Sticking-Free Reduction of Titanomagnetite Ironsand in a Fluidized Bed Reactor
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ITE (TTM) ironsand has been studied as a potential alternate low-cost iron ore due to the ease with which it can be extracted and magnetically concentrated.[1–5] Substantial deposits of TTM ironsand are found throughout the west coast of the North Island of New Zealand (NZ), which are utilized as the primary source of iron for domestic steel production.[6,7] At
SIGIT W. PRABOWO is with the Robinson Research Institute, Faculty of Engineering, Victoria University of Wellington, Lower Hutt 5046, Wellington, New Zealand and also with the Pyrometallurgy Group, School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW, 2522, Australia. RAYMOND J. LONGBOTTOM and BRIAN J. MONAGHAN are with the Pyrometallurgy Group, School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong. DIEGO DEL PUERTO and MARTIN J. RYAN are with Callaghan Innovation, Lower Hutt 5040, Wellington, New Zealand. CHRIS W. BUMBY is with the Robinson Research Institute, Faculty of Engineering, Victoria University of Wellington. Contact e-mail: chris.bumby@ vuw.ac.nz Manuscript submitted February 14, 2019. Article published online June 11, 2019. METALLURGICAL AND MATERIALS TRANSACTIONS B
present, this TTM ironsand ore is commercially processed in a coal-fired rotary kiln process.[8] However, this approach, similar to other carbothermic process, exhibits low energy efficiency and produces high emissions of gases such as CO2 and SO2. The increased focus for reducing CO2 emission in global steel production has attracted renewed interests in the gas-based reduction utilizing hydrogen gas to treat TTM ironsand.[5,9–11] Among the process technologies used for gas-based reduction, fluidized bed processing offers advantages as it enables fast processing times and direct use of the raw ironsand fines. This eliminates the need for additional pelletizing and sintering plant required when processing fines using other traditional ironmaking routes.[12–14] Moreover, NZ TTM ironsand ore exhibits a naturally occurring particle size distribution in the range 90 to 250 lm which are approximately spherical in shape, making it well suited to fluidized bed processing. A significant technical obstacle to the high throughput fluidized bed reduction of iron ores is the sticking of particles at high temperatures (Z 973 K).[12,15,16] ‘‘Sticking’’ refers to the agglomeration of particles in the whole bed during the reduction process.[15,17,18] Once
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agglomerated, fluidization is lost and the process is arrested, limiting further reduction of the iron ore fines.[19–21] This phenomenon is often associated with the growth of fibrous whiskers on the surface of freshly reduced iron particles which can lead to particles becoming entangled together upon contact.[15,21,22] Direct iron-iron contact at particle surfaces can also lead to the sticking of iron particles even in the absence of fibrous structures.[16,23–25] Several methods have been proposed to prevent the sticking of iro
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