Coal Based Sponge Iron Process

Sponge Iron

Different processes of coal-based and gas-based are discussed in detail. Forms of sponge iron, characteristics of sponge iron and re-oxidation of sponge iron …

Recovery and utilization of waste heat in a coal based sponge iron process

Coal-based sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking coal are fed to the kiln at controlled rates without pre-mixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln. In combination ...

Analyses of Different Modifications Proposed for …

The process flow diagram (PFD) of a typical coal-based sponge iron plant is shown in Fig. 1a. Different streams in PFD are assigned individual numbers and henceforth each stream will be …

EXECUTIVE SUMMARY

three decades. India, entered the sponge iron industry only in 1980, when the coal based DRI plant of Sponge Iron India Limited (SIIL) was commissioned at Kothagudem, in Andhra Pradesh. 2. The reasons for the tremendous growth of the sponge iron industry world over could be attributed to the advantages of using sponge iron

Recovery and utilization of waste heat in a coal based sponge iron process

Prasad et al. [7] suggested that by applying process integration in sponge iron process which reduces coal and water consumption by 30.5% and 72.6%, respectively resulting releases minimum waste ...

Sponge Iron

Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & physical characteristics.

Direct-Reduced Iron

2.1 Midrex Process. Midrex is the most successful gas-based DR process; it is a continuous process. It is basically a countercurrent process where a hot and highly reducing gas (95vol.% of this gas mixture being hydrogen and carbon monoxide with a ratio of H 2:CO varying from 1.5 to 1.6) reduces lump iron ore or pellets to metallic iron as …

Recovery and utilization of waste heat in a coal based sponge iron process

Coal-based sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking coal are fed to the kiln at controlled rates without pre-mixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln. In combination ...

Process flow diagram of the sponge iron plant.

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.

Direct Reduced Iron: Most Efficient Technologies for …

Because this process does not use natural gas, a lower-carbon- content product (around 0.4%) is expected. Similar to the gas-based HYL process, in the coal-based process, the furnace top gas is cooled and cleaned, and its CO 2 is removed and then recycled into a reducing gas circuit. Reducing gas is produced in a coal gasifier …

Operation of Coal-Based Sponge Iron Rotary Kiln to …

Sponge iron is the final product of coal fired rotary kilns. The schematic diagram in Fig. 1 describes the unit processes ... Fig. 1 Schematic flow sheet of coal based direct reduction process[1]

Sustainability Enhancement of the Coal Based Direct …

The principles of circular economy (CE) in systems thinking (ST) have been proposed in this paper as a measure towards augmenting the sustainability of coal …

Analyses of Different Modifications Proposed for the Sponge Iron …

Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...

Energy Survey of the Coal Based Sponge Iron Industry

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 ...

Evaluation of new equipments for utilization of waste heat in sponge …

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, …

Sponge Iron Manufacturer India

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 ...

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …

sponge iron sector, which is dominated by small-sized coal-based direct reduction of iron (DRI)-based plants. India is one of the unique countries in the world where coal-based DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is

Sponge Iron

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using …

(PDF) Operation of Coal-Based Sponge Iron …

In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.

WHAT IS SPONGE IRON AND HOW IS IT MADE?

In fact, we were the first player in the State to pioneer and successfully set up the first coal-based DRI plant in Raniganj, West Bengal in 1999. ... The process includes warming the normally occurring iron oxide in the …

SPONGE IRON INDUSTRY

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.

Sustainability Enhancement of the Coal Based Direct Reduction of Iron

Raw material utilization and waste generation for the DRI suggest that 1.6 tonnes of ore,1.2 tonnes of non-coking coal and 0.05 tonnes of dolomite are needed to produce 1 tonne of sponge iron and 0.2 tonnes of solid wastes [2, 5].This implies that for every 10 tonnes of sponge iron produced, almost 2 tonnes of solid wastes are …

Generation of Energy Conservation Measures for …

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

Chapter 1 Review of Sponge Iron Making Process …

Sponge Iron Making Process(Coal Based) Krupp-Renn Process : The Krupp-Renn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of -6.4mm ore and reducing agent like coke breeze or bituminous coal fines are fed into rotary kiln continuously. ...

Analyses of Different Modifications Proposed for the Sponge Iron …

a Process flow diagram of a typical coal based sponge iron plant. b Schematic of enclosed section of Fig. 1a as an available in plant-B Flow chart showing iteration steps Heat exchanger networks ...

Recovery and utilization of waste heat in a coal based …

The present work is an attempt to conserve energy in coal based sponge iron industry incorporating certain design modifications without disturbing the process technology. A typical sponge iron plant has been investigated to find out the potential …

Rotary Kiln Manufacturers | Electrotherm E&T

Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information. ... The quantity of coal feed is adjusted to get the required degree of production and to sustain the process. Adjustment of coal quantity can be done from the ends of the reactor ...

Sponge Iron

Sponge iron means porous iron produced by direct reduction process.Direct reduction (DR) process is a solid-state reaction process (i.e. solid–solid or solid–gas 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 …

(PDF) Energy survey of the coal based sponge …

The actual process of the coal based sponge iron production is based on SL/RN proce ss (jointly developed by the S teel Company of Canada, L urgi Chemie, R epublic Steel Company and N …

A review of ironmaking by direct reduction processes: …

DRI is often compacted to reduce its porosity and to convert it to Hot Briquetted Iron (HBI) for sale or storage (Indian Bureau of Mines, 2011). Depending on …