Reduction of Phosphate Ores by Carbon: Part I. Process Variables for Design of Rotary Kiln System

TLDR: In this paper, the feasibility of the reduction of phosphate ores in a rotary kiln, avoiding electric submerged arc furnace technology, was established, which represents a totally new approach to phosphoric acid.

Abstract: Feasibility is established for the reduction of phosphate ores in a rotary kiln, avoiding electric submerged arc furnace technology. This represents a totally new approach to phosphoric acid. Reduction rates of phosphate ore-silica mixtures by carbon in the temperature range of 1100 to 1500 °C under several CO partial pressures in nitrogen were measured in thermogravimetric analyzers. Parameters such as carbon and silica contents, particle and pellet sizes, and gas flow rate were also evaluated with various domestic and foreign phosphate ores. Furthermore, a variety of carbon sources such as subbituminous coals, bituminous coals, anthracite, petroleum coke, and metallurgical coke were tested as reducing agents. Thermodynamic considerations elucidate the temperature dependence of overall conversion as well as the role of excess silica in establishing equilibrium pressure. These findings provide the background for analysis of the kinetics of conversion in Part II of this work. These studies, in conjunction with a previously published work, indicate the importance of intergranular melt phases in the kinetics of otherwise solid state reactions.