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Energy survey of the coal based sponge iron industry

Sep 01, 2015 The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel Company of Canada, Lurgi Chemie, Republic Steel Company and National Lead Corporation in 1964), which works on direct reduction of ore.This process is adopted by worldwide conventional sponge iron industries.

Sponge iron making full process_Coal base DRI YouTube

Dec 24, 2018 Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by

SPONGE IRON PLANT

MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid. Most solid reduction process use non-coking coal as reducing agent due to abundantly available non-coking coal. The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore.

Direct reduced iron Wikipedia

Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.), in order to convert the ore to metallic iron, without melting it (below 1,200 °C (2,190 °F)). The direct reduction process is comparatively energy efficient. Steelmade using DRI requires significant

Recovery and utilization of waste heat in a coal based

Jun 01, 2012 Coal-based sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking coal are fed to the kiln at controlled rates without pre-mixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln.

sponge iron process

Jul 29, 2010 The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

Sponge Iron (DRI) The Hira Group

Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process. Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe

(PDF) Energy survey of the coal based sponge iron industry

The actual process of the coal based sponge iron production is based on SL/RN proce ss (jointly developed by the S teel Company of Canada, L urgi Chemie, R epublic Steel Company and N

SPONGE IRON PLANT

MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid. Most solid reduction process use non-coking coal as reducing agent due to abundantly available non-coking coal. The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore.

Sponge iron making full process_Coal base DRI YouTube

Dec 24, 2018 Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by

Direct reduced iron Wikipedia

Process. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.), in order to convert the ore to metallic iron, without melting it (below 1,200 °C (2,190 °F)).

Sponge Iron (DRI) The Hira Group

Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process. Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe

Sponge Iron Manufacturer India

Sponge iron produced using the non coking coal is called coal based sponge iron / DRI. For producing the sponge iron through this process requires high grade of iron ore and non coking coal. Gas Based DRI / HBI. In this process route, iron oxides are converted to the DRI / HBI by using natural gas in a vertical shaft furnace.

ENERGY INTEGRATION IN SPONGE IRON PLANT USING

Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively. Presently, there are 118 large and small sponge iron plants in India- 115 of them are coal based while only 3 are natural gas based. The advantages of sponge iron are:

ORISSA SPONGE IRON AND STEEL LTD.

In this backdrop TRFI took the first step to set up a coal based sponge iron plant in India. The process technology developed by Allis Chalmers Corporation, USA based on pilot plant studies known as ACCAR process was used initially. This process used 80% coal and 20% oil, which subsequently became uneconomical due to increase in crude prices.

sponge iron.pptx Iron Steelmaking

Gas-based sponge iron is not subjected for magnetic separation, as no contamination with nonmagnetic is possible either it can be cooled indirectly or briquetted in hot condition to get hot briquetted iron (HBI) B. Solid Reducant or Coal Based Technologies This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.

Swedish Steelmaker Uses Hydrogen Instead Of Coal To Make

Aug 31, 2020 Its pilot plant in Lulea, Sweden, will produce sponge iron, a crucial ingredient for its steel-making process, while carrying out tests between 2020 and 2024 to

Sponge Iron Industry SlideShare

Nov 17, 2012 Garbage Factor for a tonne of sponge iron unit.INPUT (in Tonnes) OUTPUT (in Tonnes)1.6-1.75 Iron Ore 1.8-2 Carbon Dioxide1.2-1.5 Coal 0.25 Dust0.035-0. 5 Dolomite 0.29 Coal Char1.5-2 Water 0.02 Kiln accretions 0.2 Sulfur Dioxide with water vapour Water vapourSource: Down to Earth, September 16,2006.

SPONGE IRON PRODUCTION FROM ORE -COAL

Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process.

(PDF) i) Direct Reduced Iron: Production

be broadly classified into two groups: (1) coal-based DR proces s and (2) gas-based DR process. Details of DR processes, reoxidation, storage, tran sportation, and application of DRI are discussed in

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are

Development of energy conservations scenarios for sponge

Jan 16, 2011 This paper presents an approach to find the best modification in the coal-based sponge iron process with an aim to integrate energy in it. For this purpose, a few energy conservation cases are formulated by integrating unutilized energy present in possible areas of process flow sheet. When unutilized energy of the process is properly integrated, energy demand from outside sources can be

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are

SPONGE IRON PRODUCTION FROM ORE -COAL

Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process.

Development of energy conservations scenarios for sponge

Jan 16, 2011 This paper presents an approach to find the best modification in the coal-based sponge iron process with an aim to integrate energy in it. For this purpose, a few energy conservation cases are formulated by integrating unutilized energy present in possible areas of process flow sheet. When unutilized energy of the process is properly integrated, energy demand from outside sources can be

ENERGY INTEGRATION IN SPONGE IRON PLANT USING

Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively. Presently, there are 118 large and small sponge iron plants in India- 115 of them are coal based while only 3 are natural gas based. The advantages of sponge iron are:

Sponge Iron Division Trimula Industries

Feed material in a DRI process is either iron ore sized to 10 to 30mm or iron ore pellets produced in an iron ore pellet plant. In a coal based plant, the reactor for the reduction reaction is an inclined horizontal rotary kiln. In this kiln, both coal and the iron ore feed material is charged from the same end of the kiln.

sponge iron.pptx Iron Steelmaking

Gas-based sponge iron is not subjected for magnetic separation, as no contamination with nonmagnetic is possible either it can be cooled indirectly or briquetted in hot condition to get hot briquetted iron (HBI) B. Solid Reducant or Coal Based Technologies This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION

1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge

Sponge Iron Industry SlideShare

Nov 17, 2012 Garbage Factor for a tonne of sponge iron unit.INPUT (in Tonnes) OUTPUT (in Tonnes)1.6-1.75 Iron Ore 1.8-2 Carbon Dioxide1.2-1.5 Coal 0.25 Dust0.035-0. 5 Dolomite 0.29 Coal Char1.5-2 Water 0.02 Kiln accretions 0.2 Sulfur Dioxide with water vapour Water vapourSource: Down to Earth, September 16,2006.

ORISSA SPONGE IRON AND STEEL LTD.

In this backdrop TRFI took the first step to set up a coal based sponge iron plant in India. The process technology developed by Allis Chalmers Corporation, USA based on pilot plant studies known as ACCAR process was used initially. This process used 80% coal and 20% oil, which subsequently became uneconomical due to increase in crude prices.

Sponge Iron Gas Based Sponge Iron Manufacturer from

Natural gas is reformed to enrich with 112 and Co mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process. When the gases are traveling upwards the charge moves downward by gravity.

The reasons for the success of Sponge Iron Industry in

Presently, coal based units produce ~90% of the total sponge iron in India. Moreover, India’s crude steel production grew at a CAGR of 6.75% between 2006-16. The production of EAF steel as a share of total steel grew at a steady rate, from 57% (2006) to 68% (2012), thereafter, this declined to ~57% in the past four years, ending 2016.

HYDROGEN SULFIDE REMOVAL FROM BIOGAS Part 3A:

Part 3A: Iron Sponge Basics November 2017 One of the oldest technologies for the removal of hydrogen sulfide (H 2 S) from gas is the use of “Iron Sponge”. A chemical-physical process, originally developed to remove H 2 S from natural and coal gas streams, iron sponge has been in use for over 140 years and more recently to remove H 2

Generation of Energy Conservation Measures for Sponge Iron

Generation of Energy Conservation Measures for Sponge Iron Plants . Anil Kumar Prasad, Vivek Kumarand Shabina Khanam, Member, IAENG Abstract During the operation, a tremendous amount of heat is generated in the coal based sponge iron plant and a significant part of this heat associated with the waste gas, remains unutilized. While utilizing this heat in the process the energy demand of the

Characterization of semi-coke generated by coal-based

Aug 06, 2015 Solid wastes derived from metallurgical industries pose a significant threat to environment. The utilization and disposal of these solid wastes are the major concern in the world. Semi-coke generated in coal-based direct reduction process of iron ore is a by-product and its suitable utilization is not available so far. In order to handle it properly, the characteristics of this by-product