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The formation mechanism of deposits in commercial gas-fired magnetization-reduction roasting rotary kiln was studied. The deposits ring adhered on the kiln wall based on the bonding of low melting point eutectic liquid phase, and the deposit adhered on the air duct head by impact deposition. The chemical composition and microstructure of the deposits sampled at different locations varied slightly. Besides a small amount of quartz and limonite, main phases in the deposits are fayalite, glass phase and magnetite. The formation of the deposits can be attributed to the derivation of low melting point eutectic of fine limonite and coal ash, and the solid state reaction between them. Coal ash, originated from the reduction coal, combining together with fine limonite particles, results in the accumulation of deposits on the kiln wall and air duct. Fayalite, the binder phase, was a key factor for deposit formation. The residual carbon in limonite may cause an over-reduction of limonite and produce FeO. Amid the roasting process, SiO2, originated from limonite and coal ash, may combine with FeO and reduce the liquefaction temperature, therewith liquid phase generates at high temperature zone, which can significantly promote the growth of deposits.

Deposits in Gas-fired Rotary Kiln for Limonite Magnetization-Reduction Roasting: Characteristics and Formation Mechanism