Optimization of sponge iron (direct reduced iron) production with Box-Wilson experimental design by using iron pellets and lignite as reductant

Turkey’s iron ores may be used to manufacture sponge iron, and the country’s coal resources, which are plentiful despite being of poor quality, can be used as a reducing agent. With such a production, Electric Arc Furnace based on scrap imports, will be an alternative raw material for steel production, and this will create high value due to the usage of domestic resources. In this study, sponge iron production was tried to be optimized by using local sources. For this purpose, the effects of time, temperature and [CFix/FeTotal] weight ratio on the Reduction Degree (%) of the important parameters effective in the production of sponge iron by using Divriği Iron Pellets and Dodurga Lignite as a reductant were studied using a Box-Wilson experimental design. The optimum parameters were determined as 82.59 min, 996.73 °C and 0.49, and the highest Reduction Degree (%) value was calculated as 96.46%. The sponge iron obtained with a 71.91% Reduction Degree contains 97.12% Fe, of which 7.12% is oxidized. It is evident that higher Fe contents may be attained with research carried out in optimum parameters.