sponge iron process
29-07-2010· 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.Energy survey of the coal based sponge iron industry,,01-09-2015· The computation points out that 4.2%, 1.12%, 43.5% and 3.6% energy is lost through streams of sponge iron, char, waste gas and volatile matter, respectively. It is clear from this figure that significant amount of heat is also lost with waste gas. (2) Hot sponge iron isIS 15774 (2007): Sponge Iron/Directed Reduced Iron (DRI,,It is defined as follows: Degree of Mass of metallic iron ~ ~~0 metallization, percent = Mass of total iron 3.10.1 Equivalent A4etallization — Carbon content in sponge iron at a given degree of metallization is important. It has the capacity to remove oxygen from the remaining iron oxides during steel making.Iron Sponge Process - an overview | ScienceDirect Topics,The natural gas should be wet when passing through an iron sponge bed as drying of the bed will cause the iron sponge to lose its capacity for reactivity. If the gas is not already water-saturated or if the influent stream has a temperature greater than 50°C (approximately 120°F), water with soda ash is sprayed into the top of the contactor to maintain the desired moisture and alkaline conditions duringSPONGE IRON INDUSTRY,The first gas based sponge iron plant, with a capacity of 1.52 MTPA, was set up by Essar Steel Limited in Hazira, Gujarat in 1990 5 . Today, India has an installed capacity of 36.7 MTPA of sponge iron 6 .SPONGE IRON PLANT,RAW MATERIAL General The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production can be classified into:-
DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE IRON
(DRI). 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. Due to a promising availability of coal, the coal based sponge iron plants share the major amount of its production.Direct reduced iron - Wikipedia,Direct reduced iron, also called sponge iron, is produced from the direct reduction of iron ore into iron by a reducing gas or elemental carbon produced from natural gas or coal. Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting point of iron. Reduced iron derives its name from these processes, one example being heating ironSponge Iron Process for Manned Space Exploration,sponge iron cycle, Based on thermodynamic considerations, conversion, cycle (oxidation of iron contact mass, reduction of gas phase) is generally endothermic. The overall thermal energy balance is thus positive for all fuels except of methanol. An additionalsponge iron process,29-07-2010· Based on our experience an ideal coal based sponge iron plant shall have the following facilities. As the manufacture of sponge iron is very sensitive to the physical and chemical characteristics of raw materials, a well designed raw material preparation plant with crushing/screening facility for iron ore and coal to control the size of input materials to the kiln is a prime requiste.CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production,,Fig. 1 Process flow diagram of the sponge iron process with material and energy balanced data ROTARY KILN (RK) (900 C) (1020 C) Total air Flue gas Kiln Feed RC Sponge iron Water Hot Water DSC Dust: 1 T/hr ABC Water Air (+1mbar) Dust: 4.4 T/h EC Waste gas Water Dust: 0.6 T/h (+1mbar) (-1mbar) ESP (-5mbar) Dust 2sponge iron process: 2010,29-07-2010· Extensive testing is required for evaluating the suitability of these raw materials for the manufacture of Sponge Iron. Iron Ore: Lump iron ore in the size range of 5-20mm can be used in all coal based rotary kiln processes. In gas based processes 70% iron ore pellets and 30% lump iron ore of 10-30mm are being used.
Biochar in the Höganäs sponge iron process – techno,
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 beensponge iron TCE NMD - SlideShare,18-05-2016· Or Hydrogen & Carbon Monoxide (Gas Based) The reducing gas, diffuses through the pores of the ore, reacts to reduce the ore. As the ore is reduced, the porosity increases. Hence, it is called as Sponge Iron. DRI is produced as a result of removal of oxygen from the iron ore, and hence has a higher porosity and is reactive with atmospheric air.M/s Bravo Sponge Iron Pvt. Ltd. - Welcome to Environment,1.7 MTPA Iron Ore Pellet Plant with grinding Unit 48000 Nm3/hr Producer Gas Plant 350 TPD Sponge Iron Plant 7 MW of Power Plant on WHRB of 350 TPD Kiln Revision from 600TPD to 1000 TPD Rolling Mill. Material Balance 13 05 Raw materials Requirement and itsDirect Reduced Iron | Industrial Efficiency Technology,,Direct Reduced Iron (DRI), also known as Sponge Iron, offers an alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron ore is reduced in its solid state – unlike BF process where a liquid metal is formed during reduction. DRI can then be transformed to steel in electric arc furnaces. DRI production is common in Middle East, South America, India and Mexico.SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE,SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE PELLETS IN TUNNEL KILN . S.C.Khattoi. 1* , G. G. Roy2 1 Project & Engineering Consultancy, Keonjhar, Odisha, India 2 . Indian Institute of Technology, Kharagpur – 721302, India. Abstract: Today India stands as the largest producer of coal based sponge iron throughDownload Sponge Iron Production By Direct Reduction Of,,12-09-2012· Download SPONGE IRON PRODUCTION BY DIRECT REDUCTION OF IRON OXIDE Books now! Available in PDF, EPUB, Mobi Format. This book provides a fascinating study of the very important emerging 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
CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production,
Fig. 1 Process flow diagram of the sponge iron process with material and energy balanced data ROTARY KILN (RK) (900 C) (1020 C) Total air Flue gas Kiln Feed RC Sponge iron Water Hot Water DSC Dust: 1 T/hr ABC Water Air (+1mbar) Dust: 4.4 T/h EC Waste gas Water Dust: 0.6 T/h (+1mbar) (-1mbar) ESP (-5mbar) Dust 2sponge iron TCE NMD - SlideShare,18-05-2016· Or Hydrogen & Carbon Monoxide (Gas Based) The reducing gas, diffuses through the pores of the ore, reacts to reduce the ore. As the ore is reduced, the porosity increases. Hence, it is called as Sponge Iron. DRI is produced as a result of removal of oxygen from the iron ore, and hence has a higher porosity and is reactive with atmospheric air.Sponge iron industry needs quick actions for survival,,24-10-2013· 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 rapid growth of coal based sponge ironSPONGE IRON PRODUCTION BY DIRECT REDUCTION OF IRON,The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production.MIDREX Processes - KOBELCO,by a sealing gas, allowing the continuous charging of raw material and discharging of DRI. The reaction occurring in the shaft furnace is the well-known reduction reaction of iron, described as follows: Fe 2O 3 + 3CO → 2Fe + 3CO 2 Fe 2O 3 + 3H 2 → 2Fe + 3H 2O The exhaust gas (top gas) emitted from the top ofIronmaking and Steelmaking - Course,Blast Furnace as an efficient counter current gas solid reactor and maximum carbon efficiency. Week 2:Overall heat and Material Balance in Blast Furnace.Rist Diagram based on oxygen balance,Rist Diagram based on heat & Material balance . Week 3:Blast Furnace as a, based sponge iron technology, inclusion control in steel by upstream,
Direct Reduced Iron | Industrial Efficiency Technology,
Direct Reduced Iron (DRI), also known as Sponge Iron, offers an alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron ore is reduced in its solid state – unlike BF process where a liquid metal is formed during reduction. DRI can then be transformed to steel in electric arc furnaces. DRI production is common in Middle East, South America, India and Mexico.Chapter 4 – Material Balances Note - Poly,CBE2124, Levicky 1 Chapter 4 – Material Balances Note: Be sure to read carefully through all the examples in this chapter.The key concepts are best learned by problem solving. _____ Material balances: material balances express the constraint of conservation of mass, as applied to a process.Direct Reduced Iron (DRI) Production Plant,and coal gas refined in coal gasifiers, as well as widely-used natural gas, may be used as reducing gases. u NSENGI, Tenova-HYL and Danieli concluded a strategic alliance agreement for the joint development of DRI steel production plant and expansion of the market of DRI in September 2013. Direct Reduced Iron (DRI) Production PlantMicroporosity - GIESSEREILEXIKON.COM,Microporosity occurs in those places of the casting which solidify last, mainly in places with material accumulations and wall thickness transitions as well as at sand edges (protruding shape and core sections, see Sand edge effect), Figures 1 and 2.. Alloys with a wide solidification interval are particularly susceptible. Microporosity can thus occur in all casting materials, independant fo,,,
