Title:
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Reduction and carburisation of iron ore in a fluidised bed
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The literature on the following subjects has been reviewed:
the reduction of iron oxides with methane, carburisation of iron
with methane, the reduction of iron ore with hydrogen and carbon
monoxide and the factors affecting the rates of gas-solid reactions
in fluidised beds.
The rates of reduction and carburisation of granular hematite
ore (±180-250
. im particles), fluidised by the reducing-carburising
gas in a quartz reactor, and measured over the temperature range
900-1100K by analysis of the outlet gas using gas chromatography,
are reported. The reactions of pure hydrogen, some H2-H20
mixtures, and various HZ-(ßi4 mixtures are covered. Also surface
areas of iron and partially reduced oxide, measured by nitrogen
i joýmariý'ý cn
adsorption, and,, solid structures, studied by optical and electron
microscopy are presented.
Established models of reactions in fluidised beds have been
adapted to give tentative rate constants for the reduction of
wustite to iron at 900K. The maximum values are similar to those
derived in other work using completely different techniques. Rate
constants have also been obtained for the reduction of magnetite to
wustite using H2-H2O and 00-OD at 973K; these have not been well
established previously. The variation of the rate constants with
degree of reduction is discussed with reference to the surface area
of the solid and the formation of non-porous product layers.
In the reaction of H2-C[ mixtures with hematite between 900
and 1100K the methane is unreactive until iron is formed (approx.
40% reduction); it then begins to decompose catalytically and the
reduction rate increases. Carbon deposition does not occur until
50-70% reduction. At 900K there is some indication from the
reduction rate and the electron micrographs that carbon blocks
pores and hinders the final stages of reduction. The initial rates
of carburisation per gram of iron are similar to those obtained in
previous work using pellets over the range of mixtures studied. At
lower temperatures there is an increased tendency for the rate of
carburisation to drop with increasing degree of carburisation of
the iron, this is accentuated by high gas flowrates and high carbon
potentials in the gas. Because of the insensitivity of the rate to
the iron surface area and gas composition, the decomposition of
methane is not thought to be rate determining. The rates of
methane decomposition, iron oxide reduction, and carburisation are
discussed with reference to the catalytic activity of iron as it
forms fron the oxide and is then contaminated with carbon and
carbides, cacd, týo the gas composition and gas dynamics in the
bed.
At 1000 and 1100K fluidisation collapses temporarily as iron
forms, but with further reduction and carburisation re-fluidisation
occurs, presumably because carburisation weakens the adhesion of
the iron particles.
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