A Review on the Kinetics of Iron Ore Reduction by Hydrogen

Review on the chemical reduction modelling of hematite iron ore to magnetite in fluidized bed reactor

Steel production is considered as one of the major backbones of many economies. Though blast furnace is the primary route of steel production, the industries are willing to alternatives technologies such as the high temperature-controlled conversion of hematite to magnetite. The geological and mineralogical characteristics of the low-grade iron ores possess difficulties in their conventional enrichment. The literature concludes the advantages of high-temperature conversion in terms of easiness in downstream operations caused by decreased hardness and increased magnetic susceptibility of magnetite. The modelling work has been primarily focused on the direct reduction of iron ore to metallic iron. The present compilation discusses the scientific and engineering developments on the reduction-roasting of iron-ore followed by the CFD–DEM modelling and simulation work performed to reduce iron ore to magnetite. It provides a comprehensive review of the experimental and industrial progress done in the area.

Clean Syngas and Hydrogen Co-Production by Gasification and Chemical Looping Hydrogen Process Using MgO-Doped Fe2O3 as Redox Material

Gasification converts biomass into syngas; however, severe cleaning processes are necessary due to the presence of tars, particulates and contaminants. The aim of this work is to propose a cleaning method system based on tar physical adsorption coupled with the production of pure H2 via a chemical looping process. Three fixed-bed reactors with a double-layer bed (NiO/Al2O3 and Fe-based particles) working in three different steps were used. First, NiO/Al2O3 is used to adsorb tar from syngas (300 °C); then, the adsorbed tar undergoes partial oxidization by NiO/Al2O3 to produce CO and H2 used for iron oxide reduction. In the third step, the reduced iron is oxidized with steam to produce pure H2 and to restore iron oxides. A double-layer fixed-bed reactor was fed alternatively by guaiacol and as tar model compounds, air and water were used. High-thermal-stability particles 60 wt% Fe2O3/40 wt% MgO synthetized by the coprecipitation method were used as Fe-based particles in six cycle tests. The adsorption efficiency of the NiO/Al2O3 bed is 98% and the gas phase formed is able to partially reduce iron, favoring the reduction kinetics. The efficiency of the process related to the H2 production after the first cycle is 35% and the amount of CO is less than 10 ppm.

Isothermal Hydrogen Reduction of a Lime-Added Bauxite Residue Agglomerate at Elevated Temperatures for Iron and Alumina Recovery

The hydrogen reduction of bauxite residue lime pellets at elevated temperatures was carried out to recover iron and alumina from the bauxite residue in a new process route. Prior to the H₂ reduction, oxide pellets were initially prepared via the mixing of an industrial bauxite residue with fine calcite powder followed by calcination and high-temperature sintering. The chemical, compositional, and microstructural properties of both oxide and reduced pellets were studied by advanced characterization techniques. It was found that iron in the oxide pellets is mainly in the form of brownmillerite, and calcium-iron-titanate phases, while upon reduction they are converted to wüstite and shulamitite intermediate phases and further to metallic iron. Moreover, it was found that the reduction at lower temperature of 1000 °C is faster than that at higher temperatures of 1100 °C and 1200 °C. The slower rate and extent of reduction at the higher temperatures is attributed to the porosity loss and reduction mechanism change to a diffusion-controlled process step. In addition, it was found that Al-containing phases in the raw materials are converted mainly to gehlenite in sintered pellets and further to the leachable mayenite phase. The alkaline leaching of selected reduced pellets by a sodium carbonate solution yielded up to 87% Al recovery into the solution, while the metallic iron was not affected.

Reduction of Acid Iron Ore Pellets under Simulated Wall and Center Conditions in a Blast Furnace Shaft

The operational conditions, including temperature and gas composition, vary along the radial position in a blast furnace. Nevertheless, very few studies can be found in the literature that discuss how the reduction behavior of the ferrous burden varies along the radial position. In this study, the effect of the radial charging position on the reducibility of acid iron ore pellets was investigated using a laboratory-scale, high-temperature furnace in CO-CO2-N2 and CO-CO2-H2-H2O-N2 atmospheres up to 1100 °C. The experimental conditions were accumulated based on earlier measurements from a multi-point vertical probing campaign that was performed for a center-working European blast furnace. The main finding of this study is that the pellet reduction proceeded faster under simulated blast furnace conditions resembling those in the center area, compared to the wall area, because of a higher share of CO and H2 in the gas. Therefore, the pellet charging position affects its reduction path in a blast furnace. Additionally, it was shown that the presence of H2 and H2O in the reducing gas enhanced the progress of reduction reactions significantly and enhanced the formation of cracks slightly, both of which are desirable in blast furnace operation. The reducibility data attained in this study are important in understanding how temperature and gas composition is connected to the reduction degree under realistic process conditions.