Investigating the Correlation between the Components of the Reducing Gas and the Percentage of Metal and Carbon in Sponge Iron Produced in the Midrex Direct Reduction Furnace
نویسندگان
1 Department of Mechanical Engineering, Kho. C., Islamic Azad University, Khomeinishahr, I.R. IRAN
2 Department of Mechanical Engineering, Kho. C., Islamic Azad University, Khomeinishahr, I.R. IRAN
3 Energy Systems Efficiency and Smartization Research Center, Kho. C., Islamic Azad University, Khomeinishahr, I.R. IRAN
4 Department of Mechanical Engineering, Is. C., Islamic Azad University, Isfahan, I.R. IRAN
doi
10.30492/ijcce.2026.2073998.7335چکیده
This study systematically investigates correlations between the metallurgical properties of sponge iron (reduced iron and C%) and reducing gas composition in a MIDREX direct reduction furnace. Using direct laboratory measurements from industrial samples, the analysis avoids common uncertainties associated with online sensors (e.g., calibration drift and malfunction) and provides a more reliable empirical basis for assessing how gas composition influences product quality and process optimization. The results show that H₂ had a weak positive correlation with reduced iron (R=+0.163), and a moderate positive correlation with C% (R=+0.242). CO showed a moderate negative correlation with reduced iron (R= –0.320) and a minimal influence on C% (R= –0.082). As a diluent, N₂ showed mild negative correlations with both reduced iron (R= –0.196) and C% (R= –0.084). CH₄ correlated positively with reduced iron (R=+0.193), but negatively with C% (R= –0.229), while CO₂ showed a positive correlation with reduced iron (R=+0.294) and a negative correlation with C% (R= –0.215). Overall, these laboratory-based findings underline the role of bustle-gas composition in metallurgical quality and offer practical insights for improving energy efficiency, product consistency, and operational control in direct reduction processes.
