Direct Reduced Iron - Revision history

Eric: Marked this Page for Later Work

2020-12-19T07:05:20Z

Marked this Page for Later Work

← Older revision		Revision as of 07:05, 19 December 2020
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	* [https://www.hybritdevelopment.com/ A Company Attempting to Commercialize This]		* [https://www.hybritdevelopment.com/ A Company Attempting to Commercialize This]

	[[Category: Materials]] [[Category:Metalworks]]		[[Category: Incomplete Pages]] [[Category: Materials]] [[Category:Metalworks]]

Eric: Added some more information

2020-12-19T07:04:27Z

Added some more information

← Older revision		Revision as of 07:04, 19 December 2020
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	*'''Direct-reduced iron is a metallic material formed by the reduction (removal of oxygen) of iron oxide (iron ore) at temperatures ''below the melting point'' of iron. DRI is produced by the use of a reducing gas (mostly a mixture of hydrogen and carbon monoxide). The temperatures for this process are significantly lower than those in a blast furnace, and capital requirements are also lower. DRI may have a sponge-like structure, leading to the alternative name "sponge iron".		*'''Direct-reduced iron is a metallic material formed by the reduction (removal of oxygen) of iron oxide (iron ore) at temperatures ''below the melting point'' of iron. DRI is produced by the use of a reducing gas (mostly a mixture of hydrogen and carbon monoxide). The temperatures for this process are significantly lower than those in a blast furnace, and capital requirements are also lower. DRI may have a sponge-like structure, leading to the alternative name "sponge iron".
	*Suitable starting materials are very high-grade iron ores (70% iron content and up) or rusted scrap steel, which is mostly iron. These could not yet be used in an [[induction furnace]], as the reduction is a chemical reaction while induction only melts the already-reduced pure metal. India is one of the global leaders in sponge iron production, having numerous small or medium-sized facilities. DRI is commonly manufactured in a rotary kiln.		*Suitable starting materials are very high-grade iron ores (70% iron content and up) or rusted scrap steel, which is mostly iron. These could not yet be used in an [[induction furnace]], as the reduction is a chemical reaction while induction only melts the already-reduced pure metal. India is one of the global leaders in sponge iron production, having numerous small or medium-sized facilities. DRI is commonly manufactured in a rotary kiln.
	*HDRI ("hot direct reduced iron"): when the still-hot iron is immediately moved for melting into an electric arc furnace or [[induction furnace]], to save energy. Caution: when HDRI is exposed to air, it may rapidly oxidize (=explode!).

			=Forms of Material Produced=
			*Direct Reduced Iron, or Sponge Iron ( '''May want to make a page for this product, and move this page's content to "Direct Reduction (Mettalurgy)" ? ''' )
			*HDRI ("hot direct reduced iron"): when the still-hot iron is immediately moved for melting into an electric arc furnace or [[induction furnace]], to save energy. Caution: when HDRI is exposed to air, it may rapidly oxidize (=explode!). '''OSE Will Use This for On-Site Usage'''
			*Hot-briquetted iron (HBI) is a form of DRI designed for ease of shipping, handling and storage. It is made via briquetting the iron while it is still hot, then letting it cool
			**Mainly used for trade (See [[Iron Shortage]] ) due to it's stability
			**Does a [[Pelletized]] version exist/make sense?
			**'''OSE Will Use This For Trade and Long Term Storage'''

	=Product ecology=		=Product ecology=

Eric: Added some more information

2020-12-19T06:57:57Z

Added some more information

← Older revision		Revision as of 06:57, 19 December 2020
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	=Product ecology=		=Product ecology=
	==In's==		==In's==
			*Energy, which will be vary depending on if onsite fuel is used, or if electric heating, and offsite reducing gas are used
			**[[Electricity]]
			**[[Heat]]
	*[[Iron Ore]] (deleted bit had some numbers on concentrations grab that + more sources later)		*[[Iron Ore]] (deleted bit had some numbers on concentrations grab that + more sources later)
	*[[Iron Scrap]] and [[Steel Scrap]]		*[[Iron Scrap]] and [[Steel Scrap]]

Eric: Added some more information

2020-12-19T06:56:44Z

Added some more information

← Older revision		Revision as of 06:56, 19 December 2020
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	*[[Iron Ore]] (deleted bit had some numbers on concentrations grab that + more sources later)		*[[Iron Ore]] (deleted bit had some numbers on concentrations grab that + more sources later)
	*[[Iron Scrap]] and [[Steel Scrap]]		*[[Iron Scrap]] and [[Steel Scrap]]
			*[[Reducing Gas]] (Either [[Syngas]] from an onsite source, or [[Hydrogen]] from remote sources)

	==Out's==		==Out's==

Eric: Added some more information

2020-12-19T06:56:02Z

Added some more information

← Older revision		Revision as of 06:56, 19 December 2020
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	=Product ecology=		=Product ecology=
	==In's==		==In's==
	*		*[[Iron Ore]] (deleted bit had some numbers on concentrations grab that + more sources later)
			*[[Iron Scrap]] and [[Steel Scrap]]

			==Out's==
	* '''Waste heat''' -- The DRI process generates waste heat that can potentially be used for pyrolyzing further biomass (pyrolysis = heating in absence of oxygen). Pyrolysis releases yet more '''syngas''' which can be fed back into the process. Everything is thus powered by biomass, generating '''[[biochar]]'''. In cold climates, any kind of waste heat can obviously be useful for heating winter greenhouses.		* '''Waste heat''' -- The DRI process generates waste heat that can potentially be used for pyrolyzing further biomass (pyrolysis = heating in absence of oxygen). Pyrolysis releases yet more '''syngas''' which can be fed back into the process. Everything is thus powered by biomass, generating '''[[biochar]]'''. In cold climates, any kind of waste heat can obviously be useful for heating winter greenhouses.

Eric: Deleted some stuff, fix it based off of edit history if need be

2020-12-19T06:54:45Z

Deleted some stuff, fix it based off of edit history if need be

← Older revision		Revision as of 06:54, 19 December 2020
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	=Product ecology=		=Product ecology=
	* first, metal oxides would be '''extracted from clay''', possibly by using hydrofluoric acid		==In's==
	* high-grade iron ore can also be produced from river sediments or beach sand using a strong magnet.		*
	* reduction of metals could also be accomplished in a '''solar carbothermic''' manner (see [[Metal_Refining\|metal refining]] for details)
	* '''[[Induction furnace]]''' -- could be fed with HDRI for energy-efficient steel production (rapid melting because metal is already hot)
	* '''[[Gasifier]]''' -- to create the reducing gas: [[Compressed_Fuel_Gas\|syngas]], a mixture of H and CO
	* '''[[Biogas]]''' -- methane from biogas can be turned into the H/CO mix. Globally, fossil gas (a.k.a. "natural" gas) is the most commonly used fuel for DRI, therefore biogas is a possible replacement, although it may have to be upgraded first (often contains sulfur compounds, likely a problem; abundant CO2 in biogas limits energy yield).
	* '''[[Biochar]]''' -- is a charcoal-like soil amendment. It is resistant to biodegradation, i.e. it is carbon that has been permanently removed from the atmosphere. The syngas that is released during pyrolysis could be used to make DRI. If these processes are combined (see [[Biochar/Iron Co-Production System]]), with biochar as a by-product, the whole process can be '''carbon negative''' ("carbon re-fossilization"). Biochar could be co-composted with spent slurry from a [[biogas]] digester, generating an excellent soil amendment.
	* '''Waste heat''' -- The DRI process generates waste heat that can potentially be used for pyrolyzing further biomass (pyrolysis = heating in absence of oxygen). Pyrolysis releases yet more '''syngas''' which can be fed back into the process. Everything is thus powered by biomass, generating '''[[biochar]]'''. In cold climates, any kind of waste heat can obviously be useful for heating winter greenhouses.		* '''Waste heat''' -- The DRI process generates waste heat that can potentially be used for pyrolyzing further biomass (pyrolysis = heating in absence of oxygen). Pyrolysis releases yet more '''syngas''' which can be fed back into the process. Everything is thus powered by biomass, generating '''[[biochar]]'''. In cold climates, any kind of waste heat can obviously be useful for heating winter greenhouses.

Eric: Minor Text Formating Fix

2020-12-19T06:53:42Z

Minor Text Formating Fix

← Older revision		Revision as of 06:53, 19 December 2020
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	=Basics=		=Basics=
	*Often abbreviated as DRI		*Often abbreviated as DRI
	'''Direct-reduced iron is a metallic material formed by the reduction (removal of oxygen) of iron oxide (iron ore) at temperatures ''below the melting point'' of iron. DRI is produced by the use of a reducing gas (mostly a mixture of hydrogen and carbon monoxide). The temperatures for this process are significantly lower than those in a blast furnace, and capital requirements are also lower. DRI may have a sponge-like structure, leading to the alternative name "sponge iron".		*'''Direct-reduced iron is a metallic material formed by the reduction (removal of oxygen) of iron oxide (iron ore) at temperatures ''below the melting point'' of iron. DRI is produced by the use of a reducing gas (mostly a mixture of hydrogen and carbon monoxide). The temperatures for this process are significantly lower than those in a blast furnace, and capital requirements are also lower. DRI may have a sponge-like structure, leading to the alternative name "sponge iron".
			*Suitable starting materials are very high-grade iron ores (70% iron content and up) or rusted scrap steel, which is mostly iron. These could not yet be used in an [[induction furnace]], as the reduction is a chemical reaction while induction only melts the already-reduced pure metal. India is one of the global leaders in sponge iron production, having numerous small or medium-sized facilities. DRI is commonly manufactured in a rotary kiln.
	Suitable starting materials are very high-grade iron ores (70% iron content and up) or rusted scrap steel, which is mostly iron. These could not yet be used in an [[induction furnace]], as the reduction is a chemical reaction while induction only melts the already-reduced pure metal. India is one of the global leaders in sponge iron production, having numerous small or medium-sized facilities. DRI is commonly manufactured in a rotary kiln.		*HDRI ("hot direct reduced iron"): when the still-hot iron is immediately moved for melting into an electric arc furnace or [[induction furnace]], to save energy. Caution: when HDRI is exposed to air, it may rapidly oxidize (=explode!).

	HDRI ("hot direct reduced iron"): when the still-hot iron is immediately moved for melting into an electric arc furnace or [[induction furnace]], to save energy. Caution: when HDRI is exposed to air, it may rapidly oxidize (=explode!).

	=Product ecology=		=Product ecology=

Eric: Minor Text Formating Fix

2020-12-19T06:53:12Z

Minor Text Formating Fix

← Older revision		Revision as of 06:53, 19 December 2020
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	* [https://www.hybritdevelopment.com/ A Company Attempting to Commercialize This]		* [https://www.hybritdevelopment.com/ A Company Attempting to Commercialize This]

	[[Category: Materials]]		[[Category: Materials]] [[Category:Metalworks]]
	[[Category:Metalworks]]

Eric: Added some more links under the "External Links" section

2020-10-31T04:33:20Z

Added some more links under the "External Links" section

← Older revision		Revision as of 04:33, 31 October 2020
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	*paper: [http://openfarmtech.org/w/images/c/c3/Lvov.pdf Mechanism of carbothermal reduction of iron, cobalt, nickel and copper oxides]		*paper: [http://openfarmtech.org/w/images/c/c3/Lvov.pdf Mechanism of carbothermal reduction of iron, cobalt, nickel and copper oxides]

	=~~See Also~~=		=Internal Links=
	* [[Open Source Direct Reduced Iron Reactor]]		* [[Open Source Direct Reduced Iron Reactor]]
	* [[Open Source Metal Recycling + Refining Construction Set]]		* [[Open Source Metal Recycling + Refining Construction Set]]
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	* [[Wikipedia: Water gas]] shift -> a way to increase the hydrogen content in syngas		* [[Wikipedia: Water gas]] shift -> a way to increase the hydrogen content in syngas
	* [http://www.time.com/time/magazine/article/0,9171,796046,00.html WW2-era (1942) TIME Magazine article on sponge iron]		* [http://www.time.com/time/magazine/article/0,9171,796046,00.html WW2-era (1942) TIME Magazine article on sponge iron]
			* [https://www.hybritdevelopment.com/ A Company Attempting to Commercialize This]

	[[Category: Materials]]		[[Category: Materials]]
	[[Category:Metalworks]]		[[Category:Metalworks]]

Eric: Added some more links under the "See Also" section

2020-04-09T02:41:36Z

Added some more links under the "See Also" section

← Older revision		Revision as of 02:41, 9 April 2020
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	=See Also=		=See Also=
			* [[Open Source Direct Reduced Iron Reactor]]
			* [[Open Source Metal Recycling + Refining Construction Set]]
	* [[Magnetite]] - incl. extraction of high-grade iron ore from beach sand		* [[Magnetite]] - incl. extraction of high-grade iron ore from beach sand
	* [[Metal]]		* [[Metal]]
	* [[Metal Refining]]		* [[Metal Refining]]
	*[[Steel from dirt]]		* [[Steel from dirt]]
	* [[Kiln]]		* [[Kiln]]
	*[[Charcoal Blast Furnace]]		* [[Charcoal Blast Furnace]]

	=External links=		=External links=