Direct reduction iron production

Expert gas analysis solutions for your DRI process and emission monitoring

Accurate gas measurements play an integral role in ensuring direct reduction iron (DRI) plants operate at the highest levels of efficiency while achieving low emissions targets. Our range of analytical solutions ensure effective results across the process.

Gas analysis is needed for process control in iron ore reduction

The Midrex DRI process is a low-carbon-dioxide-emission application in steelmaking using virgin iron ore in an electric arc furnace. The iron ore is heated as it descends through a shaft furnace, and oxygen (O2) is removed from the ore using counterflowing gases with a high hydrogen and carbon monoxide content. This process requires accurate gas monitoring for efficient operation.

Continuous emissions monitoring is a key requirement

Emissions monitoring is also an important part of the DRI process. The reaction between the counterflow gases and iron oxide in the ore produce metallic iron, water vapor, and carbon dioxide (CO2). In addition, the process may generate oxides of nitrogen (NOx) which must be continuously monitored to ensure environmental compliance.

Oxy 1900 oxygen (O2) gas analyzer

Effective solutions across the DRI process

Servomex supplies the SERVOTOUGH Oxy 1900 for essential O2 monitoring in the DRI process. This is an industry-leading Paramagnetic O2 analyzer designed for hazardous areas. This is supported by the highly flexible SERVOTOUGH SpectraExact 2500 photometric analyzer for the other measurements. The SERVOPRO 4900 Multigas and SERVOPRO NOx analyzers provide required continuous emissions monitoring.

We’re experts in gas analysis for DRI production

With wide experience in supplying solutions to industries using the direct reduction iron process, we are able to deliver the analyzers and sampling systems required for effective analysis.

Expert team

As global experts in gas analysis, we have the extensive applications knowledge to provide the best support for DRI processes, with a range of technologies to meet measurement requirements.

Ideal solutions

Our comprehensive analytical solutions provide the best-fit technologies for each measurement point in the process, delivering accurate, reliable results that support process efficiency and emissions monitoring.

Global support

All our analyzers and systems are backed by a worldwide network of trained service engineers, ensuring reliable operation at a peak level of performance.

Meet the experts

Karen leads the Industrial Process and Emissions Business Unit in providing solutions which support our customers as they overcome the challenges of making their processes safer, cleaner, and more efficient.

Karen Gargallo, Business Unit Manager, IP&E

Responsible for managing our oxygen analyzers in the Industrial Process & Emissions sector, Keith has been working with gas analysis solutions for more than 20 years, 12 of them at Servomex.

Keith Warren, Product Manager

Leading the life-cycle management of our Spectroscopic analyzer range, Rhys is responsible for the development of the markets they serve, and the strategic growth of those technologies.

Rhys Jenkins, IP&E Product Manager, Spectroscopic Analyzers

Overseeing the business development operations of our Industrial Process & Emissions team in China, Huiyu leads our pursuit of large international projects.

Huiyu Guan, Business Development Manager, IP&E, China

Stephen is responsible for managing the lifecycle of new Servomex Products, specifically, the introduction of new technologies into Servomex Analyzers. As STEM Team Leader he also coordinates the internal and external STEM program.

Stephen Firth, Product Manager- Strategic Projects

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OxyExact 2200

SERVOTOUGH Hazardous Area

The high-specification OxyExact 2200 O2 analyzer offers an unrivaled combination of precision, flexibility and performance for optimum process and safety control.

OxyExact 2200 high-specification O2 analyzer
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SpectraExact 2500F

SERVOTOUGH Hazardous Area

Flexible single and multicomponent gas analysis capability for corrosive, toxic and flammable sample streams.

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Find out more with our selection of DRI resources

To learn more about our products and solutions for the DRI process, emissions monitoring, and other related applications, download our resources.

Direct Reduction Iron application video

Discover our key measurement solutions for increased efficiency and reduced emissions in the DRI production process with this application video.

Direct reduction iron production podcast

Our experts explore the challenges of the direct iron reduction (DRI) process for steelmaking. Listen to discover how accurate gas analysis can support safety, process efficiency, and emissions monitoring.

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Gas Analysis in Steelmaking: A Deep Dive into DRI Processes

Servomex stands at the forefront of gas analysis systems, specializing in steelmaking processes that involve direct iron reduction (DRI). The steelmaking industry employs three primary DRI forms: cold (CDRI), hot (HDRI), and hot briquetted iron (HBI). Each of these forms offers flexible metallic charge materials tailored for specific DRI processes.

The majority of DRI processes utilize virgin iron ore in a gas-based shaft furnace. This furnace is powered by various fuels, including natural gas, sing gas, hydrogen, or a combination thereof. The significance of accurate gas measurements in these processes cannot be overstated. Not only does it ensure the safe and efficient operation of the furnace, but it also plays a pivotal role in meeting stringent emissions targets.

Here’s a brief overview of the DRI process:

1. Hydrogen Reduction Reaction: Fe2O3 + 3H2 -> 2Fe + 3H2O

2. Carbon Monoxide Reduction Reaction: Fe2O3 + 3CO -> 2Fe + 3CO2.

As iron ore descends through the shaft furnace, it undergoes heating. DRI is produced by two types of reduction. DRI through hydrogen removes oxygen from iron ore by direct reduction of H2 and produces iron and Water. Similarly, DRI through carbon monoxide removes oxygen from iron ore by direct reduction of CO and produces iron and CO2.

The Servomex SERVOTOUGH Oxy 1900 & OxyExact 2200, a state-of-the-art digital paramagnetic analyzer, takes the lead in essential oxygen measurements. Tailored for hazardous environments, this analyzer not only offers a cost-effective solution over its lifespan but also sets new benchmarks in measurement stability, flexibility, and reliability. It encompasses all the features one would expect from a top-tier oxygen analyzer, along with some groundbreaking value-added options.

For other crucial measurements like carbon dioxide, carbon monoxide, and water vapor, the SERVOTOUGH SpectraExact 2500 comes into play. This high-performance photometric analyzer boasts versatility, capable of contmeasuring the gaseous and liquid sampleent: present in corrosive, toxic, or flammable samples. The combined measurements from the Oxy 1900, OxyExact 2200 and SpectraExact 2500 are instrumental in controlling the DRI process. Thiese measurements ensures the process runs efficiently, reliably, and helps in cutting down fuel expenses.

It’s worth noting that DRI processes powered by natural gas or hydrogen have a reduced carbon dioxide footprint compared to coal-fired methods. However, monitoring these emissions remains crucial for adhering to regulations. Servomex addresses this need with the SERVOTOUGH 4900 Multigas, an advanced digital analyzer. This tool can measure up to four gas streams simultaneously, ensuring meticulous monitoring of pollutants and greenhouse gases produced during the DRI process.

Servomex’s analytical solutions are not just about performance; they come with the assurance of global experience in addressing DRI process challenges. Supported by an

extensive network of service centers worldwide, customers are guaranteed swift and comprehensive assistance.

For a deeper understanding of how Server Mix can optimize your DRI process, visit

To view the Servomex Gas Analysis and DRI Processes in Steelmaking video, click below.

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Not made up your mind yet? Let us convince you

We know it’s difficult to be certain you’ve found the right solution for your process. That’s why we recommend talking to one of our experts. They’ll give you peace of mind that the Servomex solution is the best you’ll find for your DRI process.

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