Patent ID: 8287619

Claim:
A process for refining iron from high-phosphorus content iron ores comprising the steps of: mixing a high-phosphorus iron oxide ore and an alkaline solution of pH between about 12.5 and 13.5, wherein a mixture of an alkaline-high-phosphorus solution and a low-phosphorus iron ore solid are obtained; screening the mixture by gravity to separate the alkaline-high-phosphorus solution from the low-phosphorus iron ore; diluting the alkaline-high-phosphorus solution to a pH of between about 11.5 and 12.5, wherein the diluting step comprises the steps of: adding water to the alkaline-high-phosphorus solution to form a diluted alkaline-high-phosphorus solution; filtering the diluted alkaline-high-phosphorus solution to separate a precipitated high-phosphorus solid from the diluted alkaline-high-phosphorus solution to form a first diluted alkaline solution; evaporating the first diluted alkaline solution, wherein the evaporation concentrates the first diluted alkaline solution to form a concentrated first diluted alkaline solution; adding fresh alkaline to the concentrated first diluted alkaline solution to form a second alkaline solution of pH of between about 12.5 and 13.5 is reached; and, recycling the second alkaline solution of pH between about 12.5 and 13.5 in the mixing step; and, treating the low-phosphorus iron ore with a natural gas.