A kinetic comparison between in situ hybrid microwave and conventional magnetising roasting of low-grade iron ore composite pellet

This article aims to comprehensively summarise the essential aspects of reduction kinetics in magnetising roasting of low-grade iron ore–coal composite pellets in the hybrid microwave and conventional furnace. The influence of crucial process parameters like temperature, time, and heating methods, including traditional and hybrid microwave heating, is explored. Investigating the impact of low-grade iron ore and coal quality on reduction kinetics is conducted to identify optimal heating methods for upgrading low-grade iron ore to blast furnace grade through magnetising roasting. The study uses diverse gas–solid reaction models to assess the reduction mechanism (Fe₂O₃ to Fe₃O₄). Results indicate the success of the contracting volume model for microwave heating, while conventional heating transitions from phase-boundary chemical control to diffusion control. XRD confirms magnetite dominance post-reduction, while scanning electron microscopy analysis establishes microwave crack-assisted efficiency over conventional heating for ease of reduction. A comparative study of apparent activation energy reveals the hybrid microwave method's four-fold lower (36.71 kJ/mol) than conventional resistance heating (156.19 kJ/mol). This underscores the potential of microwave heating for enhanced reduction kinetics and low-grade iron ore material processing applications.