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Direct reduced iron (DRI), also called sponge iron, [1] is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) into iron by a reducing gas which contains elemental carbon (produced from natural gas or coal) and/or hydrogen. When hydrogen is used as the reducing gas no carbon dioxide is produced.
Amit Chatterjee, Sponge Iron Production By Direct Reduction Of Iron Oxide, PHI Learning Private Limited, 2010, 353 p. (ISBN 978-81-203-3644-5, read online archive) "Process technology followed for sponge iron" archive, Environment Compliance Assistance Centre (ECAC) "World direct reduction statistics" archive of August 29th, 2005, Midrex, 2001.
Carbon content in the product can be controlled by changing the quantity of coal in the furnace. Noncorroding chromium steel could also be produced by using impure ore instead of hematite. Likewise, spongy iron can be cast by using coal-lime briquettes. Additionally, the Flodin furnace also can be used to produce so-called 'soft steel'. [1] [2 ...
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]
The red line shows the cooling curve for austempering. Austempering is heat treatment that is applied to ferrous metals , most notably steel and ductile iron. In steel it produces a bainite microstructure whereas in cast irons it produces a structure of acicular ferrite and high carbon, stabilized austenite known as ausferrite .
Sponge iron and iron scrap is melted in electric arc furnaces, after which liquid steel is purified in secondary purification units. The steel's chemical compound is designed by customer demand. Then, it is transported to casting machines for slab production. After cooling, slab is rolled at the hot rolling mill, creating hot coils (thickness ...
Ausforming, also known as low and high temperature thermomechanical treatments, is a method used to increase the hardness and toughness of an alloy by simultaneously tempering, rapid cooling, deforming and quenching to change its shape and refine the microstructure. [1] This treatment is an important part in the processing of steel. [2]
The steel must be heated to a temperature where the iron phase changes from ferrite into austenite, i.e. changes crystal structure from BCC (body-centered cubic) to FCC (face-centered cubic). In austenitic form, steel can dissolve a lot more carbon. Once the carbon has been dissolved, the material is then quenched.
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