Effect of Temperature on Morphology of Metallic Iron and Formation of Clusters of Iron Ore Pellets

The increase of the reduction temperature in direct reduction furnaces has been a recurring tool due to the benefits that it provides to the process. However, its increase cannot be performed without taking into account some considerations, since the sticking phenomenon is directly correlated with it and could lead to permeability problems and reactor performance. An analysis of the formation of pellets clusters at different temperatures was carried out with focus on morphological characterization of reduced materials to better understand the causes and effects of these actions. The results showed a correlation between the morphology of the metallic iron present in the samples and the clustering index. At low reduction temperatures, 1123 K (850 °C), the iron formed is eroded and deformed and the cluster hardly remains after tumbling. When forming iron with fibrous structure, 1223 K (950 °C), the clustering index increases because of anchor points which make the material to stick together. Finally, under the effect of high temperature and long time, it generates fresh precipitated iron, enhancing the resistance of the clusters so that they cannot be separated.