Innovative Method for Separating Phosphorus and Iron from High-Phosphorus Oolitic Hematite by Iron Nugget Process
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INTRODUCTION
WITH the rapid development of the iron and steel industry, China has become the biggest import country of iron ore. The iron and steel industry is confronted with shortage of raw material resources, which will be a huge threat to the development of the steel industry in China. Despite the rich high-phosphorus oolitic hematite resources in China, it is difficult to make use of them due to the complex mineral composition and dissemination in the iron minerals.[1,2] Therefore, promoting the comprehensive development and fully using high-phosphorus hematite resources could be a possible way to alleviate the shortage of iron ore resources in China. In recent years, the dephosphorization process for high-phosphorous iron ores has been studied all over the world, which has obtained some achievements already.[3–5] Jiang et al.[6] used acid leaching for dephosphorization. Wang et al.[7] developed bioleaching to reduce the content of phosphorization in iron ore. Zhou et al.[8] used direct reduction followed by magnetic separation. Yin et al.[9] developed direct reduction by microwave. Yu et al.[10] and Bai et al.[11] made an improvement on the direct reduction-magnetic separation process by adding Ca(OH)2 and Na2CO3. Tang et al.[12] put forward a process that combined the gasbased reduction with smelting of an electric furnace. Wu et al.[13] proposed an integrated process consisting of roasting, magnetic separation, and reverse flotation HONGLIANG HAN and SIMING CHEN, Assistant Researchers, DONGPING DUAN, Researcher, and XING WANG, Associate Researcher, are with the Key Laboratory of Green Process and Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, P.R. China. Contact e-mail: hlhan@home. ipe.ac.cn Manuscript submitted November 26, 2013. Article published online June 22, 2014. 1634—VOLUME 45B, OCTOBER 2014
dressing. Matinde and Hino[14] investigated the dephosphorization by using prereduction and screening methods combined with mechanical crushing or air jet milling. Among these achievements, acid leaching and bioleaching successfully improved the dephosphorization rate and iron recovery rate; however, the disadvantages are obvious. Bioleaching is usually time consuming and acid leaching is not competitive for mass production. The reduction process is proved to be beneficial for the iron recovery rate,[15–17] but it is very difficult to separate the ferrous phase from the P-containing gangue.[18–20] So how to make the full use of high-phosphorus oolitic hematite seems to be a big problem. Based on these statements, a novel approach for high-phosphorus oolitic hematite dephosphorization by a rotary hearth furnace iron nugget process was put forward. In this process, the iron mineral of highphosphorus oolitic hematite is reduced and carburized by carbon, which makes the melting point of metallic iron decrease and makes the iron melt and coalesce; P-containing gangue is not reduced by carbon and still exists in the form of apatite in slag. At a certain temperature, the metall
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