Direct Reduction Shaft Furnace

Product Specifications

Technical details and manufacturing context for Direct Reduction Shaft Furnace

Definition

The Direct Reduction Shaft Furnace is a critical component of the Integrated Direct Reduction Iron and Electric Arc Furnace Steelmaking System. It is a counter-current reactor where iron-bearing feed material (pellets or lump ore) descends by gravity while a hot reducing gas (typically a mixture of H₂ and CO derived from reformed natural gas) ascends. Within the furnace, the iron oxides in the ore are chemically reduced to metallic iron (sponge iron/DRI) at solid state, without melting, through gas-solid reactions. The produced DRI is then discharged, cooled, and transferred to the electric arc furnace for steelmaking. The furnace is designed for continuous operation, with a typical production capacity ranging from 500 to 2000 tonnes per day for merchant plants. The reducing gas temperature is maintained between 850 and 1050 °C to optimize the reduction rate, while the top gas pressure is kept at 0.2 to 0.5 MPa to ensure proper gas distribution. The reducing gas flow rate is typically 1500 to 2500 Nm³/h per tonne of DRI produced. The metallization degree, a key quality indicator, targets 92 to 95%, and the carbon content in DRI can be adjusted via gas composition to 1.5 to 4.0%. The furnace height ranges from 20 to 40 meters, with a reaction zone diameter of 5 to 8 meters. The refractory lining thickness is 300 to 500 mm, and the shell material is typically Q345R pressure vessel steel per GB 713. The design temperature is 1100 to 1200 °C, and the design pressure is 0.6 to 1.0 MPa. The total weight, including refractory and internals, is 500 to 1500 tonnes. These values are typical reference ranges and must be verified for the specific model and application.

Working Principle

Iron ore is fed into the top of the vertical shaft furnace. A hot reducing gas (syngas) is injected into a reduction zone in the lower section of the shaft. As the ore descends and the gas ascends in counter-current flow, the iron oxides (Fe₂O₃/Fe₃O₄) are reduced stepwise to metallic iron (Fe) by the hydrogen and carbon monoxide in the gas (e.g., Fe₂O₃ + 3H₂ → 2Fe + 3H₂O). The spent top gas is cleaned and recycled. The solid DRI product is discharged from the bottom.

Common Materials

Refractory Lining (e.g., high-alumina brick), Steel Shell

Technical Parameters

Parameter	Typical range	Notes & selection driver
Production Capacity	500–2000 t/d	Typical range for merchant plants
Reducing Gas Temperature	850–1050 °C	Higher temperature improves reduction rate
Top Gas Pressure	0.2–0.5 MPa	Maintains proper gas distribution
Reducing Gas Flow Rate	1500–2500 Nm³/h	Per ton of DRI produced
Metallization Degree	92–95 %	Target for high-quality DRI
Carbon Content in DRI	1.5–4.0 %	Adjustable via gas composition
Furnace Height	20–40 m	Depends on capacity and design
Furnace Diameter	5–8 m	Reaction zone diameter
Refractory Lining Thickness	300–500 mm	Ensures thermal insulation and durability
Shell Material	Q345R	Pressure vessel steelGB 713
Design Temperature	1100–1200 °C	Maximum continuous operating temperature
Design Pressure	0.6–1.0 MPa	Internal pressure rating
Total Weight	500–1500 t	Including refractory and internals

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Furnace Body
The furnace shell itself: contains the process, carries the lining and holds the working atmosphere.
Upper Seal Feeder
Seals the top of the shaft and controls the feed rate of iron ore into the furnace.

Material: steel
Reduction Zone Part
The central section of the shaft where the primary gas-solid reduction reactions occur.

Material: refractory lining
Gas Inlet Bustle
Distributes the hot reducing gas uniformly around the circumference of the shaft into the reduction zone.

Material: refractory-lined steel
Discharge System
Controls the rate of DRI withdrawal from the bottom of the furnace, typically using screw extractors or similar mechanisms.

Material: heat-resistant alloy steel

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Frequently Asked Questions

What is the typical production capacity of a direct reduction shaft furnace?

For merchant plants, the typical production capacity ranges from 500 to 2000 tonnes per day. The exact capacity depends on the furnace design and operating conditions, so it must be confirmed with the manufacturer for a specific model.

What are the key operating parameters for the reducing gas?

The reducing gas temperature is typically 850 to 1050 °C, and the top gas pressure is 0.2 to 0.5 MPa. The flow rate is 1500 to 2500 Nm³/h per tonne of DRI produced. These values are reference ranges and should be verified for the actual installation.

What is the metallization degree and why is it important?

Metallization degree indicates the percentage of iron oxides converted to metallic iron. For high-quality DRI, the target is 92 to 95%. This parameter is crucial for downstream steelmaking efficiency and must be monitored and controlled.

What materials are used in the furnace construction?

The furnace typically has a refractory lining (e.g., high-alumina brick) with a thickness of 300 to 500 mm, and a steel shell made of Q345R pressure vessel steel per GB 713. The design temperature is 1100 to 1200 °C, and the design pressure is 0.6 to 1.0 MPa.

Data Basis

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pressure:	1.5-5.0 bar (operating pressure), up to 6.0 bar (design pressure)
flow rate:	100,000-500,000 Nm³/h (reducing gas flow)
temperature:	800-1100°C (reduction zone), up to 1300°C (combustion zone)
slurry concentration:	Not applicable (handles solid pellets/lump ore, not slurries)

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