Direct reduced iron (DRI) is an alternative type of iron made by heating iron ore with a reducing agent to decrease oxygen and carbon content. It is sold as briquettes, lumps, or pellets and used in small scale steel mills. While it is more abundant in total iron content than pig iron, DRI requires large amounts of natural gas and is sensitive to oxidation and rust. India produces the most DRI due to its natural resources.
Direct reduced iron (DRI) is a type of alternative iron made by heating iron ore so that the oxygen and carbon burn while the temperature is kept below the melting point of iron. Direct-reduced iron is also known as sponge iron and is sold as briquettes, lumps, or pellets. It is typically used in small scale steel mills to improve the condition of the steel being produced.
During the reduction process in direct reduced iron production, coal or a special gas is used, commonly containing a combination of carbon monoxide and hydrogen. This mixture works as a reducing agent and helps decrease the oxygen and carbon content of the iron. The result is a type of iron that is 90-97% pure, containing only tiny amounts of carbon and other impurities.
DRI was the most widespread form of iron production in Europe and the Middle East until the 16th century. The introduction of the blast furnace helped revolutionize the ironworking process and it soon became the standard for manufacturing. As the demand for iron increased, the blast furnace made it possible to produce large quantities of iron in a relatively short period of time. The type of iron produced by blast furnaces, however, is not direct reduced iron, but pig iron, which is not as rich as direct reduced iron.
In the modern era, direct reduced iron is considered an alternative method of producing iron. The process of working iron via the direct reduction route has a distinct advantage over the more traditional, blast furnace mode of production. Not only is the resulting iron more abundant in total iron content, but it involves a much more economical production process than operating a large blast furnace.
There are also significant drawbacks to DRI. The manufacturing process requires unusually large amounts of natural gas, which limits the areas of the world where it can be produced. India, a nation rich in much-needed supplies of natural resources, produces reduced iron more directly than any other country. Other places where natural resources are not as abundant use different variations of the traditional manufacturing process.
Another disadvantage of direct reduced iron is its sensitivity to oxidation and rust. It should be stored and used under proper temperature conditions to ensure its longevity. DRI in large quantities is also known to spontaneously burst into flames when exposed to open air.
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