بروف/ أيمن منصور — مستشار الكيماء
Prof./ Ayman Mansour — Chemistry Consultant
كود الكيمياء — Chemistry Code
IRON REDUCTION
Animated Mechanisms • Blast Furnace vs Midrex DRI
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AR
Blast Furnace
Midrex DRI
Blast Furnace Reduction
HIGH TEMP • COKE + O₂
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BLAST FURNACE • REDUCTION BY CO
Source: Coke Coal (C) • High Furnace
COKE COAL + IRON ORE (Fe₂O₃)
HOT AIR
BLAST
SLAG
IRON
C(s) + O₂(g) → CO₂(g)
Combustion (from coke coal)
O₂
CO₂
CO₂(g) + C(s) → 2CO(g)
Boudouard • above 700°C
CO
CO
Fe₂O₃(s) + 3CO(g) → 2Fe(s) + 3CO₂(g)
Reduction by CO (Main Reaction)
Fe₂O₃
CO
→
Fe
CO₂
~700°C +
BLAST FURNACE KEY — REDUCTION BY CO
Reducing Agent = CO (from Coke Coal) • Fe₂O₃ + 3CO → 2Fe + 3CO₂
Coke Coal in Blast Furnace produces CO as reducing agent
⚙️ Blast Furnace Chemical Equations
C + O₂ → CO₂
(Combustion)
Exothermic
CO₂ + C → 2CO
(Boudouard)
Endothermic
3Fe₂O₃ + CO → 2Fe₃O₄ + CO₂
(Hematite → Magnetite)
Fe₃O₄ + CO → 3FeO + CO₂
(Magnetite → Wüstite)
FeO + CO → Fe + CO₂
(Wüstite → Iron)
FeO + C → Fe + CO
(Direct reduction)
CaCO₃ → CaO + CO₂
(Limestone)
CaO + SiO₂ → CaSiO₃
(Slag)
Midrex Shaft Furnace (DRI)
GAS-BASED • H₂ + CO
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MIDREX FURNACE • REDUCTION BY WATER GAS
Source: Natural Gas (93% CH₄) • Midrex Furnace
IRON ORE (Fe₂O₃)
REDUCING GAS
(CO + H₂)
TOP GAS (CO₂ + H₂O)
2CH₄(g) + CO₂(g) + H₂O(v)
→ 3CO(g) + 5H₂(g)
Water Gas from Natural Gas (Midrex)
Fe₂O₃(s) + CO(g) + 2H₂(g)
→ 2Fe(s) + CO₂(g) + 2H₂O(v)
Reduction by CO + H₂ (Water Gas)
Fe₂O₃
CO
H₂
→
Fe
CO₂
H₂O
~700°C +
MIDREX FURNACE KEY — REDUCTION BY WATER GAS
Reducing Agent = CO + H₂ (from natural gas 93% CH₄)
Natural gas in Midrex furnace produces CO + H₂ as reducing agents
⚙️ Midrex Chemical Equations
3Fe₂O₃ + H₂ → 2Fe₃O₄ + H₂O
(Hematite)
3Fe₂O₃ + CO → 2Fe₃O₄ + CO₂
(Hematite)
Fe₃O₄ + H₂ → 3FeO + H₂O
(Magnetite)
Fe₃O₄ + CO → 3FeO + CO₂
(Magnetite)
FeO + H₂ → Fe + H₂O
(Wüstite)
FeO + CO → Fe + CO₂
(Wüstite)
Reformer Reaction:
CH₄ + H₂O → CO + 3H₂
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Comparison: Blast Furnace vs Midrex
Blast Furnace
• High temperature (1500–2000°C)
• Uses coke + hot air blast
• Produces molten pig iron
• High CO₂ emissions
• Indirect reduction via CO
• Slag produced
Midrex DRI
• Moderate temperature (~950°C)
• Uses natural gas reformed to H₂ + CO
• Produces solid DRI (sponge iron)
• Lower carbon footprint
• Both H₂ and CO as reductants
• No melting / no slag
أ/ أيمن منصور — مستشار الكيمياء
|
Prof./ Ayman Mansour — Chemistry Consultant
📞 / WhatsApp:
01068018005
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01287996430
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كيمياء ٢٠٢٦ • Chemistry 2026
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