Direct Reduced Iron

Direct-reduced iron (DRI) is a metallic material of a manufacturing process formed by the reduction (removal of oxygen) of iron oxide (iron ore) at temperatures below the fusion point of iron. DRI is produced by the use of a reducing gas (often 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 fewer. DRI may have a sponge-like structure, leading to the alternative name “sponge iron”. Suitable starting materials are very high-grade iron ores (70% and up) or rusted scrap steel, which could not be used in an induction furnace.

HDRI (hot direct reduced iron): moving the still-hot iron immediately into an electric arc furnace or Induction_Furnace, to save energy.

Product ecology

Induction_Furnace - for HDRI !

Gasifier - producing the reducing gas: syngas, a mixture of H and CO

Further information needed !

Is this actually feasible on the small scale ? Are we missing something ? Does the process take place at atmospheric pressure ?

Scalability is feasible, but efficiency may not be as good. The processes of the largest plants can also be done on a table top. The question is - at what point does it still make sense to do so? If we have access to abundant energy, feasibility may occur at a village scale.

This appears as a good alternative for smaller scale, lower-cost process, worth adding to our general awareness.

External links

Wikipedia: Direct Reduced Iron