Iron ore reduction/cementation: experimental results and kinetic modelling

Abstract

Iron ore reduction and iron cementation by H2-CH4-Ar gas mixtures were investigated in a laboratory isothermal fixed bed reactor in the temperature range 600-925°C. Iron ore was first reduced to metallic iron by hydrogen, then metallic iron was carburised to cementite by methane. Increasing temperature and hydrogen content accelerated the reduction process. However, for >55 vol.-%, the effect of H2 content was not significant. Methane had almost no effect on the reduction process. Increasing temperature increased the rate of iron cementation and also the rate of free carbon deposition. Optimum conditions for cementite formation were: temperature 750°C and reducing/carburising gas contents of 40-55 vol.-%H2 and 35 vol.-%CH4. Under these conditions, reduction of iron ore to cementite was completed in ~15 min. A two interface grain model and a volume reaction model were used to simulate the process of iron ore reduction and iron cementation. The simulated results for both reduction and cementation were consistent with the experimental data.