93:
1452:
133:. DRI plants need not be part of an integrated steel plant, as is characteristic of blast furnaces. The initial capital investment and operating costs of direct reduction plants are lower than integrated steel plants and are more suitable for developing countries where supplies of high grade coking coal are limited, but where steel scrap is generally available for recycling. Many other countries use variants of the process.
31:
80:
Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting point of iron. Reduced iron derives its name from these processes, one example being heating iron ore in a furnace at a high temperature of 800 to 1,200 °C (1,470 to
925:
the iron together. This treatment usually creates wrought iron with about three percent slag and a fraction of a percent of other impurities. Further treatment may add controlled amounts of carbon, allowing various kinds of heat treatment (e.g. "steeling").
160:
The direct reduction process can use natural gas contaminated with inert gases, avoiding the need to remove these gases for other use. However, any inert gas contamination of the reducing gas lowers the effect (quality) of that gas stream and the
251:
The advantage of the bloomery technique is that iron can be obtained at a lower furnace temperature, only about 1,100 °C or so. The disadvantage, relative to a blast furnace, is that only small quantities can be made at a time.
109:
contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.) in order to convert the ore to metallic iron, without melting it (below 1,200 °C (2,190 °F)).
431:
548:
893:
638:
1172:"Comparison of the efficacy of wheat-based snacks fortified with ferrous sulfate, electrolytic iron, or hydrogen-reduced elemental iron: Randomized, double-blind, controlled trial in Thai women"
806:
734:
1076:
953:. This elemental form is not absorbed as well as ferrous forms, but the oxygen-scavenging function keeps it attractive. Purity standards for this use are established in 1977.
1294:
929:
Today, sponge iron is created by reducing iron ore without melting it. This makes for an energy-efficient feedstock for specialty steel manufacturers which used to rely upon
92:
172:, avoiding transport costs for the gas. In most cases, the DRI plant is located near a natural gas source as it is more cost effective to ship the ore rather than the gas.
1170:
Zimmermann, Michael B.; Winichagoon, Pattanee; Gowachirapant, Sueppong; Hess, Sonja Y.; Harrington, Mary; Chavasit, Visith; Lynch, Sean R.; Hurrell, Richard F. (2005).
157:
The direct reduction process uses pelletized iron ore or natural "lump" ore. One exception is the fluidized bed process which requires sized iron ore particles.
105:
Direct reduction processes can be divided roughly into two categories: gas-based and coal-based. In both cases, the objective of the process is to remove the
1800:
154:
Hot direct reduced iron (HDRI) is DRI that is transported hot, directly from the reduction furnace, into an electric arc furnace, thereby saving energy.
1007:
1287:
917:
or steel. The sponge is removed from the furnace, called a bloomery, and repeatedly beaten with heavy hammers and folded over to remove the slag,
117:
made using DRI requires significantly less fuel, in that a traditional blast furnace is not needed. DRI is most commonly made into steel using
1058:
1762:
1111:
222:(if made from scrap, not from new iron from direct reduced iron with natural gas), which needs to be removed in the steel-making process.
144:, typically 90–94% total iron (depending on the quality of the raw ore) so it is an excellent feedstock for the electric furnaces used by
1280:
293:
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1780:
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1821:
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554:
77:. When hydrogen is used as the reducing gas no carbon dioxide is produced. Many ores are suitable for direct reduction.
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if left unprotected, and is normally quickly processed further to steel. The bulk iron can also catch fire (it is
1795:
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148:, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel.
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Hot-briquetted iron (HBI) is a compacted form of DRI designed for ease of shipping, handling, and storage.
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1416:
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50:
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1077:"Direct Reduced Iron (DRI) - Cargo Handbook - the world's largest cargo transport guidelines website"
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Numerical investigation of nonisothermal reduction of hematite using Syngas: the shaft scale study
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Producing sponge iron and then working it was the earliest method used to obtain iron in the
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Direct reduction processes were developed to overcome the difficulties of conventional
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Supplies of powdered ore and raw natural gas are both available in areas such as
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Theoretical
Minimum Energies to Produce Steel (for Selected Conditions)
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of the process. The use of natural gas also produces greenhouse gases.
245:
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106:
82:
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Sponge iron is not useful by itself, but can be processed to create
1211:
Shah, Bhagwan G.; Giroux, Alexandre; Belonje, Bartholomeus (1977).
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902:
241:
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The increasing role of direct reduced iron in global steelmaking
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The direct reduction process is comparatively energy efficient.
70:
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1032:
426:{\displaystyle {\ce {3 Fe2O3 + CO/H2 -> 2 Fe3O4 + CO2/H2O}}}
1257:", Modelling Simul. Mater. Sci. Eng. 15(5), p. 487, 2007.
1035:. International Iron Metallics Association. 14 November 2019.
248:, where it remained in use until at least the 16th century.
187:
to produce DRI and eliminate production of greenhouse gases.
1008:"What is direct reduced iron (DRI)? definition and meaning"
543:{\displaystyle {\ce {Fe3O4 + CO/H2 -> 3 FeO + CO2/H2O}}}
121:
to take advantage of the heat produced by the DRI product.
96:
Production of direct-reduced iron and breakdown by process
905:
is the world’s largest producer of direct-reduced iron.
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57:(in the form of lumps, pellets, or fines) into iron by a
941:
Hydrogen-reduced iron is used as a source of food-grade
1264:", The Australasian Institute of Mining and Metallurgy.
140:
Direct-reduced iron has about the same iron content as
27:
Iron metal made from ore without use of a blast furnace
888:{\displaystyle {\ce {3 Fe + CO +H2 -> Fe3C + H2O}}}
633:{\displaystyle {\ce {FeO + CO/H2 -> Fe + CO2/H2O}}}
815:
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1213:"Specifications for reduced iron as a food additive"
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1401:
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801:{\displaystyle {\ce {3 Fe + 2CO -> Fe3C + CO2}}}
729:{\displaystyle {\ce {3 Fe + CH4 -> Fe3C + 2H2}}}
81:2,190 °F) in the presence of the reducing gas
887:
800:
728:
632:
542:
425:
215:, which is almost pure metal, DRI contains some
1103:Handbook of explosion prevention and protection
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260:The following reactions successively convert
196:Direct reduced iron is highly susceptible to
8:
1582:
1471:
1343:
1295:
1281:
1273:
1217:Journal of Agricultural and Food Chemistry
1176:The American Journal of Clinical Nutrition
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1100:Hattwig, Martin; Steen, Henrikus (2004),
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1146:"2023 World Direct Reduction Statistics"
1010:. Businessdictionary.com. Archived from
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999:
136:Factors that help make DRI economical:
7:
25:
1059:"Steel making today and tomorrow"
1450:
1260:Grobler, F. and Minnitt, R.C.A "
1106:, Wiley-VCH, pp. 269–270,
1253:Valipour MS, and Saboohi, Y, "
1045:R. J. Fruehan, et al. (2000).
846:
762:
686:
586:
492:
352:
49:, is produced from the direct
1:
1320:History of ferrous metallurgy
1563:Argon oxygen decarburization
183:gas can be used in place of
85:, a mixture of hydrogen and
1724:Differential heat treatment
1151:. Midrex Technologies. 2023
1118:(dead link 24 October 2019)
1033:"Direct reduced iron (DRI)"
921:any carbon or carbide, and
1853:
229:
179:in iron and steel making,
1699:
1648:Ferritic nitrocarburizing
1448:
1315:
276:, and ferrous oxide into
177:eliminate fossil fuel use
61:which contains elemental
1739:Post weld heat treatment
1837:Metallurgical processes
1325:List of steel producers
1553:Electro-slag remelting
1189:10.1093/ajcn/82.6.1276
889:
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730:
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427:
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1822:Hydrogen technologies
1763:Production by country
1081:www.cargohandbook.com
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428:
119:electric arc furnaces
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33:
18:Direct reduction iron
1749:Superplastic forming
1668:Quench polish quench
1558:Vacuum arc remelting
1537:Basic oxygen process
1532:Electric arc furnace
1065:on 20 December 2020.
813:
741:
659:
555:
438:
294:
1704:Cryogenic treatment
1527:Open hearth furnace
1515:Primary (Post-1850)
1506:Cementation process
1393:Direct reduced iron
1229:10.1021/jf60211a044
880:
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351:
327:
314:
89:, or pure hydrogen.
39:Direct reduced iron
34:Hot-briquetted iron
1475:Primary (Pre-1850)
963:Krupp-Renn Process
947:food fortification
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280:by reduction with
181:renewable hydrogen
170:Northern Australia
163:thermal efficiency
98:
36:
1809:
1808:
1757:
1756:
1571:
1570:
1446:
1445:
1437:Induction furnace
1113:978-3-527-30718-0
951:oxygen scavenging
883:
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16:(Redirected from
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1522:Bessemer process
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1182:(6): 1276–1282.
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1125:
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1061:. Archived from
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983:Direct reduction
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65:(produced from
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968:Blast furnace
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1691:Martempering
1686:Austempering
1595:Low hydrogen
1413:Finery forge
1409:Wrought iron
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1248:Bibliography
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1153:. Retrieved
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1084:. Retrieved
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1063:the original
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1016:. Retrieved
1012:the original
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915:wrought iron
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59:reducing gas
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1734:Forming gas
1638:Carburizing
1495:Wootz steel
1461:Steelmaking
1360:sponge iron
1155:4 September
943:iron powder
931:scrap metal
643:Carburizing
238:Middle East
67:natural gas
47:sponge iron
1816:Categories
1791:Luxembourg
1771:Bangladesh
1713:Deflashing
1623:Ausforming
1466:Steel mill
1376:Cold blast
1368:(produces
1358:(produces
1310:production
1086:2022-06-18
1018:2011-07-11
989:References
978:Steel mill
208:). Unlike
206:pyrophoric
146:mini mills
1744:Quenching
1718:Hardening
1708:Deburring
1678:Tempering
1658:Nitriding
1653:Induction
1643:Cryogenic
1610:Hardening
1587:Annealing
1546:Secondary
1429:Cast iron
1402:Secondary
1381:Hot blast
1338:Ironworks
847:⟶
763:⟶
687:⟶
647:cementite
645:produces
587:⟶
493:⟶
353:⟶
270:magnetite
256:Chemistry
217:siliceous
198:oxidation
73:) and/or
51:reduction
1628:Boriding
1420:Puddling
1370:pig iron
1356:Bloomery
1348:Smelting
1198:16332661
1129:"MIDREX"
973:Pig iron
957:See also
949:and for
286:hydrogen
266:iron ore
262:hematite
232:Bloomery
213:pig iron
192:Problems
142:pig iron
125:Benefits
75:hydrogen
55:iron ore
1796:Nigeria
1579:methods
1423:Furnace
919:oxidize
898:Economy
268:) into
226:History
202:rusting
101:Process
1237:858856
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1196:
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945:, for
264:(from
246:Europe
244:, and
220:gangue
185:syngas
107:oxygen
83:syngas
63:carbon
1786:Italy
1781:India
1776:China
1431:(via
1411:(via
1308:steel
1149:(PDF)
1132:(PDF)
994:Notes
903:India
242:Egypt
115:Steel
1832:Iron
1415:or
1306:and
1304:Iron
1233:PMID
1194:PMID
1157:2024
1108:ISBN
937:Food
923:weld
909:Uses
653:C):
278:iron
200:and
71:coal
1435:or
1225:doi
1184:doi
649:(Fe
560:FeO
500:FeO
284:or
175:To
69:or
53:of
43:DRI
1818::
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851:Fe
828:CO
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767:Fe
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691:Fe
675:CH
668:Fe
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329:+
321:3
317:O
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41:(
20:)
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