What It Is:

• Porous iron (90–94% Fe) produced by chemically reducing pellets or lumps without melting, using natural gas or coal.

Forms:

• DRI: Lumpy or powdery form, prone to rusting.

• HBI (Hot Briquetted Iron): Compressed DRI for safer transport.

How It’s Produced:

1. Reduction:

   • Gas-based (MIDREX®/HYL): Pellets reduced using syngas (H₂ + CO) at 800–1,050°C.

   • Coal-based (Rotary Kiln): Common in India and China, using coal as the reductant.

2. Cooling:

   • The reduced iron is cooled to prevent re-oxidation.

Applications:

• Electric Arc Furnaces (EAFs): DRI mixed with scrap to produce high-purity steel with low copper and other residuals.

• Alternative to scrap: Especially important in regions with limited scrap supply, such as the Middle East.

• Green steel: Has future potential through hydrogen-based DRI (e.g., HYBRIT project).

Top Producers:

• Gas-based: Iran, Saudi Arabia, USA (using MIDREX plants).

• Coal-based: India (the world’s largest DRI producer).

Comparative Summary