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Coal Based Sponge Iron Process

Indian Coal Based Sponge Iron Manufacturers & Exporters

Sponge iron, also called direct reduced iron, is a vital constituent in steel making process. Sponge iron is made either by using coal or natural gas. It is coal based sponge iron that is still the primary method of obtaining sponge iron in India. This is because India has a shortage of natural gas while there is an abundance of coal in the

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coal based dri process

Process Description and flow diagram of Coal Based DRI Plant Some of Required Properties Of Iron Ore for Sponge Iron Operation. Iron, along with its generic products, is currently the most widely utilised metal in the various sectors of the world’s economy.

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Energy Audit Methodology of Sponge Iron Manufacturing Units

Energy Audit, DRI Process, Sponge Iron, Kiln Efficiency, Sankey Diagram of Kiln, Coal Balancing. 1. Background of This Study. Sponge iron industries in India have mandatory energy performance target in terms of specific energy consumption (SEC). They shall have to achieve the target SEC by 31 st March, 2015. The non-performing industries are

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PDF Characterization of dolochar wastes generated by the

the ingredients for making sponge iron along with iron ore. Dolochar represents the non-magnetic fraction from the DRI process. The principal raw materials required for sponge iron production are iron ore, non-coking coal, and dolomite. For the production of 100 t sponge iron, there are 154 t (65wt% Fe) iron ore and 120 t (B grade) coal required.

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Sponge iron’s dirty growth - Down to Earth

Sponge iron’s dirty growth. In the years to come, India's expanding steel production will be largely driven by sponge iron. But its manufacturing process, based on coal, is highly polluting. The repercussions are already visible near sponge iron factories which have mushroomed in iron ore- and coal-rich areas.

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ORISSA SPONGE IRON AND STEEL LTD

OSIL Process subsequently became popular and was widely accepted and recognized as one of the leading coal based sponge iron technology in the world.. OSIL set up its Project & Engineering Division at Bhubaneswar in 1992 to enable setting up of Sponge Iron plants in the country based on its patented process.

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Sponge Iron Manufacturer India

Sponge iron produced using the non coking coal is called 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.

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SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE

Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process.

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Super Refractories - Sponge Iron Production

Sponge Iron. For Sponge Iron production by Direct Reduction Process CUMI offers the following solutions. COAL BASED SPONGE IRON ROTARY KILN. svenska casino spel. Application: Recommended Products: AFTER BURNING CHAMBER (ABC) CUMICRETE CK 14 SI: ABC BACK UP :

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PDF) i) Direct Reduced Iron: Production

be broadly classified into two groups: (1) coal-based DR proces s and (2) gas-based DR process. Details of DR processes, reoxidation, storage, tran sportation, and application of DRI are discussed in

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Sponge Iron Division – Trimula Industries

Feed material in a DRI process is either iron ore sized to 10 to 30mm or iron ore pellets produced in an iron ore pellet plant. In a coal based plant, the reactor for the reduction reaction is an inclined horizontal rotary kiln. In this kiln, both coal and the iron ore feed material is charged from the same end of the kiln.

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CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Sponge Iron Production Process Process description 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. Different streams in the PFD are assigned individual number and henceforth each stream

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The reasons for the success of Sponge Iron Industry in

Presently, coal based units produce ~90% of the total sponge iron in India. Moreover, India's crude steel production grew at a CAGR of 6.75% between 2006-16. The production of EAF steel as a share of total steel grew at a steady rate, from 57% (2006) to 68% (2012), thereafter, this declined to ~57% in the past four years, ending 2016.

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Coal based Direct Reduction Rotary Kiln Process - IspatGuru

The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital expenditure and no requirement of coking coal.

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Sponge iron, pig iron manufacture-Mishri international

W e mishri international are supplier, trader, distributor of Sponge iron,pig iron, gas based sponge iron, coal based sponge iron, in rajkot, gujarat, india. Manufacturing process: The reduction of Iron Ore can be achieved by using either carbon bearing material, such as non-coking coal or a suitable reducing gas in the form of reformed natural

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India - production share of sponge iron by process route

Around 86 percent of the sponge iron produced in India in fiscal year 2020 was under coal based process route. This was due to numerous coal based units present in the mineral rich states.

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Sponge iron making full process_Coal base DRI

Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by

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Development of energy conservations scenarios for sponge iron

It decreases coal consumption as coal is the only source of energy in this plant. For energy integration in sponge iron process pinch technology is applied on the actual data of plant. Based on this data, seven energy conservation cases are identified. Among these, two are selected for detailed analysis based on utility requirement.

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Direct Reduced Iron and its Production Processes - IspatGuru

In a coal based process, the reactor for the reduction reaction is a rotary kiln which is slightly inclined to the horizontal position. The process of direct reduction is carried out with the operating temperatures maintained in a range from 1,000 deg C to 1,100 deg C.

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Process Description and flow diagram of Coal Based DRI Plant

Process Description and flow diagram of Coal Based DRI Plant Description of Sponge Iron Manufacturing Process Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change.

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sponge iron.pptx | Iron | Steelmaking

Gas-based sponge iron is not subjected for magnetic separation, as no contamination with nonmagnetic is possible either it can be cooled indirectly or briquetted in hot condition to get hot briquetted iron (HBI) B. Solid Reducant or Coal Based Technologies This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.

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PDF) Modeling of Rotary Kiln for Sponge Iron Processing

Direct reduction by treating with coal as reductant.In According to the adopted technologies coal fuelled kiln based process is mostly practiced by industries widely.There are some key features which makes kiln based process different from other practiced sponge iron production. A sealed environment prevents external air to get into the system

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HYL Direct Reduction Technology: Adaptations for the

Rotary kiln coal-based DR plants, based on single module, are designed for up to a maximum of 0.250 M tonnes per year (million tpy) of DRI, requiring high capital cost for larger capacities. When using ore fines and coal, gangue and sulfur stemming from coal is normally reflected in higher transformation costs in the steelmaking step.

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SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE PELLETS IN

Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process.

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Sponge Iron - HIRA - Godawari Power & Ispat Limited

Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process. Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe

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Sponge Iron (DRI) | The Hira Group

Coal based Sponge-iron 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). Iron Ore Pellet is used for reduction. After reduction of iron ore pellet the product resembles sponge because of pores left behind after removal of oxygen.

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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.

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SPONGE IRON INDUSTRY - cdn.cseindia.org

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.

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Top PDF Sponge Iron - 1Library

In the process for the production of sponge iron, the raw materials viz., iron ore, coal and dolomite are charged into rotary kiln from the inlet end by means of a feed tube in a pre-determined ratio by electronic weighing equipment. The Rotary kiln is of 3.00 mts.

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Generation of Energy Conservation Measures for Sponge Iron

Generation of Energy Conservation Measures for Sponge Iron Plants . Anil Kumar Prasad, Vivek Kumarand Shabina Khanam, Member, IAENG Abstract - During the operation, a tremendous amount of heat is generated in the coal based sponge iron plant and a significant part of this heat associated with the waste gas, remains unutilized. While utilizing this heat in the process the energy demand of the

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN

1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge

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