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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 coking plant that feeds a battery of blast furnaces is just as expensive as the blast furnace and requires a specific quality of coal. [ 64 ] [ 65 ] Conversely, many direct-reduction processes are disadvantaged by the costly transformation of ore into pellets: these cost on average 70% more than raw ore. [ 66 ]
For blast furnaces, direct reduction corresponds to the reduction of oxides by the carbon in the coke. However, in practice, direct reduction only plays a significant role in the final stage of iron reduction in a blast furnace, by helping to reduce wustite (FeO) to iron. In this case, the chemical reaction can be trivially described as follows ...
Blast furnaces differ from bloomeries and reverberatory furnaces in that in a blast furnace, flue gas is in direct contact with the ore and iron, allowing carbon monoxide to diffuse into the ore and reduce the iron oxide. The blast furnace operates as a countercurrent exchange process whereas a bloomery does not.
Thermal efficiency is improved in shaft furnaces such as blast furnaces compared to rotary furnaces due to the air absorbing some of the Luppen heat. [14] However, the oxygen in the air partially re-oxidizes the product, meaning that the Luppen is still altered by contact with air at the end or after leaving the furnace, despite complete ...
The hot blast pumps hot air into the blast furnace. The hot blast temperature ranges from 900 to 1,300 °C (1,650 to 2,370 °F) depending on the design and condition. Oil, tar , natural gas, powdered coal and oxygen can be injected to combine with the coke to release additional energy and increase the percentage of reducing gases present ...
Integrated steel mill in the Netherlands.The two large towers are blast furnaces.. A steel mill or steelworks is an industrial plant for the manufacture of steel.It may be an integrated steel works carrying out all steps of steelmaking from smelting iron ore to rolled product, but may also be a plant where steel semi-finished casting products are made from molten pig iron or from scrap.
DRI plants need not be part of an integrated steel plant yet, we then have Hot direct reduced iron (HDRI) is DRI that is transported hot, directly from the reduction furnace, into an electric arc furnace, thereby saving energy. Well, obviously, that can only happen if the DRI plant *IS* in fact "part of an integrated steel plant"