Generally, Sponge Iron produced using natural gas has a higher carbon content compared to Sponge Iron produced using coal gas. Types of Sponge Iron. Sponge Iron is a form of direct reduced iron that is produced from the reduction of iron ore in the form of lumps, pellets, or fines using a reducing gas such as hydrogen, natural …
Pig iron is produced through the smelting of iron ore in a blast furnace, while sponge iron is produced through the direct reduction of iron ore in a rotary kiln. Pig iron has a higher carbon content, making it brittle and heavy, while sponge iron has a lower carbon content, making it more ductile and lightweight.
ScienceDirect Available online at Procedia Manufacturing 35 (2019) 242â€"245 2351-9789 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the organizing committee of SMPM 2019. 10.1016/j.promfg.2019.05.034 10.1016/j.promfg.2019.05.034 2351-9789 © 2019 The …
He highlighted the important role being played by Indian sponge iron industry in the steel production. He also informed the participants about the importance given to the sponge iron industry in the National Steel Policy 2017 which envisages the need to produce 80 million tonnes of sponge iron from the current level of about 25 million tonnes to
Direct Reduced Iron. Direct reduced iron (DRI) is the alternative iron source for steelmaking. Its advantages as a iron product and diluent for impurities, introduced with scrap, are well documented. DRI is also known as sponge iron. It refers to porous iron produced by the direct reduction (DR) process.
The basic raw materials for the production of sponge iron are iron ore, non-coking coal and dolomite. The required size of Iron ore, MPS (Mean particle size), its …
sponge iron/DRI, HBI and cold briquettes. 3.5 Metallic Iron — Itis the aggregate quantity of iron, either free or combined with carbon (as cementite) present in sponge iron/DRI, HBI and cold briquettes. 3.6 Residual Iron Oxides — These are remaining oxides of iron present in sponge iron either in the form of FeO, Fe~Od or Fe20~, though ...
It is found that during the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and a significant part of this heat associated with the …
The following characteristics are of importance in selecting the coal for sponge iron production: 1. Reactivity, 2. Ash content, 3. Ash fusion temperature, 4. …
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 areas where energy is being wasted. To recover heat from
Sponge iron is an important component in the production of steel. The many benefits of sponge iron have further increased its demand in the steel manufacturing industry. ... This ore is reduced to sponge iron using either coal-based or gas-based reduction processes. In addition to iron ore, other materials like non-coking coal and …
Sponge Iron or Direct Reduction Iron (DRI) refers to a porous metallic substance that is produced by the direct reduction of iron ore, where oxygen is removed from the iron oxide using coal or natural gas as reductants and dolomite as a desulphurizing agent [7]. Raw materials are fed into the rotary Kiln by a conveyor to generate fugitive dust
The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI).
Scheme Document for sponge iron sub-sector Page 2 of 68 Important Notice: The information contained in this Scheme Document for auction of coal-linkages in the sponge iron sub-sector ("Scheme Document") or subsequently provided to Bidder(s), whether verbally or in documentary or any other form by or on behalf of Coal India …
While the blast furnace remains an important tool for ironmaking, newer technologies such as smelting and direct iron reduction are available to produce iron with minimal byproduct generation and slag-free hot metal. Smelting reduction and direct iron reduction can reduce energy input, lower greenhouse gas emissions and minimize slag …
However, few companies (e.g. Tata Sponge Iron Ltd) still managed to earn the profit, resulting from their efforts for quality and productivity improvement through total quality management (TQM) proving the importance and necessity of implementation of TQM in SI industry in India.
Scheme Document for sponge iron sub-sector Page 2 of 66 Important Notice: The information contained in this Scheme Document for auction of coal-linkages in the sponge iron sub-sector (" Scheme Document ") or subsequently provided to Bidder(s), whether verbally
The feed size of iron ore varies from 5-20mm and up to 15mm for coal. In order to increase the productivity, a counter-current coal fines injection system of 2.5tons/hr was installed. …
The major quality requirements of coal for Sponge iron production are- 1) Non-coking characteristics 2) Low ash content 3) Low sulphur content 4) Good reactivity 5) High ash fusion temperature 6) Medium volatile matter ... An important step in solid state reduction is the forward reaction, whereby carbon dioxide generated from burning of coal ...
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 …
From a technical perspective, the challenge of decarbonization involves two processes: chemical reduction for iron ore refining (process emission), commonly with metallurgical coal and coke, and from the high-temperature heat sourced needed to operate blast furnace (BF) and other production reactor. 5 Unlike the power sector, there are …
Over the years, the coal based route has emerged as a key contributor and accounted for 79% of total sponge iron production in the country. Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. The process of sponge iron making aims to remove the oxygen from iron ore.
The availability of high-grade iron ore and the lack of matching reserves of coking coal essential for iron making through the BF route, besides the involved capital costcould be the reason for widespread adoption of DR in India. The rotary kiln / certain shaft based DR process for iron making in India predominantly use coal as reductant.
India is the largest producer of sponge iron or direct reduced iron (DRI) in the world. The important step in the manufacture of DRI is direct reduction of iron ore by coal or reducing gases such ...
Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is ...
Control of accretion growth in a coal fired rotary kiln for production of sponge iron is important to achieve a long campaign life. Temperature is measured at 11 locations with embedded ...
4.1 Direct Reduction of Iron Production Using Solid Coal 39 4.2 Direct Reduction of Iron Production Using Coal Gasification 43 4.3 Direct Reduction of Iron Production Using Gas Route 49 4.4 Hydrogen Use in Indian Iron and Steel Sector 54 5.0 Conclusion 57 Technology Vendors – Energy-efficient Equipment and Systems 60 References 65
DR processes reduce iron ore in its solid state by the use of either natural gas or coal as reducing agents, and they have a comparative advantage of low capital costs, …
The production volume of coal-based sponge iron in India accounted for more than 33.8 million metric tons at the end of 2022. ... The most important statistics. Apparent steel use (ASU) in China ...
g steel capacity, carbon dioxide emissions can be significantly reduced. This is especially true in the context of coal-based direct reduction iron-manufacturing plants (sponge …