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coal 150tph based sponge iron process

SPONGE IRON PLANT

MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid. Most solid reduction process use non-coking coal as reducing agent due to abundantly available non-coking coal. The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore.

Energy survey of the coal based sponge iron industry

Sep 01, 2015 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 Corporation in 1964), which works on direct reduction of ore.This process is adopted by worldwide conventional sponge iron industries.

Sponge iron making full process_Coal base DRI YouTube

Dec 24, 2018 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

Direct reduced iron

Process. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off 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)).

sponge iron process

Jul 29, 2010 The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

Process Description and flow diagram of Coal Based DRI Plant

Aug 07, 2016 • Sponge iron produced by the process will be the high grade which contains 80% Fe, 12% FeO and 8% gangue material. After separation of sponge iron in the magnetic screen/pulley, the remains are collected as char. Char has good amount of fixed carbon (25% 30%) and moderate GCV (2500 2600 Kcal/Kg).

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to

Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate

Process Description and flow diagram of Coal Based DRI Plant

Aug 07, 2016 • Sponge iron produced by the process will be the high grade which contains 80% Fe, 12% FeO and 8% gangue material. After separation of sponge iron in the magnetic screen/pulley, the remains are collected as char. Char has good amount

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

SPONGE IRON PRODUCTION FROM ORE -COAL

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.

sponge iron process

Jul 29, 2010 The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making. Size Distribution:

Direct reduced iron

Process. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off 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

(PDF) Energy survey of the coal based sponge iron industry

A survey is made on a typical coal based Indi an sponge iron plant of capacity 50 0 t/d in. order to identify the largest energy losses and find ways to increase the efficiency. The. required data

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION

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

sponge iron process: 2010

Jul 29, 2010 The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

reductant and therefore classified as coal based and gas based process respectively. Due to a promising availability of coal, the coal based sponge iron plants share the major amount of its production. At present, there are 118 large and small sponge iron plants operating in India, amongst them only 3 are natural gas based and the remaining 115

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 /

for Proposed 1.5 MTPA Coal Washery

Washing Technology Wet coal washing Process (Heavy media separation process) 10. Raw material Sources E-auction from Coal Mines of WCL in 70% of country’s energy/ power requirement is generated by coal based thermal power plants. Sponge iron plants, steel plants, cement industry etc. also consume coal.

Sponge Iron Iron Steelmaking

Gas-Based Process: This process utilizes natural gas as the reducing agent. Natural gas is reformed to enrich with H2 and CO mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process.

Sponge Iron Gas Based Sponge Iron Manufacturer from

Coal Based Sponge Iron. This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore. The reduction is carried out in an inclined horizontal rotary kiln, which rotates at a predetermined speed. A temperature profile ranging from 800-1050 degree centigrade is maintained along the length of the kiln at different

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535 oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced product having high degree of metallisation exhibits a „honeycomb structure‟ due to which it is named as sponge iron.

Process Description and flow diagram of Coal Based DRI Plant

Aug 07, 2016 • Sponge iron produced by the process will be the high grade which contains 80% Fe, 12% FeO and 8% gangue material. After separation of sponge iron in the magnetic screen/pulley, the remains are collected as char. Char has good amount of fixed carbon (25% 30%) and moderate GCV (2500 2600 Kcal/Kg).

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

sponge iron process: 2010

Jul 29, 2010 The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

Sponge Iron Iron Steelmaking

Gas-Based Process: This process utilizes natural gas as the reducing agent. Natural gas is reformed to enrich with H2 and CO mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process.

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 /

for Proposed 1.5 MTPA Coal Washery

Washing Technology Wet coal washing Process (Heavy media separation process) 10. Raw material Sources E-auction from Coal Mines of WCL in 70% of country’s energy/ power requirement is generated by coal based thermal power plants. Sponge iron plants, steel plants, cement industry etc. also consume coal.

Sponge Iron Industry SlideShare

Nov 17, 2012 Garbage Factor for a tonne of sponge iron unit.INPUT (in Tonnes) OUTPUT (in Tonnes)1.6-1.75 Iron Ore 1.8-2 Carbon Dioxide1.2-1.5 Coal 0.25 Dust0.035-0. 5 Dolomite 0.29 Coal Char1.5-2 Water 0.02 Kiln accretions 0.2 Sulfur Dioxide with water vapour Water vapourSource: Down to Earth, September 16,2006.

coal based sponge iron process in south africa

sponge iron process. Based on our experience an ideal coal based sponge iron plant shall have the following facilities. As the manufacture of sponge iron is very sensitive to the physical and chemical characteristics of raw materials, a well designed raw material preparation plant with crushing/screening facility for iron ore and coal to control the size of input materials to the kiln is a

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.

WELSPUN STEEL LIMITED

Sizing of the Raw materials also play vital role in sponge iron manufacturing process. The required size of Iron ore, MPS (Mean particle size),its physical properties like T.I., A.I. & chemical properties like Fe (T), LOI, gangue content In Sponge Iron Process,two types of coal are being used such as feed coal and injection coal.

Development of energy conservations scenarios for sponge

Jan 16, 2011 This paper presents an approach to find the best modification in the coal-based sponge iron process with an aim to integrate energy in it. For this purpose, a few energy conservation cases are formulated by integrating unutilized energy present in possible areas of process flow sheet. When unutilized energy of the process is properly integrated, energy demand from outside sources can be

Coal Base DRI Operation: CONCEPTION OF SPONGE IRON

Oct 11, 2017 The hematite iron ore whose chemical formula Fe 2 O 3 is most suitable raw material for DRI/Sponge Iron. the oxide ore Fe 2 O 3 during reduction reaction is converted to metallic Fe which is termed in solid state as SPONGE IRON. The Oxygen concentration in Hematite iron ore is as Follows Fe 2 O 3----> 2 X Fe + 3O 2---> 2 X 55.85 + 3 X 16 In the hematite ore 111.70 parts of iron combine with

Sponge Iron Gas Based Sponge Iron Manufacturer from

A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process. When the gases are traveling upwards the charge moves downward by gravity. Gas-based sponge iron is not subjected for magnetic separation, as no contamination with none—magnetic is possible either it can be cooled indirectly or