Coal-Based Direct Reduction for Dephosphorization of High-Phosphorus Iron Ore: A Critical Review

Conventional separation methods often prove ineffective for complex, refractory high-phosphorus iron ores. Recent advances propose a coal-based direct reduction dephosphorization-magnetic separation process, achieving significant dephosphorization efficiency. This review systematically analyzes phosphorus occurrence states in high-phosphorus oolitic iron ores across global deposits, particularly within iron minerals. We categorize contemporary research and elucidate dephosphorization mechanisms during coal-based direct reduction. Key factors influencing iron mineral phase transformation, iron enrichment, and phosphorus removal are comprehensively evaluated. Phosphorus primarily exists as apatite and collophane gangue m horization agents function by: (1) inhibiting phosphorus-bearing mineral reactions or binding phosphorus into soluble salts to prevent incorporation into metallic iron; (2) enhancing iron oxide reduction and coal gasification; (3) disrupting oolitic structures, promoting metallic iron particle growth, and improving the intergrowth relationship between metallic iron and gangue. Iron mineral phase transformations follow the sequence: Fe2O3 → Fe3O4 → FeO (FeAl2O4, Fe2SiO4) → Fe. Critical parameters for effective dephosphorization under non-reductive phosphorus conditions include reduction temperature, duration, reductant/dephosphorization agent types/dosages. Future research should focus on: (1) investigating phosphorus forms in iron minerals for targeted ore utilization; (2) reducing dephosphorization agent consumption and developing sustainable alternatives; (3) refining models for metallic iron growth and improving energy efficiency; (4) optimizing reduction atmosphere control; (5) implementing low-carbon emission strategies.