A new method (gas-based separation plus melt separation) has been proposed to remove phosphorus of the high phosphorus iron ore which was 1.25% of phosphorus content and 50.0% of iron content.HSC chemistry package and the coexistence theory of slag structure were adopted for theoretical analysis.The gas-based reduction was carried out using a fixed bed reactor and the ore sample of 80 g with an average particle size of 2 mm were reduced using CO or H2 at temperature of 1073 K for 5 hours.50 g of the reduced sample with 3.0% CaO as additive was then subjected to melt separation in an electric furnace at temperature of 1873 K under Ar atmosphere.In each run,SEM,EDS,optical microscopic examination and chemical analysis of the reduced ore sample,the metal sample and the slag sample were conducted.Results of all gas-based reduction experiments showed that iron metallization ratios were some 65% and the phosphorus compounds in the ore remained unchanged.It was agreed well with the simulations except for the iron metallization rate being less than predicted value;this difference was attributed to kinetics.Results of melt separation experiments showed that P content in metal samples is 0.33% (metal sample from H2 reduction product) and 0.27 % (metal sample from CO reduction product).The phosphorus partition ratios of both cases were less than predicted values.Some P in the metal samples existed as slag inclusion was considered to be the reason for this discrepancy.
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