Direct Reduction and Beneficiation of Iron Ores Containing Titanium, Manganese and Chromium Oxides and Alkaline Metal Sulfates

Most iron ores treated by the R-N direct reduction process yield metallic iron products considerably lower in titanium, manganese, and chromium oxides and alkaline metal sulfates/sulfides than were contained in the original ores. These metallic iron products are suitable as feed stock for the open hearth and electric steel-making furnaces. The elements which are rejected in part are acceptable in the product since the product is designed to by-pass the blast furnace. R-N reduction conditions (PCO+H2-1 atmosphere, 1830° to 2150° F.) are adjusted for each ore. The iron ore which is reduced to 90 to 95 percent metallic iron is then subjected to the conventional beneficiation techniques. Under these conditions, 55 to 80 percent of titanium oxides, 75 to 95 percent of manganese oxides, 60 to 90 percent of chromium oxides and up to 97 percent of alkaline metal sulfates contained in the ore are rejected with the gangue to the non- magnetic tailings. The metallic iron products illustrated in this work contained 89 to 96 percent total iron, one to five percent TiO2, 0.2 to one percent MnO, 0.3 to 1.6 percent Cr2O3 and/or up to one percent alkaline metal sulfide. Usually only one of these components was present. Recoveries ranged from 80 to 96 percent of the iron in ore.