Production of low phosphorus direct reduced iron from high phosp 2027 Minera

High-phosphorus oolitic hematite remains difficult to utilize efficiently because most direct reduction-magnetic separation processes rely on dephosphorization agents, which increase reagent consumption and process complexity. In this study, Huoshaoping high-phosphorus oolitic hematite was processed by direct reduction-magnetic separation without dephosphorization agents. Thermodynamic analysis and characterization of reduction atmosphere, phase transformation, iron-phosphorus distribution, microstructure, and magnetic properties were used to clarify the separation mechanism and ore-specific applicability. Under suitable conditions of 1200 °C, 70 min, and 10 wt.% anthracite, direct reduced iron with 93.07 wt.% TFe, 91.60% Fe recovery, and 0.087 wt.% P was obtained. The results show that favorable P occurrence, inherent Ca-bearing components, and spatial separation between metallic iron and P-bearing non-magnetic phases are essential. For high-phosphorus oolitic hematite with suitable mineralogical characteristics, this route can simplify the process and reduce reagent use, but its applicability still depends strongly on ore properties.