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<p>PMC copper tailings (PMC) are characterized of high TFe grade, substantial TiO<sub>2</sub> content, abundant reserves, and low cost, thereby qualifying as potential secondary resources. This study ascertained the key process parameters for the resource utilization of PMC and established preheating roasting-hydrogen-based shaft furnace direct reduction-electric furnace smelting-separation, which is an integrated technological system for resource utilization. The optimal ore blending structure meeting process requirements was 60% PMC copper tailings blended with 40% high-grade ore. For the preheating-roasting step, the key suitable process parameters are as follows: preheating temperature of 925&#xa0;°C, preheating time of 18&#xa0;min, roasting temperature of 1200&#xa0;°C, and roasting time of 25&#xa0;min. Under these conditions, the roasted pellets achieved a compressive strength of 2673 N, which met the process requirements. Upon subjecting the roasted pellets to direct reduction in hydrogen-based shaft furnace under the conditions of reduction temperature of 950&#xa0;°C and reducing atmosphere with 65% H<sub>2</sub>, the pellets attained a reducibility index of 0.0407, reduction swelling rate (RSI) of 11.40%, and reduction sticking index (SI) of 2.50%, respectively. For the low-temperature reduction disintegration index (LTD), LTD<sub>+6.3</sub> stood at 90.60%, LTD<sub>−3.2</sub> at 9.35%, and LTD<sub>up</sub> at 100%, which complied with the production specifications of the hydrogen-based shaft furnace. Electric furnace smelting-separation experiments were conducted using the 60% PMC ore-blended metallized pellets as the feedstock, with smelting-separation temperature of 1600&#xa0;°C, smelting-separation time of 30&#xa0;min, basicity of 0.5, and carbon ratio of 1.1. Under this condition, a better separation effect of slag and metal can be achieved. The yield of Fe in pig iron was 99.25%, and its mass fraction was 97.28%. The yield of TiO<sub>2</sub> in the fractionated slag was 93.36%, and the mass fraction was 40.23%.</p> Graphical Abstract <p></p>

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Optimization of Pellet Production with Copper Tailings, Hydrogen Direct Reduction, and Melting in Electric Arc Furnace Towards Green Steel Manufacturing

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Jue Tang,
  • Jialin Jiang,
  • Jinge Feng,
  • Zichuan Zhao,
  • Xicai Liu,
  • Mansheng Chu,
  • Kuixian Wei,
  • Hongyu Tian

摘要

PMC copper tailings (PMC) are characterized of high TFe grade, substantial TiO2 content, abundant reserves, and low cost, thereby qualifying as potential secondary resources. This study ascertained the key process parameters for the resource utilization of PMC and established preheating roasting-hydrogen-based shaft furnace direct reduction-electric furnace smelting-separation, which is an integrated technological system for resource utilization. The optimal ore blending structure meeting process requirements was 60% PMC copper tailings blended with 40% high-grade ore. For the preheating-roasting step, the key suitable process parameters are as follows: preheating temperature of 925 °C, preheating time of 18 min, roasting temperature of 1200 °C, and roasting time of 25 min. Under these conditions, the roasted pellets achieved a compressive strength of 2673 N, which met the process requirements. Upon subjecting the roasted pellets to direct reduction in hydrogen-based shaft furnace under the conditions of reduction temperature of 950 °C and reducing atmosphere with 65% H2, the pellets attained a reducibility index of 0.0407, reduction swelling rate (RSI) of 11.40%, and reduction sticking index (SI) of 2.50%, respectively. For the low-temperature reduction disintegration index (LTD), LTD+6.3 stood at 90.60%, LTD−3.2 at 9.35%, and LTDup at 100%, which complied with the production specifications of the hydrogen-based shaft furnace. Electric furnace smelting-separation experiments were conducted using the 60% PMC ore-blended metallized pellets as the feedstock, with smelting-separation temperature of 1600 °C, smelting-separation time of 30 min, basicity of 0.5, and carbon ratio of 1.1. Under this condition, a better separation effect of slag and metal can be achieved. The yield of Fe in pig iron was 99.25%, and its mass fraction was 97.28%. The yield of TiO2 in the fractionated slag was 93.36%, and the mass fraction was 40.23%.

Graphical Abstract