ISIJ International, Vol. 37 (1 997), No, 11 pp.

, 1050-1056

Microstructures of Self-reducing Pellets Bearing lron Ore and

Carbon

Marcelo Breda MOURAO

Ramiro Conceic~o NASCIMENTO. and Jos6 DeodoroTrani CAPOCCHl
Department of Metallurgical and Materials Engineering, Polytechnic Schoo[. The University of S~o Paulo, Av. Prof. Mello
Moraes 2463, Cidade Universitaria, S~o Paulo, SP, Brazi],
(Received on March 31. 1997, accepted in final form on August /. 1997)

The steps Fe203+Fe304,Fe304-"FeO" and "FeO"+Fe, during the reduction of self reducing pellets
1
plus charcoal (with volatile matter), between 223-1 423 K, were analysed. It
was found that typical
microstructures of the step Fe203-Fe304consisted of transgranular cracks in the hematite particles and
the Fe304 morphology was probably lame[lar. The microstructures of the step Fe304-"FeO"
were similar
to and dependent on the first step of reduction and it wasobserved the formation of superficial microcracks
in the "FeO" phase. The typicai morphology in the step "'FeO"-Fe was that of Fe whiskers between
1 223-1 323 K, but at 423 K 1
the found morphology wasa mixed one, that is a dense morphology (clusters
of cone shaped whiskers) adjacent to a porous morphology of iron.

KEYWORDS:
agglomeration; pelletization; DRl; ironmaking; charcoal.

l. Introduction +C ->2CO "'

Information on the microstructures resulting from
the reduction of iron ore in the form of carbon bearing
pellets, when these pellets are cold bonded and the
carbonaceous material contains volatile matter, is very
rare in the literature. There are few mentions about the
effect of the volatile matter, generated during the thermal
decomposition of charcoal, on the microstructures as-
sociated to the iron oxides or metallic iron formed.
Nascimento et al.1 ~4) have analysed all the steps of
the reduction of self reducing cold bondedpellets bearing
hematite and charcoal in the range 12231 423 K.
Onthe other hand, it must be pointed out the existence
of papers which deal with important technological
aspects of the reduction of self reducing pellets,5 ~ 15) as
well as of papers which emphasise
more fundamental
issues of such a technology. 16- 24)
A self reducing pellet may be regarded as a solid
mixture of iron oxide and carbon. If the solid reducing
agent contains volatile matter and if the iron oxide is
Fe203, then, on heating, the following reactions could
take place:
Charcoal~,CO, C02, H2, N2, CNHM
and C
Fe203(~) + 3C(~)•~2Fe(,) + 3CO(g)
C02(g) (s) (g) """""(6)
H20(g)+C(s)~H +CO 2(g) (g) "' .
..........(7)
Reaction (1) represents the thermal decomposition of
C
charcoal and meansfixed carbon.
The thermal decomposition of charcoal is an endo-
thermic reaction. It starts in the temperature range
573-773 K. The products of such a reaction induce
Reactions (3), (4) and (5). The products of Reactions
(3), (4) and (5)
cause the gasification of the reducing
agent-Reactions (6) and (7) which generate reducing
gases (COand H2)'
Therefore, the reduction of a self reducing pellet
involves two types of reaction: (i) direct reaction
(solid/solid), beweeniron oxide and carbon and (ii) a
sequence of gas/solid reactions.
As the solid/solid reaction is very slow comparatively
to the gas/solid reaction, then the global process occurs
via gaseous intermediates such as CO, C02. H2 and
H20, i)
The objective of the present work is to describe and
to commentthe observed microstructures during all the
stages of the reduction of self reducing pe]lets (bearing
.....(1) hematite and charcoal), carried out at 1223-1 423 K,
under argon.
..............(2)

3Fe2O3(*) + CO (g) or H2(g)~2Fe304 +CO 2(g) or H20(g) 2. Experimental

.(3)
2.1. Sample
2Fe3O4(*) + 2CO (g) 2H2(g)H>
or lron Ore Fines
6"FeO"(~) + 2CO 2(g) or 2H2O
.......(4) It
was used fines of Caueiron ore which
are suitable
••-
for industrial pelletizing.
contains 800/0 of the particles
It
"FeO"(.)+CO(g) or H2~Fe(~)+C02(g)or H20 ...(5) under IOO,Im. Thesurface area is O.3 O. I m2g~ I (BET). ~
C 1997 ISIJ 1050
 ISIJ International, Vol, 37 (1997), No. 11
The chemical composition of the iron ore fines is shown pelletat time t, when the reacted fraction is and F
in Table l.
mn~.1= the final massof the pellet (the final weight loss
comprises the volatile matter losses plus the reducible
Charcoal Fines
Eucalyptus charcoal presenting 78.42 masso/o fixed oxygen loss).
Based upon the X-ray diffractograms of the samples
carbon, 1.56masso/o ashes and 20.02masso/o Volatile
obtained during the reduction experiments It
matter was used. Particle size less than 100,4m was 95010 was pos-
and the measuredsurface area was27.0 .O m2g~ I The
~I
sible to associate each value of
F to the stage of reduc-
.
tion concerned. In order to interrupt the reaction at
chemical composition of the ashes is shownin Table 2. a
given value of F, the fo]lowing equation for
mF Was
Portland Cement used:
It
was used commercial Portland cement (990/0 Iess
than 100 ~m). Table 3 shows the chemical composition mF=mo(1
-F•w) .......
..........(9)

of the cement. where w=arithmetic meanof the ratio (mo~mn~.1)/mo

2.2. The Pellets
after 3experiments
at each temperature.

Pelletswere hand made, and the optimum humidity

Pellets were dried out at 393 during K 2hbefore each
experiment. They were introduced directly into the re-
for pelletizing was 15-1 8masso/o. The cure process lasts action zone of the furnace, without
for 30 days. Whena particular pellet was designed to any preheating step.
a
reduction heat, it had its diameter standardised to 2.5. Microstructure Observation
9.1
mm.Table 4 shows the composition of pellets. The samples of the partially reduced pellets were
inspected with the scanning electron microscope (SEM)
2.3. The Experimental Apparatus
Cambridge model 240, having an X-ray detector for
The experimental apparatus Is shown in Fig. 1. It analysis via scattered energy, and beryllium window.
consists of a furnace which is able to
moveup and down Secondary electrons and backscattered electrons images
and an balance (accuracy= l0~6 kg). A stain-
electronic
were used for the observation of microstructures.
less steel tube passes throughout the furnace. In the up-
per part of the tube there is a water jacket. The reaction 3. Results and Discussion
zone stays in the middle. Its length is O.03 m. Temperature
is uniform in this region.
An argon flux is provided into 3.1. The Fe203~Fe304Step
the tube, which is closed at the upper end. A wire of Transgranular cracks have been observed at 1223-
nickelOhrome alloy passes throughout the upper lid. The l 323 K associated to the hematiteH,magnetite transfor-
wire which is hung from the balance supports the pellet.
The lower end is also closed, however a thermocouple 1
(type K) is allowed to be introduced into the tube through
the lower lid.

2.4. The Reduction Experiment

4a
i 4b
A
thermogravimetric technique was adopted for
measuring the reacted fraction F versus time. F is define
as: 2
I 5a

IEElectronic Balance
F=(mo~m F
)/(m
o -m.f***] ) ................(8) 2Resistance Fumace
2R
3 Furnace Support
3F
where m0=initial mass of the pellet, mF=massof the 4a/4b Watef in and out
4al
5a/5b ATgonin and ovt
5al
6Sample
6s(
Table l. Chemical composition of the fines of Cau~ 7T)ermocouple
7T)
ore. 5b
Substance Al203 Si02 P MnOFe (total) IL FeO 7
mass"/o 0.34 113
,
0,01 2 0.066 68.68 O.
19 O.61
Fig. l. The experimental apparatus.

Table 2. Chemical composition of the ashes of charcoal.

Substance MgO Al203 Si02 CaO Ti02 Fe203 K20 Na20 s03 MnO
masso/o lO,1 l 3.57 18.7 28.4 3.45 12.63 l .40 8.72 l .79

Table 3. Chemical composition ofportland cement. Table 4. Pellets composition.

Substance MgO Al203 CaO Fe203 1L SiQ2 Fines lron ore Charcoal Cement

masso/* 5,45 5,60 59,20 3,lO 7,45 19.20 masso/o 70.3 19.7 l0.0

1051 C 1997 ISIJ

 ISIJ International, Vol. 37 (1997), No. 11

mation. Figure 2 shows typical transgranular cracks in
hematite grains. It corresponds to reduction at 1273 K
and F=0.203. Figure 3shows another example of crack
formation in the hematite matrix, in this case, however,
the temperature of reduction w'as 1323 Kand F=0.209.
The formation of transgr'anular cracks may be ex-
plainedl •2.25 33) according to the mechanism:
(i) during hematite reduction it occurs the form'ation
of magnetite lamellae inside the hematite matrix. The
following crystallogr',rphic relations prevail31)'
(1
1l)M//(OOOl)H and [OI I]M//[lOIO]l-1 "--(lO)
(ii) since the transformation Fe203H,Fe304occurs with
volume incrc'ase, and since Pe203 is more brittle than
magnetite, I '34) the lamei]ae of m'agnetite (under compres-
sion) generate a tractive stress field in the hematite matrix,
which Induces a transgranular crack to propagate in a
direction which is normal to the lamellae grow plan, that
is, norma] to the (OOOl) plan of the hematite system.
Although the magnetite lameilae have not been ob-
served via SEM, the transgranular cracks which can
be seen assure that magnetite lamellae have been formed
during the reduction of the pellets.
3.2. The Fe304~"FeO"Step
At 1223 and 1323 K it has been observed that the
hematite->magnetite transformatlon and the magne-
tite~,wustite transformation presented microstructures
which are quite simiiar. This maybe seen by comparing
Fig. 4 (reduction at 1323K, F=0.388) or Fig. 5
(reduction at 1223 K, F=0.357) to Fig. 2 (reduction at
l 273 K, F=0.203). Such a simllarity is probably related
to the lower tensions generated during the magnetitieH,
wustlte transformation, than those generated during the
first stage of reduction. "FeO" has a crystal structure
similar to that of Fe304 and the tensions which are
generated during the second stage of reduction maybe
relleved by plastic deformation of wustite since this Is
the most ductile oxlde of iron.1'3'33'34) Therefore the
morphology of the magnetite~,wustite transformation
appears to be conditioned by the morpho]ogy of the first
stage.33'35)
Besides the transgranular cracks generated during the
first stage of the reduction, it has been observed the
formation of porous "FeO" exhibiting superficial cracks
as shownin Fig. 6
(reduction at 1273 K, F=0.380).
According to the model by Edstrom3s) of the forma-
tion of wustite on magnetite, the model by Bogdandyand
Engell36) of the formation of pores in wustite and the
model by Matthew and Hayes37) on the cracking of
"FeO", the microstructure shown in Fig. suggests: 6
(1) the superficia] microcracks in the wustite grains
were caused by the vicinity of the boundaries gas/"FeO"
and Fe304/"FeO", that is, the pores were submitted to
such a tension that cracks were generated at the vicinity
of the magnetite/wustite interface and have propagated
to the wustitelgas interface. It
seems reasonable to

Fig. 4. Microstructure generated at 1323 K, F=0.388, during

the Fe304H,"FeO"step,
Frg. 2. Pellet reduced at 1273K, F'=0.203_ Transgranular
.

cracks in hematite particles Hematite-~magnetite step.

Fig. 5. Backsc'attered electrons image. Mlcrostructure of a

pellet reduced at 1223K. F=0,357 (Fe304H,"FeO"
step). Particles of iron oxide are white, particles of
charcoal are dark grey and particles of cemcnt are grey,
Frg. 3. Pellet reduced at 1 323 K, F=0.209. Transgranular There a]'e transgranular cracks and intergranular
cracks in hematlte particles. Hematlte magnetite step. cracks gcneraled during the first stage of lhe rcduction.
,

O 1997 ISIJ 1052

 ISIJ International, Vol. 37 (1 997), No. 11

Fig. 6. Microstructure generated at 1273 K, F=0.380, magne-

titeH,wustite step Note porous "FeO" exhibiting
superficial cracks. Fig. 8. Pellet reduced at 1
323 K, F=0.594. Clusters of
whiskers of iron (type A). "FeO"-~Fe step.

Flg 7 Pellet reduced at 1223 K. F=0.566. austers of

whiskers (type A) nucleated and
grown on "FeO". Fig. 9. Pellet reduced at 1323 K, F=0.594. Whiskers of iron
"Feo'*-Fe step. type A. Aparticle ofcharcoal is artached to the highest
whisker. "FeO"H,Fe step.
suppose the possibility of the cracks migrating to the
magnetite/wustite interface. It would produce a network
of microtunnels connecting the interfaces wustitelgas and
magnetite/wustite.
(ii) the formation of cracks on the surface of "FeO"
and perhaps the existence of small pores (approximately
0.5 klm diameter), suggest that the overal] process has not
been controlled by chemical reaction;
(iii) the superficia] microcracks on "FeO" suggest
also that hydrogen couid have a role in the stage of
reduction of magnetlte to wustite, since Matthew and
Hayes37) concluded that cracking of wustite under
COC02 mixtures is unlikely due to the thickening of
the "FeO" Iayer in such a system. The tip of a pore
would be far away from the compressedregions.
Fig. lO. Pellet reduced :It 1423K. F=0.6O5. Mixed morphol-
Under the experimental conditions of the present
ogy of iron. Cone sh'aped whiskers adj'acent to a
work the main phenomenaassociated to the increase of l'egion of porous lron. Type B morphology.
the partial pressure of the gaseous phase (CO or H2)
"FcO"-Fe step.
would be: (1) the release of the volatile matter present
in the charcoal; (2) the release of crystallisation water ing morphologies of iron were observed:
from the cement, which would react with carbon to 1
(A) In the range 223-1 323 clusters of whiskers K
produce H2 and CO; (3) the possibility of interaction nuc]eated and grew on the "FeO" substrate, as shown
between H20and COwhich leads to H2 and C02; the in Figs. 7,
8and 9;
latter COduring the gasification of char-
produces (B) at 14,_3 K
clusters of cone shaped whiskers
coal.1'2,16,38) adjacent to the lrricroregion of porous iron were ob-
served (Fig. lO), that is, an iron ITrixed morphology is
3.3. The "FeO"~FeStep formed.
Under the conditions of the present work the follow- In the range 1223-1 423 K it was not observed dense

1053 .;(:~.
1997 ISIJ
 ISIJ International, Vol. 37 (1997), No. 11
micro-regions of a particular self reducing pellet the
controlling step is the Boudouardreaction. Therefore the
CO-C02mixture has approached the composition
related to the equilibrrum Fe/"FeO" in the Fe-CO
system.
It does not mean, however, that the Boudouard re-
action is the controlling step of the overall process.
Nascimentol) has shownthat heat transfer to the inner
parts of the pellet is the controlling mechanismof the
overall reduction process.
During the "FeO"~,Fe step iron nucleates and grows
under conditions near the iron/wustite equilibrium in the
Fe-C-O system. Whiskers of iron suggest that the
Boudouardreaction is slower than the diffusion of iron
Fig, Il. Pellet reduced at 1273K, F=0.589, Dense layer of cations in the "FeO" structure. It meansthat one may
lron generated during the reduction of pellets bearing accept as correct the mechanismproposed by Nicolle
coal with 50masso/o more volatile matter than the and Rist,39) as the microstructural observations of E1
used charcoal.1) "FeO"~Festep.
Moujahid and Rist49) suggest.
In the range 1223-1 323 K, when the reduction con-
layers of iron. The absence of such a morphology sug- dition is close to the equilibrium "FeO"~Fe, the ac-
gests that volatile matter and/or water of the cement, tivation energy for heterogeneous nucleation of iron
probably, were totally released during the previous steps increased; consequently, a decrease of the nucleation
of reaction. Such hypothesis is reinforced by the results rate occurred.so) Then, only defective sites of
on some
observed by Nascimentol) concerning the "FeO"~,Fe the "FeO" surface occurred the nucleation of whiskers of
step of reduction of pellets bearing coal containing iron shownin Figs. 7-9.
50 masso/o more volatile matter than the charcoal which It has been mentioned21,22,51-56) that CaOhas
a
role the nucleation of iron on the surface of "FeO".
was used in the present work; Figure 11 shows an ex- m
ample of dense layers of iron generated at 1273K, As a matter of fact someauthors claim that Ca cations
F=0.589. promote the nucleation of ironl'4'39'57) whereas others
Therefore, the formation of dense layers of iron dur- state that calcium free micro-regions are prone for
ing the "FeO"~,Fe step strongly suggests that the rate nucleauon of lron on the "FeO" surface Gevaet a/ s8)
of the chemical step of the overall reactlon was higher observed that calcium cations in solid solution in "FeO"
than that of the diffusion of iron cations in the bulk of enhances dense morphology of iron, when pellets are
"FeO"; as can be derived from the Nicolle and Rist reduced with mixtures of COand C02or H2 and H20,
mechanism.39) According to them, if chemical reactlon near the equilibrium. In the present work the main source
at the interface is the controlling mechanism, then the for calcium is the Portland cement. Other source would
typical morphology is whiskers of iron. Whendiffusion be the ashes of the charcoal used. Therefore the Bou-
of iron ions in wustite is the controlling step, then douard reaction could possibly have enhancedthe effect
layers of iron appear. Under mixed control conical of Cacations on the formation of iron whiskers, that is,
filaments are generated. Therefore if the volatile matter whenthe reaction rate is controlled by the Boudouard
and/or the released water from the cement were present, reaction, the CO-C02mixture approaches the equi-
then the rate of the chemical step would be increased; librrum wrth "FeO"-Fe in the Fe-C-Osystem.
howeverthe noted whiskers (for example, Fig. 9) suggest
3.5. The Effect of the BoudouardReaction on the Type
the contrary.
B Morphology
3.4. The Effect of the Boudouard Reaction on the Nascimentol) based on works by Fruehan,46) Turkdo-
Morphology of Type A gan and Vinters,47,48) supposed that above 1373K the
Considering that the volatile matter of the charcoal reduction of "FeO" with CO and the Boudouardreaction
and the combined water of the cement were not present would proceed at such rates that inside the pellets the
in the step "FeO"H,Fe, then it occurred due to two CO-C02mixture would approach the equilibrium of the
gas/solid reactions: the reduction of "FeO" with CO Boudouardreaction in the FeCO
system.
and the Boudouard reactlon.1'16,17)
That is, one may El Moujahiad and Rist49) have shown that the re-
suppose that during the reduction of a self-reducing ductron of "FeO" wrth COCO mixtures at tempera-
pellet solid/solid reaction occurs at a rate muchslower tures higher than 1373 K and under high partlal pres-
than that of the solidlgas reaction. Such a hypothesis is sures of COIeads to a mixed morphology of iron.
based on the literature.21,22,38,40-45) Ra050) points out that highly reducing mixtures of
According to Fruehan46) and Turkdogan and Vin- CO-C02promote the nucleation of iron on the surface
ters47,48) jt
seems reasonab]e to suppose that at tem- of "FeO". At 1423 K
in the bulk of the observed
peratures lower than 1373 K, the Boudouard reaction morphology there was the formation of cone shaped
is muchslower than the reduction reaction of "FeO" whiskers. According to Nicolle and Rist39) this par-
with CO. That is, in these conditions in the inner ticular morphology happenswhenthe chemical step and

O 1997 ISIJ 1054

 ISIJ International. Vol. 37
the diffusion step proceed at similar rates. Therefore 2)
the formation of cone shaped whiskers strongly suggests
that the Boudouardreaction is not the controlling step 3)
of the reduction of wustite with CO. 4)
3.6. Genesis of the Porous Morpbology of lron
5)
There are authors who claim that the porous 6)
morphology of iron comesfrom the rupture of a previ-
(1 997), No, 11
R. C. Nascimento and J. D. T. Capocchi: Symp. Red.
Mat6riasPrimas, ABM,(1994).
R. C. Nascimento, M. B. Mour~o and J. D. T. Capocchi: 50"
Congresso ABM,(1995).
R. C. Nascimento, M. B. Mouraoand J. D. T. Capocchi: Symp.
Red. Mat6rias-Primas, ABM,(1996).
C, D. Brosch: Boletin ABM,(1964), No. 20, 665.
C. Takanoand C. D. Brosch: Metalu,'gia ABM,(1970), No, 146,
45.

ous dense layer of iron.58 67) C. D. Brosch: Patente INPI, (1980), No. 8.001509.
7)
8) P. V. Duran: Metalu,gia ABM,(1984), No. 40, 183,
On the other hand there are those who suggest that 9) F. J. Weiss, A. Goksel and F. T. Kaiser: I,'on Stee! Eng., 63
the porous morphology of iron is caused by the reduction (1986), No. 2, 34.
of "FeO".1'4'49) Dense morphologies which be may lO) N. Samways:I,'on Steel Eng., 63 (1986), No. 7, 53.
L.
seen in the mixed morphology generated at 1423 are K l l) J.

Anais.
B Gunter: Symp.Chileno Reduc. Direta de Minerales, (1982),
clusters ofcone shaped whiskers. Probably there was no
formation of dense layers, and therefore the source of l 2) M. Rodriguez: Rev. Meta!.-Cenin., 20 (1984), No. 2, 127.
J.

the porous morphology was the "FeO". l 3) M, Rodriguez: Rev. Meta/.-Cenin., 21 (1985), No. I, 13.
J.

14) M. B. Mour~o: 48' Congresso ABM,(1993), Anais.

3.7. Direct Reducedlron (DRI) Morphology l 5) M. A. Contrucci: 48' Congresso ABM,(1993), Anais.
16) M. B. Mourao: Ph. D. Thesis, University of S~o Paulo, Brazil,
At K
1223-1 323 and under conditions near the (1988).
equilibrium "FeO"-Fe the morphology of iron is l 7) M. B. Mour~oand J, D. T. Capocchi: Congresso ABM,(1989),
whiskers. At the later stages however, sintering of the Anais.

whiskers occurs leading to the morphology of DRI.

18) M. B. Mour~o: Symp. Red. Mat~rias-Primas, ABM, (1989),
Anais.
Therefore, sponge iron although presenting a porous
l 9) P. G. Q, Netto: M. Sc. Thesis. PUC-RJ,Brazil, (1991).
structure results from a dense morphology of iron. 20) M. B. Mour~o, H. A. Ishii and J. D. T. Capocchi: EPDCong,,
Proc, of Symp., ed. by G. V. Warren, TMS. Warrendale, PA,
4. Conclusion (1994), 1073.
21) C Seaton. J. Foster and J. Velasco: T,'ans. Iron Slee! Inst. Jp,1.,

Between 1223 and 1323 K, during the reduction of 23 (1983), 490.

self-reducing pellets bearing hematite and charcoal, cold 22) C Seaton. J. Foster and J. Velasco: T,'ans. I,'on Stee/ Inst. Jpn.,
23 (1983), 497.
bondedwith Portland cement, transgranular cracks were 23) S. K. Dutta and A. Ghosh: Meta!!. Mate,' T,'ans. B, 25B (1994),
generated at the hematite•~magnetite stage. This maybe
l 5.
explained by the formation of lamellae of magnetite. The 24) J. C. Carv'alho: Can. Meta!!. Q., 33 (1994), No. 3, 217.
morphologies generated during the magnetite-~wustite 25) A. V. Bradshawand A. G. Matyas: Meta!!. T,'ans. B, 7B (1976),
stage are related to the first stage of reduction. The 48 1 .

26) P. C. Hayes and P. Grievesson: Meta!!. Trans. B, 12B (1981),

observation of porous "FeO" having superficial micro-
319.
cracks allows the conclusion that the volatile matter 27) P. C. Hayes and P. Grievesson: Metal!. Trans. B, 12B (1981),
of the charcoal or the crystallisation water of the cement 579.
played an important role in the magnetite~,wustite step 28) A. Unal and A. V. Bradshaw: Melall. Trans. B, 14B (1983), 743.
of reaction. In fact these products are very active during 29) M. Et-Tabirou. B. Dupr~ and C. Gletzer: Meta!!. Trans. B, 19B
the second stage of reduction and since dense layers of (1988), 31 1.

30) J. R. Porter and P. R. Swann: Iron Steehaaking, (1977), No. 5,

iron were not noted during the wustite~,iron stage, when
300.
the reaction wascarried out at 1223-1 423 K, then it may 31) P. R. Swannand N. J, Tighe: Metall. Trans. B, 8B (1977), 479.
be said that volatile matter and water vapour have no 32) M. V, Srinivasan and J. S. Sheasby: Mela!l. T,'ans. B, 12B(198 I),

role during this stage. Therefore the "FeO"~,Fe stage l 77.

33) H. Brill-Edwards. B. L. Daniell and R. L. Samuel: J. Iron Stee!
occurs due to the reduction of wustite with COand hlsl., (1965), 361
due to the Boudouardreaction. At any temperature equal ,

34) J. E. Moore and D. H. Martin: Agglomeration-61, ed, by W.

to or lower than 1323 K it appears that the Boudouard A. Knepper. Interscience Publ., NewYork; London, (1962), 743.
reaction controls the chemical step and, in these reduction 35) J. O. Edstrom: J. I,'on Slee/ Inst., (1953), 289.
conditions, whiskers are generated. Onthe other hand, 36) L. Bogdandyand B. L. Engell: The Reduction of lron Ores,
Springer-Verlag, Berlin; NewYork, (1971).
due to the mixed morphology noted at 1423 K, it may
37) S. P. Matthew and P. C. Hayes: Meta!!. T,'cl,Is. B, 21B (1990), 153.
be said that Boudouard reaction does not control the 38) B. H. Huangand W. K. Lu: ISIJ Int., 33 (1993), No. lO, 1055.
chemical step any more. The porous morphology of the 39) R. Nicolle and A. Rist: Metall. Trans. B, 10B (1979), 429.
metallic phase observed at 1423 K meansthat it comes 40) B. G. Baldwin: J. Iron Stee/ Inst., (1955), Jan., 30.
from the wustite instead of from a dense layer of iron. 41) Y. K. Rao: Chem.Eng. Sci., (1974). No. 29, 1435.
The morphologies observed at the last stage support the 42) M. C. Abrahan and A. Ghosh: Iron Stee!making, 13 (1979), No.
2, 14.
idea that sponge iron (DRI) although porous, is gen- 43) C. Bryk and W. K. Lu: Iron Steelmaking, 13 (1986), No. 2, 70.
erated from a dense morphology of iron (clusters of 44) C. Bryk and W. K. Lu: Can. Metal/. Q., 25 (1987), No, 3, 241.
whiskers). 45) F. Ajersch: Can. Metall. Q., 25 (1987), No. 2, 137.
46) R. J. Fruehan: Metal!. Trans. B, 8B (1977), 279.
47) E. T. Turkdogan and J. V. Vinters: Carbon, (1970), No. 8, 39.
REFERENCES 48) E. T. Turkdogan and J. V. Vinters: Metall, T,'ans., (1972), 3
l) R. C. Nascimento: Ph. D. Thesis, The University of S~o Paulo, l 56 1 .

Brazil, (1994). 49) S. El Moujahid and A. Rist: Meta!1. Trans. B, 19B (1988), 787.

1055 C 1997 ISIJ

 ISIJ International, Vol. 37 (1 997), No. 11
50) Y. K. Rao: Meta!1. Trans, B, lOB (1979), 243. 61) D. H. St. John. S. P. Matthew and P. C. Hayes: Meta!!. T,'cl,Is.

51) R. L. Bleifuss: Trans. Soc. Min. Eng. AIME, 247 (1970), 225. B, 15B (1984), 701.
52) K. W. Lu: Scclnd. J. Metall., (1977), No. 2, 65. 62) D. H. St. John. S. P. Matthew and P. C. Hayes: Metall. T,'ans.
53) K. W. Lu: Scand. J. Metal!., (1973), No. 2, 169. B, 15B (1984), 709.
54) K. W. Lu: Scand. J. Metall., (1974). No. 3, 49. 63) S. P. Matthew. D. H. St. John. J. V. Hardy and P. C. Hayes:

55) K, W. Lu: Scand. J. Meta!l., (1973), No. 2, 272. Metallograplly, (1985), No. 17, 367.
56) H. Fredriksson and J. Svensson: Scand. J. Metall., (1974), No. 64) F. Nakiboglu, D. H. St. John and P. C. Hayes: Meia!!. T,'a,Is.
3, 185. B, 17B (1986), 375.
57) T. El Kasabgyand W. K. Lu: Metal!. T,'ans. B, IIB (1980), 409. 65) M. Farren, S. P. Matthew and P. C. Hayes: Meta!!. T,'a,Is. B,
58) S. Geva. M. Farren. D. H. St. John and P. C. Hayes: Meta!!. 21B (1990), 135.
Trans. B, 21B (1990), 743. 66) S. P. Matthew and P. C. Hayes: Meta!!. Trclns. B. 21B (1990),

59) D H. St. John and P. C. Hayes: Meta!!. T,'ans. B, 13B (1982), 141.

l 17. 67) S. P. Matthew, T. R. Cho and P. C. Hayes: Metall. T,'ans. B,

60) A. M. Watts, D. H. St. John and P. C. Hayes: Metall. T,'ans. B, 21B (1990), 733.
14B (1983), 753.

C 1997 ISIJ 1056