Dissolution Rates of Coals and Graphite in Fe-C-S Melts in Direct Ironmaking: Influence of Melt Carbon and Sulfur on Carbon Dissolution

Carbon dissolution from graphite and coals was investigated by using a carburizer cover technique in an induction furnace. The intent of the study was to investigate the influence of factors governing the rate of carbon dissolution from carbonaceous materials, especially coals, into Fe-C-S melts. The factors studied were the initial melt carbon and sulfur concentrations and the wettability between carbonaceous materials and the melt. It was found that graphite dissolves markedly faster than coal. The rate of carbon dissolution from graphite could be decreased by increasing the sulfur in the melt. Also, poor wetting could retard the rate of carbon dissolution by reducing the surface area for mass transfer. Carbon dissolution from graphite is controlled by mass transfer in the liquid boundary layer adjacent to the solid/liquid interface. The rate of carbon dissolution from coal is more sensitive to the molten iron composition. A higher initial melt carbon and sulfur content retards the rate of carbon dissolution from coal more significantly than from graphite. However, the rate constant of coal char dissolution does not show a strong dependence on the wettability. Carbon dissolution from coals is most likely governed by a mixed-control mechanism that includes liquidside mass transfer. The mechanisms underlying the influence of bath sulfur on carbon dissolution from graphite and coals are discussed.