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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 oxygen 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)).
Plants for the production of pre-reduced iron ore are known as direct reduction plants. The principle involves exposing iron ore to the reducing action of a high-temperature gas (around 1000 °C). This gas is composed of carbon monoxide and dihydrogen, the proportions of which depend on the production process.
Direct reduction is the fraction of iron oxide reduction that occurs in a blast furnace due to the presence of coke carbon, while the remainder - indirect reduction - consists mainly of carbon monoxide from coke combustion. It should also be noted that many non-ferrous oxides are reduced by this type of reaction in a blast furnace.
The HIsarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron ().The process combines two process units, the Cyclone Converter Furnace (CCF) for ore melting and pre-reduction and a Smelting Reduction Vessel (SRV) where the final reduction stage to liquid iron takes place.
Direct reduction methods such as this one offer the flexibility of using any solid fuel and in this case, 240 to 300 kg of hard coal is needed to process one metric ton of iron ore that contains 30 to 40% iron. Assuming a consumption of 300 kg/ton of ore at 30%, the hard coal consumption is 800 kg per ton of iron.
Roasting heats the ore in the presence of oxygen from air, oxidizing the ore and liberating the sulfur as sulfur dioxide gas. Smelting most prominently takes place in a blast furnace to produce pig iron, which is converted into steel. Plants for the electrolytic reduction of aluminium are referred to as aluminium smelters.
The electrolysis reaction will produce molten pure iron as a main product and oxygen as its by-product. Because this process does not add coke in the process, no CO 2 gas is produced. So no direct greenhouse gas emission. Moreover, if the electricity to run such cells comes from renewable sources, this process may have zero emissions.
For example, iron will transfer two of its electrons to oxygen, forming an oxide. This occurs all throughout as an unintended part of the steelmaking process. Oxygen blowing is a method of steelmaking where oxygen is blown through pig iron to lower the carbon content.