Optimization of Quenching Parameters for the Reduction of Titaniferous Magnetite Ore by Lean Grade Coal Using the Taguchi Method and Its Isothermal Kinetic Study

In the present study, a unique method is adopted to achieve higher reducibility of titaniferous magnetite lump ore (TMO). In this method, TMO is initially heated followed by water quenching. The quenching process generates cracks due to thermal shock in the dense TMO lumps, which, in turn, increases the extent of reduction (EOR) using the lean grade coal as a reductant. The optimum combination of parameters found by using Taguchi’s L27 orthogonal array (OA) (five factors, three levels) is − 8 + 4 mm of particle size (PS1), 1423 K of quenching temperature (Qtemp2), 15 minutes of quenching time (Qtime3), 3 times the number of quenching {(No. of Q)3}, and 120 minutes of reduction time (Rtime3) at fixed reduction temperature of 1473 K. At optimized levels of the parameters, 92.39 pct reduction is achieved. Isothermal reduction kinetics of the quenched TMO lumps at the optimized condition reveals mixed controlled mechanisms [initially contracting geometry (CG3) followed by diffusion (D3)]. Activation energies calculated are 69.895 KJ/mole for CG3 and 39.084 KJ/mole for D3.