WEBOct 31, 2023 · 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.
WEBOct 1, 2016 · Sponge Iron, (capacity 0. 09 MTPA) and S unflag Iro n Steel Ltd. The first gas based sponge iron. plant (capacity of MTPA) was setup by Essar Steel Limited in Hazira, Gujarat in 1990 2. The ...
WEBFeb 15, 2024 · DRI primarily utilizes noncoking coal, natural gas, and H 2 as the key energy sources, producing a porous "sponge iron" below the melting temperature through deoxidation (Anameric and Kawatra, 2008).Coalbased reduction methods boast high energyconversion rates and easy operation, leading to widespread adoption .
WEBApr 9, 2017 · Midrex process is simple to operate and involves three major unit operations namely (i) iron ore reduction, (ii) gas preheating, and (iii) natural gas reforming. The heart of the Midrex process is its shaft furnace. It is a cylindrical, refractorylined vessel and is a key component of the direct reduction process.
WEBIt 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). Iron Ore Pellet is used for reduction. ... Sponge Iron (dri) 4,95,000 TPA: GPIL: Gases (Oxygen, Nitrogen) a) Oxygen 12,00,000 m3 / Annum b) Nitrogen ...
WEBSponge 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. ... 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 ...
WEBDec 1, 2007 · Complete conversion of the iron oxide in the heated reactor ... (as iron ore) is commonplace, that of sponge iron ('DRI' from metal works) requires some precaution. Due to the presence of fine metal particles and the great porosity of the material, there is a possibility that spontaneous oxidation with air could create a selfsustaining ...
WEBNov 1, 2012 · Raw material utilization and waste generation for the DRI suggest that tonnes of ore, tonnes of noncoking coal and tonnes of dolomite are needed to produce 1 tonne of sponge iron and ...
WEBDirect reduction processes are of significance and can form an alternative to a conventional Blast furnace. Solid sponge iron ( direct reduced iron or DRI) is produced by removing oxygen from the ore .The technique of Direct reduction varies according to the type of reducing agents employed and the metallurgical vessel in which they are reduced.
WEBApr 1, 2021 · Direct reduction (DR) processes produce different types of reduced solid iron, such as sponge iron (DRI) or hot briquetted iron (HBI). ... The remaining 18 % of direct reduced iron is produced through coalbased reducing agents in rotary kilns ... The DRI is converted into liquid steel in an EAF operating at 1650 °C with efficiency of 60 % ...
WEBDec 1, 2015 · The iron also can be produced from its ore by the direct reduction of iron ore by a reducing agent which is coal based or may be a gaseous reducing agent, which is called direct reduced iron (DRI) or sponge iron. DRI is a good substitute of scrap for making steel in electric arc furnace, basic oxygen furnace, etc. and there has been a .
WEB1) DRI Unit : In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a rotary kiln (which is inclined and rotates at a predetermined range of speeds) at a stipulated temperature (850°C 1,500 ...
WEBJan 1, 2014 · Coalbased 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 coalbased sponge iron plants use mostly thermal ...
WEBMar 11, 2024 · About Sponge Iron: Directreduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) by a reducing gas produced from natural gas or coal. The reducing gas is a mixture, the majority of which is hydrogen (H2) and carbon monoxide (CO), which act as reducing agents.; .
WEBDec 1, 2018 · Iron ore is preheated and fed into a reduction shaft, where it is converted to direct reduced iron (DRI) and further compacted to hot briquetted iron (HBI). Hydrogen generated in an electrolysis unit is preheated in a condenser before being supplied to the shaft where it acts as the reducing agent.
WEBJul 16, 2023 · A sponge iron plant, also known as a directreduced iron (DRI) plant, is a facility where iron ore is converted into a metallic iron product known as sponge iron. This process is called direct reduction because it does not involve the use of coke or coal, which are typically used in traditional ironmaking processes such as blast furnaces.
WEBThe name of the product is due to its form of porous spherical (pellet) with a spongelike appearance. Sponge Iron has a high grade of iron, which is more used today due to the shortage of iron scrap and its high price and its making environmental problems. Sponge iron grade: The grade and amount of iron in sponge iron is between 84% to 95%.
WEBMay 6, 2018 · Where non – metallurgical coal can be used as a reduction agent. Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 8388% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel through ...
WEBVarious types of raw materials for making sponge iron and steel products such as coal, iron ore and dolomite iron ore and Dolomite coal are the main raw materials for producing sponge iron. They are used to rotary kiln in the required fit together with some dolomite as a drying agent. Coal plays a double role in this process, both as a ...
WEBMar 12, 2024 · About sponge iron. 1. About: i) It is made from directly changing iron ore (in any form whatsoever) to iron by a cutback gas or carbon, produced from natural gas or coal. Sponge iron is also called direct reduced iron (DRI). ii) Direct reduction processes can be divided roughly into two egories: gasbased, and coalbased.
WEBMar 2, 2022 · The sponge iron industry in India uses a mix of domestic and imported iron ore, coal and dolomite. ... Emissions from oretopellet conversion are also included in the analysis (KIOCL, ... Similar to the trend observed with the coalbased DRI processes, iron ore pelletization is the most sensitive parameter, ...
WEBJan 1, 2013 · Contrary to the almost pure iron of meteoric origin, manufactured iron (pig iron or hot metal) and steel are ferrous alloys of iron with carbon and further impurities (Fig. ).Carbon lowers the melting point of iron from 1538 °C in pure iron to 1147 °C in the eutectic with % C. Carbon content in steel is up to % that corresponds to .
WEBIn the years to come, India's expanding steel production will be largely driven by sponge iron. Sponge iron, also known as direct reduced iron(DRI), is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. Sponge iron gives a cheaper way of producing steel which has a .
WEBDec 1, 2023 · Usually, Iron Ore is manufactured and converted into Pellets. These are oval lumps of iron ore that are hardened using fuel. This process of converting iron ore into pellets is known as Pelletization. Iron Ore Pellets are then used in the production of steel. Pellets are usually preferred instead of raw Iron Ore because it allows for maximum ...
WEBOct 9, 2023 · The chemical composition of direct reduction iron requires that the metallization ratio be 92–96%, FeO content 3–15%, gangue content 1–4%, phosphorus content less than %, sulfur content less than %, and content of each of the nonferrous metal impurities Cr, Ni, Cu, and Pb less than %. Other indiors, .
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