Two-Stage Reduction of Iron Scale with Intermediate Magnetic Separation for High-Purity Iron Powder Production
Zholdubayeva Z. Arystanova D. Sidorina Y. Chalaya O. Mazhitova L.
2025SciCell s.r.o.
Acta Metallurgica Slovaca
2025#31Issue 3163 - 166 pp.
A two-stage process is proposed for reducing iron-containing mill scale waste, involving an initial carbon-based reduction step, followed by hydrogen reduction, with magnetic separation in between. The purpose is to produce high-purity iron powder while optimizing hydrogen usage. The carbon stage, using powdered charcoal as a reducing agent, reduces most of the iron oxides economically at 900°C for 60 minutes. Intermediate magnetic separation, conducted using a permanent magnet to attract the iron-rich phase, removes non-magnetic impurities (e.g., silicon, calcium, tungsten oxides). The final hydrogen stage, carried out at 900°C for 60 minutes under flowing hydrogen gas, achieves nearly 100% iron purity as confirmed by EDS analysis. This process reduces hydrogen consumption and promotes the sustainable recycling of metallurgical waste for high-quality iron powder applications.
Carbon reduction , Hydrogen reduction , Iron powder , Iron scale , Magnetic separation , Metallurgical waste recycling
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Karaganda Technical University named after Abilkas Saginov, Department of Nanotechnology and Metallurgy, Nursultan Nazarbayev Avenue No. 56, Karaganda, 100003, Kazakhstan
Karaganda Industrial University, 30 Republic Avenue, Karaganda Region, Temirtau, 101400, Kazakhstan
S. Seifullin Kazakh Agrotechnical Research University, 62 Zhenis Avenue, Astana, 010011, Kazakhstan
Karaganda Technical University named after Abilkas Saginov
Karaganda Industrial University
S. Seifullin Kazakh Agrotechnical Research University
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