Mechanism of phosphorus removal in beneficiation of high phosphorous oolitic hematite by direct reduction roasting with dephosphorization agent

High phosphorous oolitic hematite ore is one of typical intractable iron ores in China, and the conventional beneficiation methods are found to be impracticable to , remove phosphorus from the ore effectively. Better beneficiation index were gotten by direct reduction roasting with dephosphorization agent followed by two stages of grinding and magnetic separation. P content decreases from 0.82% in the raw ore to 0.06% in the magnetic concentrate, and the total iron grade increases from 43.65% to 90.23%, the recovery of iron can reach 87%. Mechanisms of phosphorus removal in the beneficiation of high phosphorous oolitic hematite ore by direct reduction roasting with dephosphorization agent were studied using XRD, SEM and EPMA. The results showed that about 20% of the apatite in the raw ore transferred into phosphorus and volatilized with the gas in the process of reduction roasting, while the rest 80% apatite was not involved in the reaction of generation of phosphorus, and remained as apatite in the roasted products, which was removed to tailings by grinding and magnetic separation. A small amount of phosphorus existed in the magnetic concentrate as apatite. The oolitic texture of raw ore was partly changed during roasting, resulting in the formation of nepheline in the reaction between the dephosphorization agent, SiO2 and Al2O3 in the raw ore, which greatly improved the liberation degree of minerals in the roasted products, and it was beneficial to the subsequent grinding and magnetic separation.

Recovery of iron from high phosphorus oolitic iron ore using coal-based reduction followed by magnetic separation

Oolitic iron ore is one of the most important iron resources. This paper reports the recovery of iron from high phosphorus oolitic iron ore using coal-based reduction and magnetic separation. The influences of reduction temperature, reduction time, C/O mole ratio, and CaO content on the metallization degree and iron recovery were investigated in detail. Experimental results show that reduced products with the metallization degree of 95.82% could be produced under the optimal conditions （i.e., reduction temperature, 1250℃; reduction time, 50 min; C/O mole ratio, 2.0; and CaO content, 10wt%）. The magnetic concentrate containing 89.63wt% Fe with the iron recovery of 96.21% was obtained. According to the mineralogical and morphologic analysis, the iron minerals had been reduced and iron was mainly enriched into the metallic iron phase embedded in the slag matrix in the form of spherical particles. Apatite was also reduced to phosphorus, which partially migrated into the metallic iron phase.

Strengthening iron enrichment and dephosphorization of high-phosphorus oolitic hematite using high-temperature pretreatment

The efficient development and utilization of high-phosphorus oolitic hematite is of great strategic significance for the sustainable supply of iron-ore resources in China.In this paper,the mechanism of high-temperature pretreatment for enhancing the effect of iron enrichment and dephosphorization in the magnetization roasting–leaching process was studied by X-ray diffraction(XRD),vibration sample magnetometer(VSM),scanning electron microscopy and energy dispersive spectrometry(SEM–EDS).Compared with the process without high-temperature pretreatment,the iron grade of the magnetic separation concentrate after high-temperature pretreatment had increased by 0.98%,iron recovery rate had increased by 1.33%,and the phosphorus content in the leached residue had decreased by 0.12%.High-temperature pretreatment resulted in the dehydration and decomposition of hydroxyapatite,the dehydration of limonite and the thermal decomposition of siderite,which can produce pores and cracks and weaken the compactness of the ore,improve the magnetization characteristics of roasted ore,and strengthen the iron enrichment and dephosphorization during the magnetization roasting and leaching process.

Magnetizing Roasting Mechanism and Effective Ore Dressing Process for Oolitic Hematite Ore

Magnetizing roasting of oolitic hematite ore from western Hubei Province was investigated.The mechanism for reduction roasting of oolitic hematite ore was discussed and analyzed.It is found that flash magnetizing roasting-magnetic separation process is a promising approach for the processing of oolitic hematite ore from western Hubei Province.

Comparison of basic features and origins of oolitic shoal reservoirs between carbonate platform interior and platform margin locations in the Lower Triassic Feixianguan Formation of the Sichuan Basin,southwest China

The oolitic shoal reservoirs of the Lower Triassic Feixianguan Formation carbonates in the Sichuan Basin of southwest China are an important target for gas exploration in the basin.Their occurrence,like other cases worldwide,can be divided into two locations in general,i.e.,platform interior and platform margin locations.Their differences of reservoir features and origins,however,have not been investigated comprehensively due to different exploration degrees.This issue is addressed in this paper,to provide basic data and information for the basin＇s hydrocarbon exploration and for the study of carbonate platform sedimentology and reservoir geology worldwide.We compared the features of these two types of reservoirs in detail,including the depositional and diagenetic features,pore types and petrophysical features.Based on the comparison,the origin of the reservoirs was further discussed.It is shown that the reservoirs in platform interior and platform margin locations differ significantly.The interior carbonates were deposited in moderate to high energy settings and the dominant lithologic type was limestone,which was weakly compacted and intensely cemented and has undergone meteoric dissolution.Pore types include intragranular dissolution and moldic pores,with low porosities（6%） and low permeabilities（0.1 mD）.By contrast,the platform margin carbonates were deposited in relatively high energy settings and mainly consisted of dolostones with some limestones.The rocks were strongly compacted but incompletely cemented.As a result,some primary intergranular pores were preserved.Both meteoric solution and burial solution have taken place.There are various types of pore spaces including intergranular and intercrystalline solution pores and residual intergranular pores.This type of reservoir generally has better petrophysical properties（9% porosity and 0.1 mD permeability） and pore-throat structures than the interior reservoirs.These differences were influenced by both primary depositional features and secondary diagenesis.For the interior carbonate reservoirs,early meteoric dissolution,weak compaction and strong cementation are important controlling factors.By contrast,the factors controlling the formation of the margin carbonate reservoirs mainly include dolomitization,preservation of primary pores and burial dissolution.

Migration behaviors and kinetics of phosphorus during coal-based reduction of high-phosphorus oolitic iron ore

To understand the migration mechanisms of phosphorus(P)during coal-based reduction,a high-phosphorus oolitic iron ore was reduced by coal under various experimental conditions.The migration characteristics and kinetics of P were investigated by a field-emission electron probe microanalyzer(FE-EPMA)and using the basic principle of solid phase mass transfer,respectively.Experimental results showed that the P transferred from the slag to the metallic phase during reduction,and the migration process could be divided into three stages:phosphorus diffusing from the slag to the metallic interface,the formation of Fe P compounds at the slag metal interface and P diffusing from the slag metal interface to the metallic interior.The reduction time and temperature significantly influenced the phosphorus content of the metallic and slag phases.The P content of the metallic phase increased with increasing reduction time and temperature,while that of the slag phase gradually decreased.The P diffusion constant and activation energy were determined and a migration kinetics model of P in coal-based reduction was proposed.P diffusion in the metallic phase was the controlling step of the P migration.

Process mineralogy and characteristic associations of iron and phosphorus-based minerals on oolitic hematite

The chemical compositions,mineralogical characteristics,as well as dissemination of iron-and phosphorus-based minerals were studied for the E’xi oolitic hematite from western Hubei Province in China by using chemical analysis,optical microscope,electron probe micro-analyzer(EPMA)and energy dispersive spectroscopy(EDS).It is found that this kind of oolitic hematite ore contains 47.71%TFe,10.96%SiO_2,as well as 0.874%P,with hematite as the dominant Fe-bearing minerals,and quartz,chamosite,illite and cellophane as main gangue minerals.The microscope examination showed that the ore has an oolitic structure,with some ooids principally formed by a series of concentric layers of hematite collophanite around nucleus that is hematite in the association with collophanite.Based on the EPMA and EDS analysis,it can be known that some ooids are primarily composed of hematite and collophanite.The separation can be achieved through fine grinding for those collophanite laminae with a higher P content.However,the dissemination of two minerals at the interface will result in the difficulty in effective separation.Besides,some ooids are made of chamosite with some nucleus formed of quartz,which is principally finely disseminated with hematite.In view of the close association and dissemination of iron-and phosphorus-based minerals in the ooids,it is found that the process of stage-grindings and stage-separations can be adopted to effectively increase the iron recovery and decrease the P content in the concentrate to some extent.

Mechanism of microwave assisted suspension magnetization roasting of oolitic hematite ore

Oolitic hematite is an iron ore resource with rich reserves,complex composition,low grade,fine disseminated particle sizes,and a unique oolitic structure.In this study,a microwave-assisted suspension magnetization roasting technology was proposed to recover and utilize the ore.The results showed that under the conditions of microwave pretreatment temperature of 1050℃ for 2 min,a magnetic concentrate with an iron grade of 58.72%at a recovery of 89.32%was obtained by microwave suspension magnetization roasting and magnetic separation.Moreover,compared with the no microwave pretreatment case,the iron grade and recovery increased by 3.17%and 1.58%,respectively.Microwave pretreatment increased the saturation magnetization of the roasted products from 24.974 to 39.236(A∙m^(2))/kg and the saturation susceptibility from 0.179×10^(−3) m^(3)/kg to 0.283×10^(−3) m^(3)/kg.Microcracks were formed between the iron and gangue minerals,and they gradually extended to the core of oolite with the increase in the pretreatment time.The reducing gas diffused from outside to inside along the microcracks,which promoted the selective transformation of the weak magnetic hematite into the strong magnetic magnetite.

Phase transformation in suspension roasting of oolitic hematite ore

Suspension roasting followed by magnetic separation is a promising method to upgrade oolitic hematite ore.An oolitic hematite ore was roasted using suspension roasting technology at different temperatures.The phase transformation for iron minerals was investigated by XRD and Mossbauer spectrum,and the characteristics of roasted product were analyzed by VSM and SEM-EDS.Results indicate that the magnetic concentrate is of 58.73% Fe with iron recovery of 83.96% at 650 °C.The hematite is rapidly transformed into magnetite during the roasting with transformation ratio of 92.75% at 650 °C.Roasting temperature has a significant influence on the phase transformation of hematite to magnetite.The transformation ratio increases with increased temperature.After roasting,the magnetic susceptibility is significantly improved,while iron ore microstructure is not altered significantly.

Application of multi-stage dynamic magnetizing roasting technology on the utilization of cryptocrystalline oolitic hematite:A review

A large number of studies have shown that oolitic hematite is an iron ore that is extremely difficult to utilize because of its fine disseminated particle size, high harmful impurity content and oolitic structure.To recover iron from oolitic hematite, we developed a novel multistage dynamic magnetizing roasting technology. Compared with traditional magnetizing roasting technologies, this novel technology has the following advantages: firstly, the oolitic hematite is dynamically reduced in a multi-stage roasting furnace, which shortens the reduction time and avoids ringing and over-reduction;secondly, the novel dynamic magnetizing roasting technology has strong raw material adaptability, and the size range of raw materials can be as wide as 0–15 mm;thirdly, the roasting furnace adopts a preheating-heating process, and the low-calorific value blast furnace gas can be used as the fuel and reductant, which greatly reduces the cost. The actual industrial production data showed that the energy consumption in the roasting process can be less than 35 kg of standard coal per ton of raw ore. The iron grade of the concentrate and iron recovery reached 65% and 90%, respectively.

The Major Controlling Factors and Different Oolitic Shoal Reservoir Characteristics of the Triassic Feixianguan Formation,Eastern Longgang Area,NE Sichuan Basin,SW China

Based on comprehensive analyses of occurrence,petrological observation,pore structure and geochemistry,the different reservoir characteristics and reservoir evolutionary pathways between different oolitic shoal reservoir types of the Feixianguan Formation on the west side of the Kaijiang-Liangping Trough have been studied.There exist three stages of high-energy slope break belts in the Feixianguan period,the corresponding three stages of oolitic shoals gradually migrating in the direction of the trough.Three types of oolitic shoal reservoirs,namely,residual-oolitic dolomite,mold-oolitic dolomite and sparry oolitic limestone,were formed during sedimentary-diagenetic evolution,the pore types being intergranular dissolved pore,mold pore(or intragranular dissolved pore)and residual intergranular pore,respectively.The petrology,physical properties and pore structure of the different types of oolitic shoal reservoirs are quite different.Residual-oolitic dolomite reservoirs have the best quality,while sparry oolitic limestone reservoirs have the poorest.Combined with analyses of trace elements,rare earth elements and carbon-oxygen isotopes,it is suggested that the formation of residual-oolitic dolomite reservoirs is jointly controlled by penesaline seawater seepage-reflux dolomitization and hydrothermal dolomitization.Mold-pore oolitic dolomite reservoirs are controlled by penesaline seawater seepage-reflux dolomitization and meteoric water solution.The burial dissolution of organic acid not only further improves the reservoir qualities of previously formed oolitic dolomite reservoirs,but also preserves residual intergranular pores in the sparry oolitic limestone reservoirs.

Effect of coal levels during direct reduction roasting of high phosphorus oolitic hematite ore in a tunnel kiln

The effect of coal levels on phosphorus removal from a high phosphorus oolitic hematite ore after direct reduction roasting have been investigated. Raw ore, coal, and a dephosphorizatiou agent were mixed and the mixture was then roasted in a tunnel kiln. The roasted products were treated by two stages of grind- ing followed by magnetic separation. XRD and SEM-EDS examination of the products was used to analyze differences in the roasted products. The results show that coal is one of the most important factors affect- ing the direct reduction roasting process. When the inner coal levels increased from 0% to 15% the iron grade decreased linearly from 94.94%to 88.81% and the iron recovery increased from 55.94% to 92.94%. At the same time the phosphorus content increased from 0.045% to 0.231%. Increasing the inner coal levels also caused more hematite to be reduced to metallic iron but the oolitic structure of the roasted product was preserved in the presence of high coal loading. The phase of the phosphorus in raw ore was not changed after direct reduction roasting. The effect of coal on the phosphorus content in the H-concentrate arises from changes in the difficulty of mechanically liberating the metallic iron from the phosphorus bearing minerals.

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

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%Na_(2)SO_(4)and reducing at 1050℃ 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.

Thermodynamic analysis of the carbothermic reduction of a high-phosphorus oolitic iron ore by FactSage

A thermodynamic analysis of the carbothermic reduction of high-phosphorus oolitic iron ore（HPOIO） was conducted by the Fact Sage thermochemical software. The effects of temperature, C/O ratio, additive types, and dosages both on the reduction of fluorapatite and the formation of liquid slag were studied. The results show that the minimum thermodynamic reduction temperature of fluorapatite by carbon decreases to about 850°C, which is mainly ascribed to the presence of SiO_2, Al_2O_3, and Fe. The reduction rate of fluorapatite increases and the amount of liquid slag decreases with the rise of C/O ratio. The reduction of fluorapatite is hindered by the addition of CaO and Na_2CO_3, thereby allowing the selective reduction of iron oxides upon controlled C/O ratio. The thermodynamic results obtain in the present work are in good agreement with the experimental results available in the literatures.

Microwave Assisted Liberation of High Phosphorus Oolitic Iron Ore

The influence of microwave treatment on the liberation of iron ore from the high phosphorus oolitic iron ore from Aswan region, Egypt was studied. The effect of microwave power, exposure time and grain size on the liberation of iron ore was investigated. The microfractures and cracks of the samples were characterized before and after microwave treatments. The heating rate of high phosphorus oolitic iron ore was studied. Crystallinity of hematite was characterized before and after microwave pretreatment. The results indicated that intergranular fractures formed between the gangues (fluorapatite and chamosite) and hematite after microwave treatment, leading to improved liberation of iron ore and a significant reduction in comminution energy. Percentages of fraction ≤ -0.125 mm increased from 46.6% to 59.76% with increased exposure time from 0 to 60 seconds. The heating rate of iron ore showed that microwave treatment was less efficient at smaller particle sizes for a fixed applied power density. Crystallinity of hematite increased with the microwave exposure time.

A composite sphere assemblage model for porous oolitic rocks:Application to thermal conductivity

The present work is devoted to the determination of linear effective thermal conductivity of porous rocks characterized by an assemblage of grains(oolites) coated by a matrix. Two distinct classes of pores, i.e.micropores or intra oolitic pores(oolite porosity) and mesopores or inter oolitic pores(inter oolite porosity), are taken into account. The overall porosity is supposed to be connected and decomposed into oolite porosity and matrix porosity. Within the framework of Hashin composite sphere assemblage(CSA)models, a two-step homogenization method is developed. At the first homogenization step, pores are assembled into two layers by using self-consistent scheme(SCS). At the second step, the two porous layers constituting the oolites and the matrix are assembled by using generalized self-consistent scheme(GSCS) and referred to as three-phase model. Numerical results are presented for data representative of a porous oolitic limestone. It is shown that the influence of porosity on the overall thermal conductivity of such materials may be significant.

Effect of Na2CO3 and CaCO3 on Coreduction Roasting of Blast Furnace Dust and High-phosphorus Oolitic Hematite

Iron was recovered from blast furnace dust and high-phosphorus oolitic hematite in the presence of Na2CO3 and CaCO3 additives. The functions of Na2CO3 and CaCO3 during the coreduction roasting process were investigated by XRD and SEM-EDS analyses. Results indicate that these additives not only hinder the reduction of fluorapatite, CaCO3 also decreases the P content of direct reduced iron（DRI） by increasing the reduction alkalinity. P remains as fluorapatite in the slag, which can be removed by grinding and magnetic separation under optimal conditions. The Na2CO3 promotes hematite reduction and improves the iron recovery（εFe） by replacing the FeO from fayalite, which results in quick growth and aggregation of metallic iron and improvement of ε（Fe） in DRI. A DRI with 91.88 mass% Fe, and 0.065 mass% P can be achieved at a recovery of 87.86 mass% under the optimal condition.

Kinetics and Dissolution Mechanisms of Oolitic Limestone Under Burial Condition

In order to study the control factors and mechanism of oolitic limestone reservoir being corroded by organic acid produced in burial stage,the reactions of acetic acid(pH=3) with oolitic limestone were investigated using the rotating-disk Corrosion Reactor System(CRS).The effects of disk rotational speed, temperature and system pressure were examined. Scanning Electron Microscope attached with Energy Dispersive X-Ray Analyzer(SEM-EDX) was

Corrosion and Penetration Resistance of Corundum Bricks to High Phosphorus Oolitic Hematite Reducing Materials

The paper aims at investigating whether corundum bricks can be used for the bottom, of the direct reduction furnace of high phosphorus oolitic hematite. The reducing materials including high phosphorus oolitic hematite, bitumite, Ca（OH） 2 and Na2CO3 at a mass ratio of 1：0. 15：0. 15：0. 03 were mixed and pressed into carbon containing cylindrical specimens with the size of Ф15 mm × 20 mm. The specimens were placed on the corundum bricks and reduced in a high temperature tube furnace at 1 200 ℃ for 40, 60, 80, 140 and 220 min, respective- ly. The corrosion and penetration resistance of corundum. bricks to high phosphorus oolitic hematite reducing materials were analyzed with XRD, SEM and EDS. It shows that the reducing slag formed in the reduction process corrodes the surface of corundum bricks to form a product layer of anorthite and hercynite, retarding the further corrosion of the reducing slag; the reducing slag which has penetrated into the interior of the brick goes through the gaps between the particles and generates anorthite and hercynite, filling the gaps and hindering the reducing slag penetration.

Geology, Mineralogy and Geochemistry of the Oligocene Oolitic Iron Ore of the Continental Terminal Formation, Kandi Basin, North-East Benin

The Oligocene Continental Terminal Formation of the Kandi Basin contains high grades of iron mineralization (~56.72% Total Fe). The microscopic study under the polarized and reflected light showed that the iron ore consists of silicate minerals (quartz 50% and zircon 1%) and non-silicate minerals (goethite 30%, hematite 7%, magnetite 3%, pyrite 1%, chalcopyrite 1%, blende 3%, galena 3%, scheelite 1% and gold 2%). The X-rays fluorescence shows that the iron ore is characterized by various elements, such as Fe2O3 (57.91% to 91.33%), SiO2 (3.07% to 33.19%), aluminum (2.94% to 7.74%), vanadium (0.04% to 0.11%), phosphorus (0.79% to 2.29%) and sulfur (<0.3%). The deleterious elements grade is above the permissible limit in metallurgy (0.05% - 0.07% for phosphorus and 0.1% for sulfur). Their high grades indicate that the Kandi Basin iron ore characteristics are not favorable for steel manufacturing despite its good vanadium contents (0.04% to 0.11%). However, it could be used for the cast iron manufacture. Spectrometric analysis by atomic absorption confirms the presence of low-grade gold associated to the iron ore (from 0.006 to 0.015 ppm). The comparative study of discontinuous stratiform iron ore of the Kandi Basin with other oolitic iron ores in exploitation from other countries such as Brazil, Australia, China, Russia, Uganda and the United States shows that iron ore of the Kandi Basin can be mined despite its high silica content.