Direct reduced iron (DRI) is also known as sponge iron (Hasambeigi et al. 2014 ). This high porous material has a metallization degree in the range 8595% with a carbon content in the range % depending on the processing route. During the process, the iron oxides are reduced at the solid state.
WhatsApp: +86 18838072829Coalbased 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
WhatsApp: +86 18838072829Coal 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.
WhatsApp: +86 18838072829In 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 ...
WhatsApp: +86 18838072829Recovery 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.
WhatsApp: +86 18838072829Coal 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.
WhatsApp: +86 18838072829The 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 ...
WhatsApp: +86 18838072829Direct 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.
WhatsApp: +86 18838072829However, for coalbased DR the reductant is generated from noncoking coal and rotary kilns, rotary hearth furnaces and multihearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 6575% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
WhatsApp: +86 18838072829With 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).
WhatsApp: +86 18838072829It is also known as sponge iron since its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is around 10,000 times greater than the internal surface area of solid iron. ... Coal based process. In a coal based process, the reactor for the reduction reaction is a rotary ...
WhatsApp: +86 18838072829Coalbased direct reduction systems have been discussed previously in the section, "Solid Reductant Systems." ... Meyer, G. and U. Bongers, "Reduction by Solid Fuels with the Krupp Sponge Iron Process", 2nd Latin American Seminar on Direct Reduction, Porto Alegre, Brazil, May 49, 1975. 38. Staff, "Krupp Waste Recovery Process", Metal Bulletin ...
WhatsApp: +86 18838072829Sponge iron, also known as direct reduced iron (DRI) and used widely in the steel making process, resembles a honeycomb in its structure. As India has adequate coal deposits and its utilization for steel plants is considered to be of prime importance, production of coalbased sponge iron is considered as a viable option (Agrawal et al. 2000).In DRI production, India deserves special attention ...
WhatsApp: +86 18838072829A 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.
WhatsApp: +86 18838072829This 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 ...
WhatsApp: +86 18838072829Sponge 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 ...
WhatsApp: +86 18838072829Given that the EAF process's primary inputs are scrap iron, coalbased sponge iron, and gasbased sponge iron, three scenarios are defined in Table 5, and their impacts are assessed. Scenario 1: 90% gasbased sponge iron is used alongside 10% scrap iron (which is the actual modus operandi of the factory).
WhatsApp: +86 18838072829The 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.
WhatsApp: +86 18838072829Fig 3 Process flow diagram for coal based sponge iron The hot reduced sponge iron along with semiburnt coal, discharged from kiln is cooled in watercooled cylindrical rotary cooler to a temperature of 100200°C. The discharge from cooler consisting of sponge iron, char other contaminations are passed on through
WhatsApp: +86 18838072829Reducing 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.
WhatsApp: +86 18838072829SAFETY 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
WhatsApp: +86 18838072829Brief 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 ...
WhatsApp: +86 18838072829Sponge 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.
WhatsApp: +86 18838072829Coalbased 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.
WhatsApp: +86 18838072829This 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
WhatsApp: +86 18838072829VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coalbased sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore
WhatsApp: +86 18838072829process of HYLSA. These contribute over 80% of world sponge iron production today. Out of the coal based technologies SL/RN technology of Lurgi GmbH, West Germany has been the most successful one. Little success has been achieved by other coal based technologies namely CODIR technology of Krupp Industriatechnik now Mannesmann Demag,, DRC
WhatsApp: +86 18838072829The present work investigates the design modifications which can lead to efficient energy integration in coalbased 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 coalbased sponge iron plant, a tremendous amount of heat is generated and a ...
WhatsApp: +86 18838072829Market 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.
WhatsApp: +86 18838072829Apart 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.
WhatsApp: +86 18838072829The 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 ...
WhatsApp: +86 18838072829Sponge 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. ...
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