Synthesis and Characterization of Metallic Iron Reduced from Low-grade Coal in Rajasthan
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Synthesis and Characterization of Metallic Iron Reduced from Low-grade Coal in Rajasthan Akshay Kumar 1 & Vinayaka R. Kiragi 2,3 & Saurav Kumar 1 & Amar Patnaik 2
&
Vinod Kumar 4 & M. K. Banerjee 1
Received: 19 December 2019 / Accepted: 27 July 2020 # Society for Mining, Metallurgy & Exploration Inc. 2020
Abstract Today’s industrial technology offers to optimize and reutilize the resources available in terms of scum that remains after hot rolling in steel rerolling mills in Rajasthan, India. Vast reserves of low-grade coal exist and tons of mill scale are produced everyday after hot rolling in steel rerolling mills in Rajasthan, India. The present research work aimed to optimize the various parameters of solid-state reduction of mill scale using low-grade coal from Rajasthan, India. This study investigates the effect of reduction temperature (850–950 °C in steps of 50 °C), reduction time (60 to 180 min, in step of 60 min), mill scale size (800– 300 μm), and mill scale to coal ratio (1:1, 1:2 and 1:3) on achievable metallic iron percentage and its metallization. A higher percentage of iron content is obtained at a lower particle size of 300 μm. The structural analysis is carried out on 300 μm mill scales using XRD analysis, which shows the percentage of iron is approximately 63%, and metallization above 80% can be obtained under the reduction temperature at 900 °C for 180 min, for 1:3 ratio (mill scale to coal ratio). The chemical composition of the mill scale is obtained using X-ray fluorescence (XRF), and particle sizes as well as distribution of mill scale are determined by scanning electron microscopy (SEM). The elements present in the mill scale are also verified using EDS, which indicates the presence of a major portion of Fe, followed by Fe2O3, Si, and C, respectively. Keywords Mill scale reduction . Low-grade coal . Metallization . X-ray fluorescent . Scanning electron microscopy
1 Introduction Mill scale is abundant in India, including in Rajasthan, and is composed of iron oxides, low quantity nonferrous phases, and alkaline compounds, accounting for almost 5 million tons a year [1–5]. This cannot be processed directly because it possesses a low grade of iron particles in it and dumped into the tailings dam during steel making. With a legal limitation on the extent of CO2 emissions and to maintain economical processes, it is required to optimize and reutilize waste resources available in steel rerolling mills. Therefore, reducing the mill scale to
* Amar Patnaik [email protected] 1
Department of Metallurgical and Materials Engineering, MNIT, Jaipur 302017, India
2
Department of Mechanical Engineering, MNIT, Jaipur 302017, India
3
Department of Mechanical Engineering, SGES Government Rural Polytechnic, Tarihal, Hubli, Karnataka 580026, India
4
Discipline of Metallurgy Engineering and Materials Science, IIT, Indore 453552, India
extract iron can be an added advantage of reusing the byproducts of the steel industry. Steel is considered to be the most extensively used material in the world,
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