Production of Metallic Iron from Iron Oxide (Fe2O3) Using End-of-Life Rubber Tyre and its Blends with Metallurgical Coke as Reductants

2013 ◽  
Vol 10 ◽  
pp. 1-12
Author(s):  
James Ransford Dankwah ◽  
Pramod Koshy
Keyword(s):  
Iron Oxide ◽  
End Of Life ◽  
High Purity ◽  
Metallic Iron ◽  
Horizontal Tube ◽  
Metallurgical Coke ◽  
Argon Gas ◽  
Composite Pellets ◽  
Infrared Gas Analyser ◽  
Horizontal Tube Furnace

The production of metallic iron from iron oxide using end-of-life tyres (RT) and its blends with metallurgical coke as reductants has been investigated through experiments conducted in a laboratory scale horizontal tube furnace. Composite pellets of iron oxide (96.89 % Fe2O3) with RT, coke and coke/RT blends (in four different proportions) were rapidly heated at 1500 °C under high purity argon gas and the off gas was continuously analysed for CO and CO2 using an online infrared gas analyser (IR). The extent of reduction after ten minutes, level of carburisation of the reduced metal and the total amount of CO2 emissions were determined for each carbonaceous reductant. The results indicate that metallic iron can be effectively produced from Fe2O3 using RT and its blends with coke as reductant. The extent of reduction and level of carburisation are significantly improved when coke is blended with RT. Blending of coke with RT resulted in significant decrease in CO2 emissions.

Reduction of FeO in EAF Steelmaking Slag by Blends of Metallurgical Coke and Waste Polypropylene

2014 ◽  
Vol 33 (2) ◽  
pp. 107-114 ◽  
Author(s):  
James R. Dankwah ◽  
Pramod Koshy
Keyword(s):  
High Purity ◽  
Horizontal Tube ◽  
Metallurgical Coke ◽  
Steelmaking Slag ◽  
Argon Gas ◽  
Composite Pellets ◽  
Infrared Gas Analyser ◽  
Eaf Slag ◽  
Waste Polypropylene ◽  
Horizontal Tube Furnace

AbstractThe reduction of FeO-containing slag by blends of metallurgical coke and waste polypropylene (PP) has been investigated through experiments conducted in a laboratory scale horizontal tube furnace. Composite pellets of EAF slag (47.1% FeO) with coke, PP and blends of coke/PP (in three different proportions) were rapidly heated at 1500 °C under high purity argon gas and the off gas was continuously analysed for CO and CO2 using an online infrared gas analyser (IR). The extent of reduction after fifteen minutes, level of carburisation and desulphurization were determined for each carbonaceous reductant. The results show that FeO can be effectively reduced from EAF slag to produce metallic iron using waste PP and its blends with coke as reductants; improvements in the extent of reduction and levels of carburisation and desulphurisation of the reduced metal were observed when coke was blended with PP.

Effect of HDPE addition on the Pre-reduction of Mn3O4 to MnO by Metallurgical Coke

2014 ◽  
Vol 33 (4) ◽  
pp. 345-353 ◽  
Author(s):  
J.R. Dankwah ◽  
P. Koshy
Keyword(s):  
Mass Balance ◽  
High Density Polyethylene ◽  
Horizontal Tube ◽  
Gas Analysis ◽  
High Density ◽  
Metallurgical Coke ◽  
Argon Gas ◽  
Pure Argon ◽  
Composite Pellets ◽  
Horizontal Tube Furnace

AbstractThe effect of high density polyethylene (HDPE) addition on the pre-reduction of Mn3O4 to MnO by metallurgical coke (Coke) has been investigated through experiments conducted in a laboratory horizontal tube furnace coupled with off-gas analysis through an infrared (IR) gas analyser. Composite pellets of Mn3O4 with Coke, HDPE and blends of Coke with HDPE (in three different proportions) were rapidly heated at 1150 °C under pure argon gas and the off gas was analysed continuously for CO, CO2 and CH4. The extent of pre-reduction of Mn3O4 to MnO was then calculated by mass balance for removable oxygen. The results showed improvements in the extent of pre-reduction of Mn3O4 to MnO when coke is blended with HDPE. The time for complete pre-reduction was found to decrease with an increase in the amount of HDPE that was blended with coke. A decrease in CO2 emissions was observed with HDPE addition.

scholarly journals Recycling Waste Polyurethane as a Carbon Resource in Ironmaking

2017 ◽  
Vol 17 (1) ◽  
pp. 73-77
Author(s):  
J. R. Dankwah ◽  
W. K. Buah
Keyword(s):  
Iron Oxide ◽  
Metallic Iron ◽  
Horizontal Tube ◽  
Metal Extraction ◽  
Polyurethane Composite ◽  
Elemental Analyses ◽  
Composite Pellets ◽  
Continuous Stream ◽  
Two Temperatures ◽  
Extraction Processes

Globally, major avenues available for dealing with waste Poly-Urethane (PU) are disposal at landfill sites and incineration. However, PU contains high levels of carbon and hydrogen that can be recovered for use as reductant in metal extraction processes. In this work the use of post-consumer PU as reductant for the production of metallic iron from iron oxide was investigated in a horizontal tube furnace through the composite pellet approach. Composite pellets were formed from mixtures of iron oxide and post-consumer PU. The iron oxide-PU composites were heated from room temperature to 1200 °C and then between 1200-1600 °C in a continuous stream of pure argon and the off gas was analysed continuously using an infrared (IR) gas analyser. Elemental analyses of samples of the reduced metal were performed chemically for its oxygen content using a LECO oxygen/nitrogen analyser. The extent of reduction was then determined at two temperatures 1200 °C and 1550 °C. Gas emission studies revealed the emission of large volumes of the reductant gas CO along with CO2. It is further demonstrated that post-consumer PU is effective at reducing iron oxide to produce metallic iron with complete reduction achieved in less than 4 min at 1550 °C. Keywords: Polyurethane, Composite Pellets, Infrared gas Analyser, LECO Carbon/Sulphur Analyser

scholarly journals Production of Metallic Iron from the Pudo Magnetite Ore using End-of-Life Rubber Tyre as Reductant: The Role of an Underlying Ankerite Ore as a Fluxing Agent on Productivity

2020 ◽  
Vol 20 (2) ◽  
pp. 36-42
Author(s):  
E. Abotar ◽  
J. B. Dankwah ◽  
P. Koshy ◽  
J. R. Dankwah
Keyword(s):  
End Of Life ◽  
Metallic Iron ◽  
Research Work ◽  
Magnetite Ore ◽  
Domestic Microwave Oven ◽  
West Region ◽  
Titaniferous Magnetite ◽  
Composite Pellets ◽  
Fluxing Agent

This research work investigated the nature of a nonmagnetic ore from Pudo in the Upper West Region of Ghana and its fluxing effect on the extent of reduction of the Pudo titaniferous magnetite ore using pulverised samples of charred carbonaceous materials generated from end-of-life vehicle tyres (ELT) as reductants. Reduction studies were conducted on composite pellets of the Pudo titaniferous magnetite iron ore containing fixed amounts of charred ELT and varying amounts (0%, 10%, 15%, 20%, 30%, 40% and 50%) of the nonmagnetic fluxing material in a domestic microwave oven and the extent of reduction was calculated after microwave irradiation for 40 minutes. Analyses by XRF, SEM/EDS and XRD of the nonmagnetic ore revealed an Ankerite type of ore of the form Ca0.95Fe0.95Mn0.1 (CO3)2. From the microwave reduction studies it was observed that premium grade metallic iron could be produced from appropriate blends of the Pudo iron ores using ELT as reductant, with a measured extent of reduction up to 103.8%. Further, the extent of reduction was observed to increase with an increase in the amount of the nonmagnetic fluxing material (Ankerite) that was added as fluxing agent.   Keywords: Ankerite, End-of-life Rubber Tyres, Fluxing Agent, Extent of Reduction

Effect of Silica Sources on Synthesis of Alumina-Mullite-Silicon Carbide Composite

2012 ◽  
Vol 488-489 ◽  
pp. 607-611 ◽  
Author(s):  
Sutham Niyomwas
Keyword(s):  
Silicon Carbide ◽  
Carbothermal Reduction ◽  
Rice Husk Ash ◽  
Horizontal Tube ◽  
Argon Gas ◽  
Carbide Composite ◽  
Whisker Morphology ◽  
Horizontal Tube Furnace ◽  
Sem Analyses

Synthesis of alumina-mullite-silicon carbide composite (Al2O3-Al6Si2O13-SiCw) was obtained in situ by carbothermal reduction of a mixture of kaolin and two different silica sources. The carbothermal reduction was carried out in a horizontal tube furnace under flow of argon gas. The synthesized products were mixtures of alumina, mullite and silicon carbide in the form of whiskers. The effects of adding two different silica sources of rice husk ash and silica powder to the mixture of kaolin and activated carbon were investigated. XRD and SEM analyses indicate complete reaction of precursors to yield Al2O3-Al6Si2O13-SiC as product powders, with the SiC having whisker morphology.

scholarly journals Feasibility of nickel extraction from Indian chromite overburden by solid state reduction and smelting route

2020 ◽  
Vol 56 (2) ◽  
pp. 229-235
Author(s):  
P. Ganesh ◽  
Dishwar Kumar ◽  
S. Agrawal ◽  
Mandal Kumar ◽  
N. Sahu ◽  
...  
Keyword(s):  
Solid State ◽  
Horizontal Tube ◽  
Low Grade ◽  
State Reduction ◽  
Nickel Extraction ◽  
Reducing Atmosphere ◽  
Chromite Overburden ◽  
Solid State Reduction ◽  
Horizontal Tube Furnace ◽  
Direct Smelting

The present work demonstrates the extraction of nickel from low-grade chromite overburden by using solid state reduction and direct smelting route. Goethite & Quartz are present as major phases whereas chromite, hematite were identified as minor phases in the mineral. Solid state reduction of pellets were carried out inside a horizontal tube furnace at 1000?C, 1200?C, 1400?C for 30, 60, 90 and 120 minutes respectively with creating reducing atmosphere. Pellets of varying basicity (i.e. 0.5, 0.6, 0.7, 0.8 and 0.9) were used directly in the EAF for smelting studies. Highest percent of nickel (2%) having ~ 91% recovery were obtained in solid state reduction route for pellets which was reduced at 1400?C for 120 minute. Similar recovery (~90%) of nickel was obtained inside the ingot (0.67% Ni ) by using pellets of 0.9 basicity through smelting route. From the present investigation, it could be concluded that the solid state reduction as well as smelting routes are feasible for the recovery of nickel from low grade chromite overburden. The production of nickel pig (low grade ferronickel) could also be feasible by smelting route.

Regeneration of hydrogen through thermal micronisation of end-of-life polymers for sustainable reduction of iron oxide

2022 ◽  
Vol 226 ◽  
pp. 107038
Author(s):  
Mohammad Assefi ◽  
Sajjad S. Mofarah ◽  
Samane Maroufi ◽  
Rasoul Khayyam Nekouei ◽  
Wei Wang ◽  
...  
Keyword(s):  
Iron Oxide ◽  
End Of Life ◽  
Reduction Of Iron

Microstructure, Stiffness and Corrosion of Bare and Phosphated Specimens Made by Sintering of Structured Iron-Iron Oxide Spheres

2020 ◽  
Vol 405 ◽  
pp. 411-416
Author(s):  
Miriam Kupková ◽  
Martin Kupka ◽  
Renáta Oriňáková ◽  
Radka Gorejová
Keyword(s):  
Iron Oxide ◽  
Iron Oxides ◽  
Metallic Iron ◽  
Galvanic Corrosion ◽  
Iron Phosphate ◽  
Reduction Reaction ◽  
Diffusion Control ◽  
Iron Oxide Particles ◽  
Flow Through ◽  
Iron Iron

Granulated iron oxide particles were incompletely reduced to structured particles comprised metallic iron and residual iron oxides. Structured particles were pressed into prismatic compacts and sintered. Some of sintered specimens were subsequently phosphatized and calcined. Specimens with an iron phosphate coating were found stiffer than specimens without coating. In Hanks' solution, a galvanic corrosion was induced by more noble iron oxides coupled to a less noble metallic iron. This could explain higher corrosion potentials and higher rates of iron dissolution in comparison with a pure iron. The coating of specimens with iron phosphates shifted corrosion potentials towards more negative values and slowed down the dissolution of iron. This was most likely caused by a reduction in oxygen flow through the coating to iron-oxide cathodes, which has enhanced the influence of diffusion control on the kinetics of reduction reaction.

scholarly journals Single-Crystalline Metal Oxide Nanostructures Synthesized by Plasma-Enhanced Thermal Oxidation

Nanomaterials ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1405 ◽  
Author(s):  
Guo ◽  
Košiček ◽  
Fu ◽  
Qu ◽  
Lin ◽  
...  
Keyword(s):  
Metal Oxide ◽  
Horizontal Tube ◽  
Single Crystalline ◽  
Oxide Nanostructures ◽  
Plasma Species ◽  
Custom Made ◽  
Metal Oxide Nanostructures ◽  
Metal Oxide Nanomaterials ◽  
Crystalline Metal ◽  
Horizontal Tube Furnace

To unravel the influence of the temperature and plasma species on the growth of single-crystalline metal oxide nanostructures, zinc, iron, and copper foils were used as substrates for the study of nanostructure synthesis in the glow discharge of the mixture of oxygen and argon gases by a custom-made plasma-enhanced horizontal tube furnace deposition system. The morphology and microstructure of the resulting metal oxide nanomaterials were controlled by changing the reaction temperature from 300 to 600 °C. Experimentally, we confirmed that single-crystalline zinc oxide, copper oxide, and iron oxide nanostructures with tunable morphologies (including nanowires, nanobelts, etc.) can be successfully synthesized via such procedure. A plausible growth mechanism for the synthesis of metal oxide nanostructures under the plasma-based process is proposed and supported by the nanostructure growth modelling. The results of this work are generic, confirmed on three different types of materials, and can be applied for the synthesis of a broader range of metal oxide nanostructures.

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