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A Novel Devolatilization Technique of Pre-reduction of Iron Ore Using Lean Grade Coal

Neuartige Entgasungstechnik zur Vorreduktion von Eisenerz mittels minderwertiger Kohle

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Abstract

The problem of properly utilizing non-coking coals in alternative iron making processes dates back to long ago. Lean grade coals with higher ash and volatile matter content (e.g. boiler grade coals) have always challenged the metallurgists to develop a suitable process for their utilization. The aim of this work is to achieve an energy efficient method for the reduction of briquetted iron ore fines using ‘SYNGAS’—which is the gaseous product (enriched with reducing agents) generated by pyrolysis of coal along with fine sized carbon particles produced during pyrolysis. A laboratory scale reduction furnace with pyrolysis facility has been designed and fabricated after in depth thermo-gravimetric analysis (TGA), differential thermal analysis (DTA), and gas chromatograph (GC) studies. A particular temperature profile has been maintained inside the furnace to achieve the optimum reduction temperature. The briquettes are reduced in the pyrolysis furnace and the extent of reduction has been calculated from the weight loss. The reduced specimens are characterized using X-ray diffractometer (XRD), scanning electron microscope (SEM), energy dispersive X-ray spectrometer (EDX), field emission scanning electron microscope (FESEM), and chemical analysis method. It is observed that iron ore can be significantly reduced to metallic iron by using the devolatilization product of lean grade coal.

Zusammenfassung

Das Problem der richtigen Anwendung von nichtkokenden Kohlen in alternativen Eisenherstellungsverfahren ist schon lange bekannt. Minderwertige Kohlen mit höherem Aschegehalt und flüchtigen Bestandteilen (z. B. Kesselkohlen) und die Entwicklung eines geeigneten Verfahrens zu ihrer Nutzung haben schon immer die Metallurgen herausgefordert. Das Ziel dieser Arbeit ist die Entwicklung eines energieeffizienten Verfahrens zur Reduktion des brikettierten Feineisenerzes unter Verwendung von SYNGAS. SYNGAS ist das gasförmige Produkt einer Kohleentgasung, welches mit feinen Kohlepartikeln vermischt wird. Dazu wurde ein Reduktionsofen im Labormaßstab mit Entgasungsmöglichkeit nach thermo-gravimetrischen Analysen (TGA), Differentialthermoanalysen (DTA) und Gaschromatographie (GC) Untersuchungen entwickelt. Um die optimale Reduktionstemperatur zu erreichen, wird ein besonderes Temperaturprofil innerhalb des Ofens eingestellt. Die Briketts werden im Pyrolyseofen reduziert, und das Ausmaß der Reduktion wird aus dem Gewichtsverlust berechnet. Die reduzierten Proben werden unter Verwendung von Röntgen-Diffraktometrie (XRD), Rasterelektronenmikroskopie (REM), energiedispersive Röntgenspektrometer (EDX), Feldemissions-Rasterelektronenmikroskop (FE-REM) und chemischen Analyseverfahren charakterisiert. Es wurde beobachtet, dass Eisenerze durch Verwendung des Entgasungsprodukts aus minderwertigen Kohlen zu einem hohen Anteil zu metallischen Eisen reduziert werden können.

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Acknowledgements

The authors would like to thank Mr. Saikat Samanta, Mr. Supratim Biswas, and Mr. Bitan Kumar Sarkar, Research Scholar, Metallurgical & Material Engineering, Jadavpur University, Kolkata. The authors would also like to express their heartfelt gratitude to Mr. Anirban Sur, Chemist, GSI (Eastern Region), Kolkata (India). One of the authors (Chanchal Biswas) acknowledges the financial support from Technical Quality Improvement Programme (TEQIP) phase-11, Jadavpur University for funding and providing fellowship.

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Authors and Affiliations

  1. Department of Metallurgical and Material Engineering, Jadavpur University, 700032, Kolkata, India

    Chanchal Biswas, Gopes Chandra Das & Rajib Dey

  2. Chair of Ferrous Metallurgy, Montanuniversität Leoben, 8700, Leoben, Austria

    Anrin Bhattacharyya

  3. School of Materials Science and Nano Technology, Jadavpur University, 700032, Kolkata, India

    Mahua Ghosh Choudhuri

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  1. Chanchal Biswas
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  2. Anrin Bhattacharyya
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  3. Gopes Chandra Das
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  4. Mahua Ghosh Choudhuri
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  5. Rajib Dey
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Correspondence to Chanchal Biswas.

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Biswas, C., Bhattacharyya, A., Chandra Das, G. et al. A Novel Devolatilization Technique of Pre-reduction of Iron Ore Using Lean Grade Coal. Berg Huettenmaenn Monatsh 161, 95–101 (2016). https://doi.org/10.1007/s00501-015-0401-2

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