Market share: About 23% of sponge iron total production. 4) Tunnel furnace process . This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction temperature, and reduction is performed on Silicon Carbide (SiC) Crucibles in a tunnel furnace.
sponge iron sector, which is dominated by smallsized coalbased direct reduction of iron (DRI)based plants. India is one of the unique countries in the world where coalbased DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is
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. For steel producers, it is a preferred metallic, energy efficient and ...
In coalbased DRI process, accretion formation inside the rotary kiln is a genuine complex problem. Accretion formation in a rotary kiln of 100 tpd DRI plant has been investigated. ... Metallic iron Fe (m) in sponge iron varied between 84 and 62%. Approximately 300 ton of accretion was generated for a running of 25 days. Table 1 Iron ore ...
With such dimension of notion We in our Sponge Iron Manufacturing process through 4 Kilns (2 * 50T and 2 * 40T) laid up the best DRI making process of India. It is Coal Fuel based DRI. Coal based Spongeiron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron (DRI).
Recovery and utilization of waste heat in a coal based sponge iron process (PDF) Recovery and utilization of waste heat in a coal based sponge iron process | Vivek kumar bir98bir no longer supports Internet Explorer.
A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency.
Yes, sponge iron making is a primary or can be a primar metallurgical process base on the Chemistry information that is provided. What process causes the mass of the drying sponge to change ...
Such coal based sponge iron is mainly used by induction furnace steel producers leading to technical deficiencies in the steel making process. Further, energy consumption wise, the coal based sponge iron plants are not efficient which can be improved by cogeneration using kiln off gas. CONSIDERATIONS IN SETTING UP COAL BASED SPONGE IRON PLANTS
SIPL is operating 4 x 100 TPD Direct Reduced Iron Rotary Kilns for production of 2000 TPA Sponge Iron at Purulia, using the proven German SL/RN technology. Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and ...
Coal based direct reduction process is based on the solid reducing agent which is noncoking coal. The reaction takes place at high temp (1000 deg C to 1100 deg C). Coal plays a dual role in the kiln. Part of coal is used as fuel to supply the desired heat so as to take the raw materials to the desired temperature.
Recovery and utilization of waste heat in a coal based sponge iron process. by Vivek Kumar. 2012, Chemical Engineering and Processing: Process Intensification. See Full PDF Download PDF. Create a free account. Access 47 million research papers for free; Keep uptodate with the latest research;
SAFETY GUIDELINES FOR IRON STEEL SECTOR MINISTRY OF STEEL, Direct Reduction GOVT. OF INDIA Plant (Coal Based) Doc. No: SG/32 Rev no. : 00 Effective Date: 1. OBJECTIVE: The main function of making Sponge Iron in the Kiln is to convert Iron ore into sponge iron by using Iron ore, coal and dolomite / limestone. The Sponge Iron is processed
The process flow sheet of a typical coalbased sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd. In this process screened iron ore (), coal () and dolomite () are charged into the rotary kiln. About 40% of total tph coal ...
Making of mild steel in the induction furnace was first experimented during early 1980s and it gained popularity when the production of sponge iron utilizing coal based process of rotary kilns became popular. Induction furnace is a type of electric melting furnace which uses electric current to melt metal.
Coalbased sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation
Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coalbased sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.
Process. Direct reduction processes can be divided roughly into two categories: gasbased, and coalbased. In both cases, the objective of the process is to remove 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)).
Coal based: 9293: : ... The principle of the water gas shift reactor (or also called sponge iron process) is not new (see [2, 3] and the references therein). This reaction involves a redox reaction, in which the carbon within the carbon monoxide is oxidised and the hydrogen within the water is reduced.
Sponge Iron Making Process(Coal Based) KruppRenn Process : The KruppRenn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of ore and reducing agent like coke breeze or bituminous coal fines are fed into rotary kiln continuously. The ...
Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H2 and CO.
Sponge Iron Making Process(Coal Based) KruppRenn Process : The KruppRenn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of ore and reducing agent like coke breeze or bituminous coal fines are fed into rotary kiln continuously. ...
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. ... The modified PFD for sponge iron process based on HEN is shown in Fig. 4 where grey lines shows the ducts to carry waste gas from chimney to exchanger1 (shown through G
therefore classified as coal based and gas based process respectively. Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production [5]. At present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the ...
This paper presents an approach to find the best modification in the coalbased sponge iron process with an aim to integrate energy in it. For this purpose, a ... Engineering, Environmental Science. 2011; During the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and significant part of this heat ...
Sponge iron means porous iron produced by direct reduction reduction (DR) process is a solidstate reaction process ( solidsolid or solidgas reaction) by which removable oxygen is removed from the iron ore, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or agglomerates of fine ore [].
Sponge iron is a type of iron produced by coal based or gasbased reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...
The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel ... In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no ...
During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as ...
A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency.
In chemical industry: Benzene. .from the carbonization (heating) of coal, which produces coke, combustible gas, and a number of byproducts, including benzene. Carbonization of coal to produce illuminating gas dates back in England to the very early years of the 19th century. The process is still employed in some countries, but more use is..
Brief description of sponge iron plant process 40 Technological options for coal based plants 42 Status of Sponge Iron Plants in India 67 Questionnaire Survey 67 Identified stakeholders for consultations 67 Questionnaire Survey Analysis 68 General outlook of green house emission measures and practice ...
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