Effect of Coal Blended on the Physical Properties of Iron Ore Briquette for Direct Reduction Iron

Iron production by using the direct method has been promoted in order to produce iron effectively, low cost, and environmentally safe. The method was optimal requirements with respect to the feed materials especially iron ore, coal as well as a binder. In this study, the experiments were conducted on physical properties of iron ore briquette from Aceh (Indonesia) to analyze its suitability to meet the feed requirements for iron production. The term iron ore briquette refers to the materials compressed under high pressure formed by variable mixtures of iron ore, coal and binders. In the experiments, the physical properties such as the tumbler index (TI), abrasion index (AI) and shatter indices of the iron ore briquette were carried out. The experimental results show that the iron ore briquette blended with coal and using asphalt as a binder has a high tumbler index (TI) or not easily breakable compared to the iron ore briquette using dammar powder as a binder. On the other hand, the blended coal in iron ore briquette with dammar powder as the binder significantly increases the shelter index or easily breakage.

Preparation of a Master Fe–Cu Alloy by Smelting of a Cu-Bearing Direct Reduction Iron Powder

Generally, the Cu-bearing direct reduction iron powder (CBDRI) obtained from a direct reduction-magnetic separation process of waste copper slag contains a high content of impurities and cannot be directly used to produce Cu-bearing special steel. In this paper, further smelting treatment of CBDRI was conducted to remove its impurities (such as S, SiO2, Al2O3, CaO and MgO) and acquire a high-quality Fe–Cu master alloy. The results show that the Fe–Cu master alloy, assaying 95.9% Fe, 1.4% Cu and minor impurities, can be obtained from the smelting process at 1550 °C for 40 min with 1.0 basicity. Meanwhile, the corresponding iron and copper recoveries are 98.6% and 97.2%, respectively. Theoretical calculations and experimental results show that appropriate basicity (0.9~1.1) is beneficial for the recovery of Fe and Cu from a thermodynamic viewpoint due to the excellent fluidity of the slag in this basicity range. Moreover, the mechanism of desulfurization was revealed by calculating the sulfide capacity and the desulfurization reaction kinetics. Increasing the binary basicity of the slag benefits both the sulfide capacity and diffusion coefficient of the sulfur in the molten slag, resulting in higher desulfurization efficiency and lower S content in the master alloy.

Smelting process of direct reduction iron bearing Ni and Cu to prepare Fe-Ni-Cu ternary alloy

The smelting behavior of direct reduction iron powder containing Ni and Cu from co-reduction followed by a magnetic separation of copper slag and nickel laterite was investigated in this paper. The results show that the perfect ternary alloy with 90.66% Fe, 5.24% Ni, 1.20% Cu and minor impurities can be prepared by smelting under optimum conditions at 1550 ?C for 30 min with 1.1 slag basicity. The corresponding recoveries of Fe, Ni, and Cu were 92.77%, 96.27% and 96.24%, respectively. In addition, basicity has a significant effect on slag fluidity. The optimum basicity of slag is approximately 1.1, which is beneficial for both metal recovery and desulfuration. Compared with the direct reduction iron powder, the Fe-Ni- Cu ternary alloy contains a higher metal content and less sulfur from the smelting process and is a superior material for producing weathering steel. Hence, it is very feasible to use an electric arc furnace to smelt direct reduction iron powder to produce a high quality Fe-Ni-Cu ternary alloy.

Preparation of Direct Reduction Sponge Iron (DRI) Using Pyrite Cinder Containing Nonferrous Metals

Pyrite cinder is a solid waste generated by the sulfuric acid industry and is considered environmentally hazardous. It contains abundant iron, such as Fe2O3 and Fe3O4, and nonferrous metals, such as zinc, lead and copper. In order to try and recycle this material as a source of Fe units, preparation of direct reduction iron (DRI) using pyrite cinder was investigated by coal-based grate rotary kiln process. This process includes chloridizing and reduction roasting. The results show that 97 % lead was removed after the chloridizing process. Copper was only detached in chloridizing process with the removal rate of 78.49 %. Furthermore, the removal of zinc was carried out in both chloridizing and reduction process, and the removal rate of 96.76 % was achieved after reduction roasting. The final product representing a metallization degree of 93.36 % with compressive strength of 1,198 N/pellet was obtained after the oxidized pellets were reduced at 1,050 °C for 80 min.

The Effects of Reduction Parameter to Composite Pelet of Iron Ore and Coal Using Single Conveyor Belt Hearth Furnace

Iron ores should be separated from oxygen and impurities which are coming along during the mining process. The separation process is known as reduction. There are two types of reduction process, and the most common is direct reduction process (DRP). There are several parameters in DRP which will determine the quantities of the product known as direct reduction iron (DRI). This worked discussed the effect of reduction temperature and pellet heap to the quantities of DRI using single conveyer belt Hearth furnace. The worked was done in laboratory scale using composite pellets with 14 mm in diameter. The ratio of iron ore to coal in the composite pellet is 1 to 1. The reduction process temperatures are 500oC, 700oC and 900oC. The reduction time is 25 minutes. While the pellets heap are also varied to 1, 3, 5, 7, 8 and 9 layers. The results show that DRI was formed in 700OC and the quantities of DRI are in line with the reduction temperatures and layers of composite pellets heap.