For high-grade iron ores with an iron grade higher than 60%, the recommended mainstream smelting processes are as follows

For high-grade iron ores with an iron grade higher than 60%, the recommended mainstream smelting processes are as follows

1. Blast furnace ironmaking method (mainstream process)

Process principle: Iron ore reacts with coke and flux (limestone) at high temperature (2000 ℃), reducing iron oxides with carbon monoxide to produce liquid iron, and impurities form slag separation.

Applicability:

Mature and reliable, with low coke consumption (about 0.4-0.5 tons/ton of crude steel) when processing high-grade ores (≥ 60%).

Supporting sintering/pellet pretreatment is required: the mineral powder is made into sintered ore or pellet ore to improve the permeability and reaction efficiency of the furnace charge.

Advantages: Mature technology, large production capacity, accounting for over 70% of global steel production.

Limitations: Dependence on coke, high carbon emissions, requiring the use of gas circulation or carbon capture technology to reduce emissions.

2. Direct Reduction of Iron (DRI, environmentally friendly alternative)

Process principle: Reduce iron ore with natural gas or hydrogen at a temperature below the melting point of iron to produce solid sponge iron (DRI).

Applicability:

Suitable for high-grade block ore or ball ore (>67% Fe), with less impurities that facilitate direct reduction.

No need for coking and sintering, carbon emissions are 30% -50% lower than blast furnaces.

Advantages: Short process, minimal pollution, pure product suitable for electric arc furnace steelmaking.

Limitations: Dependence on natural gas resources, high equipment investment.

3. Flash ironmaking (cutting-edge technology)

Process principle: Mineral powder is sprayed into a high-temperature reaction tower and rapidly reduced within 3-6 seconds without the need for sintering pretreatment.

Applicability:

Efficiently processing low-grade ores, but also applicable to high-grade ores.

The energy consumption is only one-third of that of a blast furnace, and the carbon emissions are close to zero (if hydrogen is used).

Advantages: Increased efficiency by 3600 times and wide adaptability to raw materials.

Limitations: Currently in the experimental stage, large-scale industrialization still needs to be validated