Electrolytic Reduction of Iron Oxides in Molten Salt with a Mineralogical Investigation of Magnetite Ore of Tapuli

Abstract: This master's thesis covers an investigation of the reduction behavior of different iron oxides when electrolytically reduced with molten salt electrolysis (MSE). The tested iron oxides were wüstite (FeO), hematite (Fe2O3), magnetite (Fe3O4) and magnetite ore concentrate from the Tapuli deposit in Pajala, Norrbotten, Sweden. The properties of the Tapuli magnetite ore and magnetite ore concentrate were analysed from a mineralogical perspective to evaluate how the raw ore material influences the concentrate and its reduction by the MSE technology. The electrolytic experiments were performed in an Inconel 625 cell body within a pit-furnace. The different iron oxides were tested separately. The reduction samples were constructed of one or three iron oxide briquettes of 20 g each within a molybdenum mesh attached on a molybdenum tray with molybdenum wires. The molten electrolyte was kept at 500°C with an applied voltage of 1.7 or 2.1 V. The used electrolyte was sodium hydroxide (NaOH). The mineralogical examination shows that the Tapuli ore varies in composition between different locations of the deposit with respect to magnetite grain size and skarn composition and grain size. Point analyses with Laser Ablation Single Collector Inductively Coupled Plasma Mass Spectrometry (LA-SC-ICP-MS) on magnetite grains in thin sections from five drill cores fromdifferent parts of the deposit show that the element composition in the magnetite grains vary between the samples. Core-to-rim analyses for Fe, Mg, Mn and Al reveal relatively homogenous grades throughout the grains, with a few exceptions. Phase analysis with XRD shows that reduction has occurred in all tested iron oxides. Without prevention, the reduction products from trials on Fe2O3, Fe3O4 and magnetite ore concentrate show distinct XRD peaks of the by-product NaFeO2. According to XRD, the addition of Na2O seems to have reduced the NaFeO2 formation. Interestingly, no NaFeO2 was formed in the FeO trials. This might be explained by the absence of Fe3+ in FeO. The variation of the current-time curves of the trials is interpreted to depend on the voltage applied, the number of briquettes, briquette decomposition and Na2O addition. Electrolysis in molten NaOH can be used to reduce iron oxides. Despite this, NaOH might not be a suitable electrolyte for this process due to its interaction with Fe2O3 and Fe3O4 resulting information of NaFeO2. Na2O can be used as an additive to prevent formation of NaFeO2 but sharply decreases the current response, thus having an apparent negative effect on the process efficiency. Another preventive measure that can be tested is to calibrate the process voltage to decompose the NaFeO2 but not NaOH. Due to the shown interaction tendency of NaOH, other electrolytes should however be considered for this process. Regarding the Tapuli ore concentrate, more tests are needed to draw conclusions about how the trace elements effects its electrolytic behavior.