The demands for increasing the efficiency and lowering the environmental effects in iron and steelmaking industries have given rise to interests in application of direct reduction (DR) processes for production of iron by different gases. These advancements require comprehensive models for better control of the process conditions and the product properties. In the present thesis fundamental aspects in reduction of iron oxide were investigated. The experimental studies on reduction of iron oxide pellets were performed under well-controlled conditions in a setup designed for thermogravimetric investigations. The results indicated that the reaction rates by the applied procedure are higher compared to the procedure similar to conventional thermogravimetric analysis (TGA). This difference was caused by the time required for replacing the inert gas by the reaction gases. Reduction by H2-CO mixtures was accompanied by deposition of carbon and formation of cementite. The variations of cementite contents in the industrial iron ore pellets reduced isothermally for different durations, showed that cementite formation starts from the initial stages of reduction. The experimental conditions such as reaction temperature, carbon activity in the reaction gas and reaction time have a large impact on carbide content of the reduced samples. The kinetics of reduction of iron ore powder by H2 and CO gas mixtures with different compositions were studied using a commercial TGA setup. The results showed that the apparent rates of reaction vary linearly with the H2 and CO contents of the gas. Larger amount of H2 resulted in higher reaction rates. The data were employed in the developed reduction model for pellets. The model was based on the mechanism observed in the commercial iron ore pellets reduced by pure hydrogen. The microstructure of reacted pellets showed that reduction of the examined industrial samples is controlled by both chemical reaction and gaseous diffusion. The reduction model was developed by combining computations for the flow and mass transfer in the gas phase, diffusion of gases in the solid phase and chemical reaction at the reaction sites. The modelling and experimental results were in reasonably good agreement. The present model provides a good foundation for a dynamic multi-particle process model. The results highlighted the importance of considering the reduction mechanisms in different types of pellets prior to modelling. Experiments were undertaken to investigate the selective reduction of iron oxide in zinc ferrite. It was observed that gaseous reduction by hydrogen at temperatures up to 873 K is a potential method for reduction of iron oxide to metallic iron, while the zinc oxide remains in the product and losses of metallic zinc are negligible. Using this primary step in the hydrometallurgical processing of EAFD can overcome the difficulties for leaching of zinc ferrite. / <p>QC 20160823</p>

The blast furnace is still the dominant form of iron production, but over the years, direct reduction methods have increased due to a number of reasons. Overall, iron production methods have optimal requirements with respect to the feed materials especially iron ore. In this study, tests were carried out on Muko iron ore from Uganda to analyse its suitability to meet the feed requirements of today's dominant iron production methods. More specifically, the Tumbler, Abrasion, and Shatter Indices of the ore were determined. In addition, porosity, thermoanalysis, and reducibility tests were performed. Overall, the Muko ore was found to have good mechanical properties exemplified with tumble and shatter index data &gt;89.0 wt% and &lt;2.5 wt%, respectively. Furthermore, its reducibility at 0.87%/min is within the acceptable range as a natural material feed for blast furnace and direct reduction furnaces. Also, the energy requirement for heating the ore to 1100°C was found to be higher in the samples containing a wider size range of irregular grains and the largest contaminations. In summary, it is concluded that the Muko iron ore has good physical and metallurgical properties to serve as a natural material for the blast furnace and direct reduction furnaces. / <p>QC 20130531</p> / Sustainable Technology Development in the Lake Victoria Region

Thesis (Ph. D.)--University of New South Wales, 2005. / Also available online.

This project examined the reduction and formation of cementite from hematite and titanomagnetite ores and cementite stability. The aim of the project was to develop further understanding of cementite stability under conditions relevant to direct ironmaking and the mechanism of cementite decomposition. The reduction of hematite and ironsand by hydrogen-methane-argon gas mixtures was investigated from 600??C to 1100??C. Iron oxides were reduced by hydrogen to metallic iron, which was carburised by methane to form cementite. The hematite ore was reduced more quickly than the ironsand. Preoxidation of the ironsand accelerated its reduction. Hematite was converted to cementite faster than preoxidised ironsand. The decomposition of cementite formed from hematite was investigated from 500??C to 900??C. This cementite was most stable at temperatures 750-770??C. The decomposition rate increased with decreasing temperature between 750??C and 600??C and with increasing temperature above 770??C. The stability of cementite formed from pre-oxidised titanomagnetite was studied from 300??C to 1100??C. This cementite was most stable in the temperature range 700-900??C. The rate of decomposition of cementite increased with decreasing temperature between 700??C and 400??C and with increasing temperature above 900??C. Cementite formed from ironsand was more stable than cementite formed from hematite

This project examined the reduction and formation of cementite from hematite and titanomagnetite ores and cementite stability. The aim of the project was to develop further understanding of cementite stability under conditions relevant to direct ironmaking and the mechanism of cementite decomposition. The reduction of hematite and ironsand by hydrogen-methane-argon gas mixtures was investigated from 600??C to 1100??C. Iron oxides were reduced by hydrogen to metallic iron, which was carburised by methane to form cementite. The hematite ore was reduced more quickly than the ironsand. Preoxidation of the ironsand accelerated its reduction. Hematite was converted to cementite faster than preoxidised ironsand. The decomposition of cementite formed from hematite was investigated from 500??C to 900??C. This cementite was most stable at temperatures 750-770??C. The decomposition rate increased with decreasing temperature between 750??C and 600??C and with increasing temperature above 770??C. The stability of cementite formed from pre-oxidised titanomagnetite was studied from 300??C to 1100??C. This cementite was most stable in the temperature range 700-900??C. The rate of decomposition of cementite increased with decreasing temperature between 700??C and 400??C and with increasing temperature above 900??C. Cementite formed from ironsand was more stable than cementite formed from hematite

[pt] As pelotas de minério de ferro têm suas propriedades fortemente dependentes da natureza das fases escorificadas que se formam durante o processo de queima. Neste trabalho são apresentados os resultados de uma das pesquisas que compõem o projeto cooperativo entre a Samarco e o Grupo de Siderurgia do DEMa / PUC-Rio, envolvendo a possibilidade de utilização de minérios de ferro portadores de fósforo (pellet feed), na produção de pelotas para redução direta. Com este objetivo foram geradas amostras de escórias sintéticas de mesma composição que as das pelotas RD comerciais, as quais foram submetidas a condições experimentais análogas as do processo industrial. Inicialmente a ciclos térmicos em forno tipo pot-grate e, posteriormente, em escala laboratorial, usando forno de mufla, seguido de etapas de resfriamento em velocidades distintas. Foi possível então constatar que velocidades mais altas de resfriamento, aplicadas na etapa final dos ciclos térmicos, produziam escórias sintéticas sensivelmente amorfas, o que levou a conclusão que as fases escorificadas das pelotas RD também se apresentariam como estruturas não cristalinas. Finalmente, por meio de teste especificamente desenvolvido para a análise seletiva de fósforo em fases oxídicas, conseguiu-se obter uma maior eficiencia na mensuração deste elemento quando dissolvido em escórias amorfas, o que viabilizou a medida das quantidades de fósforo que efetivamente migraram para as mesmas, quando se submetiam as amostras de pellet feed a diferentes temperaturas, variados tempos de residencia e distintas basicidades. Por fim, foi possivel concluir ser o incremento de basicidade do pellet feed um fator de significativa melhoria para o transporte e a dissolução do fósforo pelas escórias, em particular quando submetidos a temperaturas superiores a 900 graus Celsius. / [en] Iron ore pellets have their properties strongly dependent on the nature of the phases present in the slags formed during pelletization. In this work are presented the first results of a research program involving the utilization of phosphorous bearing iron ores in the production of DR pellets (Direct Reduction pellets). Aiming at this, synthetic slags, produced with same composition of the gangue of a commercial DR pellet, were submitted to operational conditions similar to those of the industrial pelletizing process, but performed in a pot-grate reactor and in a laboratory furnace. The obtained slags samples were cooled at different rates, permitting to observe that at high cooling rates the slags obtained were amorphous, suggesting the occurrence of a similar amorphous structure for the slags present in the DR pellets. Finally, tests developed for a selective analysis of phosphorous in oxide phases, showed better efficiency when applied to amorphous slags than in crystalline ones. Further, the behavior of the phosphor dissolution in the obtained slags during the heating of pellet feed samples was evaluated. In this phase different temperatures, resident times and basicities were tested using a laboratory furnace. The results indicated improvements in the phosphor dissolution with the basicity increase when temperatures above 900 Celsius degrees were applied.

[pt] O presente trabalho apresenta uma análise da influência da temperatura, composição gasosa, vazão e pressão sobre a cinética da redução de dois tipos de pelotas de minério de ferro para redução direta, de baixo conteúdo de sílica, na faixa de temperatura de 500 a 900°C. Os valores adotados para cada parâmetro operacional procuraram reproduzir as condições reais da zona de redução de um processo industrial de redução direta, utilizando o forno de cuba, onde existe um perfil térmico longitudinal, além de gradientes de pressão e potencial redutor. A metodologia experimental envolveu um modelo estatístico fatorial de múltiplos níveis, ou seja, 3 níveis para a temperatura e 2 níveis para o poder redutor, a pressão e a vazão, com o intuito de avaliar os efeitos destas variáveis no processo de redução. A partir dos dados experimentais foi proposto um modelo semiempírico baseado no princípio da superposição e reação exponencial, que mostrou uma correlação de 99,2% para a pelota A e 98,5% para a pelota B. O coeficiente de saturação da redução (B), o parâmetro da escala temporal (t) e o tempo correspondente ao grau de reação global máximo (tG.R.máx), obtidos pelo modelo, foram plotados em função da temperatura, todos apresentando um erro global inferior a 10%. Mediante este formalismo se pode também prever que, na faixa de 500°C até 900°C, o coeficiente B e t se mostraram dependentes da temperatura e do potencial redutor da mistura gasosa. Verificou-se ainda a dependência de tG.R.máx com a pressão total. O estudo em questão é parte de um programa de doutorado em andamento e que envolve a PUC-RJ e a Samarco Mineração S/A. / [en] An analysis of the influence of the temperature, flow, pressure and gas composition on the kinetic of reduction for two types of lo w silica hematite pellets for direct reduction, over the temperature range 500°C to 900°C is presented. The values adopted for each variable tried to reproduce the real parameters of the reduction zone of the shaft furnaces where exists gradients of reducing potential, gradients of pressure and longitudinal thermal profile. The experimental methodology involved a factorial statistical model of multiple level, i.e. 3 levels for the temperature and 2 levels for the reducing potential, pressure and flow, with the aim to evaluate the effects of the variables on the reduction process. One semi-empiric model was developed from the experimental data. It was based on the superposition principle and exponential reaction. The model showed a correlation of 99.2% for the pellet A and 98.5% for the pellet B. The reduction saturation coefficient (B), time scale factor (t) and the time of the maximum reaction grade (tG.R.máx), all obtained through the model, were plotted versus temperature and they had presented an inferior global error to 10%. The coefficient B and t had depended of the temperature and reducing potential and allowed the prediction of its behavior over the temperature range 500°C to 900°C. Also, the analysis showed the tG.R.máx is dependent of total pressure. The investigation in question is part of a doctorate in progress at Catholic University in Rio de Janeiro/Brazil, counting on professionals from the academic area and experts from the iron ore agglomeration industry.

M.Ing. (Mechanical) / The goal of this study was to determine whether a SLIRN direct reduction process could be modelled with a neural network. The full name of the SLIRN process is the Stelco, Lurgi, Republic Steel, and National Leadprocess. A parallel goal was to identify, and test an alternative method to reduce the dimensionality of a model. A neural network software package named Process Insights was used to model the process. Two independent data reduction methods were used along with various Process Insights functions, to build, train, and test models. The best model produced by each of the two data reduction methods was used to report on. The results showed that a SLIRN direct reduction process could be modelled successfully with a neural network. The large number of variables normally identified with such a process can be reduced without significant loss in model performance, The results also showed that the removal of the most significant variable does not affect the model accuracy significantly, which bodes well for the fault tolerance of the model in terms of individual sensor failures. The Process Insights functions important to the modelling process were highlighted.

This study aims to find how density affects the reduction extent and reduction rate. H2-CO gas mixture is used as reducing agent. Five groups of different density pellets were reduced at four different temperatures. Light optical microscope (LOM) and scanning electron microscope with energy dispersive X-ray spectroscopy (SEM-EDS) used to detect completely and partially reduced pellets to investigate how density affects the reduction mechanisms. Results illustrate that density affects reduction extent and reduction rate a lot. However, when reaction temperature is 1123 K, density has less influenc on reduction extent. The carbon deposition occurred for high density pellets at 973 K and 1023 K. The reduction process cannot be described by a single rate controlling step. Reduced layer is denser compared with unreduced layer. Reaction at initial stages goes much faster than later stages.

Around 50 million tones hematite iron ores with high iron content at a grade of 68% were found in Muko area of Uganda. Currently, the iron and steel making industry in the country has not yet developed to meet the demand to process the natural ores. Based on the analysis of its composition and mechanical properties, I infer that the natural iron lump ores can charge directly into reduction furnace without any prior treatment, so that the cost of whole process without additional enrichment and sintering will be reduced quite much. Also direct reduction iron (DRI) process use natural gases instead of coals which can greatly reduce the environmental pollution and lower the processes cost. If the raw materials that fit for requirements of majority plants, the seller´s market can get greater control over prices, terms due to the easy and cheap processing. All lump ores were from Butare area which is one occurrence of Muko and named sample A in this work. This research aims to use the lowest cost method to reduce Butare area iron ores and find out the optimum parameters on reduction reactions of Butare iron lump ores, such as flow rate, temperature, size of samples. Base on experiments with different designed parameters, Butare iron lump ores successfully reduced by DR furnace and microstructure was found to be an important parameter that strongly influent reduction degree of Butare iron lump ores.