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Direct-reduced iron has about the same iron content as pig iron, 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 mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel.
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.
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.
Using a specially constructed electric arc furnace, a mixture of hematite with +0.2% carbon content and coal (or charcoal) is smelted in a continuous process, with the reduced metal accumulating at the bottom of the furnace, where it can be tapped off. Carbon content in the product can be controlled by changing the quantity of coal in the furnace.
Iron ore pellets produced by LKAB, from ore mined in northern Sweden. Pellets are a processed form of iron ore utilized in the steel industry, specifically designed for direct application in blast furnaces or direct reduction plants. These pellets are spherical in shape, with diameters ranging from 8 to 18 millimeters.
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