Synchronous enrichment of phosphorus and iron from a high-phosphorus oolitic hematite ore to prepare Fe-P alloy by direct reduction-magnetic separation process

Abstract

In this study, direct reduction-magnetic separation process was applied to enrich phosphorus and iron to prepare Fe-P crude alloy from a high phosphorus oolitic hematite ore (HPOH). The results show that at lower temperatures and with absence of any of additives, Fe cannot be effectively recovered because of the oolitic structure is not destroyed. In contrast, under the conditions of 15% Na₂SO₄ and reducing at 1050 °C for 120 min with a total C/Fe ratio (molar ratio) of 8.5, a final Fe-P alloy containing 92.40% Fe and 1.09% P can be obtained at an overall iron recovery of 95.43% and phosphorus recovery of 68.98%, respectively. This metallized Fe-P powder can be applied as the burden for production of weathering resistant steels. The developed process can provide an alternative for effective and green utilization of high phosphorus iron ore.

Keywords

high-phosphorus oolitic hematite ore / direct reduction / magnetic separation / Fe-P alloy

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