Rio Tinto and other steel and mining groups have highlighted the need to adapt processes for DRI plants which have traditionally run on reformed natural gas as new plants are developed for hydrogenbased reduction. Many such projects expect to create hydrogen for DRI with electrolysis using renewable power from wind and solar projects.
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In a DR process, iron ore pellets and/or lump iron ores are reduced by a reducing gas to produce DRI or hot briquetted iron (HBI). Depending on the generation of the reducing gas, two different DR processes are commercially available: gasbased and coal/oilbased.
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Switching from blast furnaces that consume coal to green hydrogenbased direct reduced iron (DRI) processes is widely considered a key step in the global steel sector's decarbonisation pathway. ... the dominant global process. DRgrade iron ore ideally has an iron (Fe) content of 67% or more and such deposits are scarce only a small ...
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efficiency. Both coal and gasbased DRI plants are operational in India. However, the share of coalbased DRI production is quite substantial and in comparison to gasbased production, this route is energy and carbonintensive. To meet the DRI production target of 80 million tonne by 203031 as envisaged under the
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The carbon footprint of H 2based DRI in France is comparably low due to a high share of nuclear energy in the national grid mix. The carbon footprint of NGbased DRI is kg CO 2 eq/kg DRI. In countries with moderatetohigh carbon intensity in electricity production, it is better to use natural gas directly in the DR plant than using hydrogen.
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DRI or sponge iron refers to porous iron produced by the DR process.a solidstate reaction process (, solidsolid or solidgas reaction) in which removable oxygen is removed from the iron oxide, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or agglomerates of fine ore.
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To reach a reduction degree of the hot DRI product of 95%, t of iron oxide input material containing input materials per ton of DRI are required for the DRNG as well as the DRH 2 process. Based on NG which contains approximately 95% methane, the simulation results in an NG demand of approximately 259 m 3 STP t −1 DRI for the reference case.
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In Fig. 1, we show the design of the hydrogen direct reduction (HDR) process on which the developed chemical process model presented later on in this chapter is based. Iron ore is preheated and fed into a reduction shaft, where it is converted to direct reduced iron (DRI) and further compacted to hot briquetted iron (HBI).
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In India, steel produced through DRI is about 3 t CO 2 /t of steel, due to its large reliance on coal (82%) as an input into DRI production, with the remainder of DRI using natural gas (18%) [25, 33, 34]. Natural gasbased Midrex direct reduction process along with EAF has one of the lowest carbon dioxide (CO 2) emissions of steel production ...
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2. Overview of DR processes. Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing. gas to produce Direct Reduced Iron (also known ...
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Successful design of HYL ZR process plants based on coal gasification and COG. 2005 First coal gasificationbased Energiron DRI plant for Jindal Steel, India. This 2 Mtpy module is the largest plant of this kind ever to be built in the world. 2006 First Mtpy Energiron DR plant with HYTEMP® system order from Emirates Steel, UAE. 2006
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DRI has been fast gaining ground throughout the world since the 1980s mainly because of the shortage of coking coal for BF and steel scrap in steelmaking. DRI is produced by the DR of iron ore by ...
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In comparison to gasbased processes, the coalbased DRI production process is quite energy intensive and poses environmentrelated issues. Being a developing country with steel demand projected to reach between 500 and 760 million tonne (Mt) by 2050, the country needs to adopt energyefficient and environmentfriendly steel production ...
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Coal based Direct Reduced Iron (DRI) / Sponge Iron Plant Process Flowchart. CHAIN CONV. CHAMBER SAF1 SAF3 SAF5 SAF7. CONV. COMPRESSOR WATER PUMP. BC12 Fe >50mm.
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producing this, the hot DRI is directly discharged into hot briquetting machine and cooling circuit is eliminated. Hot HBI from briquetting is separated to individual briquettes and cooled. Coal Based Direct Reduction : Coal based direct reduction technologies involve reduction of iron oxides in a rotary kiln by using noncoking coal as reductant.
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Kobe Steel has developed coalbased direct reduction (DR) technologies, the FASTMET, FASTMELT and ITmk3 processes, which reduce carbon composite agglomerates (pellets or briquettes) on the hearth of a rotary hearth furnace (RHF). This paper outlines the features of each process, status of technical development and commercialization.
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Among the various DR processes, the MIDREX process dominates the market accounting for % of the total DRI production in 2019, followed by % from the coalbased rotary kiln process and % from the ENERGIRON process (MIDREX, 2019). As the gasbased DR processes are producing about 76% of the world's DRI, and MIDREX and ENERGIRON ...
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The DRI processes are categorized in two groups based on the use of reducing agent, natural gasbased direct reduction (DR) processes like MIDREX, HYL and Finmet, and coalbased DR processes like ...
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Global productions of blast furnace iron (BFI) and direct reduced iron (DRI) between 1980 and 2012 (Anon 1, 2014; Anon 2, 2014). ... However in the coal/oilbased DR process, the reducing gas is generated from hydrocarbons (primarily coal, but sometimes oil and natural gas) in the reduction zone of the furnace, which is typically a rotary ...
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DRI is produced through the removal (reduction) of oxygen from iron ore in its solid state. This technology encompasses various processes based on different feedstocks, reactors, and reducing agents. DRI processes can reduce CO 2 emissions by using natural gas instead of coal due to the replacement of carbon reductant by hydrogen from the methane.
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Important limitations among other coalbased DR processes are: size of single moduleplants available, restrictions on the use of high sulfur coals, undesirable amount of gangue and sulfur in the DRI product, unproven technologies and high operating costs. A summary of existing and emerging coalbased DR processes is included in Table 1. Table 1
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The DR process may be adapted for coalbased processing, which will contribute to the stable supply of direct reduced iron (DRI). This paper outlines the DR technologies developed by Kobe Steel and includes a survey on the contribution of DRI as a substitute for scrap used in electric arc furnaces (EAFs) and as a burden material in BFs.
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The consumption of DR pellets necessary for gasbased DRI production can be estimated to 117 Mt, when assuming an Fe content of % in the DR pellets and % in the DRI. Since little gasbased DRI production takes place in China, it can be stated that the BFpellet consumption outside China is 244 Mt or slightly more than twice the DR ...
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Coalbased reduction (DR) technologies using syngas are of recent origin. MIDREX, in association with Praxair, has developed a process called MXCOL, where coalbased synthetic gas can be used in the reduction shaft. ... A coalbased dual fuel DRI process (FASTMET) shows lower gross CO 2 emission ( t CO 2 /t DRI) compared to rotary kiln (RK ...
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DR process configuration, from the total Carbon input to the DR plant, only 1025% (depending on the Carbon content in the DRI) exits the process as combined Carbon in the DRI. By the principle of mass conservation, the balance must leave the process, which for the DR process, is in the gaseous form as CO 2.
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The main raw materials for the production of DRI by the rotary kiln process are (i) sized graded iron ore or iron ore pellets, (ii) noncoking coal, and (iii) dolomite in small quantities to scavenge the sulphur. Iron ore of the right quality is the basic input for the coal based direct reduction process.
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The Circofer process is a coalbased DR process developed by Outotec . The fine ore is prereduced to DRI in a ... substances, mainly natural gas or a coal, at high temperatures but below the melting point of iron. The product, direct reduced iron (DRI), is a porous solid, also known as sponge iron. It consists primarily of metallic iron ...
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To avoid locking in further coalbased steelmaking capacity for decades, some technology switching to DRIelectric arc furnace (EAF) processes will be required before then. Potential new DRgrade iron ore capacity by 2030 ranges from 40 million tonnes per annum (Mtpa) to an optimistic high of 100Mtpa. Unless technology innovations allow use of ...
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Direct reduced iron (DRI) is the alternative iron source for steelmaking. Its advantages as a iron product and diluent for impurities, introduced with scrap, are well documented. DRI is also known as sponge iron. It refers to porous iron produced by the direct reduction (DR) process.
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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 or elemental carbon produced from natural gas or coal. Many ores are suitable for direct reduction.
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