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 speed and inclination of the kiln. In combination ...
The major difference between the gas and coal based DRI processes is the incorporation of coal in the later. In fact in coal used by sponge iron produces in India contains as high as 40% ash.
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 [].
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 ...
Apart from these research publications, an article entitled "PROCESS INTEGRATION OF COAL BASED SPONGE IRON PLANT" has been published in DRI UPDATE Magazine, November 2020, Sponge Iron Manufacturing Association (SIMA), New Delhi. It is circulated to all sponge iron fraternity of the world through SIMA.
Simulation of rotary kiln for sponge iron process is based on combustion of coal particles and reduction of iron ore. The heat transfer inside the kiln is done through radiation. The model equations used for computation of desired parameters, such as temperature profile and % metallization, are tabulated in Table 3.
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 few energy conservation cases are ...
India is the world's largest producer of sponge iron, accounting for 13 per cent of the global production 8. Sponge iron is produced using either coal or natural gas. Since coal is available in India, the sector largely depends on coal based sponge iron which contributes about 80 per cent of the total capacity in the country9.
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.
Coal gasificationbased sponge iron plant of Jindal Steel Power Ltd in Angul, Odisha, may become a game changer in the coming years. This plant is likely to be commissioned in 2013. Cost of syn gas and efficient running of gasifiers will be the key of success of this promising sponge iron process route.
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 manufacturing process is an alternative process to manufacturing of Steel through blast furnace route. Sponge Iron is also widely known as Direct Reduced Iron (DRI). ... S. Mondal, Operation of CoalBased Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation, 2012, pp. 727732.
Coal based DRI making process. Iron Ore and noncoking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite which acts as a desulphurized. ... The process of sponge iron making aims to remove the oxygen from iron ore and when the same occurs ...
Broadly two types of technologies are used for producing sponge iron, for coal based plants, coa l . ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of .
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)).
This is a coalbased reduction technology, applicable to both steel mill waste and iron ore fines, with coal as a Creductant agent. The reduced iron can be fed to a BF or directly into a melting process. If exposed to air for a long time, the metallic iron reoxidizes into iron oxide, deteriorating its quality.
Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H 2 and CO. Although DRI production is more energy efficient than pig iron production from BF, additional processing (typically EAF) is needed to upgrade DRI sponge iron for market.
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 present paper proposes two energy integration options, Option1 and Option2, to compare power generation and preheating scheme in sponge iron accounts power generation whereas in Option2 preheating of feed material, slinger coal and kiln air is considered. These options utilize heat of waste gas that exits the after burning chamber of the process, which is available from ...
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 ...
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.
After the reduction process, a mixture of sponge iron and char is discharged from the kiln into the cooler where cooling takes. Water is sprayed at the cooler shell to indirectly cool the material from about 1000 ℃ to 120 ℃. ... Kaltenthaler, E.: Healthrelated qualityoflife of coalbased sponge iron plant workers in Barjora, India: a ...
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 speed and inclination of the kiln.
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