Effect of Na_2CO_3 on reduction and melting separation of ludwigite/coal composite pellet and property of boron-rich slag

The effects of Na_2CO_3 on the reduction and melting separation behavior of ludwigite/coal composite pellet, the desulfurization ratio and the property of the separated boron-rich slag were investigated at laboratory scale in the present work. Na_2CO_3 could improve the reduction rate of the composite pellet to some extent. The melting separation of the composite pellet became increasingly difficult with the increase of Na_2CO_3 in the pellet due to the sharply increasing of the melting point of slag. The sulfur content of the iron nugget gradually decreased from 0.27% to 0.084%（mass fraction） with the Na_2CO_3 content in the pellet increasing from 0 to 6%. The efficiency of extraction of boron（EEB） of the slow cooled boron-rich slag decreased from 86.46% to 59.52% synchronously. Na_2CO_3 had obviously negative effect on melting separation of the composite pellet and boron extraction of the boron-rich slag.

Recovery of Ferric Oxide from Bayer Red Mud by Reduction Roasting-Magnetic Separation Process

A great amount of red mud generated from alumina production by Bayer process was considered as a low-grade iron ore with a grade of 5wt% to 30wt% iron.We adopted the reduction roastingmagnetic separation process to recover ferric oxide from red mud.The red mud samples were processed by reduction roasting,grinding and magnetic separating respectively.The effects of different parameters on the recovery rate of iron were studied in detail.The optimum techqicalparameters were proposed with 700 ℃roasting for 20 min,as 50wt% carbon and 4wt% additive were added.The experimentalresults indicated that the iron recovery and the grade of totaliron were 91% and 60%,respectively.A novelprocess is applicable to recover ferric oxide from the red mud waste fines.

Comprehensive recovery of lead, zinc, and iron from hazardous jarosite residues using direct reduction followed by magnetic separation

Lead, zinc, and iron were recovered from jarosite residues using direct reduction followed by magnetic separation. The influence of the coal dosage, reduction temperature, and reduction time on the volatilization rates of lead and zinc and the metallization rate of iron were investigated. The results show that the volatilization rates of lead and zinc were 96.97% and 99.89%, respectively, and the iron metallization rate was 91.97% under the optimal reduction roasting conditions of a coal dosage of 25.0 wt% and reduction roasting at 1250°C for 60 min. The magnetic concentrate with an iron content of 90.59 wt% and an iron recovery rate of 50.87% was obtained under the optimum conditions in which 96.56% of the reduction product particles were smaller than 37 μm and the magnetic field strength was 24 k A/m. Therefore, the results of this study demonstrate that recovering valuable metals such as lead, zinc, and iron from jarosite residues is feasible using the developed approach.

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.

Effect of Sodium Sulfate on Direct Reduction of Beach Titanomagnetite for Separation of Iron and Titanium

The effect of sodium sulfate on direct reduction of beach titanomagnetite,followed by magnetic separation,to separate iron and titanium was investigated. Direct reduced iron（ DRI） with a high Fe content,low TiO_2 content and low iron recovery was obtained after adding sodium sulfate. When the sodium sulfate dosage was increased from 0 to 10 mass%,the Fe content of the DRI increased from 90. 00 mass% to 93. 55 mass% and the TiO_2 content decreased from 1. 27 mass% to 0. 70 mass%. The reduction mechanism of sodium sulfate was investigated by X-ray diffraction（ XRD） and scanning electron microscopy（ SEM） with energy dispersive spectrometer（ EDS）. Results revealed that the metallic iron grains in the reduced ore with sodium sulfate were larger than those in the ore without sodium sulfate. Sodium sulfate promoted the migration of iron as well as the accumulation and growth of metallic iron grains by low-melting-point carnegieite and troilite formed in the redox system. Low-melting-point carnegieite decreased the melting point of the system and then promoted liquefaction. Troilite could decrease the surface tension and melting point of metallic iron grains.

A method for recovery of iron,titanium,and vanadium from vanadium-bearing titanomagnetite

An innovative method for recovering valuable elements from vanadium-bearing titanomagnetite is proposed. This method involves two procedures： low-temperature roasting of vanadium-bearing titanomagnetite and water leaching of roasting slag. During the roasting process, the reduction of iron oxides to metallic iron, the sodium oxidation of vanadium oxides to water-soluble sodium vanadate, and the smelting separation of metallic iron and slag were accomplished simultaneously. Optimal roasting conditions for iron/slag separation were achieved with a mixture thickness of 42.5 mm, a roasting temperature of 1200°C, a residence time of 2 h, a molar ratio of C/O of 1.7, and a sodium carbonate addition of 70 wt%, as well as with the use of anthracite as a reductant. Under the optimal conditions, 93.67% iron from the raw ore was recovered in the form of iron nugget with 95.44% iron grade. After a water leaching process, 85.61% of the vanadium from the roasting slag was leached, confirming the sodium oxidation of most of the vanadium oxides to water-soluble sodium vanadate during the roasting process. The total recoveries of iron, vanadium, and titanium were 93.67%, 72.68%, and 99.72%, respectively.

Effects of embedding direct reduction followed by magnetic separation on recovering titanium and iron of beach titanomagnetite concentrate

Embedding direct reduction followed by magnetic separation was conducted to fully recover iron and titanium separately from beach titanomagnetite （TTM）. The influences of reduction conditions, such as molar ratio of C to Fe, reduction time, and reduction temperature, were studied. The results showed that the TTM concentrate was reduced to iron and iron-titanium oxides, depending on the reduction time, and the reduction sequence at 1 200℃ was suggested as follows ： Fe2.75 Ti0.25O4→Fe2TiO4→FeTiO3→FeTi2O5. The reduction temperature played a considerable role in the reduction of TTM concentrates. Increasing temperature from 1 100 to 1 200℃ was beneficial to recovering titanium and iron, whereas the results deteriorated as temperature increased further. The results of X-ray diffraction and scanning electron microscopy analyses showed that low temperature （≤1100℃） was unfavorable for the gasification of reductant, resulting in insufficient reducing atmosphere in the reduction process. The molten phase was formed at high temperatures of 1250-1 300℃, which accelerated the migration rate of metallic particles and suppressed the diffusion of reduction gas, resulting in poor reduction. The optimum conditions for reducing TTM concentrate are as follows： molar ratio of C to Fe of 1.68, reduction time of 150 min, and reduction temperature of 1 200℃. Under these conditions, direct reduction iron powder, assaying 90.28 mass% TFe and 1.73 mass% TiO2 with iron recovery of 90.85%, and titanium concentrate, assaying 46.24 mass% TiO2 with TiO2 recovery of 91.15%, were obtained.

Recovery of boron from high-boron iron concentrate using reduction roasting and magnetic separation

The comprehensive utilization of abundant high-boron iron concentrate is of particular significance to Chi- na, and the high-boron iron concentrate has not yet been utilized as a source for boron at an industrial scale due to its complex mineralogy and fine mineral dissemination. An innovative method was proposed for recovery of boron and iron from high-boron iron concentrate by reduction roasting and magnetic sepa- ration. The effects of reduction temperature and roasting time were investigated and their optimum condi- tions were determined. The mineralogical changes during roasting were characterized by X-ray diffraction （XRD） and scanning electron microscopy （SEM）. The results showed that the pyrrhotite （FeS） contained in the high-boron iron concentrate and the new-formed FeS-Fe solid solution softened or melted at high temperatures owing to their low melting points, and then decreased the metallic iron ratio and accelerated the growth of metallic iron particles. Meanwhile, the magnetite and szaibelyite were converted into metal- lic iron and suanite, respectively. Consequently, boron was readily enriched into the non-magnetic product and the metallic iron was aggregated to the magnetic concentrate by magnetic separation. Boron recovery of 88.6% with corresponding B2O3 content of 14.5% and iron recovery of 95.1% with an iron grade of 92.7% were achieved when high-boron iron concentrate was reduced at 1 125℃ for 150 min. Besides, the boron reactivity of the boron-rich non-magnetic product was up to 80.8%.

Preparation of Chromium-iron Metal Powder from Chromium Slag by Reduction Roasting and Magnetic Separation

Chromium slag（CS）has become one of the most hazardous solid waste containing chromium and iron.Based on its characteristics,the technology of reduction roasting and magnetic separation was employed to treat CS.The major impurity element of CS is magnesium and it exists in magnesium ferrite phase,which is hard to recover iron in the absence of additives.During reduction roasting,additives（Al2O3and CaF2）could destroy the structure of magnesium ferrite and improve the iron grade and recovery.The final product,i.e.chromium-iron powder,contains 72.54% Fe and 13.56% Cr,with the iron recovery of 80.34% and chromium recovery of 80.70%.

Controlling reduction degree of graphene oxide membranes for improved water permeance

Tailoring tire pore structure and surface chemistry of graphene-based laminates is essentially important for their applications as separation membranes. Usually, pure graphene oxide （GO） and completely reduced GO （rGO） membranes suffer florn low water permeance because of the lack of pristine graphitic sp2 domains and very small interlayer spacing, respectively. In this work, we studied the influence of reduction degree on the structure and separation pertornrance of rGO membranes, tt was found that weak reduction retains the good dispersion and hydrophilicity of GO nanosheets. More importantly, it increases the number of pristine graphitic sp2 domains in rGO nanosheets while keeping the large interlayer spacing of the GO membranes in most regions at the same time. The resultant mernbranes show a high water permeance of 56.3 L m^-2 h^ -1 bar^ -1, which is about 4 times and over 10^4 times larger tban those of the GO and completely reduced rGO membranes, respectively, and high rejection over 95700 for various dyes. Furthermore, they show better structure stability and more superior separation perfor- mance than GO membranes in acid and alkali environments.