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Journal of Alloys and Compounds 650 (2015) 741e747

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Journal of Alloys and Compounds


journal homepage: http://www.elsevier.com/locate/jalcom

Experimental research on mechanism and process of direct iron


making reduction of mechanically milling scale with coal
S. Osman Yilmaz a, Tanju Teker b, *
a , Turkey
Namık Kemal University, Faculty of Engineering, Department of Mechanical Engineering, 59860, Çorlu, Tekirdag
b
University of Adıyaman, Faculty of Engineering, Department of Metallurgical and Materials Engineering, 02040, Adıyaman, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: This study delved into the fundamental mechanisms of a mill scale reduction. To achieve this objective,
Received 20 April 2015 the DRI process was applied to facilitate the mechanical milling of coal-scale mixtures. Temperatures of
Received in revised form 700e1000  C were used to sinter the mechanically milled coal-scale mixtures. The powders were sub-
7 July 2015
jected to scanning electron microscopy (SEM) and X-ray diffraction (XRD). In order to identify the
Accepted 19 July 2015
Available online 31 July 2015
reduction of milled scale-coal mixture with the temperature, iron phase analytical techniques and the
XRD were used. The differential thermal analysis (DTA) technique was used to determine the mea-
surements of the thermal property. Based on the findings of the experiments, it was concluded that coal
Keywords:
Mill scale
devolatilisation and scale reduction forms concurrently when the mixture is being heated. By 40 h
Coal milling, the milled coal-scale mixture's reduction start temperature decreased to 750  C.
Thermal analysis © 2015 Elsevier B.V. All rights reserved.
Iron ore reduction

1. Introduction [2e4]. This process concerns milling coke with ore and following
reduction process. Mechanical milling (MM) introduces high en-
Traditional iron making techniques reduce iron ores of metallic ergy into the material being processed. This energy can be stored in
iron in blast furnaces. These methods require separate coke making the material as atomic disorder and/or grain boundaries, i.e.,
and sintering plants. Coals used in coke making are classified as DGmilling ¼ DGdisorder þ DGgrain boundaries. The atomic disorder in an
premium with higher costs and limited reserves. Much of the intermetallic can be manifested in three different ways [1e11].
recent developments in the field have been focused on applying Firstly, the two atomic species involved can occupy the “wrong”
lower and cheaper grade of coals leading to the development of a sublattices and this is referred to as anti-site disorder. This in-
number of new emerging in direct reduction iron making (DRI) troduces strain into the lattice [4,5]. Secondly, triple-defects can be
technologies [1]. The largest advantage of the DRI technologies generated. In an equiatomic compound and this is anti-site disor-
relies on the fact that DRI does not require coke making and der. This leads to the presence of vacancies in the lattice to maintain
sintering. Both coke making and sintering, being at the front end of the stoichiometry. Thus, vacancies on the sublattice in combination
the conventional blast furnace iron making technology, are with anti-site atoms in a ratio of 2:1 constitute the triple defects.
considered as costly for the new process construction and are Third, there could also be a redistribution of interstitial wherein the
consistently causing environmental concerns. The DRI process, on interstitial atoms in the octahedral sites are transferred to the
the other hand, consists of carbothermic reduction of iron oxide tetrahedral sites. Additionally, grain refinement increases the grain
directly with the volatiles liberated during coal devolatilisation as boundary area and this also raises the free energy of the system.
well as the carbon monoxide regenerated from coal char. In addi- The sum of the energy of these two effects (disordering and crea-
tion to, DRI process it is possible to produce iron from scale at solid tion of grain boundaries) will be the total energy introduced into
state conditions. This process provides an advanced utilization the material during milling [6e12].
opportunity for the low operational temperatures that means, The aim of this work is to investigate the effect of mechanical
800e900  C, a temperature lower than sintering temperatures milling on coal-scale reaction temperatures of the mixtures during
heating. Thermal properties, and iron phase changes during heat-
* Corresponding author. Tel.: þ90 416 2233800; fax: þ90 416 2233809. ing of the mixtures were determined, through which fundamental
E-mail address: tteker@adiyaman.edu.tr (T. Teker). insights into coal and scale behavior.

http://dx.doi.org/10.1016/j.jallcom.2015.07.172
0925-8388/© 2015 Elsevier B.V. All rights reserved.
742 S.O. Yilmaz, T. Teker / Journal of Alloys and Compounds 650 (2015) 741e747

2. Materials and methods Table 2


Mechanical milling time and sintering temperature of the samples.

2.1. Experimental material Sample S1 S2 S3 S4 S5 S6 S7 S8 S9



Sintering temp, C 800 850 900 800 850 900 800 850 900
The main materials that were used in this experiment were coal Sintering time, h 1 1 1 1 1 1 1 1 1
and mill scale. Table 1 illustrates the chemical composition of coal Mechanical milling time, h 30 30 30 40 40 40 60 60 60
as established by this study. The coal was found to have volatile
matter and ash in air-dry base of 33.5 wt.% and 6.5 wt.%, respec-
tively. In terms of daff base, it was found to have 85.1% C, 6.6% O, the surface area for reactions by reducing the size of the reactants.
5.5% H, 2.1% N, and 0.7% S. The byproduct was comprised of 62.1% The size reduction using this metal alloying is achieved through the
Fe, 4.33% SiO2 and 1.98% Al2O3. process of welding and fracturing of powder particles. The
increased surface area for the reactions increases the chances for
2.2. Experimental methods the particles to collide and initiate the reactions without the need
for particle diffusion through the produce layers. Consequently, the
Prior to the initialization of the experiments, both samples were reactions that take place at extremely high temperature can occur
dried for 2 h under vacuum at a temperature of 80  C. The average at a lower temperature, or even without heat application using the
particle size of coal was 80 mm while that of the scale was 50 mm. metal alloying method. Apart from increasing the surface area, the
A ratio of the mass of coal and scale mixture used in the study was metal alloying method also increases the rate of reaction through
25:75. The first step of preparing the samples entailed milling the increasing the density of the particles, which in turn increases the
mill scale and coal powders mechanical mixture using a high- rate of the diffusion process [14,15]. Ideally, the reduction of particle
energy ball (Table 2), under argon atmosphere, in an attrition size and increasing of diffusion rate through (through increasing
made of hardened steel vial and balls. In the course of the experi- the density of the particle) can reduce the temperature at which the
ments, the milling settings were kept constant (i.e. a 30:1 ball-to- reactions are likely to take place significantly, even if they are not
powder mass ratio, a 600 rev/min speed of rotation and a likely to take place at room temperature.
30e40e60 h milling time). The powders were subjected to scan- There are two reaction kinetics reaction that is likely to take
ning electron microscopy (SEM: JEOL JSM 7001F) and X-ray place, and this depends on the condition of the milling used. The
diffraction (XRD). At room temperature, the patterns XRD were first reaction is a gradual transformation, which occurs when the
acquired by means of an XRD-6000 which had a Cu Ka/tube, 40 MA reaction extends to a very small percentage after the collision. The
current, 40 kV voltage, and a wave length of a ¼ 1.54056 Å. The second form of reaction is the self-combustion reactions, which
differential thermal analysis (DTA) technique was used to deter- occurs when the adequate reaction enthalpy. The second form of
mine the thermal properties. The Perkin Elmer A 400 atomic ab- reaction requires a critical milling time to be reached in order for
sorption spectrometer was used for the determination of the reaction to start. When the temperature in the vial is recorded
metallization. during the milling process, the temperature is found to increase
gradually up to the certain point when it increases abruptly. This
increase of the temperature abruptly signifies the ignition, which
3. Results
initiate the combustion process has started. After the ignition, the
temperature in the mill relatively decreases slowly. The tempera-
Mechanical milling is a strategy that can be used to reduce metal
ture at which the temperature increases abruptly is recognized as
oxides when combine with more reactive elements at room tem-
the ignition temperature abbreviated as Tig. Determination of this
perature. The process in reactivity literature is referred to mecha-
temperature is very important while differentiating between the
nosynthesis or mechanochemical synthesis [13]. Reduction process
structural and chemical evolution in metal alloying process [16].
is also called displacement reaction because one element is dis-
Research has shown that milling achieves only particle refinement
placed by another. Displacement reactions are some the most
until combustion reaction occurs. It is after the combustion reaction
common form of mechanosynthesis reactions commonly studied in
that the reduction reaction occurs.
the literature.
Research has further shown that the large enthalpy changes
This process involves two metals, whereby, one is more reactive
associated with chemical changes are responsible for the occur-
than the others. For example, a metal oxide (MO) when mix with a
rence of the combustion reaction. Combustion reaction is a result of
more reactive metal (reductant R), is reduced to pure metal. It is
the temperature difference between the temperature produced by
observed that all reactions involving solids lead to a development
the milling process (caused by ball-to-ball or ball-to-powder col-
of a product phase (s) at the interphases of the reactants. In regard,
lisions) Tc and the ignition temperature Tig. The combustion reac-
during the reaction as the product increases, the reaction process
tion only occurs when the milling temperature Tc is more than the
slows down. During the reactions, the reactant atoms diffuse
ignition temperature Tig.
through the product phase, creating a barrier that reduces the rate
The ignition temperature of particular reactions depends on the
of reactions. The rate of the reaction depends on the extent to
enthalpy change and the microstructural parameters, including
which the reactant atoms can collide to initiate the process [14].
particle size and crystal size [16]. Since metal alloying focuses on
However, in order to increase the rate of reactions increase of the
reducing the size of the particles, the Tig reduces as the milling time
temperature of the reactant is required. Additionally, metal alloying
increases. On the other hand, when the milling time increases, the
is yet another strategy possible to increase the rate reactions ki-
Tc also increases until it reaches a steady state. The two temperature
netics in reduction processes substantially. Metal alloying increases
are very important in combustion reactions. Combustion reactions
occur when the graph of Tig and that Tc intersect, a time that is also
Table 1 referred to critical milling time. Critical milling time is also called
Chemical composition of the coal used in experiments. the Tig at which the combustion reaction occurs in a reduction re-
C H N S O
action. Other interpretation that occur during Tig that lead to
combustion is that intermixing of particles, particle refinements
Coal 76.35 5.5 2.1 0.63 6.6
that occur during milling. Additionally, during milling the milling
S.O. Yilmaz, T. Teker / Journal of Alloys and Compounds 650 (2015) 741e747 743

Fig. 1. DTA of a) scale, b) scale-coal mixture 40 h milled and not sintered, c) coal mixture 40 h milled and sintered at 850  C, d) coal mixture 40 h milled and sintered at 900  C.

time significantly reduced because the room temperature aging tremendous after 600  C. It is accurate to assume that iron oxide
was seen to accelerate the onset of combustion significantly [16]. was directly reduced by coal for the temperatures interval of 700
and 800  C which led to the generation of CO2 as a primary product.
3.1. Apparent specific heat There was a substantial gasification of carbon occurred when
temperature rose above 600  C, and the reduction of the gaseous
Fig. 1 illustrates the apparent specific heats for coal and scale phase facilitated the reduction of iron oxide and the weight lost was
which were calculated under Ar atmosphere at a 10  C/min rate of 81 wt.%. The weight lost in the 900  C sintering and 40 h MM
heating. When scale's apparent specific heat was measured, a sample was 86 wt.%.
number of sharp peaks were observed. The first peak occurred at The sample at room temperature i.e. 25  C was dominated by
400  C as a result of the generation of hematite (Fe2O3) [16]. As the phases of Fe3O4, and FeO. In the first step Fe2O3 was reduced
illustrated in Fig. 1a, the second peak occurred at 685  C due to the leading to the formation of Fe3O4. This formation takes place at
magnetic transformation of Fe2O3 [17]. At 700  C, the weight ratio temperatures below 530  C and ends between 620 and 670  C. The
of scale dwindled to 99.6 wt. %. It however, rose after this tem- transformation, in this study, took place at temperatures between
perature through the magnetic transformation. 420 and 480  C. At temperatures between 420 and 480  C, Fe2O3
As documented in the literature [18], the evolution of CO for coal was thermally decomposed and consequently, it disappeared. In
commences at a temperature of 450  C and ends at temperatures of the second step, which according to literature happens between
around 950  C. The highest rate of evolution is attained at 720  C. 670 and 740  C and ends at temperatures below 870  C, Fe3O4 was
On the other hand that of H2 commences at 495  C reaches the reduced leading to the formation of FeO. The transformation, in this
highest rate of evolution at 785  C and ends at 1000  C. As illus- study, took place at temperatures between 480 and 600  C as
trated in Fig. 1b, the mixture of scale and cola produces a rapid and illustrated in Fig. 1c. During 560 and 900  C, the reduction rate was
significant exothermic reaction which takes place at temperatures accelerated. At 560  C, the third step commenced where FeO was
between 450 and 580  C. This reaction is thought to be a result of reduced leading to the formation of metallic Fe.
the physical and chemical changes that pertain to the coal plastic For the rates of these reactions to be reasonable, elevated tem-
region (i.e. the formation, vaporization and solidification of tar). peratures are required. The reaction kinetics of the reduction can be
The temperature of the exothermic reaction was about 580  C and immensely increased through mechanical milling. Mechanical
the weight lost was 72 wt.% milling causes repeated fracturing and welding of powder particles,
As shown in Fig. 1c, the concentrations of CO and CO2 were very which in turn, augments the contact area of the reactant powder
low and stay constant below 400  C for the 40 h sample at 850  C particles as a result of a their reduce particle size. Consequently, the
sintering. After 400  C, the concentrations rose and became reaction carries on without the need for diffusion through the
744 S.O. Yilmaz, T. Teker / Journal of Alloys and Compounds 650 (2015) 741e747

product layer. As a result, reactions that usually need elevated level the increase of metallization ratio, and when temperatures went
temperatures will take place at lower temperatures in the course beyond 1000  C, a steady-state behavior was observed. In grind of
MM without application of an external source of heat. Moreover, 40 h, the success in the metallization ratio seems to be higher.
the rate of the diffusion process is increased by the high defect Fig. 3b illustrates the correlation between MM time and the
densities produced by MM. Alternatively, the reaction tempera- metallization ratio. A change in the metallization ratio is observed
tures can be considerably reduced by the particle refinement and between 30 and 60 h. As evidenced in the agglomeration of the
resultant reduction in the diffusion distances (as a result of powder, the MM period worsens after 40 h Fig. 3c illustrates the
microstructural refinement) regardless of whether they occur at correlation between metallization and sinter time. At 900  C, the
room temperature or not. rate of metallization increases with time and stable period is
observed after 2 h.
3.2. XRD analysis Fig. 4 shows an SEM micrograph of sample S3 showing the size
of the metallic iron particulates. The percentage of Fe after 1 h in
Prior to being analyzed using XRD, samples of mechanically activation process is approximately 85 wt.%, after 2 h it rises to
milled coal and scale were prepared in a furnace at temperatures 93.61 wt.% and after 4 h, it rises to 97 wt.%. There was an increase in
ranging between 700 and 1000  C then cooled at a cooling rate of the surface area as well as the surface energy of the large size of the
around 100  C/min. Fig. 2 illustrates the XRD analysis of coal-scale material after activation process. As a result, the rate of reaction
mixture that is prepared at varied sintering temperatures, the time also augmented. Once a rigid body is subjected to a strong external
for mechanical milling as well as the time for sintering. At tem- force, its internal connection weakens and the body breaks into
peratures of 850  C, the sample was mainly comprised of metallic smaller pieces. After the body is broken into smaller pieces, some of
Fe and small traces of FeO. Metallic Fe phase was the sole dominant its surfaces re-occur. This leads to an increment of the body's sur-
phase at temperatures of 900  C, and the crystal size of metallic iron face energy and a decline in its particle volume. According to Rit-
in sample S3 was detected as 9.8 nm. tinger, downsizing helps in increasing surface energy as well as the
surface growth [13].

3.3. Iron phases analysis


3.4. Kinetic analysis
The changes in sintering temperature, between 700  C and
1000  C as well as the temperature for MM, and the change of time The knowledge in the kinetic analysis is very important in the
between 40 and 60 h are illustrated in Fig. 3a. There was a decline in model industrial conversion process. Specifically, the kinetic

Fig. 2. X-ray diffraction analysis of mixture of coal/scale at 1/3 ratio showing the effect of sintering temperature for a) 40 h milling time, b) 60 h milling time, c) effect of milling time
900  C sintering temperature, d) effect of sintering time.
S.O. Yilmaz, T. Teker / Journal of Alloys and Compounds 650 (2015) 741e747 745

Fig. 3. Effect of sintering temperature on metallization rate.

analysis helps in understanding and predicting thermal conversion reduction reaction was used to measure the activation energy
processes, which are essential for modeling industrial conversion required to activate a thermal reduction reaction [19]. The study
processing. A research conducted to understand the kinetic analysis first integrated the heat of reaction cumulatively on a graph to
of a conversion process indicated that the measured heat of represent the degree of reaction. In order to effectively determine
the degree of reaction, the degree was set at zero before the reac-
tion began and then set at one it was completed. After the reaction,
the kinetics of each reaction was present a function of Arrhenius,
and the model of the reaction is as follows:

da
¼ kðTÞf ðxÞ (1)
dt

Where represent time (s), T represent temperature in (K), a


represent the progress of reaction (no units) f(a) represent the
reaction model and k(T) represent the temperature dependent
rate constant, which is further described below using the
Arrhenius

 
E
kðTÞ ¼ Aexp  (2)
RT
In this model, a represents the frequency factor also called pre-
exponential factor denoted as (s1), E denotes the activation energy
in (J/mol) and R denotes the gas constants (8.314 J/mol K).
Activation energy used in the above formulae refers to the
Fig. 4. SEM of sample S3 showing the size of the metallic iron particulates. energy that must be overcome in order to initiate the bond
746 S.O. Yilmaz, T. Teker / Journal of Alloys and Compounds 650 (2015) 741e747

redistribution state, which is very critical for the conversion of that were selected. The reduction processes of different iron ores
reactant into products [17]. The frequency factor as indicated in may differ they may have different properties such as different
the above model refers to the number of occurrences of the forms of hydroxyl mineral and/or different phases of metallic oxide.
reactive situation. However, in order to calculate A (frequency In addition, there might be some impurities such as paints in the
factor) and E (activation energy) there is a need to integrate coal from previous treatments which might impinge on the reac-
equation (1). The first order of the equation is regarded as the tion. They can also be impinged on agricultural wastes which are
right-hand side of the equation (3) and has no exact integral. Coats comprised of large amounts of mineral matter as they would
and Redfern [11] evaluated and simplified expression of the further react with the compounds of iron oxide. As a result,
equation is as shown below: different biomass types, contingent on their origin, will behave
differently when being processed and should therefore be evalu-
Za ZT   ated independently.
dx A E
¼ expð  dT (3)
ð1  aÞ b RT
0 0 5. Conclusions

    Below is a summary of this study's principal findings:


ART 2 2RT E
lnð1  aÞ ¼ 1 exp  (4)
bE E RT
1. The percentage of Fe2O3 in the initial iron ore that was reduced
Take the logarithm of equation (4) yields to metallic Fe at temperatures between 700  C and 1000  C was
98.7%. This took place under a heating rate of 10  C/min heating
     rate and Ar atmosphere. The mass ratio mixture of coal and iron
lnð1  aÞ ART 2RT E ore was 20:80.
ln ¼ LN 1   (5)
T2 bE E RT 2. The reduction of Fe2O3 using CO and H2, which are products of
the devolatilisation of coal, led to the formation of Fe3O4. This
occurred at temperatures between 420  C and 480  C.
Develop a graph by plotting the left-hand side of the equation
3. The H2 and CO were also used to reduce Fe3O4 which lead to the
(5) against 1/T for every reduction reaction conducted. This will
formation of FeO. This occurred at temperatures between 480
result in a straight line with a slope E/R see in (Fig. 1). The results
and 740  C. A low rate of reduction was observed between 480
as observed from the graph showed that the activation energy of 
and 600 C but the rate spiked up between 670 and 740  C.
40 h MM sample was 1787 J/mol and that for 60 h MM sample was
4. The reduction of FeO was facilitated by CO from char gasification
1359 J/mol.
and occurred at temperatures between 800 and 900  C. At
temperatures between 800 and 900  C, a high rate of reduction
4. Discussion was observed.
5. There were three major temperature events that were observed
There are a number of measuring techniques that have been in the reduction reactions. The first event was exothermic while
used in a bid to delve into the properties of coal-scale mixtures the other two subsequent events were endothermic.
when the heating rates are below 10  C/min as well as to provide 6. Nucleation rate (N) and growth rate (G) of a-iron increased with
a consistent comprehension of the fundamental reactions that mechanical milling time.
take place in the course of the reduction process. The conclusion 7. The activation energy of the reduction reaction decreased by
is that the reactions of coal and scale in the coal-scale mixture mechanical milling up to 40 h MM.
system are very intricate. In addition, the transformations in the 8. The reaction degree of the three examined thermal regions
reactions are highly contingent on the parameters of heat followed the first-order kinetic mechanism.
transfer such as shape, sample density, size, and heating rate. It is
imperative to note that the findings provided in this work Acknowledgments
represent a reaction mechanism for the current parameters and
conditions of heating. The authors are grateful for the financial support provided by
The temperature range where reduction Fe2O3 occurred is be- the FUBAP/Firat University-Elazıg/Turkey (NKUBAP.00.17.KR.14.01
tween 580  C and 670  C while that of Fe3O4 was between 670  C number Project NKUBAP/Namık Kemal University-Tekirdag /
and 870  C. The reduction of FeO by CO, which was produced after Turkey).
gasification of carbon, occurred thereafter. The reduction of iron
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