Direct Reduced Iron
Mazdaco Your Trusted DRI Partner for Premium Steel
Nature and Structure of Direct Reduced Iron (DRI)
Direct Reduced Iron (DRI), also known as sponge iron, is a metallic product obtained by the direct reduction of iron ore (Fe₂O₃ or Fe₃O₄) to metallic iron at a temperature below the melting point of iron. This process occurs at approximately 800–1100°C and employs reducing gases such as carbon monoxide (CO) and hydrogen (H₂) to remove oxygen from the iron ore.
Chemical Composition and Molecular Structure
The chemical composition of DRI typically consists of 90–94% iron. Impurities such as silicon (SiO₂), carbon (C), sulfur (S), and phosphorus (P) may also be present. Carbon, often in the form of Fe₃C (cementite), plays a significant role in the properties of sponge iron. Its porous molecular structure provides a high surface area, making DRI an ideal raw material for producing high-quality steel in Electric Arc Furnaces (EAF).
Technical Specifications and Characteristics
- Metallization
The metallization rate of DRI indicates the percentage of metallic iron present. Higher metallization corresponds to superior DRI quality. - Residual Oxygen
The amount of residual oxygen in DRI significantly affects energy consumption and the quality of the produced steel. Lower residual oxygen levels indicate higher-quality DRI. - Energy Consumption in EAF
The chemical composition of DRI directly influences energy consumption and refractory material usage in Electric Arc Furnaces. DRI with high metallization and low residual oxygen requires less energy during steel production.
Types of Direct Reduced Iron for Trade and Market
DRI can be classified into two main types based on the production method and reducing agent:
Gas-based DRI
- Description: Produced using reducing gases such as hydrogen and carbon monoxide
- Features: High metallization (approximately 92–94%), low impurities, excellent quality for low-alloy steel.
- Production Process: Iron ore reacts with reducing gases at 800–1100°C, removing oxygen from the ore.
Coal-based or Solid DRI (Coal-based DRI)
- Description: Produced using coal or coke as the reducing agent.
- Features: Medium metallization (85–92%), higher residual carbon, suitable for conventional steel.
- Production Process: Iron ore is reduced in rotary or SL/RN kilns using coal, with oxygen removed during the process.
Based on Form and Packaging
- Granules: Easy to transport and charge into furnaces.
- Lumps (Sponge): The initial form after direct reduction, highly porous.
- Pellets: Compressed and durable, suitable for export and industrial use.
Gas-based DRI, due to its higher quality and iron content, is preferred by industrial customers seeking low-alloy steel that meets international standards. Although it has a higher price, its high metallization and low impurity levels make it ideal for producing high-value-added steel. In contrast, coal-based DRI, with lower production costs, is suitable for markets producing conventional steel or those with energy and resource limitations. This variety allows international traders and customers to select products that best fit their production requirements and budget, achieving optimal industrial and economic efficiency.
Advantages of DRI for International Customers
1. High Quality and Uniformity
Due to precise production processes, DRI contains a high iron (Fe) content with minimal impurities. This ensures a consistently high-quality product that is widely used in the steelmaking industry.
2. A Suitable Alternative to Scrap Iron
Due to the shortage of scrap iron in some countries, Direct Reduced Iron (DRI) serves as an effective substitute in Electric Arc Furnaces (EAF) and induction furnaces. This enables the production of high-quality steel.
3. Easy Transportation
Thanks to its porous structure and appropriate packaging, DRI can be transported easily to various parts of the world. This feature is especially important for international customers seeking raw materials with cost-effective logistics.
4. Reduced Environmental Impact
The production of DRI through direct reduction methods generates less pollution compared to traditional ironmaking processes. This represents a significant advantage for countries prioritizing environmental sustainability.
Production Process of Direct Reduced Iron
1. Direct Reduction of Iron Ore
In this process, iron ore (usually with 67% Fe content) is reduced without melting, using reducing gases such as carbon monoxide (CO) or hydrogen (H₂). The operation occurs at temperatures of 800–1100°C, resulting in the production of sponge iron.
2. Production Methods
MIDREX Process: Natural gas is decomposed into hydrogen and carbon monoxide in a reformer unit. These gases then react with iron ore in the reduction furnace to produce DRI.
HYL Process: Similar to the MIDREX method, but steam is added to increase hydrogen production. This results in DRI with a higher carbon content.
SL/RN Process: Coal is used as the carbon source. Iron ore reacts with coal in horizontal kilns to produce DRI.
3. Shaping and Packaging
The produced DRI is formed into granules, lumps, or pellets. These products are packaged and prepared for transport to various international markets.
Global Position of DRI and the Leading Brand
Today, DRI is recognized as a vital raw material in the steelmaking industry. This leading brand, leveraging advanced technologies and an extensive supply network, has secured a prominent position in supplying this product to international markets.
Transportation and Standardized Packaging
The company provides advanced logistics solutions, transporting DRI through two main methods:
- Bulk Shipment: Suitable for large-scale and cost-efficient orders.
- Container Shipment: Ideal for small orders or urgent and secure delivery.
All products are offered in standardized packaging, including granules, pellets, or jumbo bags, ensuring that the quality and purity of DRI are fully preserved during transportation.
Wide Applications Across Industries
The DRI produced by our group is utilized in various industries:
- Steelmaking: For use in Electric Arc Furnaces and induction furnaces to produce high-quality steel.
- Foundry and Industrial Parts: For manufacturing castings with superior mechanical properties.
- Automotive and Heavy Industries: Used in steel production for critical and durable components.
This product range, with high purity and uniform quality, provides a reliable alternative to scrap iron and contributes to reducing environmental impact.
Comparison with Other Steel Raw Materials
We provide our products according to customer requirements:
- Direct Reduced Iron: Produced from the direct reduction of iron ore using reducing gases, featuring high iron content and lower environmental impact.
- Pig Iron: Produced in blast furnaces using coke, suitable for conventional steel.
International Standards and Certifications
The company delivers all products in compliance with international standards, ensuring customer confidence in both quality and performance.
ISO 11323: Sampling and analysis of DRI
IS 15774: Technical specifications for HBI and CBI
IMSBC Code: Safety regulations for bulk cargo transportation
ISO 9001: Quality management
ISO 14001: Environmental management
ISO 45001: Occupational health and safety
Adherence to these standards demonstrates a commitment to high quality, safety, and environmental protection, fully assuring the trust of international clients and business partners.
Comparison with Other Steel Raw Materials
We provide our products according to customer requirements:
- Direct Reduced Iron: Produced from the direct reduction of iron ore using reducing gases, featuring high iron content and lower environmental impact.
- Pig Iron: Produced in blast furnaces using coke, suitable for conventional steel.
