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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In 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 ...
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In chemical industry: Benzene. .from the carbonization (heating) of coal, which produces coke, combustible gas, and a number of byproducts, including benzene. Carbonization of coal to produce illuminating gas dates back in England to the very early years of the 19th century. The process is still employed in some countries, but more use is..
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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.
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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.
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sponge iron sector, which is dominated by smallsized coalbased direct reduction of iron (DRI)based plants. India is one of the unique countries in the world where coalbased DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is
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On sponge ironmaking in coalbased rotary kilns, there are studies on process modeling (Gaurav and Khanam, 2016), ... Switching from coal to NG as the feedstock leads to a 58% reduction in the GHG emissions of the coalbased DRI process plants (including electricity use). On a life cycle basis, GHG emissions from the NG reformer DRI process ...
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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 ...
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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. The required data are ...
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Coal 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.
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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.
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The process flow diagram of conventional coal based sponge iron plant is shown in Fig. 1. The operating data, shown in Fig. 1, is taken from a typical Indian coal based sponge iron plant where iron ore, feed coal and dolomite are fed to the rotary kiln. A separate conveyor collects different size fractions of coal for injection into the kiln
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2. Overview of DR processes. Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing. gas to produce Direct Reduced Iron (also known ...
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Sponge 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 ...
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Sponge 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 ...
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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)).
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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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It 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 ...
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VOL. 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
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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. For steel producers, it is a preferred metallic, energy efficient and ...
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process of HYLSA. These contribute over 80% of world sponge iron production today. Out of the coal based technologies SL/RN technology of Lurgi , 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
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Iron ore or pellets, reductant ( noncoking coal or natural gas) and limestone/dolomite are the main raw materials for DR technology. For the successful operations, the process of DR technology has specified the characteristics of the raw materials to be used in the process. The principal raw materials used in DR/sponge iron processes are ...
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Making of mild steel in the induction furnace was first experimented during early 1980s and it gained popularity when the production of sponge iron utilizing coal based process of rotary kilns became popular. Induction furnace is a type of electric melting furnace which uses electric current to melt metal.
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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 ...
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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 [].
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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.
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The 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 ...
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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 ...
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Given 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).
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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.
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With 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).
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Smelting reduction (SR) processes are the latest development in pig iron production. The SR process emerged during the 1990s. In SR processes, iron ore and coal are added directly to a metalslag phase where the ore is reduced. The SR process combines the gasification of coal with the smelting reduction of iron ore.
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The 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 ...
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A material supplier from Belgium would like to produce limestone powder for his custome...
India is rich in various mineral resources and it is an important mineral processing market
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