The invention relates to a method for producing carburized direct-reduced sponge iron from iron oxide material (2). First, direct reduction is performed by means of a reducing gas consisting at least predominantly of H2, thereafter the carbon content in the sponge iron is increased by means of a supplied carburizing gas, after which carburizing gas used in this process is at least partially ...
natural gas, separating hydrogen gas from the syngas to replace current hydrogen produced from natural gas, and finally producing a biochar product, intended for utilization as a reducing agent in the sponge iron process (Pettersson et al. 2016). Experiments with utilizing biochar as a reducing agent for the sponge iron process have been
Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3. Kiln temperature distribution for the base case The feed material (bed) enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard.
metal iron content by directly reducing iron ore (or iron ore pellets) with reducing gases. u While the produced DRI is mainly used as the raw material of electric steelmaking, it is also used as blast furnace feed for energy saving (reduction in coke consumption) and increased production of molten iron at integrated blast furnace steelworks.
From 2003, coal based sponge iron route dominated because of limited availability of natural gas and fast growing demand of metallics. In fact, no gas based sponge iron/HBI plant came up after 1994 (19 years). During 2003-2008, there had been a …
This book provides a fascinating study of the newly emanating field of direct reduction in which iron ore is 'directly reduced' in the solid state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron, which is subsequently melted in electric arc furnaces (sometimes in induction furnaces) to produce liquid steel.
All India production of Sponge Iron during April 2008- January 2009 is reported as 15.94 MT with share of 4.03 MT from gas based units and balance 11.91 MT from coal based units. Capacity utilization in gas based DRI Units, on all-India basis during 2008-09 …
2.4 Material Balance 12 2.5 Energy Balance 15 ... DRI production is quite substantial and in comparison to gas-based production, this route is energy- and carbon-intensive. To meet the DRI production target of 80 million tonne by 2030–31 as envisaged under the ... The Sponge Iron Manufacturers Association (SIMA) acts as an apex body to ...
Keywords- Sponge iron plant, Heat integration, Material and Energy balance I. INTRODUCTION Sponge iron is a metallic mass with honeycomb structure. It is a form of iron produced from direction reduction of iron oxide below the fusion temperature of iron ore (1535ºC) by utilizing hydrocarbon gases or carbonaceous fuels as coal.
liquid steel from iron ore by the direct reduction route. The report was examined at the meeting of experts and environmental management guidance for the direct reduction route to steel making was drafted (2). A period of two months was allowed for participants to submit additional material for inclusion in a revised
523-1 Designing of an Intelligent Fuzzy Logic System for Accretion Prevention in Sponge Iron SL/RN Rotary Kiln Based 100TPD Dri Process By Tawanda Mushiri and talon garikayi Industrial and Process Furnaces: Principles, Design and Operation
Raw material system mainly consist Vibro Feeder, Crusher and Screen. Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of
Sponge iron provides the base feedstock for all iron-based, self-lubricating bearings and still accounts for around 30% of iron powder usage in PM structural parts. Solid state reduction is also used for the production of refractory metal powders, using hydrogen as the reducing agent, and for the production of specialist iron powders by the ...
Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.
Fig. 2.5 Material balance in a rotary kiln sponge iron plant. ... But even then, gas-based Figure 2.4 indicates the essential features processes have generally found favour due which are needed in the reduction kiln of a to better and more consistent quality, sponge iron rotary kiln plant. However ...
The flue gas at about ... to utilize the waste heat content of flue gases. Material Balance for Sponge Iron Plant An Indicative Material Balance showing input of raw materials and the resultant output for the Sponge Iron Plant are presented in ... An Indicative coal based Sponge Iron Plant process flow diagram is presented below, MA AMBA SPONGE ...
The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant. The sponge iron is also known as Direct Reduced ...
The first model uses a material balance to solve for the salinity given the distilled water volume and gravimetric weight difference of the sample before and after leaching. The second model iteratively estimates the salinity required to achieve of total fluids saturation at reservoir condition after correcting for the bleeding, stress and ...
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.
ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3 …
In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, India producing 57% of …
Iron ore and non-coking coal are main raw materials used to produce sponge iron. The minister noted that India's sponge iron production has grown 25 per cent to …
IS 12929: 1990 Feedstock (iron oxides and natural gas) for gas based direct reduction-guidelines. IS 13839: 1993 Specification for sponge iron/direct reduced (DRI) fines/briquettes for steel making. IS 13885: 1993 Non-magnetic/char in sponge iron – method of determination. IS 13905: 1993 Hot briquette sponge iron(HBI) for steel making.
Reducing gases are produced from natural gas (gas-based DRI) or coal (coal-based DRI) called syngas, a mixture of H2 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. These processes operate with different feedstocks.
plant was established using coal-based technology during 1980's by Sponge Iron India Limited. In the year 1989 ESSAR steel made a beginning in the production of …
Table 2.1: Raw Materials for Production of Sponge Iron Material Size Iron Ore 5-18 mm Coal 3-20 mm Dolomite 2-6 mm Air - 2.1.3. Theory In any rotary kiln process based on coal, the reduction of iron oxide takes place by the carbon monoxide produced from coal. The …
An improved method for operating a blast furnace wherein a portion of the charge is prereduced iron ore with a relatively low metallization in the range of 75% to 90% and a relatively high carbon content in the range of 1.5% to 4.5% by weight. The composition of the sponge iron is selected so as to realize an increase in the production of pig iron and a decrease in the consumption of coke ...
sponge iron manufacturing and recommended improvement in that [1]-[4]. It is found that during the operation in the coal based sponge iron plant, an incredible amount of heat is generated and a significant part of this heat associated with the waste gas, remains unutilized. A …
It is seen that the growth of sponge iron industry in last few years is remarkable and today India is the largest producer of sponge iron as it covers 16% of global output1. Sponge iron is produced primarily both by using non-coking coal and natural gas as reductant and therefore classified as coal based and gas based process respectively.
The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coal-based sponge iron plant, a tremendous amount of heat is generated …
