Research Thesis Title Proposal

Title : Optimizing (the Process Parameters of) Direct Reduction Process for Low-Grade Iron
Ores from Pangpet Region Utilizing Carbon Powder

1. Abstract

This thesis aims to investigate and optimize the direct reduction process of low-grade
iron ores sourced from Pangpet region through the utilization of carbon powder. The study
seeks to enhance the efficiency and cost-effectiveness of iron production by exploring key
variables, such as temperature, reduction time, carbon-to-ore ratio, and particle size, to
achieve an optimal reduction yield.

2. Introduction
The iron and steel industry stands at the core of global industrialization, providing
essential materials for construction, infrastructure, and countless other applications. As the
demand for steel continues to rise, the exploration of innovative and sustainable iron
production methods becomes imperative. Traditional processes, such as blast furnace
technology, face challenges related to energy consumption, greenhouse gas emissions, and
dependence on high-grade iron ores.

In response to these challenges, direct reduction processes have gained prominence,

offering a more energy-efficient and environmentally friendly alternative. Direct reduction
involves the use of a reducing agent to extract iron from ores, bypassing the carbon-intensive
steps of traditional ironmaking. This research focuses on optimizing the direct reduction
process, specifically tailored for low-grade iron ores sourced from Pangpet.

Low-grade iron ores are characterized by lower iron content and the presence of
impurities, making them economically less attractive for conventional ironmaking processes.
However, their abundance makes them a valuable resource, especially in regions where high-
grade ores are scarce. Pangpet, with its unique ore composition, presents an opportunity to

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explore tailored solutions for maximizing iron recovery while addressing the challenges
associated with low-grade ores.

The integration of carbon powder as a reducing agent holds promise in enhancing the
efficiency of direct reduction. Carbon powder not only serves as a potent reducing agent but
also presents the advantage of being potentially derived from renewable sources, contributing
to the sustainability of the overall iron production process. This research aims to harness the
synergy between low-grade iron ores from Pangpet and carbon powder, seeking to unlock the
full potential of direct reduction for sustainable and economically viable iron production.

By delving into the intricacies of this novel approach, the study not only addresses the
specific challenges posed by Pangpet's low-grade ores but also contributes to the broader
discourse on advancing direct reduction technologies. As industries strive to meet ever-
increasing global demands while minimizing environmental impact, the optimization of
direct reduction processes becomes a pivotal avenue for transformative change in the iron
and steel sector. The outcomes of this research could potentially redefine the landscape of
iron production, offering a pathway towards a more sustainable and resilient future for the
industry.

3. Problem Statement

The iron and steel industry faces a critical challenge in reconciling the growing demand
for steel with the environmental and economic constraints associated with conventional
ironmaking processes. In particular, low-grade iron ores, exemplified by those from Pangpet,
pose a unique challenge due to their reduced iron content and increased impurities, making
them less favorable for traditional methods. The inefficiencies in extracting iron from these
low-grade ores contribute to increased energy consumption, greenhouse gas emissions, and
economic limitations.

Existing direct reduction processes, while promising, lack optimization strategies tailored
to the distinct characteristics of low-grade iron ores from Pangpet. The utilization of carbon
powder as a reducing agent offers a potential solution to enhance the efficiency of the direct
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reduction process, yet a comprehensive understanding of the optimal conditions remains
elusive. Therefore, the overarching problem addressed by this thesis is the need for a
systematic investigation and optimization of the direct reduction process for Pangpet's low-
grade iron ores, with a specific focus on the integration of carbon powder, to develop a more
sustainable and economically viable iron production method.

4. Objectives

This research thesis aims for the optimization of direct reduction process for low-grade
iron ores locally sourced from Pangpet region using carbon powder (i.e. optimizing the
process parameters such as iron ore particles size, reduction temperature, reduction time,
carbon to ore ratio) to achieve the optimal reduction yield. Particularly this study has the
following sub-objectives:

1. To investigate the chemical composition and mineralogy of low-grade iron ores from
Pangpet region.

2. To analyze the effects of varying temperature and time on the direct reduction process
using carbon powder.

3. To evaluate the impact of different carbon-to-ore ratios on the reduction yield.

4. To assess the influence of particle size on the overall efficiency of the direct reduction
process.

5. Preliminary Literature Review

The investigation into the direct reduction process of low-grade iron ore from Pangpet
utilizing carbon powder is situated within a context shaped by historical developments,
current challenges, and emerging trends in ironmaking technologies. Historically, the
evolution of direct reduction methods has marked a shift towards more sustainable and
energy-efficient iron production. Pioneering studies by Midrex and HYL have been pivotal in

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establishing the foundation for modern direct reduction technologies, emphasizing the need
to move beyond traditional blast furnace processes.

Challenges specific to low-grade iron ores, such as those found in Pangpet, have driven
the exploration of innovative solutions. The lower iron content and increased impurities
inherent in these ores necessitate tailored approaches for efficient extraction. Preliminary
studies addressing the challenges of low-grade iron ores underscore the importance of
understanding the unique composition of Pangpet's ores to devise effective and economically
viable processing methods.

Carbon powder, as a reducing agent, plays a central role in the direct reduction process.
Investigations into carbon-based reduction mechanisms reveal insights into the reactivity of
carbon and its influence on reaction kinetics. Understanding the optimal carbon-to-ore ratio
and the impact of particle size on the overall efficiency of the reduction process becomes
crucial for achieving maximum yield and economic viability. Preliminary literature studies
provide essential groundwork for optimizing the role of carbon powder in the forthcoming
experiments.

The literature also delves into the broader aspects of direct reduction. Sustainable
ironmaking practices are emphasized, urging a departure from traditional processes with high
energy consumption and emissions. Additionally, the integration of locally sourced
resources, such as iron ore from Pangpet, aligns with regional development goals, offering
potential economic benefits and fostering environmental sustainability. Exploring emerging
technologies and future trends ensures that the proposed study remains adaptable to the
evolving landscape of iron production.

In summary, this literature review synthesizes historical perspectives, addresses the

unique challenges of low-grade iron ores, explores the role of carbon powder as a reducing
agent, and considers broader sustainability aspects. This comprehensive foundation informs
the forthcoming research, contributing to the optimization of the direct reduction process for
low-grade iron ore from Pangpet using carbon powder.

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6. Methodology

The research will involve laboratory-scale experiments, employing a controlled

environment to study the direct reduction process. Various parameters, including
temperature, carbon-to-ore ratio, and particle size, will be systematically manipulated to
identify optimal conditions for achieving maximum reduction yield. The process steps are as
follows:

1. Sample Collection and Characterization:

- Obtain representative samples of low-grade iron ores from Pangpet for detailed analysis
using XRD and SEM.

- Conduct thorough chemical and metallurgical characterization to understand the ore's

composition and identify key parameters influencing the reduction process.

2. Carbon Powder Preparation:

- Source or produce carbon powder for use as a reducing agent in the direct reduction
process.

- Characterize the properties of the carbon powder, including particle size distribution and
purity.

3. Experimental Setup:

- Design and set up a laboratory-scale direct reduction reactor.

- Establish controlled conditions, including temperature, gas atmosphere, and residence

time, to replicate the direct reduction process.

-Fine Iron Ores and Carbon Powder are packed into open-ended cylindrical sample
holders and placed into Vacuum Tube Furnace in vacuum environment.

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4.. Particle Size Optimization: Sieve Analysis and Characterization

- By using Sieve Analyzer, investigate for obtaining the optimal particle sizes of both iron
ore and carbon powder on the overall efficiency of the reduction process.

5. Temperature Variation Experiments:

- Perform a series of experiments at different temperatures to investigate the influence on

the kinetics and thermodynamics of the reduction reactions using Vacuum Tube Furnace in
vacuum environment.

Temperature Range: 900°C, 1000°C, 1100°C

Fixed Reduction Time : (???)

Carbon-to-Ore Ratio: 1:1

- Analyze the reduction yield using XRD, SEM and other relevant parameters.

Optimal Temperature : x °C

6. Reduction Time Variation Experiments:

- Perform a series of experiments at different reduction time to investigate the influence on

the kinetics and thermodynamics of the reduction reactions using Vacuum Tube Furnace in
vacuum environment.

Reduction Time Range: ?????

Temperature: x °C

Carbon-to-Ore Ratio: 1:1

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 - Analyze the reduction yield using XRD, SEM and other relevant parameters.

Optimal Reduction Time: y Hr

7. Carbon-to-Ore Ratio Studies:

- Systematically vary the carbon-to-ore ratio in the direct reduction process.

Fixed Temperature: x °C

Fixed Reduction Time: y Hr

- Assess the impact on reduction efficiency, iron recovery, and by-products formation.

Optimal Carbon-to-Ore Ratio: Z

8. Data Collection and Analysis:

- Collect comprehensive data from each experiment, including product analysis, gas
composition, and reaction kinetics.

9. Iterative Refinement:

- Based on initial results, iteratively refine experimental parameters to approach optimal

conditions.

- Fine-tune temperature, reduction time, carbon-to-ore ratio, and particle sizes for enhanced
reduction yield.

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10. Validation Experiments:

- Conduct additional experiments to validate the optimized conditions and ensure

reproducibility.

- Compare results with initial experiments to confirm the effectiveness of the refined
parameters.

10. Documentation and Reporting:

- Systematically document all experimental procedures, data, and findings.

- Compile results into a comprehensive report, highlighting key insights, challenges, and
recommendations for future research or industrial application.

Throughout the experimental process, adherence to safety protocols and quality control
measures will be paramount to ensure reliable and meaningful results.

7. Expected Outcomes

This study anticipates providing a comprehensive understanding of the direct reduction

process of low-grade iron ores from Pangpet using carbon powder. The outcomes will
contribute valuable insights to the field, potentially leading to improved industrial practices
and increased sustainability in iron production.

8. Significance of the study

The findings of this research have the potential to enhance the efficiency of
iron production from low-grade ores, contributing to the sustainable
development of the iron and steel industry. Additionally, the study may pave

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the way for the utilization of locally available resources, such as Pangpet iron
ores, in economic and environmentally friendly iron-making processes.

9. Research Time Frame

The research is expected to be conducted over a span of 6-7 months, encompassing

literature review, experimental setup, data collection, analysis, and thesis writing.

The expected time frame is attached in the last page.

10. Application of Direct Reduced Iron

Direct Reduced Iron (DRI) has several applications across various industries due to its
unique properties. DRI is produced by reducing iron ore (usually in the form of pellets or
lumps) using a reducing gas made from natural gas or coal. Here are some key applications
of Direct Reduced Iron:

1. Steel Production:
DRI is a valuable feedstock for electric arc furnaces (EAFs) in steel production. It is
often used as a substitute for traditional iron ore and can be melted directly in EAFs to
produce high-quality steel.

2. Iron and Steelmaking Integration:

DRI can be used in integrated steel plants to complement blast furnace-produced iron.
It helps in optimizing raw material usage and reducing dependence on traditional iron ore
sources.

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 3. Mini-Mills:

Mini-mills, which primarily use electric arc furnaces for steel production, find DRI,
particularly advantageous. The direct use of DRI in these facilities eliminates the need for
a blast furnace, resulting in a more flexible and cost-effective steel production process.

4. Iron Powder Production:

DRI can be further processed into iron powder, which finds applications in various
industries, including metallurgy, electronics, and chemical manufacturing.

5. Direct Use in Foundries:

DRI can be directly used in foundries for the production of iron castings. This
provides an alternative source of iron for casting applications.

6. Export and Trade:

DRI is often traded as a raw material in the global market, contributing to the
international supply chain for steel production.
The application of Direct Reduced Iron continues to evolve as industries seek more
sustainable and efficient ways to produce iron and steel.

11. Conclusion

This thesis proposal outlines a comprehensive investigation into the direct reduction
process of low-grade iron ores from Pangpet utilizing carbon powder. The research aims to
contribute valuable knowledge to the field of iron and steel production, with potential
implications for more sustainable and cost-effective industrial practices.

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12. Reference

1) Cavaliere, Pasquale, Angelo Perrone, and Debora Marsano. “Effect of Reducing

Atmosphere on the Direct Reduction of Iron Oxides Pellets.” Powder Technology 426
(August 2023): 118650. https://doi.org/10.1016/j.powtec.2023.118650.

2) Gandra, Beatriz Fausta, Gerson Evaristo De Paula Junior, Maurício Covcevich Bagatini,
and Eduardo Osório. “Analysis of Self-Reducing Composites with Different Iron Ore-
Carbon Ratio.” Journal of Materials Research and Technology 26 (September 2023):
6433–45. https://doi.org/10.1016/j.jmrt.2023.08.289.

3) Luo, Yanhong, Deqing Zhu, Xianlin Zhou, Bengjing Shi, and Feng Zhang.
“Coproduction of DRI Powder and Semi-Coke from Siderite Ore and Low Rank Coal by
Excessive Coal-Based Direct Reduction in Rotary Kiln.” ISIJ International 56, no. 1
(2016): 78–87. https://doi.org/10.2355/isijinternational.ISIJINT-2015-390.

4) Ünal, H. İbrahim, Enes Turgut, Ş. H. Atapek, and Attila Alkan. “Direct Reduction of
Ferrous Oxides to Form an Iron-Rich Alternative Charge Material.” High Temperature
Materials and Processes 34, no. 8 (December 1, 2015): 751–
56. https://doi.org/10.1515/htmp-2014-0125.

5) Colás, Rafael, and George E. Totten, eds. Encyclopedia of Iron, Steel, and Their Alloys.
CRC Press, 2016. https://doi.org/10.1081/E-EISA.

6) Anameric, Basak, and S. Komar Kawatra. “PROPERTIES AND FEATURES OF

DIRECT REDUCED IRON.” Mineral Processing and Extractive Metallurgy Review 28,
no. 1 (January 2007): 59–116. https://doi.org/10.1080/08827500600835576.

7) Ekhebume Ogbezode, Joseph, Olusegun Olufemi Ajide, Oluleke Olugbemiga Oluwole,

and Olusoji Ofi. “Recent Trends in the Technologies of the Direct Reduction and
Smelting Process of Iron Ore/Iron Oxide in the Extraction of Iron and Steelmaking.”
In Iron Ores and Iron Oxides - New Perspectives, edited by Brajesh Kumar. IntechOpen,
2023. https://doi.org/10.5772/intechopen.1001158.

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8) Wright, J. K., K. McG. Bowling, and A. L. Morrison. “Reduction of Hematite Pellets
with Carbonized Coal in a Static Bed.” Transactions of the Iron and Steel Institute of
Japan 21, no. 3 (1981): 149–55. https://doi.org/10.2355/isijinternational1966.21.149.

9) Srinivasan, N. S., and A. K. Lahiri. “Studies on the Reduction of Hematite by

Carbon.” Metallurgical Transactions B 8, no. 1 (March 1977): 175–
78. https://doi.org/10.1007/BF02656367.

10) Liu, Gui-su, Vladimir Strezov, John A Lucas, and Louis J Wibberley. “Thermal
Investigations of Direct Iron Ore Reduction with Coal.” Thermochimica Acta 410, no. 1–
2 (February 2004): 133–40. https://doi.org/10.1016/S0040-6031(03)00398-8.

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