of DRI. Degradation of samples in tumbling tests is least significant for the hydrogen-reduced – and hence carbon-free – DRI type. The DRI type containing the most carbon (3 wt%) exhibits the most fines generation and lowest compression strength. Furthermore, apparent porosity and fractures formed during reduction have a small though not as significant impact as carbon content on mechanical properties.

Particle-resolved computational modeling of hydrogen-based direct reduction of iron ore pellets in a fixed bed. Part I: Methodology and validation

In the pursuit of more sustainable steelmaking, stakeholders are engaging in a transformative exploration of hydrogen-based direct reduction as an alternative to conventional blast furnaces. As a bridging step between single iron ore pellets and industrial shaft furnaces, direct reduction modeling in a fixed bed configuration can play a central role for subsequent process optimization. However, this task involves numerous challenging steps: generation of a realistic packed bed structure along with a good quality mesh and, foremost, reliable transport and kinetic processes for the individual pellets. Therefore, the present work formulates a sound methodology to progress from single particle considerations to 3D-CFD simulations of iron ore reduction using hydrogen in fixed beds, further supported by validations regarding the bed structure and the overall reduction against experimental data from the literature of a 500 g iron ore bed. The current results offer new insights into the direct reduction process, revealing, for instance, the non-uniform reduction of pellets within the bed, the presence of gas pockets, or the importance of the temperature deviation due to the endothermic reduction of iron oxides with hydrogen.

Fit-for-Purpose Model of HP500 Cone Crusher in Size Reduction of Itabirite Iron Ore

Cone crushers have a central role in the processing of quarry rocks, besides coarser ore preparation in several mineral processing plants. This is particularly true in the case of Itabirite iron ore preparation plants in Brazil, so optimizing their performance is of central importance for reaching maximum productivity of the circuit. The work presents results of modeling the HP500 cone crusher in operation in an industrial plant in Brazil (Minas Rio), from surveys carried out over a few years with different feeds and crushing conditions. A version of the Andersen–Whiten cone crusher model was implemented in the Integrated Extraction Simulator featuring a non-normalizable breakage response and a fit-for-purpose throughput model. The results demonstrate the good ability of the model to predict crusher performance when dealing with different closed-side settings and feed size distributions.

Solar-aided direct reduction of iron ore with hydrogen targeting carbon-free steel metallurgy

Steel metallurgy accounts for about 7 % of global greenhouse gas emissions and its decarbonation is a major issue. The direct reduction of iron ore with H2 using concentrated solar heat offers a carbon-free route for the iron metallurgical process. Such a solar process for clean ironmaking has never been implemented before. This study aims to investigate the reaction characteristics of direct iron ore reduction and further proposes a first experimental demonstration of direct reduced iron production in a packed-bed solar reactor under real solar irradiation. Fe2O3 reduction with H2 was first studied by thermogravimetric analysis to unravel the effect of temperature, H2 mole fraction, and particle size. The reaction rate increased with temperature (400–800 °C) and H2 mole fraction (25–75 %), and the reaction reached completion with an initial conversion starting from 370 °C. An activation energy of 38.5 and 30.4 kJ/mol was determined for commercial Fe2O3 and iron ore, respectively. The size of iron ore particles after pellets crushing (in the range 0.25–2 mm) did not significantly affect the reaction rate. However, fine micron size powder with low bulk density showed improved conversion rates. Finally, the reduction process was demonstrated in a solar-heated packed-bed reactor up to 1000 °C, confirming the feasibility of renewable iron production from complete ore reduction at moderate temperatures (starting above 400 °C), and thus paving the way toward decarbonation of the iron and steel metallurgical industry.

Modeling, parameter estimation and optimization of fluidized bed-based alternative ironmaking process for CO2 emission reduction

This study presents the development of a comprehensive process model for simulating and optimizing the FINEX process consists of the multi-stage fluidized beds, the melter-gasifier unit, and a gas recycling system. The model is developed using Pyomo, a Python-based open-source software package that provides extensive capabilities for formulating, solving, and analyzing optimization models. It incorporates heat and mass balance equations and captures a wide range of chemical reactions, including the reduction of iron ore by hydrogen and carbon monoxide, the calcination of carbonate materials, the water–gas shift reaction, and coal gasification and combustion. Unknown parameters in the model, such as heat loss in each reactor, the extent of the calcination reaction, and the outlet gas temperature from the melter-gasifier, were estimated to calibrate the model. These parameters were estimated by solving an optimization problem that minimizes the gap between the model and real plant data. The optimized model was employed to investigate various scenarios for minimizing CO2 emissions in the FINEX process. This included assessing the impact of HBI charging rates, iron ore quality, and the integration of a CCUS unit. For each scenario, an optimization problem was formulated to minimize production costs across a range of CO2 tax levels. The optimal solutions revealed the relationships between process economics and CO2 emissions for each variable.

A study of options to enhance the operation of a H2 direct reduction shaft furnace using a two-dimensional model

With the intent to explore techno-economically feasible options for improving the performance of the hydrogen (H2) -operated direct reduction shaft furnace for iron ores, a two-dimensional computational fluid dynamics model was applied to assess the potential of a new top gas recycling system featuring dual-row injection. A special numerical routine was developed to bridge data communication during the iterative calculation, where the composition of the gas injected in the upper (tuyere) row varies with the conditions. The results showed that a poor gas utilization is inevitable for a (conventional) single-row recycling system since it cannot properly address the strong heat demand of the process. For dual-row top gas recycling with a reduced lower-row feed rate, the in-furnace thermochemical state is inappropriate if the upper-row feed rate is low, but is gradually improved as the upper-row feed rate increases, since more thermal energy is supplied to the part of the furnace where it is needed. With an appropriate configuration of the upper- and lower-row feed rates, the overall furnace performance can be substantially improved particularly with respect to gas utilization degree. The findings of this work are expected to aid the future design of more efficient operation of H2-based direct reduction of iron ores.

Study on strength and reduction characteristics of iron ore powder-green carbon composite briquettes

The metallurgical industry is a key sector for carbon emissions, and in recent years, there has been widespread attention on the use of biomass resources as a green, renewable, and carbon–neutral energy source material for low carbon ironmaking processes. The waste wood after hydrothermal-pyrolysis carbonization has the characteristics of low content of harmful elements and high content of fixed carbon. In this study, the waste wood after hydrothermal-pyrolysis two-step carbonization treatment was used as a reducing agent for the reduction of iron ore to prepare iron ore powder- green carbon composite briquettes (ICCB) with two carbon–oxygen ratios. The study investigated the effects of reduction behavior and reaction temperature on the reduction performance of the ICCB. The results indicate that with the increase in reaction temperature, the volume of the ICCB gradually contracts, leading to a reduction in mass. The shrinkage rate of the ICCB during self-reduction at 1200℃ is significantly higher than during co-reduction, and the shrinkage effect of the C/O 0.5 ICCB is more pronounced than that of the C/O 0.8 ICCB. Due to the excessive carbon content in the C/O 0.8 ICCB, the carbon cannot be fully consumed during the reaction process, resulting in consistently low compressive strength of the ICCB, with a compressive strength of 12 N after reduction at 1200℃. In contrast, the iron phase in the C/O 0.5 ICCB gradually recrystallizes during the reduction process, ultimately yielding plastic iron briquettes with compressive strengths exceeding 3000 N after different reaction behaviors at 1200℃. In summary, reducing the carbon-to-oxygen ratio and increasing the reaction temperature contribute to the volume contraction and enhanced compressive strength of the ICCB during the reduction process.

Chlor-Iron Process for the Low-Temperature, Direct Reduction of Iron Oxide for Green Steel

The reduction of iron ores to metal for steelmaking produces comparable carbon emissions to all light-duty vehicles. We have identified a scalable electrochemical pathway for iron (Fe) production, which we term the chlor-iron process, that consumes only iron and salt water as reactants and could potentially be cost-competitive with iron produced in blast furnaces. Here, we report recent investigations on the mechanism of direct oxide reduction using naturally occurring and synthetic ores and identify key impurities that influence the current efficiency towards Fe. We present device-level data for continuous production of Fe and Cl2 at cell efficiencies < 5 MWh per tonne and with repeated harvesting of iron combined with technoeconomic analysis of pathways to cost competitive iron production. Lastly, we share ongoing scale-up efforts including recent data from a 100 cm2 bifacial cell. The process is unique in that the co-production of NaOH can lead to a net-negative emissions pathways for metals production.

Iron Production By Molten Sulfide Electrolysis

With urgency and incentives to cut CO2 emissions, alongside increasing demand for steel, there is a need for technologies that use solely electricity for iron ore reduction, eliminating the role of carbon as a reductant. Herein, we propose the electrolytic production of liquid cast iron using a novel sulfide route, molten sulfide electrolysis (MSE). The process operates using sulfide chemistry and an inert anode. Sulfides are well known from non-ferrous metallurgy1 and the exclusion of oxygen supports a virtual elimination of green-house gases(GHG) emissions from the reduction step. The electrolytic decomposition of iron sulfide into iron and elemental sulfur gas operates in a multi-component molten sulfide electrolyte. The underlying thermodynamics suggests the absence of trivalent iron species (Fe3+) in such conditions, supporting the reduction of only divalent iron (Fe2+) and reducing the energy need proportionally, as compared to other oxide-based routes. Iron sulfide deposits or tailings, as well as conventional iron oxide ores after sulfidation2 are some of the suitable feedstocks for MSE.Both thermal only, and galvanostatic electrochemical experiments were carried out on electrolyte droplets (~200mg) in a thermal imaging furnace, to confirm the electrolytic deposition of Fe and the evolution of sulfur in a 2-electrode set-up. Faradaic efficiency estimates based on mass-loss measurements – i.e. with respect to gaseous sulfur anodic evolution – are of the order of 90%. Key electrochemical attributes of MSE to be reported include impedance measurement at various fixed DC potentials, measurements at various current densities up to 2A/cm2, and the role of the total charge passed, to highlight the potential limitations observed in such an experimental set up. Characterization of the electrochemical deposits are also presented.

Experimental investigation and CFD study of direct reduction of iron ore in the conical fluidized bed

The reduction behavior of iron ore is the fundamental process in ferrous metallurgy. Considering the gas–solid interface-structure relationship, heterogeneous transfer-reaction behavior, and multiple reaction kinetics, this work provides an effective analytical tool to investigate the fluidized reduction of iron ore. The conical fluidized bed is numerically examined to be capable of preventing de-fluidization induced by the sticking behavior, due to the steady circulation of flow pattern and full fluidization of coarse agglomerates. Compared with the hydrogen concentration, the gas velocity shows a stronger influence on the agglomerate reduction rate for the more efficient gas–solid contact. For the simulated transitions of Fe2O3 → Fe3O4 → Fe(1-x)O → Fe are assumed to overlap each other, there exist discrepancies between computed and theoretical reduction degrees. The experimental and numerical findings can be used to develop a methodology for optimizing the operational complexity and economic benefits of the fluidized reduction of iron ore.

Mechanisms and elemental partitioning during simultaneous dephosphorization and reduction of Fe-O-P melts by hydrogen plasma

The major obstacle to render steelmaking more sustainable is undoubtedly the decarbonization of its process chains. Accompanied by this challenge, the scarcity of high-grade iron ores to be exploited as feedstock is a near reality. This creates a massive dilemma that will force steelmakers to produce green steel from low-grade iron ores. The hydrogen plasma smelting reduction of iron ores (HPSR) emerges as an attractive CO2-lean pathway to produce iron, where the ore is exposed to a reducing hydrogen-containing plasma (Ar-10 % H2) to get simultaneously melted and reduced. Here, we investigate the reduction of low-quality and low-cost model hematite ore samples containing 0.79 wt.% P via HPSR using an electric arc furnace (EAF). The dephosphorization mechanism of the ore was monitored by inspecting the evolving microstructure of the fast-solidified samples, condensed gas on the surface of electrostatic filters installed inside the EAF, as well as quantifying the corresponding P concentration in all constituents (i.e., unreduced oxides, iron and gas). We found that most of the P evaporates already in the beginning of the process (2 min) where the global O concentration in the melt varies from ∼29 to 21 wt.%. The remaining quantities of P, together with other minor gangue-related impurities (especially Si), allocates within the interdendritic domains of the partially reduced samples, as revealed by high-resolution scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX) and atom probe tomography (APT). Complementary thermodynamic modelling underpins the experimental observations, revealing that the evaporation of P is a thermodynamically-driven process, and it is dependent on the oxygen content of the melt. About 97 % dephosphorization was achieved, and only residual amounts of P were found within metallic iron domains, as revealed by APT and chemical analysis of the bulk iron (0.07 wt.% P). Our work aims at providing novel scientific-based perspectives in iron and steelmaking, permitting the production of clean and sustainable iron without the need for secondary metallurgical steps to remove undesired impurities.

DDPM Simulation for Fluidization Behavior and Reduction of Iron Ore Fines with Hydrogen in the Fluidized Bed

DDPM Simulation for Fluidization Behavior and Reduction of Iron Ore Fines with Hydrogen in the Fluidized Bed

Mathematical optimization modeling for scenario analysis of integrated steelworks transitioning towards hydrogen-based reduction

To reduce carbon dioxide emissions from the steel industry, efforts are made to introduce a steelmaking route based on hydrogen reduction of iron ore instead of the commonly used coke-based reduction in a blast furnace. Changing fundamental pieces of steelworks affects the functions of most every system unit involved, and thus warrants the question of how such a transition could optimally take place over time, and no rigorous attempts have until now been made to tackle this problem mathematically. This article presents a steel plant optimization model, written as a mixed-integer non-linear programming problem, where aging blast furnaces and basic oxygen furnaces could potentially be replaced with shaft furnaces and electric arc furnaces, minimizing costs or emissions over a long-term time horizon to identify possible transition pathways. Example cases show how various parameters affect optimal investment pathways, stressing the necessity of appropriate planning tools for analyzing diverse cases.

Green Ironmaking at Higher H2 Pressure: Reduction Kinetics and Microstructure Formation During Hydrogen-Based Direct Reduction of Hematite Pellets

Hydrogen-based direct reduction (HyDR) of iron ores has attracted immense attention and is considered a forerunner technology for sustainable ironmaking. It has a high potential to mitigate CO2 emissions in the steel industry, which accounts today for ~ 8–10% of all global CO2 emissions. Direct reduction produces highly porous sponge iron via natural-gas-based or gasified-coal-based reducing agents that contain hydrogen and organic molecules. Commercial technologies usually operate at elevated pressure, e.g., the MIDREX process at 2 bar and the HyL/Energiron process at 6–8 bar. However, the impact of H2 pressure on reduction kinetics and microstructure evolution of hematite pellets during hydrogen-based direct reduction has not been well understood. Here, we present a study about the influence of H2 pressure on the reduction kinetics of hematite pellets with pure H2 at 700 °C at various pressures, i.e., 1, 10, and 100 bar under static gas exposure, and 1.3 and 50 bar under dynamic gas exposure. The microstructure of the reduced pellets was characterized by combining X-ray diffraction and scanning electron microscopy equipped with electron backscatter diffraction. The results provide new insights into the critical role of H2 pressure in the hydrogen-based direct reduction process and establish a direction for future furnace design and process optimization.Graphical

On controllability of fluidized bed reduction of iron ore by CH4 for selective formation of magnetite

Magnetization roasting technology is one of the most representative ways to improve the magnetic separation efficiency and iron recovery of refractory weakly magnetic iron ores. However, utilization of CO-rich or H2-rich gas of strong reducibility as reducing agent for magnetization roasting would lead to over-reduction of Fe2O3 in the ore to non-magnetic FeO, which makes the magnetism of the roasted ore be lower than its maximum, and hence leads to a lower iron recovery than expected. To explore the possibility of using CH4 as reducing agent for controllable reduction of Fe2O3 in iron ores to selectively forming magnetic Fe3O4, i.e., for maximizing the magnetism of the reduced ore for efficient iron separation and recovery, a series of fluidized bed reduction tests in CH4 were carried out on two iron ores of 55 % and 33 % iron at different temperatures for different periods of time, and the resultant reduced ore particles were magnetically separated for recovery of iron concentrate. XRD and ICP analyses were performed on all recovered iron concentrates to identify the crystal forms of their iron species and to quantify their iron contents. The results have shown that the controllable reduction by CH4 of Fe2O3 in the iron ores to strongly magnetic Fe3O4 can be realized by controlling the reduction temperature and time condition applied. The resultant concentrates can be fully recovered by magnetic separation in a weak magnetic field of 60 kA/m to attain a maximum iron recovery of 98 % for the high-grade ore and that of 65 % for the low-grade ore. Besides, the results have also shown that the most critical factor affecting the controllability of the ore reduction process and the selectivity to the generation of magnetic Fe3O4-containing particles is the reduction temperature, and that the upper temperature threshold for the controllable reduction and selective generation of strongly magnetic iron concentrate is about 650℃.

Exergy analysis of a novel ironmaking process combining coal gasification with the smelting reduction of iron ore

The global iron and steel industry is an energy-intensive industry, and energy-saving in this industry is of great significant. A novel ironmaking process combining coal gasification with the smelting reduction of iron ore (CCGSR) is proposed, and an exergy analysis is applied to evaluate its thermodynamic performance. The results show that the exergy efficiency of the entire system is 88.15 % whereas the energy efficiency is 98.64 %. The exhaust gas of pre-reduction furnace is the main exergy output and has great energy-saving potential. The local exergy loss rates in the pyrolysis, pre-reduction, and smelting reduction furnaces are 55.81 %, 7.24 %, and 36.95 %, respectively. The pyrolysis and smelting reduction furnaces exhibit the largest exergy loss, owing to the mixing of high-temperature gas of the smelting reduction furnace and circulating gas, coke powder gasification, and heat transfer. In addition, after the exhaust gas is utilized to form a cogeneration system of iron and electricity, the exergy efficiency increases from 40.18 % to 50.06 % comparable with 600 MW ultra-supercritical coal-fired generating units. The present work also provides some suggestions for reducing exergy destruction.

Investigation of the Phenomena Associated with Iron Ore Reduction by Raw Biomass and Charcoal Volatiles

Investigation of the Phenomena Associated with Iron Ore Reduction by Raw Biomass and Charcoal Volatiles