SCI和EI收录∣中国化工学会会刊

Chinese Journal of Chemical Engineering ›› 2025, Vol. 79 ›› Issue (3): 81-90.DOI: 10.1016/j.cjche.2024.10.033

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Sustainable iron recovery from iron ore tailings using hydrogen-based reduction roasting and magnetic separation: A pilot-scale study

Xinran Zhu1,2, Xuesong Sun1,2, Yanjun Li1,2, Yuexin Han1,2   

  1. 1. School of Resources and Civil Engineering, Northeastern University, Shenyang 110819, China;
    2. National-local Joint Engineering Research Center of High-efficient Exploitation Technology for Refractory Iron Ore Resources, Shenyang 110819, China
  • Received:2024-08-01 Revised:2024-10-27 Accepted:2024-10-28 Online:2025-01-09 Published:2025-03-28
  • Supported by:
    The authors thank the National Natural Science Foundation of China (52104249), Liaoning Joint Fund General Support Program Project (2023-MSBA-126), and the Fundamental Research Funds for the Central Universities (N2401019).

Sustainable iron recovery from iron ore tailings using hydrogen-based reduction roasting and magnetic separation: A pilot-scale study

Xinran Zhu1,2, Xuesong Sun1,2, Yanjun Li1,2, Yuexin Han1,2   

  1. 1. School of Resources and Civil Engineering, Northeastern University, Shenyang 110819, China;
    2. National-local Joint Engineering Research Center of High-efficient Exploitation Technology for Refractory Iron Ore Resources, Shenyang 110819, China
  • 通讯作者: Xuesong Sun,E-mail:2210464@stu.neu.edu.cn
  • 基金资助:
    The authors thank the National Natural Science Foundation of China (52104249), Liaoning Joint Fund General Support Program Project (2023-MSBA-126), and the Fundamental Research Funds for the Central Universities (N2401019).

Abstract: Iron tailings are a common solid waste resource, posing serious environmental and spatial challenges. This study proposed a novel hydrogen-based reduction roasting (HRR) technology for the processing of iron tailings using a combined beneficiation and metallurgy approach. Pilot-cale experiment results indicated that under the gas composition of CO:H2 = 1:3, and optimal roasting conditions at a reduction temperature of 520 ℃, the majority of weakly magnetic hematite transforms into strongly magnetic magnetite during the reduction process. Combining roasting products with a magnetic separation–grinding–magnetic selection process yields a final iron concentrate with a grade of 56.68% iron and a recovery rate of 86.54%. Theoretical calculations suggested the annual production value can reach 29.7 million USD and a reduction of 20.79 tons of CO2 emissions per year. This highlights that the use of HRR in conjunction with traditional beneficiation processes can effectively achieve comprehensive utilization of iron tailings, thereby reducing environmental impact.

Key words: Iron ore tailings, Hydrogen, Reduction roasting, Magnetic separation, CO2 emissions

摘要: Iron tailings are a common solid waste resource, posing serious environmental and spatial challenges. This study proposed a novel hydrogen-based reduction roasting (HRR) technology for the processing of iron tailings using a combined beneficiation and metallurgy approach. Pilot-cale experiment results indicated that under the gas composition of CO:H2 = 1:3, and optimal roasting conditions at a reduction temperature of 520 ℃, the majority of weakly magnetic hematite transforms into strongly magnetic magnetite during the reduction process. Combining roasting products with a magnetic separation–grinding–magnetic selection process yields a final iron concentrate with a grade of 56.68% iron and a recovery rate of 86.54%. Theoretical calculations suggested the annual production value can reach 29.7 million USD and a reduction of 20.79 tons of CO2 emissions per year. This highlights that the use of HRR in conjunction with traditional beneficiation processes can effectively achieve comprehensive utilization of iron tailings, thereby reducing environmental impact.

关键词: Iron ore tailings, Hydrogen, Reduction roasting, Magnetic separation, CO2 emissions