N. Alavifard - Department of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad
H. Shalchian - Department of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad
A. Rafsanjani-Abbasi - Department of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad
J. Vahdati Khaki - Department of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad
A. Babakhani - Department of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad

In the present work, iron recovery from a low-grade hematite ore (containing less than ۴۰% iron), which is not applicable in common methods of ironmaking, was studied. Non-coking coal was used as reducing agent. Reduction experiments were performed under various coal to hematite ratios and temperatures. Reduction degree was calculated using the gravimetric method. Reduced samples were subjected to magnetic separation followed by X-ray diffraction analysis. Total iron content, degree of metallization and recovery efficiency in magnetic part were determined by quantitative chemical analysis, which were obtained about ۸۲%, ۹۵% and ۶۴% respectively under optimal conditions. CaO as an additive improved ore reducibility and separation efficiency. The microstructure of reduced samples and final products were analyzed by scanning electron microscopy. Final product with a high degree of metallization can be used in steel making furnaces and charging of blast furnaces which can improve production efficiency and decrease coke usage.

Low-grade iron ore, Coal-based direct reduction, Sponge iron, Lime, Magnetic separation