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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)).
The sponge iron reaction (SIR) is a chemical process based on redox cycling of an iron-based contact mass, the first cycle is a conversion step between iron metal (Fe) and wuestite (FeO), the second cycle is a conversion step between wuestite (FeO) and magnetite (Fe 3 O 4). [1]
In the iron and steel industry, direct reduction is a set of processes for obtaining iron from iron ore, by reducing iron oxides without melting the metal. The resulting product is pre-reduced iron ore. Historically, direct reduction was used to obtain a mix of iron and slag called a bloom in a bloomery.
Two main reactions comprise the direct reduction process: Natural gas is partially oxidized (with heat and a catalyst): [108] 2 CH 4 + O 2 → 2 CO + 4 H 2. Iron ore is then treated with these gases in a furnace, producing solid sponge iron: [108] Fe 2 O 3 + CO + 2 H 2 → 2 Fe + CO 2 + 2 H 2 O. Silica is removed by adding a limestone flux as ...
A bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a bloom. The mix of slag and iron in the bloom, termed sponge iron, is usually consolidated and further forged into ...
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.
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.
Reductive elimination is an elementary step in organometallic chemistry in which the oxidation state of the metal center decreases while forming a new covalent bond between two ligands. It is the microscopic reverse of oxidative addition , and is often the product-forming step in many catalytic processes.