Title

: Microwaves Applied To Carbothermic Reduction Of Iron Ore Pellets

Author : J. A. Aguilar and I. Gomez

Synopsis Made By : Wina Khatrini Darwin, H31113505
Obtaining a metal from its oxide is a chemical process called reduction, and to conduct
this process energy must be provided to the system. The most common way is by combustion
of fuels or electricity. Although there are several studies on microwave applications for
supplying energy for non-metal-lic transformations, it is only recently that microwaves have
been applied to the production of metals (Standish and Worner, 1990); (Standish and Huang,
1991). The objective of this work is to demonstrate that iron ore can absorb energy from
microwaves. If so, it is possible to conduct the reduction process with microwaves as a power
source. This has been previously demonstrated with hematite-to make magnetic separation
possible.
A single pellet was placed inside the microwave oven, at the location previously
determined to be the best. The temperature increased very rapidly. Despite radiation loss, in
less than ten seconds it passed from room temperature to 8000C. A single pellet was placed in
a carbon bed, so that one third of the pellet was under the carbon bed and the upper two thirds
was exposed. The data indicated that some CO from the carbon bed covers the pellet, and
reduction from hematite to magnetite take place.
Once the described test were conducted and analyzed, it was possible to comment
about degreed reduction, temperature estimation and factors affecting the reduction rate.
When the pellet is covered with a melted iron film the reducing agent (CO) cannot reach the
reaction site. When this film does not develope, reduction can be conducted almost to 100%.
However, in this case, reduction could not exceed 40% because the process was controlled by
the diffusion of CO, and the melted film did not allow it to move through the reduced layer.
To prove this assertion tests were carried out on dust mixed with carbon. It was found
that the maximum degree of reduction was not greater than that obtained for pellets. This
indicated that there was not another reason, in addition to diffusion controling the reduction
process when conducted with microwave energy. The answer to this apparent contradiction is
that the obtained degree of reduction is an average of the mixture made of dust taht was
exposed to the microwave field. Taking the external particles of the mixture, the reduction
degree is higher than 90% while the particles that were at the center of the mixture were
practically unreacted. An advantage of volumetric heating is that it can avoid the cold center.
But when the controling process is the mass transport instead of the heat supply there will be
an unreacted center that cannot be avoided by microwave heating.