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Hydrogen Reduction Kinetics of Hematite Concentrate Particles Relevant to a Novel Flash Ironmaking Process

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Abstract

As an integral part of developing a novel ironmaking process, the hydrogen reduction kinetics of hematite concentrate particles (average particle size 21 µm) were measured in the temperature range from 1423 K to 1623 K (1150 °C to 1350 °C). The novel ironmaking process aims at producing iron from iron oxide concentrates in a flash reactor using gaseous fuels and reductants, which will help reduce energy consumption and minimize greenhouse gas emissions. More than 90 pct reduction of hematite concentrate particles could be obtained by hydrogen at a temperature of 1573 K (1300 °C) and 3 seconds of residence time, indicating that hematite concentrate is suitable for the flash reduction process under development largely aimed at the use of magnetite concentrates. The nucleation and growth rate equation with the Avrami parameter, n, of 1.0 well described the kinetics of hematite reduction. The reduction rate has a 1st-order dependence on the partial pressure of hydrogen. The activation energy of the reaction was 214 kJ/mol, indicating strong temperature dependence. The following complete rate equation was developed that can satisfactorily predict the kinetics of hematite concentrate particles and is suitable for the design of a flash reactor: \( \frac{{{\text{d}}X}}{{{\text{d}}t}} = 4.41 \times 10^{7} \times {\text{e}}^{{\frac{ - 214{,}000}{RT}}} \times \left( {p{\text{H}}_{2} - \frac{{p{\text{H}}_{2} {\text{O}}}}{K}} \right) \times (1 - X), \) where X is fractional reduction degree, R is 8.314 J/mol K, T is in K, p is in atm, and t is in seconds.

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Acknowledgments

The authors thank Udo Fischer, Andrew Laroche, Omar Kergaye, Mohamed Elzohiery, and Deqiu Fan for the help with the analytical work using ICP and the experimental runs. In addition, the authors would like to thank the staff of Micron Microscopy Core at the University of Utah, especially Dr. Brian Van Devener, for the valuable help with SEM imaging. Feng Chen acknowledges the financial support from China Scholarship Council for her work at the University of Utah. The authors acknowledge the financial support from the U.S. Department of Energy under Award Number DE-EE0005751 with cost share by the American Iron and Steel Institute (AISI) and the University of Utah.

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This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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Correspondence to Hong Yong Sohn.

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Manuscript submitted January 6, 2015.

Appendix

Appendix

See Table IV.

Table IV Complete Experimental Data (Excess Hydrogen >500 pct)

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Chen, F., Mohassab, Y., Jiang, T. et al. Hydrogen Reduction Kinetics of Hematite Concentrate Particles Relevant to a Novel Flash Ironmaking Process. Metall Mater Trans B 46, 1133–1145 (2015). https://doi.org/10.1007/s11663-015-0332-z

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