This study investigates the non-isothermal reduction of iron ore fines with two different carbon-bearing materials using the thermogravimetric technique. The iron ore fines/carbon composites were heated from room temperature up to 1100 °C with different heating rates (5, 10, 15, and 20 °C/min) under an argon atmosphere. The effect of heating rates and carbon sources on the reduction rate was intensively investigated. Reflected light and scanning electron microscopes were used to examine the morphological structure of the reduced composite. The results showed that the heating rates affected the reduction extent and the reduction rate. Under the same heating rate, the rates of reduction were relatively higher by using charcoal than coal. The reduction behavior of iron ore-coal was proceeded step wisely as follows: Fe₂O₃ → Fe₃O₄ → FeO → Fe. The reduction of iron ore/charcoal was proceeded from Fe₂O₃ to FeO and finally from FeO to metallic iron. The reduction kinetics was deduced by applying two different methods (model-free and model-fitting). The calculated activation energies of Fe₂O₃/charcoal and of Fe₂O₃/coal are 40.50–190.12 kJ/mol and 55.02–220.12 kJ/mol, respectively. These indicated that the reduction is controlled by gas diffusion at the initial stages and by nucleation reaction at the final stages.

The isothermal reduction of iron oxide pellet fines–carbon composites was investigated at temperatures of 900–1100 °C. The reduction reactions were monitored using the thermogravimetric (TG) technique. Alternatively, a Quadruple Mass Spectrometer (QMS) analyzed the CO and CO₂ gases evolved from the reduction reactions. The effect of temperature, carbon source, and reaction time on the rate of reduction was extensively studied. The phase composition and the morphological structure of the reduced composites were identified by X-ray diffraction (XRD) and a scanning electron microscope (SEM). The results showed that the reduction rate was affected by the temperature and source of carbon. For all composite compacts, the reduction rate, as well as the conversion degree (α) increased with increasing temperature. Under the same temperature, the conversion degree and the reduction rate of composites were greater according to using the following carbon sources order: Activated charcoal > charcoal > coal. The reduction of the different composites was shown to occur stepwise from hematite to metallic iron. The reduction, either by activated charcoal or charcoal, is characterized by two behaviors. During the initial stage, the chemical reaction model (1 − α)⁻² controls the reduction process whereas the final stage is controlled by gas diffusion [1 − (1 − α)^1/2]². In the case of reduction with coal, the reduction mechanism is regulated by the Avrami–Erofeev model [−ln (1−α)²] at the initial stage. The rate-controlling mechanism is the 3-D diffusion model (Z-L-T), namely [(1−α)^−1/3−1]² at the latter stage. The results indicated that using biomass carbon sources is favorable to replace fossil-origin carbon-bearing materials for the reduction of iron oxide pellet fines.