Reduced Iron

Direct-Reduced Iron (DRI): Direct-Reduced Iron (DRI) is a type of metal substance produced through the direct reduction of iron ore in the solid state, using gases such as carbon monoxide and hydrogen derived from natural gas or coal. This process occurs at temperatures below the melting point of iron, resulting in a purer iron product that is largely free of impurities and fillers. However, DRI is highly reactive and prone to oxidation, which necessitates careful handling and storage to prevent self-heating and fires[1][2]. Use in Food and Beverages: In the context of food and beverages, the term "reduced iron" typically refers to forms of iron used for nutritional supplementation and fortification, rather than DRI. Reduced iron in this sense is often used in food products to combat iron deficiency anemia. For example, Ferrazone® (Ferric Sodium EDTA) is a bioavailable form of iron used to fortify various food products such as wheat and maize flour, fortified cereals, sport drinks, and other dry or liquid food items. This form of iron is chosen because it is readily absorbed by the body and does not impart a metallic taste, making it suitable for use in a wide range of food and beverage applications[3].

Direct Reduced Iron (DRI), also known as sponge iron, is produced through a process that reduces iron oxides to metallic iron at temperatures below the melting point of iron. This process can be categorized into two main types: gas-based and coal-based. In the gas-based process, iron ore in the form of lumps, pellets, or fines is reduced using a reducing gas that contains elemental carbon (derived from natural gas or coal) and/or hydrogen. The reducing gas is generated by reforming a mixture of natural gas, hydrogen, and process gases at high temperatures. This gas stream is then fed into a direct reduction tower or shaft furnace, where the oxygen is stripped from the iron oxide at temperatures between 700 and 900 degrees Celsius, resulting in the production of sponge iron[1][2].

The sponge iron produced is highly porous and resembles a sponge, hence the name. To prevent oxidation and rusting, the DRI is quickly processed further into steel. The sponge iron is transported hot to electric arc furnaces, where it is melted along with other materials to produce crude steel. This process is more energy-efficient compared to traditional blast furnace methods and does not require the use of coke, which reduces the carbon content of the final product. The process gases produced during reduction are recycled back into the system to maintain efficiency and minimize waste[1][2].

The safety profile for human consumption of Reduced Iron, particularly in the context of food and beverages, is complex and depends on several factors. Reduced Iron, often used in food fortification, can be safer when provided in lower quantities within a food matrix, as this approach minimizes the risk of adverse effects associated with high-dose iron supplements. However, excessive intake of iron over prolonged periods can lead to negative health impacts, such as liver toxicity, gastrointestinal adverse effects, and potential interactions with other minerals like zinc, copper, and calcium. The European Food Safety Authority (EFSA) has set safe levels of total iron intake to avoid these risks, ranging from 5 mg/day for infants to 40 mg/day for adults, including pregnant and lactating women[1].

Regarding potential contamination risks, Reduced Iron used in food fortification or production can be vulnerable to several contaminants. Heavy metals contamination is a significant concern, as fertilizers and soil amendments used in agriculture can contain trace amounts of heavy metals like cadmium, lead, and mercury, which can accumulate in the soil and subsequently in the crops. Additionally, the use of biosolids and composts in farming can introduce heavy metals such as arsenic, copper, and zinc into the soil. Pesticide residues are another risk, as the application of certain pesticides can leave residues on crops that may be used in fortified foods. Furthermore, pathogen risks can arise from improper handling and processing of fortified foods, highlighting the need for stringent quality control measures to ensure the safety of the final product[2][1].