WhatsApp)
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 noncoking 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).
Most of the plants in India use DRI processa solid state direct reduction process by which iron ore is reduced to sponge without phase change. Raw material mixiron ore, dolomite and coal are fed to one end of rotary Kiln as well as some fine coal also fed from discharge end and product sponge iron along with char is taken out from the other end.
MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid. Most solid reduction process use noncoking coal as reducing agent due to abundantly available noncoking coal. The process proposed to be adopted is the rotary kiln proposes using Noncoking coal and iron ore.
Energy survey of the coal based sponge iron industry ScienceDirect
29/07/2010#0183;#32;The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og % to %.The carbon content in gas based processes can be controllrd to a level of % to % based on requirement for steel making.
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 prime requiste.
Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe) for steel making instead of facing crisis of good quality scrap, international/national demand of solid metallic, availability of large reserves of iron ore amp; noncoking coal in India. Our product simply denotes our process, our commitment and also our best Pellet making ability as Raw Material to Sponge Iron.
Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as to prevent its reoxidation.
First Indonesia SPONGE IRON PLANT. Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 20 mm size) / Iron Oxide pellets (6 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as fuel and reducing agent in Rotary Kiln.
09/11/2014#0183;#32;Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2. IRON ORE Iron = 6567 % SiO2 + Al2O3 = 23 % CaO + MgO = 0,51 % Sulphur = 0,02 % max Phosphorus = 0,04 % max Chemical Composition Size = 518 mm Shatter Index = +95 % Tumbler index = +88 % Reducibility Index = +94 % Thermal Degradation Index = 5 % Physical Composition
kiln t echnology for production of sponge iron in Indonesia due to direct utilization of bituminous. coal. Besides rotary kiln based process, some blast furnaces are also installed in Indonesia
#0183;#32;Coal gasificationbased sponge iron plant of Jindal Steel amp; 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
14/12/2013#0183;#32;Direct Reduced Iron. Direct reduced iron (DRI) is also known as sponge iron. It is produced by the reduction of iron ore (in the form of lumps or pellets) by either noncoking coal or a reducing gas produced by reforming of natural gas. The reducing gas can also be produced by the gasification of coal. The reducing gas is normally a mixture.
69 TECHNOLOGY REVIEW NO. 29 DEC. 2010 Prospects for Coalbased Direct Reduction Process Haruyasu MICHISHITA1, Hidetoshi TANAKA2 1 Technology amp; Process Engineering Department, Iron Unit Division, Natural Resources amp; Engineering Business 2 Research amp; Development Department, Iron Unit Division, Natural Resources amp; Engineering Business
This paper presents an approach to find the best modification in the coalbased 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 reduced.
In Case1, feed to kiln and injected coal is preheated by waste gas from ESP and ABC thus coal consumption reduced to t/h but the productivity is same as conventional coal based sponge iron
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, amp; 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.
WhatsApp)