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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
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].
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
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
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
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analysis of hematite, goethite and kaolinite in western-australian iron-ores, [18] Gui-su Liu, Vladimir Strezov, John A. Lucas, Louis J. Wibberley, Thermal in-
Thermochim. Acta 239 (1994) 147e156. vestigations of direct iron ore reduction with coal, Thermochim. Acta 410
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nochemical synthesis of metal-organic frameworks: a fast and facile approach [19] T. Turanyi, A.S. Tomlin, Storage of chemical kinetic information, in: F. Battin-
toward quantitative yields and high specific surface areas, Chem. Mater. 22 Leclerc, J.M. Simmie, E. Blurock (Eds.), Cleaner Combustion: Developing
(2010) 5216e5221. Detailed Chemical Kinetic Models, Springer, London, 2013.
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