Iron-Ore Reduction in Fluidized Beds: Review of Commercial Technologies, Status, and Challenges

Ironmaking through direct reduction of iron ore (DRI) using CO and/or H2 significantly reduces CO2 emissions in comparison to the traditional blast furnace route which uses coke. Fluidized bed DRI due to direct utilization of fine ore eliminates the firing/induration and cooling steps in the pelletization process used in shaft furnace DRI and blast furnace and thus has the potential to become an energy-efficient carbon neutral technology with cost competitive to shaft furnace DRI. In this paper, the commercial fluidized bed-based fine iron ore reduction technologies (FINEX, FINMET, FIOR, CIRCORED, NU-IRON, H-IRON, and IRON-CARBIDE) are reviewed. The advantages and disadvantages of the technologies are summarized, and the process conditions, energy consumptions, and DRI properties are compared. Additionally, the challenges associated with fluidizing and reducing the most widely available ultrafine ore in commercial fluidized bed technologies are addressed.