Direct Reduced Iron

The kiln operates at 1020-1070°C whilst the gas temperature is around 1100 °C. The product is formed by direct reduction of Iron ore in the reaction zone. Depending on formation of low-melting complex compounds accretion build-up takes place which includes ferro-silicate -aluminate phases.
Ring formation is a common phenomenon caused by the formation of low-melting phases and is also facilitated by the partial melting of coal ash at 400–700°C. This reacts with FeO and can also combine with Fe2SiO4 causing ring formation.
Towards approx 30% of the Kiln length from the discharge end/the main reduction zone, the stability of Wustite(FeO) is highest which reduces the fusion temp of all above ingredients and increases the compression strength & contraction of the resulting compacts. In reduction zone refractory temperature can shoot up to 1200°C

Construction quality steel is produced mostly by using DRI in Induction furnaces all over India.
The standard charge is 40% DRI, 50% scrap & 10% cast iron. The technology of melting these inputs varies according to availability of raw materials and location of the steel plant.
A heavily crowned bath surface is obtained in low frequency Induction furnaces with high power input, which facilitates DRI charging. The slag is pushed towards furnace wall and DRI added directly to the clean bath surface. DRI is automatically stirred into the liquid metal by the bath movement and heat is transferred quickly at the solid/liquid interface.
Slag also gets stirred into the metal. As a result, the slag temperature becomes the same as melt. Intimate contact promotes mass transfer between slag/ metal.