Effect of additives on iron recovery and dephosphorization by reduction roasting-magnetic separation of refractory high-phosphorus iron ore

The effect of CaCO3, Na2CO3, and CaF2 on the reduction roasting and magnetic separation of high-phosphorus iron ore containing phosphorus in the form of Fe3PO7 and apatite was investigated. The results revealed that Na2CO3 had the most significant effect on iron recovery and dephosphorization, followed by CaCO3, the effect of CaF2 was negligible. The mechanisms of CaCO3, Na2CO3, and CaF2 were investigated using X-ray diffraction (XRD), scanning electron microscopy and energy dispersive spectrometry (SEM-EDS). Without additives, Fe3PO7 was reduced to elemental phosphorus and formed an iron-phosphorus alloy with metallic iron. The addition of CaCO3 reacted with Fe3PO7 to generate an enormous amount of Ca-3(PO4)(2) and promoted the reduction of iron oxides. However, the growth of iron particles was inhibited. With the addition of Na2CO3, the phosphorus in Fe3PO7 migrated to nepheline and Na2CO3 improved the reduction of iron oxides and growth of iron particles. Therefore, the recovery of iron and the separation of iron and phosphorus were the best. In contrast, CaF2 reacted with Fe3PO7 to form fine Ca-3(PO4)(2) particles scattered around the iron particles, making the separation of iron and phosphorus difficult.

Automated summary

In the reduction roasting and magnetic separation process of high-phosphorus iron ore, Na2CO3 had the most significant effect on iron recovery and dephosphorization, while the effect of CaF2 was negligible. Na2CO3 can promote the reduction of iron oxides and growth of iron particles, resulting in better iron recovery and separation of iron and phosphorus.