Study on Iron Formation During the Carbothermic Reduction of Iron Ore in Carbon Composite Pellets in the Temperature Range 1423 K-1623 K

The aim of this work is to study the reaction rate and the morphology of the intermediary reaction products during reduction of iron ore, when iron ore and carbonaceous material are agglomerated together as a carbon composite iron ore pellet. The reaction was performed at high temperatures, and in order to avoid heat transfer constraints small size samples were used. The carbonaceous materials employed were coke breeze and pure graphite. Portland cement was employed as a binder, and the pellets diameter was 5.2 mm. The experimental technique involved the measurement of the pellets weight loss, as well as interruption of the reaction at different stages in order to submit the partially reduced pellet to scanning electron microscopy. It has been observed that above 1523 K there is the formation of liquid slag inside the pellets, which partially dissolves iron oxides. The apparent activation energies obtained were 255 kJ/mol for coke breeze containing pellets, and 230 kJ/mol for those pellets containing graphite. It was possible to avoid heat transfer control of the reaction rate up to 1523 K by employing small composite pellets.

Reaction rate and product morphology in carbon composite iron ore pellets with and without Portland cement

The aim of this work is to study the reaction rate and the morphology of intermediate reaction products during iron ore reduction when iron ore and carbonaceous materials are agglomerated together with or without Portland cement. The reaction was performed at high temperatures, and used small size samples in order to minimise heat transfer constraints. Coke breeze and pure graphite were the carbonaceous materials employed. Portland cement was applied as a binder, and pellet diameters were in the range 5.6-6.5 mm. The experimental technique involved the measurement of the pellet weight loss, as well as the interruption of the reaction at different stages, in order to submit the partially reduced pellet to scanning electron microscopy. The experimental temperature was in the range 1423-1623 K, and the total reaction time varied from 240 to 1200 s. It was observed that above 1523 K the formation of liquid slag occurred inside the pellets, which partially dissolved iron oxides. The apparent activation energies obtained were 255 kJ mol(-1) for coke breeze containing pellets, and 230 kJ mol(-1) for those pellets containing graphite. It was possible to avoid heat transfer control of the reaction rate up to 1523 K by employing small composite pellets.

Carbothermal Reduction of Iron Ore Applying Microwave Energy

This paper presents the results of a study on carbothermal reduction of iron ore made under the microwave field in equipment specially developed for this purpose. The equipment allows the control of radiated and reflected microwave power, and therefore measures the microwave energy actually applied to the load in the reduction process. It also allows performing energy balances and determining the reaction rate with high levels of confidence by simultaneously measuring temperature and mass of the material upon reduction with high reproducibility. We used a microwave generator of 2.45?GHz with variable power up to 3000?W. Self-reducing pellets under argon atmosphere, containing iron ore and petroleum coke, with 3.5?g of mass and 15?mm of diameter were declined. We obtained the kinetic curves of reduction of iron ore and of energy consumption to the process in the maximum electric field, in the maximum magnetic field and at different values of power/mass. The data allow analyzing how the microwave energy was actually consumed in the reduction of ore.

Pellets prepared with mechanically activated iron ore

This work analyses pellets prepared with iron ore that has been mechanically activated by high energy ball milling. Pellet feed iron ore was submitted to high-energy ball milling for 60 minutes, and the resulting material was analysed through measurements of particle size and specific surface area, as well as X-ray diffraction. Pellets were prepared from this material. The pellets were heated at temperatures ranging from 1000 to 1250 degrees C in a muffle furnace, and submitted to the maximum temperature during 10 - 12 minutes. The samples were then tested regarding crushing strength, densification and porosity, and were examined in a scanning electronic microscope. The results were compared to those obtained with similar samples made from non-milled pellet feed. It has been shown that through high-energy ball milling of iron ore it is possible to achieve pellets presenting high densification and compressive strength at firing temperatures lower than the usual ones.

Role of oxidation-reduction cycle of iron in direct leaching of zinc concentrate

Direct leaching is an alternative to conventional roast-leach-electrowin (RLE) zinc production method. The basic reaction of direct leach method is the oxidation of sphalerite concentrate in acidic liquid by ferric iron. The reaction mechanism and kinetics, mass transfer and current modifications of zinc concentrate direct leaching process are considered. Particular attention is paid to the oxidation-reduction cycle of iron and its role in direct leaching of zinc concentrate, since it can be one of the limiting factors of the leaching process under certain conditions. The oxidation-reduction cycle of iron was experimentally studied with goal of gaining new knowledge for developing the direct leaching of zinc concentrate. In order to obtain this aim, ferrous iron oxidation experiments were carried out. Affect of such parameters as temperature, pressure, sulfuric acid concentration, ferrous iron and copper concentrations was studied. Based on the experimental results, mathematical model of the ferrous iron oxidation rate was developed. According to results obtained during the study, the reaction rate orders for ferrous iron concentration, oxygen concentration and copper concentration are 0.777, 0.652 and 0.0951 respectively. Values predicted by model were in good concordance with the experimental results. The reliability of estimated parameters was evaluated by MCMC analysis which showed good parameters reliability.

FACTORS INFLUENCING MATERIAL LOSS DURING IRON ORE PELLET HANDLING

Iron ore concentrate pellets have the potential to fracture and abrade during transportation and handling, which produces unwanted fine particulates and dust. Consequently, pellet producers characterize the abrasion resistance of their pellets, using an Abrasion Index (AI), to indicate whether their products will produce unacceptable levels of fines. However, no one has ever investigated whether the AI correlates to pellet dustiness. During the course of this research, we investigated the relationship between AI and iron ore concentrate pellet dustiness using a wide range of industrial and laboratory pellet samples. The results showed that, in general, AI can be used to indicate high levels of dust. However, for good-quality pellets, there was no correlation between the two. Thus, dust generation from shipping and handling pellets will depend on the quantity of pellets handled and how much they are handled. These results also showed that the type of industrial furnace used to harden iron ore concentrate pellets may affect their fines generation and potential dustiness.

Effects of iron-ore particles on propagule release, growth and photosynthetic performance of Sargassum vulgare C. Agardh (Phaeophyta, Fucales)

The effect of iron-ore particles on the propagule release and growth of Sargassum vulgare C. Agardh was tested under treatments with different concentrations of iron-ore particles: 0.1, 1.0, 10.0 g.L-1 and a solution of 10.0 g.L-1 of filtered iron-ore. Filtered seawater was used as control. Photosynthesis vs. irradiance (P-I) curves were calculated for S. vulgare in the presence of iron-ore and in seawater. There was no significant difference in the number of propagules released by the receptacles or in the percentage of zygote formation among the treatments. The released propagules acted like aggregation centers for the particles, those more heavily coated with iron (10.0 g.L-1) exhibiting the highest sinking velocity (32.6 ± 9.8 mm.s-1). No difference in the percentage of embryo survival was detected during the first week in culture. After four weeks the embryos grew in all treatments. Maximum frond development (5.3 ± 0.8 mm) was observed in treatment of seawater enriched with Provasoli's medium (PES) while initial filoids did not develop in three treatments without PES and with iron-ore (0.1 g.L-1, 1.0 g.L-1 and 10.0 g.L-1). The values for Pmax, alpha and respiration showed no significant differences between the P-I curves. The calculated value for I K was 106.26 µmol.m-2.s-1 to the control curve and 981.49 µmol.m-2.s-1 to the iron-ore curve. The results indicate that the iron-ore particles in high concentration reduce the growth of S. vulgare as they recovered the embryos, juveniles and young plants. In contrast, the presence of the particles did not affect the release of gametes, percentage of zygote formation or the percentage of embryo survival.

The Gandarela Mountain Range and the “resistance space” against iron ore mining threat: a focus on the contrapositions

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Mineralogy and trace-element geochemistry of the high-grade iron ores of the Aguas Claras Mine and comparison with the Capao Xavier and Tamandua iron ore deposits, Quadrilahero Ferrifero, Brazil

Several major iron deposits occur in the Quadrilatero Ferrifero (QF), southeastern region of Brazil, where metamorphosed and heterogeneously deformed banded iron formation (BIF) of the Caue Formation, regionally called itabirite, was transformed into high- (Fe >64%) and lowgrade (30%ores. Based on their mineralogical composition, three major types of itabirites occur in the QF: siliceous, dolomitic, and amphibolitic itabirite. Unlike other mines in the QF, the Aguas Claras Mine contained mainly high-grade ores hosted within dolomitic itabirite. Two distinct types of high-grade ore occurred at the mine: soft and hard. The soft ore was the most abundant and represented more than 85% of the total ore mined until it was mined out in 2002. Soft and hard ores consist essentially of hematite, occurring as martite, anhedral to granular/tabular hematite and, locally, specularite. Gangue minerals are rare, consisting of dolomite, sericite, chlorite, and apatite in the hard and soft ores, and Mn-oxides and ferrihydrite in the soft ore where they are concentrated within porous bands. Chemical analyses show that hard and soft ores consist almost entirely of Fe(2)O(3), with a higher amount of detrimental impurities, especially MnO, in the soft ore. Both hard and soft ores are depleted in trace elements. The high-grade ores at the Aguas Claras Mine have at least a dual origin, involving hypogene and supergene processes. The occurrence of the hard, massive high-grade ore within ""fresh"" dolomitic itabirite is evidence of its hypogene origin. Despite the contention about the origin of the dolomitic itabirite (if this rock is a carbonate-rich facies of the Caue Formation or a hematite-carbonate precursor of the soft high-grade ore), mineralogical and geochemical features of the soft high-grade ore indicate that it was formed by leaching of dolomite from the dolomitic itabirite by meteoric water. The comparison of the Aguas Claras, Capao Xavier and Tamandua orebodies shows that the original composition of the itabiritic protore plays a major role in the genesis of high- and low-grade soft ores in the QF. Under the same weathering and structural conditions, the dolomitic itabirite is the more favorable to form high-grade deposits than siliceous itabirite. Field relations at the Aguas Claras and Capao Xavier deposits suggest that it is not possible to form huge soft high-grade supergene deposits from siliceous itabirite, unless another control, such as impermeable barriers, had played an important role. The occurrence in the Tamandua Mine of a large, soft, high-grade orebody formed from siliceous itabirite and closely associated with hypogene hard ore suggests that large, soft, high-grade orebodies of the Quadrilatero Ferrifero, which occur within siliceous itabirite, have a hypogene contribution in their formation.

Operational and environmental assessment on the use of charcoal in iron ore sinter production

A study was carried out into the use of charcoal as a supplementary fuel in the iron-ore sintering process. The primary fuel was coke breeze and anthracite with 0, 10, 25, 50 and 100% replacement of the energy input with charcoal to produce sinter. This was achieved by considering the carbon content of each fuel and its corresponding participation on fuel blending, in order to have the same carbon input in each test run. An extensive analysis of the environmental impact was carried out regarding the atmospheric pollutants characterization (dust, sulphur dioxide, nitrogen oxides, carbon monoxide, carbon dioxide, methane, total hydrocarbons, and dioxins and furans). Experimental results indicate that fuel blending where 50% of the heat input was provided by charcoal may be comparable with those using 100% coke, under normal sintering conditions, and may result in a 50% reduction on greenhouse gas emission. It was also observed that while dust, methane and hydrocarbons emissions increased, the total dioxins and furans, expressed as polychlorinated dibenzodioxins/furans, decreased approximately 50% when compared with operation with 100% coke.

Oxygen isotope compositions of iron oxides from high-grade BIF-hosted iron ore deposits of the Central Hamersley Province, Western Australia: Constraints on the evolution of hydrothermal fluids

The Hamersley province of northwest Australia is one of the world's premier iron ore regions with high-grade martite-microplaty hematite iron ore deposits mostly hosted within banded iron formation (BIF) sequences of the Brockman Iron Formations of the Hamersley Group. These high-grade iron ores contain between 60 and 68 wt percent Fe, and formed by the multistage interaction of hydrothermal fluids with the host BIF formation. The oxygen isotope compositions of magnetite and hematite from BIF, hydrothermal alteration assemblages, and high-grade iron Ore were analyzed from the Mount Tom Price, Paraburdoo, and Charmar iron ore deposits. The delta(18)O values of magnetite and hematite from hydrothermal alteration assemblages and high-grade iron ore range from -9.0 to -2.9 per mil, a depletion of 5 to 15 per mil relative to the host BIF. The delta(18)O values are spatially controlled by faults within the deposits, a response to higher fluid flux and larger influence the isotopic compositions by the hydrothermal fluids. The oxygen isotope composition of hydrothermal fluids (delta(18)O(fluid)) indicates that the decrease in the (18)O content of iron oxides was due to the interaction of both basinal brines and meteoric fluids with the original BIF. Late-stage talc-bearing ore at the Mount Tom Price deposit formed in the presence of a pulse of delta(18)O-enriched basinal brine, indicating that hydrothermal fluids may have repeatedly interacted with the BIFs during the Paleoproterozoic.