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Abstract <p>India’s steel industry faces growing challenges from the rising cost of imported metallurgical coal and the need to reduce CO<sub>2</sub> emissions. Coke flue dust, a steel plant by-product with high fixed carbon content, is typically underutilised despite its strong potential as a reductant. This study investigates the reduction behavior and kinetics of composite pellets made from blue dust iron ore and coke flue dust, aiming to assess their suitability for direct reduced iron (DRI) production. Composite pellets were prepared at varying carbon-to-oxygen (C/O) ratios (1.0–2.5) and reduced isothermally in a horizontal tube furnace under an argon atmosphere at 900–1200&#xa0;°C for up to 80&#xa0;min. The optimal C/O ratio was identified as 2, yielding the highest degree of reduction (DR) and metallization. At 1100&#xa0;°C, DR and metallization reached ~ 76.61% and ~ 66.81%, respectively, while at 1200&#xa0;°C, DR exceeded 90% with ~ 80% metallization. X-ray diffraction (XRD) analysis confirmed a stepwise reduction sequence (Fe<sub>2</sub>O<sub>3</sub> → Fe<sub>3</sub>O<sub>4</sub> → FeO → Fe), with the FeO → Fe transformation identified as the rate-limiting step, especially at lower temperatures. Kinetic analysis confirms that the overall reaction is in a mixed control regime at higher temperatures rather than a single control step, with an activation energy ranging from 70 to 176&#xa0;kJ/mol.</p> Graphical Abstract <p></p>

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Metallization Behavior and Reduction Kinetics of Iron Ore Blue Dust–Coke Flue Dust Composite Pellets for Sustainable Steelmaking

  • 期刊论文

  • 发表日期：

    2026年1月17日

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  • Ramesh Kumar,
  • A. Ashish Babu,
  • Syed Furqan Bukhari,
  • Ashok Kamaraj

摘要

Abstract

India’s steel industry faces growing challenges from the rising cost of imported metallurgical coal and the need to reduce CO2 emissions. Coke flue dust, a steel plant by-product with high fixed carbon content, is typically underutilised despite its strong potential as a reductant. This study investigates the reduction behavior and kinetics of composite pellets made from blue dust iron ore and coke flue dust, aiming to assess their suitability for direct reduced iron (DRI) production. Composite pellets were prepared at varying carbon-to-oxygen (C/O) ratios (1.0–2.5) and reduced isothermally in a horizontal tube furnace under an argon atmosphere at 900–1200 °C for up to 80 min. The optimal C/O ratio was identified as 2, yielding the highest degree of reduction (DR) and metallization. At 1100 °C, DR and metallization reached ~ 76.61% and ~ 66.81%, respectively, while at 1200 °C, DR exceeded 90% with ~ 80% metallization. X-ray diffraction (XRD) analysis confirmed a stepwise reduction sequence (Fe2O3 → Fe3O4 → FeO → Fe), with the FeO → Fe transformation identified as the rate-limiting step, especially at lower temperatures. Kinetic analysis confirms that the overall reaction is in a mixed control regime at higher temperatures rather than a single control step, with an activation energy ranging from 70 to 176 kJ/mol.

Graphical Abstract