Wow, I hope that this is an academic question. I cannot understand at all many of these acronyms and jargon. (Metallurgy is not my field.) Are the numbers (62,63,64) of iron percentage by the molecular weight or mole of the ore?

If it's not an academic question, I suggest that you hire a metallurgy consultant to answer this question and not rely on a fixed number from anyone here.

The major uncertainty I see here is the type of processing equipment used to get this refinement step completed will likely significantly change the final result. You will certainly have some number of BTUs of heat required to just get all of this equipment and ore to the temperature for the chemical reduction you're looking for. Then the added BTUs will be applied to the chemical reaction that makes dri(?). But you don't just ask for the number of BTUs required, you ask for the amount of coal used in producing synthesis gas to make this BTU quantity.

I suspect that there is no number that can be theoretically derived for your answer. I expect that you have so many variables that your answer can only be empirically discovered and not theoretically found.

But I don't work in metallurgy.

sauravjain, we are talking about you and this question on your identical previous thread. Why not come over there and visit with us?

I would suspect that this is an academic question, but cannot be answered at this point without further information. I also hesitate to muddy the waters by answering it at all since every detail of the production of DRI and about every process that has attempted to produce DRI has been published Mr. Saurajain is trying to get his research done for him.

1. What Indian conditions are you referring to?

2. What flame temperatures are you referring to?

3. Pure iron oxide (hematite) is Fe2O3. At 62 grade means that other constituents are in there like, Silica, alumina, sulfur and whatever other materials that were mined with it or in compounds with the iron. 62 is the percent of total iron in the mix.

4. What type of DRI do you wish to produce, DRI that can be fed to a blast furnace or BOF furnace, DRI that can be fed to an electric arc furnace in place of scrap or as prime materials. this would determine how high it should be reduced and at what residual carbon in the DRI and what type of carbon, graphite or iron carbide?

5. What type of furnace is going to be used to melt the DRI and what are going to be the products made from that furnace, construction materials, rebar like or stainless/alloys?

6. In general, let's muddy the waters some more, about 10 million BTU's are required to reduce somewhat pretty good iron oxide feed stock. What is good feed stock and again what are you producing, why and for what? One process which is a nat. gas based shaft type can produce DRI pretty close to theoretical, which is a bit less than 10 million BTU's. Another process also of the same type shaft and nat. gas based is also pretty close to theoretical. Generally speaking most other technologies use upwards to 15 million BTU's of fuel per ton of DRI.

It is difficult to assess the coal based technologies since they do not produce the quality of DRI that would be considered comparable to the gas based shafts. They have the potential to do so but the designers and operators do not understand the basics of DRI technology and steel making in order to accomplish the efficient operation and requirements of DRI or its use. In using coal to produce a synthesis gas for DRI use their figures are also in the same ball park. And new DRI rotary hearths also can use coal directly with the same or even better use of fuels, but are yet proven.

There are also direct steel making technologies that make steel directly from coal and iron oxide without first reducing the ore as in the blast furnace or in DRI, which would make them far more fuel efficient and less poluting.

You give us more info, including what this is for and perhaps we can help.

1. What Indian conditions are you referring to?

Ans. As per Indian condition we meant to be the quality of iron ore(lumps,fines) that is being mined in India.

2. What flame temperatures are you referring to? No idea ,please take the industry std.

3. Pure iron oxide (hematite) is Fe2O3. At 62 grade means that other constituents are in there like, Silica, alumina, sulfur and whatever other materials that were mined with it or in compounds with the iron. 62 is the percent of total iron in the mix.

Ans.For this please take the generalised silica and other contituents usually found in Indian Iron ore.

4. What type of DRI do you wish to produce, DRI that can be fed to a blast furnace or BOF furnace, DRI that can be fed to an electric arc furnace in place of scrap or as prime materials. this would determine how high it should be reduced and at what residual carbon in the DRI and what type of carbon, graphite or iron carbide?

Ans. We are looking for DRI that could be fed to Induction Furnaces.

We would request you to let us know the amount of carbon and type we should have in the DRI to be use In I.F

5. What type of furnace is going to be used to melt the DRI and what are going to be the products made from that furnace, construction materials, rebar like or stainless/alloys?

Ans. Medium Frequency Induction furnaces of various capacities like 15mt,25mt.

The products to be manufactrued will construction materials and billets of ALLOY and en grades.

There are also direct steel making technologies that make steel directly from coal and iron oxide without first reducing the ore as in the blast furnace or in DRI, which would make them far more fuel efficient and less poluting.

Please do let us know about the direct steel making technologies along with min capacity that should be viable to be implemented in India.

Well it sounds like you should either do your own homework or hire somebody like Mr. Coyne.

I think that you should contact some local (Indian) consultants that would point you in the right direction. Your inquiry is too vague for the answers to be given in a forum such as this. We are familiar with Indian conditions and raw materials, but they can't be generalized for this and the only place in the world that uses extensively the induction furnace for melting DRI is India.

I will give you the name of a consulting colleague in India that might be willing to help. If you need anything further please contact me.

Indian consultant: TRR Rao

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thank you , plz let me know the contact of mr TRR Rao or any other consultant who has a deep knowledge on gas based dri and how to implement the same from scratch.plz provide the email id by mailing us on

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