Decarbonizing steel with direct reduced iron (DRI)
Steelmakers around the world are accelerating the shift to low-carbon production. DRI technology is at the center of this transformation. Lhoist provides lime, dolime, and minerals solutions to support the transformation and to help iron- and steelmakers to produce sustainable steel with a reduced footprint.
As the industry moves from traditional blast furnaces and basic oxygen furnace (BOF) to advanced direct reduced iron plants (DRI) and electric arc furnaces (EAF), new challenges arise. Pellet sticking can clog the furnace and disrupt production.
Tackling sticking in DRI production
During DRI production, iron ore pellets can stick together and form clusters. These clusters block gas flow and reduce furnace performance. The main causes include iron whiskers that lock pellets together, high surface energy of fresh metallic iron, low-melting phases at high temperatures, and variations in pellet composition, size, and reduction conditions.
As the industry adopts hydrogen-based reduction and higher temperatures to cut carbon emissions, these sticking issues become even more critical. Lhoist anticipates and solves these challenges.
Lime- and dolime-based pellet coatings as the solution
Lhoist develops innovative lime- and dolime-based coatings that prevent pellet sticking at the source. By applying a thin, even layer, the whisker formation is avoided, minimizing direct metallic contact, and maintaining smooth gas flow and stable furnace operation.
Leading furnace manufacturers recommend this approach. Our solutions deliver less sticking and clustering, higher productivity, and greater energy efficiency.
Why Lhoist’s coatings deliver - Proven results in lab and industry
Sticking in DRI production is a complex challenge. With Lhoist’s lime-based coatings, you achieve higher efficiency, lower emissions, and greater reliability.
Our research and innovation team tested two types of iron ore pellets with both CaO-based (lime) and MgO-based (dolime) coatings. The results are clear:
- Coated pellets show much lower cluster indices, especially with CaO-based coatings
- Reduction efficiency remains high, with no compromise on performance
- Handling improves, with fewer fines, less material loss, and reduced dust
Lime-based coatings reshape pellet surfaces, fill pores, and build a granular structure that resists sticking. These coatings stand up to handling and reduction, protecting the DRI process from start to finish.
Driving Innovation with Lhoist – partnering for cleaner, more efficient steel
As the industry advances toward greener technologies, we invite you to innovate with us. We continuously explore optimal dosages, application methods, and new material combinations. By working with Lhoist, iron- and steelmakers access cutting-edge research and solutions that support your sustainability goals.
Ready to drive results?
Download our comprehensive study, “Enhancing DRI Production Efficiency Using Lime-Based Products,” and discover the data, methods, and results behind Lhoist’s breakthrough solutions for the steel industry.
Download the full study now
Any questions? Contact our experts:
Joyce Aderhold
Christopher Pust