Reducing Gas for Iron Ore

Plummer, O. J. Quartulli, W. Turner, and H. Watson, Symposium der Internationalen Gas-Union, Karlsruhe, 1972, preprint 17. 

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Synthesis gas or shortly syngas is a term used for a mixture of hydrogen and carbon monoxide. Synthesis gas is an important building block for a number of petrochemicals as well as an important feedstock for liquid fuels via the Fischer Tropsch route or as reducing gas for iron ore reduction (Fig. 1). 

Another new application of coal briquetting that is already being used, is the den-sification and shaping of solid reductant for the direct reduction of iron ores. Such briquettes are mixed with iron ore and fed into the reactor where controlled combustion provides heat and reducing gas for the production of direct reduced iron (DRI). 

Direct Reduction. Direct reduction processes are distinguished from other ironmaking processes in that iron oxide is converted to metallic iron without melting. Because this product, called direct reduced iron (DRI), is soHd, it is most suitable for melting in an electric arc furnace (EAF) as a substitute for scrap (see Furnaces, electric). The briquetted form of DRI, hot briquetted iron (HBI) is used when the product is to be transported. Briquetting increases density and chemical stabiUty. The predominant direct reduction processes (MIDREX and HyL III) are based on natural gas as a fuel and reductant source. They are economically attractive in regions where natural gas is cheap and abundant, especially if iron ore is available nearby (see Iron BY DIRECT reduction). ... 

MIDREX Process. The primary components of a MID REX process plant include the shaft furnace, reformer, and heat recuperator. These components are supported by ancillary systems for handling iron ore, gas, water, and direct reduced iron. A flow sheet is shown in Figure 1. 

FIOR Process. In the FIOR process, shown in Figure 5, sized iron ore fines (0.04—12 mm) are dried in a gas-fired rotary dryer. A skip hoist dehvers the dry fines to lock hoppers for pressurizing. The fines pass through four fluidized-bed reactors in series. Reactor 1 preheats the ore to 760°C in a nonreducing atmosphere. Reactors 2, 3, and 4 reduce the ore at 690—780°C. At higher (ca 810°C) temperatures there is a tendency for the beds to defluidize as a result of sticking or hogging of the reduced material. 

Methods exist to make impure iron direcdy from ore, ie, to make DRI without first reducing the ore in the blast furnace to make pig iron which has to be purified in a second step. These processes, generally referred to as direct-reduction processes, are employed where natural gas is readily available for the reduction (see also Ironbydirectreduction). Carbonization of iron ore to make iron carbide as an alternative source of iron units is in its infancy as of the mid-1990s but may grow. 

Fluid Iron Ore Reduction (FIOR) is a process for reducing ore to iron with a reducing gas in a fluid bed. For thermodynamic efficiency, iron ore reduction requires counter current flow of ore and reducing gas. This is achieved in FIOR in a multiple bed reactor. Precautions are necessary to prevent significant back mixing of solids between beds, since this would destroy counter current staging. 

One of the more important alternatives to the blast furnace for the production of iron is direct reduction of pelletised ore in a shaft reactor. The reducing gas mixture is usually obtained by steam reforming of natural gas and flows upward,countercurrent to the downward flow of solids. Sponge iron obtained by direct reduction may be used directly in arc furnaces for steel production. 

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