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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.
The reduced iron agglomerates into 3 to 8 mm metal nodules called Luppen. If the infusibility of the gangue is high, the temperature must be increased, up to 1,400 °C for a basic charge. [22] It is crucial to control the gangue's hot viscosity. [9] Among rotary drum direct reduction processes, it stands out for using high temperatures.
Direct-reduced iron can be produced from iron ore as it reacts with atomic hydrogen. Renewable hydrogen allows steelmaking without fossil fuels. Direct reduction occurs at 1,500 °F (820 °C). The iron is infused with carbon (from coal) in an electric arc furnace. Hydrogen electrolysis requires approximately 2600 kWh per ton of steel. Hydrogen ...
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.
The Corex Process is a smelting reduction process created by Primetals Technologies as a more environmentally friendly alternative to the blast furnace. [1] Presently, the majority of steel production is through the blast furnace which has to rely on coking coal [2] and requires a sinter plant in order to prepare the iron ore for reduction. [3]
Pig iron, also known as crude iron, is an intermediate good used by the iron industry in the production of steel. It is developed by smelting iron ore in a blast furnace . Pig iron has a high carbon content, typically 3.8–4.7%, [ 1 ] along with silica and other dross , which makes it brittle and not useful directly as a material except for ...