Effect of additives on iron recovery and dephosphorization by reduction roasting–magnetic separation of refractory high-phosphorus iron ore

Shi-chao Wu; Zheng-yao Li; Ti-chang Sun; Jue Kou; Xiao-hui Li

doi:10.1007/s12613-021-2329-8

Volume 28 Issue 12

Dec. 2021

Turn off MathJax

Article Contents

Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2021 > 28(12): 1908-1916

Shi-chao Wu, Zheng-yao Li, Ti-chang Sun, Jue Kou, and Xiao-hui Li, Effect of additives on iron recovery and dephosphorization by reduction roasting–magnetic separation of refractory high-phosphorus iron ore, Int. J. Miner. Metall. Mater., 28(2021), No. 12, pp. 1908-1916. https://doi.org/10.1007/s12613-021-2329-8

Cite this article as:

Shi-chao Wu, Zheng-yao Li, Ti-chang Sun, Jue Kou, and Xiao-hui Li, Effect of additives on iron recovery and dephosphorization by reduction roasting–magnetic separation of refractory high-phosphorus iron ore, Int. J. Miner. Metall. Mater., 28(2021), No. 12, pp. 1908-1916. https://doi.org/10.1007/s12613-021-2329-8

Citation:

PDF( 1843 KB)

Research Article

Effect of additives on iron recovery and dephosphorization by reduction roasting–magnetic separation of refractory high-phosphorus iron ore

+ Author Affiliations

Corresponding author:
Zheng-yao Li E-mail: zyli0213@ustb.edu.cn
Received: 4 March 2021; Revised: 8 June 2021; Accepted: 5 July 2021; Available online: 7 July 2021

Abstract

Abstract

The effect of CaCO₃, Na₂CO₃, and CaF₂ on the reduction roasting and magnetic separation of high-phosphorus iron ore containing phosphorus in the form of Fe₃PO₇ and apatite was investigated. The results revealed that Na₂CO₃ had the most significant effect on iron recovery and dephosphorization, followed by CaCO₃, the effect of CaF₂ was negligible. The mechanisms of CaCO₃, Na₂CO₃, and CaF₂ were investigated using X-ray diffraction (XRD), scanning electron microscopy and energy dispersive spectrometry (SEM–EDS). Without additives, Fe₃PO₇ was reduced to elemental phosphorus and formed an iron–phosphorus alloy with metallic iron. The addition of CaCO₃ reacted with Fe₃PO₇ to generate an enormous amount of Ca₃(PO₄)₂ and promoted the reduction of iron oxides. However, the growth of iron particles was inhibited. With the addition of Na₂CO₃, the phosphorus in Fe₃PO₇ migrated to nepheline and Na₂CO₃ improved the reduction of iron oxides and growth of iron particles. Therefore, the recovery of iron and the separation of iron and phosphorus were the best. In contrast, CaF₂ reacted with Fe₃PO₇ to form fine Ca₃(PO₄)₂ particles scattered around the iron particles, making the separation of iron and phosphorus difficult.
- high-phosphorus iron ore;
- additives;
- reduction roasting;
- magnetic separation;
- iron recovery;
- dephosphorization

FullText(HTML)

Supplements(0)

References(29)

References

[1]	X.H. Li, J. Kou, T.C. Sun, S.C. Wu, and Y.Q. Zhao, Effects of calcium compounds on the carbothermic reduction of vanadium titanomagnetite concentrate, Int. J. Miner. Metall. Mater., 27(2020), No. 3, p. 301. doi: 10.1007/s12613-019-1864-z
[2]	X.H. Li, J. Kou, T.C. Sun, S.C. Wu, and Y.Q. Zhao, Formation of calcium titanate in the carbothermic reduction of vanadium titanomagnetite concentrate by adding CaCO₃, Int. J. Miner. Metall. Mater., 27(2020), No. 6, p. 745. doi: 10.1007/s12613-019-1903-9
[3]	Z.D. Tang, P. Gao, Y.S. Sun, Y.X. Han, E.L. Li, J. Chen, and Y.H. Zhang, Studies on the fluidization performance of a novel fluidized bed reactor for iron ore suspension roasting, Powder Technol., 360(2020), p. 649. doi: 10.1016/j.powtec.2019.09.092
[4]	J. Tang, M.S. Chu, F. Li, C. Feng, Z.G. Liu, and Y.S. Zhou, Development and progress on hydrogen metallurgy, Int. J. Miner. Metall. Mater., 27(2020), No. 6, p. 713. doi: 10.1007/s12613-020-2021-4
[5]	Y.Q. Zhao, T.C. Sun, H.Y. Zhao, C. Chen, and X.P. Wang, Effect of reductant type on the embedding direct reduction of beach titanomagnetite concentrate, Int. J. Miner. Metall. Mater., 26(2019), No. 2, p. 152. doi: 10.1007/s12613-019-1719-7
[6]	K. Ionkov, S. Gaydardzhiev, A. Correa de Araujo, D. Bastin, and M. Lacoste, Amenability for processing of oolitic iron ore concentrate for phosphorus removal, Miner. Eng., 46-47(2013), p. 119. doi: 10.1016/j.mineng.2013.03.028
[7]	F. McGregor, E. Ramanaidou, and M. Wells, Phanerozoic ooidal ironstone deposits—Generation of potential exploration targets, Appl. Earth Sci., 119(2010), No. 1, p. 60. doi: 10.1179/037174510X12853354810660
[8]	M. Omran, T. Fabritius, and R. Mattila, Thermally assisted liberation of high phosphorus oolitic iron ore: A comparison between microwave and conventional furnaces, Powder Technol., 269(2015), p. 7. doi: 10.1016/j.powtec.2014.08.073
[9]	A.P.L. Nunes, C.L.L. Pinto, G.E.S. Valadão, and P.R.D.M. Viana, Floatability studies of wavellite and preliminary results on phosphorus removal from a Brazilian iron ore by froth flotation, Miner. Eng., 39(2012), p. 206. doi: 10.1016/j.mineng.2012.06.004
[10]	Q.P. Bao, L. Guo, and Z.C. Guo, A novel direct reduction–flash smelting separation process of treating high phosphorous iron ore fines, Powder Technol., 377(2021), p. 149. doi: 10.1016/j.powtec.2020.08.066
[11]	S.C. Wu, T.C. Sun, Z.Y. Li, C.Y. Xu, and X.H. Li, Research progress of direct reduction–magnetic separation of high phosphorus iron ore, Met. Mine, 50(2021), No. 2, p. 58.
[12]	K. Quast, A review on the characterisation and processing of oolitic iron ores, Miner. Eng., 126(2018), p. 89. doi: 10.1016/j.mineng.2018.06.018
[13]	B. Khassen, N. Baltynova, and L. Dakhno, Investigation of dephosphorization of brown iron ore concentrates by sintering and magnetic beneficiation, Int. J. Miner. Process., 126(2014), p. 136. doi: 10.1016/j.minpro.2013.11.013
[14]	H.Q. Tang, Y.Q. Qin, and T.F. Qi, Phosphorus removal and iron recovery from high-phosphorus hematite using direct reduction followed by melting separation, Miner. Process. Extr. Metall. Rev., 37(2016), No. 4, p. 236. doi: 10.1080/08827508.2016.1181628
[15]	J.T. Yu, Z.C. Guo, and H.Q. Tang, Dephosphorization treatment of high phosphorus oolitic iron ore by hydrometallurgical process and leaching kinetics, ISIJ Int., 53(2013), No. 12, p. 2056. doi: 10.2355/isijinternational.53.2056
[16]	L. Zhang, R. Machiela, P. Das, M.M. Zhang, and T. Eisele, Dephosphorization of unroasted oolitic ores through alkaline leaching at low temperature, Hydrometallurgy, 184(2019), p. 95. doi: 10.1016/j.hydromet.2018.12.023
[17]	H.Q. Zhang, Z.Q. Zhang, L.Q. Luo, and H. Yu, Behavior of Fe and P during reduction magnetic roasting-separation of phosphorus-rich oolitic hematite, Energy Sources A, 41(2019), No. 1, p. 47. doi: 10.1080/15567036.2018.1496195
[18]	W.T. Zhou, Y.X. Han, Y.S. Sun, and Y.J. Li, Strengthening iron enrichment and dephosphorization of high-phosphorus oolitic hematite using high-temperature pretreatment, Int. J. Miner. Metall. Mater., 27(2020), No. 4, p. 443. doi: 10.1007/s12613-019-1897-3
[19]	Y.L. Li, T.C. Sun, J. Kou, Q. Guo, and C.Y. Xu, Study on phosphorus removal of high-phosphorus oolitic hematite by coal-based direct reduction and magnetic separation, Miner. Process. Extr. Metall. Rev., 35(2014), No. 1, p. 66. doi: 10.1080/08827508.2012.723648
[20]	Y. Xu, T.C. Sun, Z.G. Liu, and C.Y. Xu, Phosphorus occurrence state and phosphorus removal research of a high phosphorous oolitic hematite by direct reduction roasting method, J. Northeast. Univ. Nat. Sci., 34(2013), No. 11, p. 1651.
[21]	G.H. Li, S.H. Zhang, M.J. Rao, Y.B. Zhang, and T. Jiang, Effects of sodium salts on reduction roasting and Fe–P separation of high-phosphorus oolitic hematite ore, Int. J. Miner. Process., 124(2013), p. 26. doi: 10.1016/j.minpro.2013.07.006
[22]	M.J. Rao, C.Z. Ouyang, G.H. Li, S.H. Zhang, Y.B. Zhang, and T. Jiang, Behavior of phosphorus during the carbothermic reduction of phosphorus-rich oolitic hematite ore in the presence of Na₂SO₄, Int. J. Miner. Process., 143(2015), p. 72. doi: 10.1016/j.minpro.2015.09.002
[23]	W. Yu, T.C. Sun, J. Kou, Y.X. Wei, C.Y. Xu, and Z.Z. Liu, The function of Ca(OH)₂ and Na₂CO₃ as additive on the reduction of high-phosphorus oolitic hematite–coal mixed pellets, ISIJ Int., 53(2013), No. 3, p. 427. doi: 10.2355/isijinternational.53.427
[24]	S.C. Wu, T.C. Sun, and H.F. Yang, Study on phosphorus removal of high-phosphorus oolitic hematite abroad by direct reduction and magnetic separation, Met. Mine, 48(2019), No. 11, p. 109.
[25]	C.Y. Cheng, V.N. Misra, J. Clough, and R. Muni, Dephosphorisation of western Australian iron ore by hydrometallurgical process, Miner. Eng., 12(1999), No. 9, p. 1083. doi: 10.1016/S0892-6875(99)00093-X
[26]	W.S. Huang, L. Yan, S.C. Wu, and T.C. Sun, Study on the process mineralogy of a high phosphorus ooliticiron ore in abroad, Met. Mine, 49(2020), No. 9, p. 137.
[27]	B.Z. Ma, X. Li, W.J. Yang, D. Hu, P. Xing, B. Liu, and C.Y. Wang, Nonmolten state metalized reduction of saprolitic laterite ores: Effective extraction and process optimization of nickel and iron, J. Clean. Prod., 256(2020), art. No. 120415. doi: 10.1016/j.jclepro.2020.120415
[28]	T.Y. Hu, T.C. Sun, J. Kou, C. Geng, and Y.Q. Zhao, Effects and mechanisms of fluorite on the co-reduction of blast furnace dust and seaside titanomagnetite, Int. J. Miner. Metall. Mater., 24(2017), No. 11, p. 1201. doi: 10.1007/s12613-017-1512-4
[29]	Y.S. Sun, Y.F. Li, D.Z. Wang, and Y.X. Han, Thermodynamic analysis of the reduction process of fluorapatite, J. Northeast. Univ. Nat. Sci., 40(2019), No. 6, p. 875.