Journals →  Obogashchenie Rud →  2021 →  #4 →  Back

SECONDARY RAw MATERIAL PROCESSING
ArticleName Research on the reduction of iron oxide from red mud pellets using coke
DOI 10.17580/or.2021.04.08
ArticleAuthor Khalifa A. A., Bazhin V. Yu., Ustinova Ya. V., Shalabi M. E. H.
ArticleAuthorData

St. Petersburg Mining University (St. Petersburg, Russia).

Khalifa A. A., Postgraduate Student
Bazhin V. Yu., Head of Chair, Doctor of Engineering Sciences, Professor, bazhin_vyu@pers.spmi.ru
Ustinova Ya. V., Associate Professor, Candidate of Engineering Sciences, Kuskova_YaV@pers.spmi.ru

 

Central Metallurgical Research and Development Institute (Cairo, Egypt):
Shalabi M. E. H., Head of Laboratory, Candidate of Engineering Sciences

Abstract

The use of red mud as an alternative raw material for the production of iron and steel has been studied for several decades. The proposed methods for its disposal are not widely used in the industry. The fine particle sizes and the large amount of impurities negatively affect the properties of red mud pellets and its direct reduction. The proposed method for the direct reduction of slime using coal with the addition of bentonite as a binder allows obtaining high-strength pellets with reduced iron. The effect of temperature, pellet and coal particle sizes at their different ratios on the reduction rates has been studied. The transformation of the iron phases has been analyzed by the X-ray diffraction (XRD) analysis method. The results indicate that the increased compressive strength of the red mud and coal composite pellets is explained by the higher bentonite content. The optimal conditions for pelletizing red mud with coal include the 2 % bentonite and 15 % moisture content. The reduction rate increases rapidly with higher temperatures and is more intense in the range of 1050 to 1100 °C. The pellet reduction processes with the particle size of red mud and coke fines in the range of 45 to 75 μm are much faster than in any other case. At 1100 °C, pellets with the carbon to oxygen molar ratio of 1 : 1 demonstrate a good reducing ability, with metallic iron becoming the dominant phase in the reduced samples. The reduction degree in the product reached 80.02 %, which is confirmed by the results of the X-ray structural analysis. The proposed technology, therefore, ensures the required conditions for obtaining high-strength pellets with a significant content of reduced iron, which creates good prospects for their further use as a charge material in blast-furnace smelting.

keywords Red mud, carbon particles, direct reduction, combined pellets, ferric phase
References

1. Pasechnik L. A., Medyankina I. S., Skachkov V. M., Sabirzyanov N. A., Pyagay I. N., Yatsenko S. P. Extraction of zirconium from red mud of alumina production. Fluorine Notes. 2018. Iss. 3. URL: http://ru.notes.fluorine1.ru/public/2018/3_2018/article_3.html (accessed: 29.07.2021).
2. Pyagay I. N. Extraction of scandium and other metals from red mud of alumina production with the absorption of toxic gases in sintering furnaces: diss. for the degree of Doctor of Engineering Sciences. St. Petersburg, 2016. 318 p.
3. Zinoveev D. V., Grudinskii P. I., Dyubanov V. G., Kovalenko L. V., Leont'ev L. I. Global recycling experience of red mud – A review. Part 1: Pyrometallurgical methods. Izvestiya Vysshikh Uchebnykh Zavedeniy. Chernaya Metallurgiya. 2018. Vol. 61, No. 11. pp. 843–858.
4. Piirainen V. Y., Boeva A. A., Nikitina T. Y. Application of new materials for red mud immobilization. Key Engineering Materials. 2020. Vol. 854. pp. 182–187.
5. Besedin А. А., Utkov V. А., Brichkin V. N., Sizyakov V. М. Red mud sintering. Obogashchenie Rud. 2014. No. 2. pp. 28–31.
6. Pyagay I. N., Kremcheev E. A., Pasechnik L. A., Yatsenko S. P. Carbonization processing of bauxite residue as an alternative rare metal recovery process. Tsvetnye Metally. 2020. No. 10. pp. 56–63. DOI: 10.17580/tsm.2020.10.08.
7. Kashcheev I. D., Zemlyanoy K. G., Doronin A. V., Kozlovskikh E. Yu. New possibilities of the acidic method for producing aluminum oxide. Novye Ogneupory. 2014. No. 4. pp. 6–12.
8. Khalifa A. A., Utkov V. A., Brichkin V. N. Red mud effect on dicalcium silicate polymorphism and sinter selfdestruction prevention. Vestnik Irkutskogo Gosudarstvennogo Tekhnicheskogo Universiteta. 2020. Vol. 24, No. 1. pp. 231–240.
9. Ashok P., Sureshkumar M. P. Experimental studies on concrete utilising red mud as a partial replacement of cement with hydrated lime. Journal of Mechanical and Civil Engineering (IOSR-JMCE). 2014. Vol. 6. 10 p.
10. Vegman E. F. Ores and concentrates pelletizing. Moscow: Metallurgiya, 1984. 256 p.
11. Trushko V. L., Dashko R. E., Kuskov V. B., Klyamko A. S. Technology of «cold» briquetting of rich ores of the Jakovlevsky deposit. Zapiski Gornogo Instituta. 2011. Vol. 190. pp. 133–137.
12. Sizyakov V. M., Litvinova T. E., Brichkin V. N., Fedorov A. T. Modern physicochemical equilibrium description in Na2O–Al2O3–H2O system and its analogues. Zapiski Gornogo Instituta. 2019. Vol. 237. pp. 298–306.
13. Lancellotti I., Barbieri L., Leonelli C. Use of alkaliactivated concrete binders for toxic waste immobilization. Handbook of alkali-activated cements, mortars and concretes. Elsevier Ltd., 2015. pp. 539–554.
14. Dodoo-Arhin D., Nuamah R. A., Agyei-Tuffour B., Obada D. O., Yaya A. Awaso bauxite red mud-cement based composites: Characterization for pavement applications. Case Studies in Construction Materials. 2017. Vol. 7. pp. 45–55.
15. Liu X., Zhang N. Utilization of red mud in cement production: A review. Waste Management. 2011. Vol. 29, No. 10. pp. 1053–1063.
16. Newson T., Dyer T., Adam C., Sharp S. Effect of structure on the geotechnical properties of bauxite residue. Journal of Geotechnical and Geoenvironmental Engineering. 2006. Vol. 132, No. 2. pp. 143–151.
17. Romano R. C. O., Bernardo H. M., Maciel M. H., Pileggi R. G., Cincotto M. A. Hydration of Portland cement with red mud as mineral addition. Journal of Thermal Analysis and Calorimetry. 2017. Vol. 131. pp. 2477–2490.
18. Paramguru R. K., Rath P. C., Misra V. N. Trends in red mud utilization – A review. Mineral Processing and Extractive Metallurgy Review. 2004. Vol. 26, Iss. 1. pp. 1–29.
19. Rai S., Wasewar K., Mukhopadhyay J., Yoo C., Uslu H. Neutralization and utilization of red mud for its better waste management. Archives of Environmental Science. 2012. Vol. 6. pp. 13–33.
20. Bhoi B., Rajput P., Mishra C. R. Production of green direct reduced iron (DRI) from red mud of Indian origin: A novel concept. Proc. of 35th International ICSOBA conference, 2–5 October 2017. Hamburg, Germany. pp. 565–574.
21. Cong Y. L., He Z. J., Zhang J. H., Pang Q. H. Experimental study on iron recovery by microwave carbon heat reduction-magnetic separation from red mud. Metalurgija. 2018. Vol. 57, No. 1–2. pp. 75–78.
22. Mombelli D., Barella S., Gruttadauria A., Mapelli C. Iron recovery from bauxite tailings red mud by thermal reduction with blast furnace sludge. Applied Sciences. 2019. Vol. 9, No. 22. pp. 1–23.
23. Forsmo S. P. E., Apelqvist A. J., Björkman B. M. T., Samskog P. Binding mechanisms in wet iron ore green pellets with a bentonite binder. Powder Technology. 2006. Vol. 169. pp. 147–158.
24. Litvinenko V. The role of hydrocarbons in the global energy agenda: The focus on liquefied natural gas. Resources. 2020. Vol. 9, No. 5. pp. 59–81.
25. Litvinenko V. S. Digital economy as a factor in the technological development of the mineral sector. Natural Resources Research. 2020. Vol. 29. pp. 1521–1541.

Language of full-text russian
Full content Buy
Back