Abstract
Reduced iron (1.74% P) is produced from oolitic hematite ore by coal-based reduction and magnetic separation. To realize the comprehensive utilization of Fe and P, the dephosphorization behavior of the reduced iron is investigated in the presence of CaO–SiO2–FeO–Al2O3 slag. The P content of the final iron and the P2O5 content of the high-P-containing slag are determined, and the phase composition and P2O5 solubility of the slag are analyzed. The P content can be decreased to 0.2% when the initial slag has a basicity of 3.5 and contains 55% FeO and 6% Al2O3. The phases of the high-P-containing slag are mainly Ca2Al2SiO7, Ca2SiO4, Ca5(PO4)2SiO4, and FeO, and P exists in the form of Ca5(PO4)2SiO4. Excessively high basicity or low content of FeO and Al2O3 results in free CaO, which affects the dephosphorization results. The change rule of the intensity of the Ca5(PO4)2SiO4 diffraction peak agrees well with the dephosphorization indexes, which further verify the accuracy of the dephosphorization experiments. Moreover, the P2O5 content and P2O5 solubility of the high-P-containing slag reached as high as 14.41 and 94.54%, respectively, indicating that it can be used as a phosphate fertilizer.
1 Introduction
Iron ores are listed as strategic raw materials in the iron and steel industry by some countries. With the consumption of high-quality iron ores, the utilization of refractory iron ores has attracted increased interest [1]. Oolitic hematite ore is regarded as one of the most refractory iron ores because of its layered oolitic texture, fine-grained hematite size, and high P content [2]. It is difficult to obtain a qualified iron concentrate from oolitic hematite ore using traditional processing methods, including fine grinding and froth flotation, gravity separation, and magnetic separation [3,4,5].
Previous research has shown that coal-based reduction followed by magnetic separation is a promising method to utilize oolitic hematite ore [6,7]. In the reduction process, the hematite is reduced to iron which is then aggregated together to iron particles, which can then be easily recovered by magnetic separation [8,9]. Reduced iron is produced with iron recovery and a metallization ratio above 90%. However, parts of the apatite in oolitic hematite are also reduced to P and migrate into the iron phase. The P content of the reduced iron is considerably higher than that of direct reduced iron [10,11]. Therefore, the reasonable disposition of P is a challenge in this technology.
Some researchers have attempted to decrease the P content of reduced iron because P is deleterious to many steel grades. In normal practice, dephosphorization reagents, such as sodium carbonate, sodium sulfate, and borax, are added to oolitic hematite ore during the reduction process, and the reduction temperature is controlled to not exceed 1,473 K [12,13,14,15]. The reduction reaction of apatite is restricted, which effectively decreases the generation of P. Therefore, the P content of the reduced iron is low. For example, Li et al. [13] reported that the P content of reduced iron decreased to 0.09% when an oolitic hematite ore was reduced at 1,323 K and in the presence of 7.5% sodium sulfate and 1.5% borax.
Concurrently, another approach was proposed to enhance P migration into the reduced iron. The high-P-containing reduced iron could be converted to molten iron and high-P-containing slag by a dephosphorization process [16,17]. This method was expected to realize the comprehensive utilization of Fe and P in oolitic hematite ore because the high-P-containing slag could be used as a phosphate fertilizer. Li et al. [16] and Han et al. [18] found that increasing the temperature or C/O molar ratio (the molar ratio of fixed C in coal to O in the iron oxides of the ore) was beneficial for promoting the reduction of apatite and improving the P content of the reduced iron. When the oolitic hematite ore with a C/O molar ratio not lower than 2.0 was reduced at temperatures exceeding 1,523 K, approximately 80% apatite was reduced to P, and the P content of the reduced iron reached approximately 2%. However, the dephosphorization of reduced iron with a high P content has not been systematically studied.
This study focuses on the dephosphorization behavior of high-P-containing reduced iron in the presence of the CaO–SiO2–FeO–Al2O3 slag. The effect of the chemical composition of the initial slag on the P content of the final metal and high-P-containing slag was investigated in detail. Meanwhile, the phase compositions of the high-P-containing slag and the solubility of P2O5 in the slag were analyzed, which will boost the comprehensive utilization of Fe and P in the oolitic hematite ore.
2 Experimental
2.1 Materials
The reduced iron was produced from an oolitic hematite ore, which contained 1.31% P and 42.21% Fe. First, the oolitic hematite ore was reduced in a unidirectional heating furnace at a 1,548 K reduction temperature, 2.0 C/O molar ratio, and 60 min reduction time. The ore sample used for each test was 3 kg. The reduction products were ground to 85% passing 74 μm using a Φ460 mm × 500 mm ball mill. Then, the grinding products underwent a two-stage magnetic separation by a Φ240 mm × 120 mm low-intensity magnetic separator with the magnetic field intensities of 79.62 kA/m and 47.77 kA/m, respectively. The magnetic concentrates were the reduced iron. The chemical composition of the reduced iron is listed in Table 1.
Chemical compositions of the reduced iron (mass %)
| TFe | MFe | FeO | P | C | SiO2 | Al2O3 |
|---|---|---|---|---|---|---|
| 92.27 | 84.34 | 10.19 | 1.74 | 0.19 | 2.12 | 1.19 |
As shown in Table 1, the reduced iron contained 92.27% total Fe, of which metallic Fe accounted for 84.34%. The P content of the reduced iron was 1.74%. The impurities were mainly 10.19% FeO, 2.12% SiO2, and 1.19% Al2O3, which will become part of the CaO–SiO2–FeO–Al2O3 slag in the dephosphorization process.
Table 2 shows the particle sizes of the reduced iron. Most of the iron particles were <0.1 mm and accounted for 87.24% of the Fe content.
Size distribution of the reduced iron (mass %)
| Size fraction (mm) | −0.15 + 0.1 | −0.1 + 0.074 | −0.074 + 0.063 | −0.063 + 0.045 | −0.045 |
| Content | 12.76 | 30.41 | 18.95 | 19.84 | 18.04 |
The materials used for slag-making included analytically pure CaO, SiO2, Al2O3, and FeO reagents.
2.2 Experimental method
The dephosphorization experiments were conducted at 1,873 K, and the mass ratio of slag to reduced iron was fixed at 0.2. Based on the designed basicity (
About 40 g of reduced iron and 8 g of initial slag were loaded in a 50 mm-diameter corundum crucible. The crucible was then placed in an MXGL1700-80 vertical tube-type furnace at 1,873 K. The dephosphorization reaction started when the reduced iron and slag were melted under the protection of an N atmosphere. After 2 to 30 min of dephosphorization, the corundum crucible was removed from the furnace. The final metal and high-P-containing slag were obtained after cooling the crucible to room temperature under an N atmosphere. The P content of the final metal and the P2O5 content of the high-P-containing slag were determined by chemical analysis. The dephosphorization ratio of the reduced iron was calculated using equation (1):
where
Furthermore, the high-P-containing slag produced under suitable dephosphorization conditions was ground to different particle sizes using an XPM-Φ120 × 3 three-head grinder. The P2O5 in the ground product was insoluble in water but was soluble in a 2% citric acid solution. Therefore, the soluble P2O5 content was determined by chemical analysis according to the national standard GB 20412-2006 [19]. The solubility of P2O5 was calculated using equation (2):
where
2.3 Characterization
The phase compositions of the high-P-containing slag were analyzed using a PANalytical X’pert PW3040 X-ray diffraction analyzer (XRD). The sample was scanned at a voltage of 40 kV and a current of 40 mA, while the diffraction angle ranged from 10 to 90°.
2.4 Dephosphorization process
The dephosphorization process can be described by the theoretical model of molten slag ions, given by equation (3) [20]:
If the [O] is provided by the FeO in the slag, then
The overall process can be written as equation (5):
3 Results and discussion
3.1 Dephosphorization behavior of reduced iron
3.1.1 Determination of dephosphorization time
Before investigating the effect of the slag composition on the dephosphorization indexes, a suitable dephosphorization time needed to be determined. Figure 1 shows the P content of the final metal and the P2O5 content of the high-P-containing slag as a function of time where the initial slag composition was 55% FeO and 6% Al2O3 content with 3.5 basicity.

Effect of the dephosphorization time on the P content of the final metal and the P2O5 content of the high-P-containing slag: (a) P content and dephosphorization ratio and (b) P2O5 content.
Figure 1 shows that as the dephosphorization time increased from 2 to 5 min, the P content of the final metal decreased to 0.23% from 0.88% and the dephosphorization ratio increased from 49.43 to 86.78%, while the P2O5 content of the high-P-containing slag increased from 7.58 to 13.90%. With a further extension of the dephosphorization time from 10 to 30 min, the P content of the final metal slightly decreased to 0.20 ± 0.01%, and the P2O5 content of the high-P-containing slag was approximately 14.4%. The dephosphorization reaction was considered to be almost complete after 10 to 30 min because the experiments were not thermodynamic equilibrium tests. Therefore, the dephosphorization time was determined to be 20 min in follow-up studies.
3.1.2 Effect of basicity
Figure 2 shows the effect of basicity on the dephosphorization results at a FeO content of 55% and an Al2O3 content of 6%.

Effect of basicity on the P content of the final metal and the P2O5 content of the high-P-containing slag: (a) P content and dephosphorization ratio and (b) P2O5 content.
Figure 2 shows that the basicity considerably affected the dephosphorization of the reduced iron. The P content of the final metal decreased from 0.29 to 0.20% and the dephosphorization ratio increased from 83.33 to 88.51% as the basicity increased from 3.0 to 3.5. The corresponding P2O5 content of the high-P-containing slag increased from 13.12 to 14.41%. However, a further increase in basicity was unfavorable for dephosphorization. The P content of the final metal and the P2O5 content of the high-P-containing slag were 0.34 and 12.37%, respectively, at a basicity of 5.0. This is because high basicity increases the CaO content in the slag system, which reduces the activity of P2O5 in the molten slag and improves the phosphorus storage capacity of the molten slag. However, the excess CaO did not melt completely, which was not conducive to dephosphorization.
3.1.3 Effect of FeO content
Figure 3 plots the effect of the FeO content on the P content of the final metal and the P2O5 content of the high-P-containing slag at a basicity of 3.5 and an Al2O3 content of 6%.

Effect of the FeO content on the P content of the final metal and the P2O5 content of the high-P-containing slag: (a) P content and dephosphorization ratio and (b) P2O5 content.
Figure 3 shows that the P content of the final metal decreased from 0.45 to 0.20% as the FeO content increased from 40 to 55%, while the dephosphorization ratio increased from 74.14 to 88.51%. The corresponding P2O5 content of the high-P-containing slag increased from 7.88 to 14.41%. However, when the FeO content reached 60%, the P content of the final metal increased to 0.31%. This may be attributed to an excess FeO content that decreases the CaO content of the slag system, reducing the P storage capacity of the molten slag. Furthermore, excess FeO reduced the stability of phosphate and deteriorated the dephosphorization effect.
3.1.4 Effect of Al2O3 content
The basicity and FeO content were fixed at 3.5 and 55%, respectively. Figure 4 shows the effect of the Al2O3 content on the dephosphorization indexes.

Effect of the Al2O3 content on the P content of the final metal and the P2O5 content of the high-P-containing slag: (a) P content and dephosphorization ratio and (b) P2O5 content.
Figure 4 shows that as the Al2O3 content increased from 4 to 6%, the P content of the final metal decreased from 0.26 to 0.20%, the dephosphorization ratio increased from 85.06 to 88.51%, and the P2O5 content of the high-P-containing slag increased from 11.66 to 14.41%. A further increase in the Al2O3 content resulted in a higher P content in the final metal and a lower P2O5 content in the high-P-containing slag. This phenomenon occurs because an appropriate amount of Al2O3 can generate low melting point materials with other oxides in the slag, which is favorable for reducing the melting point of the slag and improving the rheological properties of the molten slag. However, the high-melting-point substances may be formed when the Al2O3 content exceeds 6% [21].
3.2 Phase compositions of high P-containing slag
3.2.1 Effect of basicity
Figure 5 shows the XRD patterns of the high-P-containing slag at different initial basicity. The basicity affected the phase composition of the slag and the intensity of the diffraction peaks. The high-P-containing slag was mainly composed of Ca2Al2SiO7, Ca2SiO4, Ca5(PO4)2SiO4, and FeO. Phosphorus existed in the form of Ca5(PO4)2SiO4, and its diffraction peak intensity increased with a basicity increase from 3.0 to 3.5 but decreased when the basicity exceeded 4.0. The intensity of the Ca2SiO4 diffraction peaks decreased and the intensity of the Ca2Al2SiO7 and FeO diffraction peaks increased with an increase in the basicity. Additionally, the diffraction peak of free CaO could not be detected when the basicity was below 3.5, but the peak appeared and became stronger when the basicity reached and exceeded 4.0.

XRD patterns of the high-P-containing slag at different basicities.
3.2.2 Effect of FeO content
The effect of the FeO content on the phase composition of the high-P-containing slag was analyzed at basicity of 3.5. The XRD patterns are shown in Figure 6.

XRD patterns of the high-P-containing slag at different FeO contents.
Figure 6 shows that the diffraction peak of free CaO was visible at a 40% FeO content but decreased gradually and even disappeared with a further increase in FeO. The intensities of the Ca2SiO4 and FeO diffraction peaks exhibited an increasing trend, while the intensity of the Ca2Al2SiO7 diffraction peaks decreased with an increase in the FeO content. Furthermore, the intensity of the Ca5(PO4)2SiO4 diffraction peaks increased as the FeO content increased from 40 to 55% but decreased slightly at a 60% FeO content.
3.2.3 Effect of Al2O3 content
The effect of the Al2O3 content on the phase composition of the high-P-containing slag was investigated at a basicity of 3.5 and FeO content of 55%. The XRD patterns are shown in Figure 7.

XRD patterns of the high-P-containing slag at different Al2O3 contents.
Figure 7 shows that the diffraction peak of free CaO appeared at a 4% Al2O3 content but disappeared when the Al2O3 content reached 6%. Meanwhile, the presence of free CaO resulted in low-intensity Ca2SiO4 diffraction peaks. The intensity of the Ca2Al2SiO7 diffraction peaks did not increase with increasing Al2O3 content, while the intensity of the FeO diffraction peaks decreased slightly. This phenomenon may be attributed to the formation of Fe aluminates, which were present in small quantities and were not detected by the XRD analyzer. Moreover, the intensity of the Ca5(PO4)2SiO4 diffraction peaks increased with increasing Al2O3 content from 4 to 6% but decreased with an Al2O3 content above 6%.
In summary, the change rule of the intensity of the Ca5(PO4)2SiO4 diffraction peaks with basicity, FeO content, and Al2O3 content was consistent with the P2O5 content of the high-P-containing slag in Section 3.2. This further verifies the accuracy of the dephosphorization tests.
3.3 P2O5 solubility of high-P-containing slag
The slag was ground to different particle sizes, and the effect of particle size on the specific surface area and P2O5 solubility of the high-P-containing slag is shown in Figure 8.

Effect of particle size on the P2O5 solubility of the high-P-containing slag.
Figure 8 shows that the specific surface area and the P2O5 solubility were affected by the fineness of the high-P-containing slag. When the particle size decreased from d 90 = 92.4 to 38.7 μm, the specific surface area of the slag increased from 682.1 to 1,606 m2/kg, but the P2O5 solubility changed slightly and ranged from 87.59 to 87.65%. Moreover, the specific surface area of the slag increased to 2,373–2,677 m2/kg when the particle size further decreased to d 90 = 23.8–20.7 μm, while the P2O5 solubility reached 93.81–94.54%. This can be attributed to the lattice energy of the slag increasing during the grinding process, which resulted in the breakage of chemical bonds and a decrease in the degree of crystallinity on the particle surface [22]. The solubility of P2O5 in the slag was then improved.
4 Conclusion
The dephosphorization of high-P-containing reduced iron was investigated in the presence of CaO–SiO2–FeO–Al2O3 slag. The properties of the high-P-containing slag, including phase composition and P2O5 solubility, were also analyzed. The following conclusions were drawn from the experimental results:
The composition of the initial slag affected the dephosphorization of the reduced iron. Higher basicity, FeO content, and Al2O3 content favored dephosphorization to a certain extent. The P content of the final iron was decreased from 1.74 to 0.2% with a basicity of 3.5, FeO content of 55%, and Al2O3 content of 6%. The dephosphorization ratio reached 88.51%.
The high-P-containing slag was obtained apart from the final iron, which was composed of Ca2Al2SiO7, Ca2SiO4, Ca5(PO4)2SiO4, and FeO, and P existed in the form of Ca5(PO4)2SiO4. The intensity of the Ca5(PO4)2SiO4 diffraction peaks changed with the initial slag composition, and the change rule was in accordance with the indexes of dephosphorization.
The P2O5 content of the high-P-containing slag was 14.41% under suitable dephosphorization conditions, while the P2O5 solubility of the slag reached approximately 94%, which indicates that the slag could be used as a phosphate fertilizer.
Acknowledgments
The authors gratefully acknowledge financial support from the the National Natural Science Foundation of China (No. 51804123) and the Natural Science Foundation of Hebei Province, China (No. E2018209089).
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Funding information: This research was supported by the National Natural Science Foundation of China (No. 51804123) and the Natural Science Foundation of Hebei Province, China (No. E2018209089).
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Author contributions: Liwei Liu: writing the original draft, conducting the experiments; Guofeng Li: methodology, reviewing the document; Yanfeng Li: phase composition analysis of the high-P-containing slag; Libing Zhao: project administration.
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Conflict of interest: The authors state that there are no conflicts of interest.
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Data availability statement: All authors can confirm that all data used in this article can be published the Journal “High Temperature Materials and Processes”.
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© 2021 Liwei Liu et al., published by De Gruyter
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- Investigation on ultrasonic assisted friction stir welding of aluminum/steel dissimilar alloys
- Analysis of oxide scale thickness and pores position of HCM12A steel in supercritical water
- Behavior of MnS inclusions during homogenization process in low-alloyed steel FAS3420H
- Preparation and cutting performance of nano-scaled Al2O3-coated micro-textured cutting tool prepared by atomic layer deposition
- Prediction of hot metal temperature based on data mining
- Effect of TiO2 content in slag on Ti content in molten steel
- Performance evaluation of titanium-based metal nitride coatings and die lifetime prediction in a cold extrusion process
- Effect of different drilling techniques on high-cycle fatigue behavior of nickel-based single-crystal superalloy with film cooling hole
- Effect of CO2 injection into blast furnace tuyeres on the pulverized coal combustion
- Microstructure and properties of Co–Al porous intermetallics fabricated by thermal explosion reaction
- Evolution regularity of temperature field of active heat insulation roadway considering thermal insulation spraying and grouting: A case study of Zhujidong Coal Mine, China
- Evolution of reduction process from tungsten oxide to ultrafine tungsten powder via hydrogen
- A thermodynamic assessment of precipitation, growth, and control of MnS inclusion in U75V heavy rail steel
- Effect of basicity on the reduction swelling properties of iron ore briquettes
- Effect of Cr and Al alloying on the oxidation resistance of a Ti5Si3-incorporated MoSiBTiC alloy
- Microstructure and mechanical properties of 2060 Al–Li alloy welded by alternating current cold metal transfer with high-frequency pulse current
- Effects of composition and strain rate on hot ductility of Cr–Mo-alloy steel in the two-phase region
- Effect of K and Na on reduction swelling performance of oxidized roasted briquettes
- Dephosphorization mechanism and phase change in the reduction of converter slag
- Parametric investigation and optimization for CO2 laser cladding of AlFeCoCrNiCu powder on AISI 316
- Optimization of heat transfer and pressure drop of the channel flow with baffle
- Quantitative analysis of microstructure and mechanical properties of Nb–V microalloyed high-strength seismic reinforcement with different Nb additions
- Visualization of the damage evolution for Ti–3Al–2Mo–2Zr alloy during a uniaxial tensile process using a microvoids proliferation damage model
- Research on high-temperature mechanical properties of wellhead and downhole tool steel in offshore multi-round thermal recovery
- Dephosphorization behavior of reduced iron and the properties of high-P-containing slag
- Jet characteristics of CO2–O2 mixed injection using a dual-parameter oxygen lance nozzle for different smelting periods
- Effects of ball milling on powder particle boundaries and properties of ODS copper
- Heat transfer behavior in ultrahigh-speed continuous casting mold
- Solidification microstructure characteristics of Cu–Pb alloy by ECP treatment
- Luminescence properties of Eu2+ and Sm3+ co-doped in KBaPO4
- Research on high-temperature oxidation resistance, hot forming ability, and microstructure of Al–Si–Cu coating for 22MnB5 steel
- The differential analysis for temperature distribution diagnostics of arc current-carrying region in sheet slanting tungsten electrode inert gas welding with the electrostatic probe
- Reactions at the molten flux-weld pool interface in submerged arc welding
- The effect of liquid crystalline graphene oxide compared with non-liquid crystalline graphene oxide on the rheological properties of polyacrylonitrile solution
- Study on manganese volatilization behavior of Fe–Mn–C–Al twinning-induced plasticity steel
- Physical modeling of bubble behaviors in molten steel under high pressure
- Rapid Communication
- The new concept of thermal barrier coatings with Pt + Pd/Zr/Hf-modified aluminide bond coat and ceramic layer formed by PS-PVD method
- Topical Issue on Science and Technology of Solar Energy
- Solution growth of chalcopyrite Cu(In1−xGax)Se2 single crystals for high open-circuit voltage photovoltaic device
- Copper-based kesterite thin films for photoelectrochemical water splitting