The Reduction of Composite Iron Ore-Coal Pellets to Liquid Iron

Abstract

<p>An ironmaking process has been proposed in which composite iron ore-coal pellets are smelted to produce liquid iron. Studies have determined the manner in which individual composite pellets react, their compositional limitations and the chemical compositions of the resultant slag and iron.</p> <p>Laboratory reduction experiments were performed on various composite pellets bonded with bentonite, cement or calcium carbonate. Ore-coal pellets bonded with bentonite reacted to form a fayalite-type slag high in iron oxide content and an iron melt low in carbon (2%) but high in sulphur (0.3%) contents. Ore-coal pellets which were made self-fluxing by being bonded with cement or calcium carbonate produced a basic slag low in iron oxide content and an iron melt containing over 3% carbon and below 0.05% sulphur. The off-gas from reaction of ore-coal pellets was profound to be mostly carbon monoxide and hydrogen which in combustion with oxygen is to supply the heat required by the process.</p> <p>A computer model of the process was constructed using heat and mass balance equations which illustrated the effects of changes in process variables on input material requirements. Indications from a process analysis are considered to be positive for an ironmaking process based on composite pellet smelting. However, the ultimate success of the process will depend on whether sufficient heat can be retained within the reaction vessel where it is needed. To this end, hot-model "pilot plant" experimental trials are recommended.</p>