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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 2,190 °F) in the presence of the reducing gas syngas, a mixture of hydrogen and carbon monoxide, or pure hydrogen. [2] Production of direct-reduced iron and breakdown by process
Reducing agents can be ranked by increasing strength by ranking their reduction potentials. Reducers donate electrons to (that is, "reduce") oxidizing agents, which are said to "be reduced by" the reducer. The reducing agent is stronger when it has a more negative reduction potential and weaker when it has a more positive reduction potential.
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.
Scrap steel can be recycled in an electric arc furnace; and an alternative to making iron by smelting is direct reduced iron, where any carbonaceous fuel can be used to make sponge or pelletised iron. To lessen carbon dioxide emissions hydrogen can be used as the reducing agent [27] and biomass or waste as the source of carbon. [28]
Self-Reducing Pellets: Self-reducing pellets are composed of iron ore and coal, which serve as an internal reducing agent during smelting. This design allows the pellets to undergo reduction without the need for additional reducing materials, enhancing efficiency in certain metallurgical processes. [6]
Iron ore was also used as a flux in the smelting of copper. These agents served various functions, the simplest being a reducing agent, which prevented oxides from forming on the surface of the molten metal, while others absorbed impurities into slag, which could be scraped off molten metal. [4]
Smelting is a process of applying heat and a chemical reducing agent to an ore to extract a desired base metal product. [1] It is a form of extractive metallurgy that is used to obtain many metals such as iron, copper, silver, tin, lead and zinc.
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.