The technology used to process titanomagnetite is currently limited to the rotary kiln-electric furnace. Other techniques are being developed, including the separation of iron in the form of iron nugget from the reduction of titanomagnetite with coal without any flux addition. The effect of different temperature patterns on the formation of iron nuggets from titanomagnetite was studied. The initial temperature was varied from 700 to 1380 °C, while the final temperature was kept constant at 1380 °C. The experiment results showed that the initial temperature affected the formation of iron nuggets. Initial temperatures of 700–1100 °C produced many iron nuggets up to 3 mm in size and an initial temperature of 1200 °C produced one nugget with a size of about 4 mm. Initial temperatures of 1300 and 1380 °C did not produce any iron nuggets due to the formation of metallic iron crust on the surface of the reduced briquettes. The optimum initial temperature was 1000 °C to achieve high iron recovery in the nuggets.

Recently, the titanomagnetite by coal producing iron nugget under isothermal – temperature gradient profile is introduced. The reduction process is divided into three stages where in the first stage the initial temperature is kept constant for a certain of time and then the temperature is increased to 1380°C with a certain heating rate in the second stage and finally in the third stage the temperature is maintained at 1380°C for a certain time. The results of the experiments show that the initial temperature in the first stage affects the formation of iron nuggets. Initial temperatures of 700 to 1100°C produce many nuggets up to 3 mm in size, initial temperature of 1200°C produces one nugget with a size of about 4 mm and the initial temperatures of 1300 and 1380°C do not produce nuggets. Optimal iron recovery is achieved at an initial temperature of 1000°C. The slag contains titanium oxide, armalcolite and rest of metallic iron with a size of less than 0.5 mm. The nugget formation is believed due to the aggregation and agglomeration of iron particle during the increasing temperature from initial stage to 1380°C.