Kinetics of reduction of FeO from slag by graphite and coal chars

The rates of reduction of FeO from iron-saturated FeO-CaO-Al2O3-SiO2 slags by graphite, coke, bituminous coal and anthracitic coal chars at temperatures in the range 1 673-1873 K have been measured using a sessile drop technique. The extents of reaction were determined using EPMA analysis of quenched samples, and on line gas analysis using a quadrupole mass spectrometer. The reaction rates have been shown to be dependent critically on carbon type. For the reaction geometry used in this investigation the reduction rates of graphite and coke are observed to be faster than with coal chars. This unexpected finding is shown to be associated with differences in the dominant chemical and mass transfer mechanisms occurring at the reaction interface. High reaction rates are observed to occur with the formation of liquid Fe-C alloy product and the associated gasification of carbon from the alloy. The rates of reduction by coal chars are determined principally by the chemical reaction at the carbon/gas interface and slag phase mass transfer.

Observations of the reduction of FeO from slag by graphite, coke and coal char

The reduction of FeO from iron-saturated FeO-CaO-Al2O3-SiO2 slags by graphite, coke and coal char at 1 673 K has been investigated using a sessile drop technique. Metallographic analysis of samples quenched from the reaction temperature, and in situ observations of the reaction interface, reveal significant differences in the slag/carbon contact, and in the morphologies of the product iron and its composition; these differences were found to depend on the carbon type used in the reduction. In particular it has been shown that, in the case of graphite and coke, liquid Fe-C droplets were rapidly formed at the slag/C interface. Reactions of the slag with coal chars, in contrast, result predominantly in the formation of solid iron. These observations indicate that the reaction pathways, and hence reaction kinetics, are dependent on carbon type.

Microstructures of ISF sinters in air

The microstructures of industrial ISF and synthetic sinters were examined. The principle phases present were found to consist of zincite, spinel and glass. The morphologies of the zincite phase in these complex multiphase materials were shown to relate directly to the bulk chemical compositions and thermal histories of the sinters. The conditions favouring the formation of plate-like zincite, essential for the development of refractory networks in the ISF sinters, were identified. The proportion of framework zincite present in the sinters was found to increase with increasing peak bed temperature and an increasing CaO/SiO2 ratio. The aspect ratio of the zincite increases by increasing iron in the solid solution in zincite.

The relationships between microstructure and crystal structure in zincite solid solutions

Single phase (Zn,Fe)(1-x) O zincite solid solution samples have been prepared by high temperature equilibration in air and in reducing atmospheres, followed by quenching to room temperature. The Fe2+/Fe3+ concentrations in the samples have been determined using wet chemical and XPS techniques. Iron is found to be present in zincite predominantly in the form of Fe3+ ions. The transition from an equiaxed grain morphology to plate-like zincite crystals is shown to be associated with increasing Fe3+ concentration, increasing elongation in < 001 > of the hexagonal crystals and increasing anisotropic strain along the c-axis. The plate-like crystals are shown to contain planar defects and zincite polytypes at high iron concentrations.

Reply to Paparazzo

We would like to reply to the comments made by Paparazzo on our recent paper [1] on the “effect of curve fitting parameters on quantitative analysis of Fe0.94O and Fe2O3 using XPS”. There have been many studies on the characterisation of the properties of iron oxide surfaces. The main purpose of writing the paper was to demonstrate the extent to which the selection of input parameters for curve fitting can affect the results of the quantitative analysis, and to use this analysis to develop more consistent, reproducible and quantitative methods of analysis of these data.

Magnetic susceptibility measurement applied to the minerals industry

The efficiency of numerous mineral processing operations can be determined by measuring the magnetic properties of the process streams. This measurement, if done at all, is currently performed by laboratory testing of spot samples. This is an inherently slow process and, where feed grades are variable, optimum performance is generally not achieved. This paper describes the rapid measurement of the magnetic properties of minerals. AC measurement techniques, including the analysis of the phase component of the magnetic vector; frequency dependent magnetic susceptibility and the effect of applied magnetic field strength will be discussed. Industrial applications in mineral sands, copper smelting, ferrosilicon testing and drill core scanning will be reported. (C) 2006 Elsevier Ltd. All rights reserved.