Directreduced

Directreduced refers to a method of producing metallic iron from iron ore by removing oxygen without melting the ore. The resulting product is direct reduced iron (DRI), also known as sponge iron, which is typically created from iron oxides such as hematite or magnetite using a reducing gas mixture. This gas is mainly carbon monoxide and hydrogen, produced from natural gas, coal, or syngas. Processing occurs at temperatures below the iron melting point, roughly 800 to 1050 degrees Celsius, so the iron remains solid.

Common direct reduction technologies include shaft furnace and moving bed processes, as seen in systems such as MIDREX and HYL, as well as rotary kiln-based methods. Ore in the form of pellets or lump is fed into a reducing atmosphere, and the iron oxide is converted to metallic iron. The product is often shipped as direct reduced iron or further processed into hot-briquetted iron (HBI) to improve handling and reduce oxidation during storage and transport. DRI/HBI is widely used as a feedstock for electric arc furnaces (EAFs) and can be blended with other iron units or, in some cases, used in BOF operations with suitable adjustments.

Benefits of direct reduction include lower capital requirements relative to integrated blast-furnace plants, flexibility to use natural gas or hydrogen as reducing agents, and potential emissions advantages when cleaner reducing gases are employed. Limitations include the material’s reactivity with oxygen and moisture, which necessitates protective handling and rapid downstream processing, as well as challenges related to scale, energy efficiency, and consistency of product quality. Direct reduction remains an important route for ironmaking in regions with suitable feedstock and energy supplies.