|Cite this article as:|
|Hua Zhang, Tuoxiao Wang, Guoyang Zhang, Wenjie Wu, Long Zhao, Tao Liu, Shuai Mo, and Hongwei Ni, Cleaner production of Fe-based amorphous soft magnetic alloys via smelting reduction of high-phosphorus iron ore and apatite, Int. J. Miner. Metall. Mater.,(2023). https://doi.org/10.1007/s12613-023-2722-6|
The separated preparation of pre-alloys and amorphous alloys leads to severe solidification-remelting and beneficial elements removal-readdition contradictions, which greatly increases the energy consumption and emissions. In this study, a novel strategy for the direct production of FePC amorphous soft magnetic alloys via smelting reduction of high-phosphorus iron ore (HPIO) and apatite was proposed. The thermodynamic conditions and equilibriums of the carbothermal reduction reactions in HPIO were first calculated and the elements content in reduced alloys were theoretically determined. Experimentally, the phase and structure evolutions as well as the elements migration and enrichment behaviors during the smelting reduction of HPIO and Ca3(PO4)2 were then verified. The addition of Ca3(PO4)2 in HPIO contributes to the enrichment of P element in reduced alloys and the successive appearance of Fe3P, Fe2P phases. The content of P, C elements in the range of 1.52-14.63wt% and 0.62-2.47wt% can be well tailored by adding 0-50 g Ca3(PO4)2 and controlling the C/O ratio of 0.8-1.1, which is quite consistent with the calculated results. These resultant FePC alloys were then successfully prepared into amorphous ribbons and rods. Compared with the conventional production process, the energy consumption of our proposed strategy was estimated to be 680 kgce/t, which can be reduced by 30%. These results are quite vital for the comprehensive utilization of mineral resources and pave the way for the cleaner production of Fe-based amorphous soft magnetic alloys.