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a) Presentation on 'New Paradigms in Process Control and Optimization of Rotary Kilns for Sponge Iron Production'by Dr. Brahma Deo, IIT Bhubaneswar b) Presentation on 'Energy Integration in Coal based Sponge Iron Process' by Dr. Shabina Khanam, IIT Roorkee 2.Industry Perception 12.40 pm –01.00 pm 01.00 pm –01.20 pm


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Sponge Iron - Sambhv Steel

Sponge iron is a highly processed form of iron ore that contains metallic iron in the range of 83-88% obtained by direct reduction through reaction with carbon in the form of coal at approx. 1100 degree Celsius. Due to high porosity, the resulting iron is called sponge iron. Sponge iron is also referred to as direct reduced iron or metalized iron.


Sep 29, 2019· Such coal-based sponge iron making from iron ore is popular both in India and China. However, in the world, almost 80% of sponge iron is being produced by the gas-based DR process. Both the gas and coal based DRI technology are gaining importance due to comparatively less investment cost, flexibility in using raw materials like cheap iron ore ...


Rotary Kiln with SL/RN Process. Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, and 500 TPD) Solid-state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI). Since DRI is produced by removing oxygen from ...


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.


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).


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 ...


The process flow sheet of a typical coal-based sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd. In this process screened iron ore (6.5tph), coal (3.529tph) and dolomite (0.2tph) are charged into the rotary kiln. About 40% of total 5.958 tph coal ...


Sep 04, 2014· Thus, the sector depends mostly on coal-based sponge iron and nearly 80% of the total coal-based sponge iron plants are located in India. 1 About 60% of this production comes from small-scale industries in the unorganised sector with poor pollution control facilities. 1 During the past decade, these sponge iron plants have rapidly grown in the ...


Gas Based Sponge Iron. This process utilizes natural gas the reducing agent. Natural gas is reformed to enrich with 112 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.


Jan 16, 2011· Coal based sponge iron plant: a conventional process. 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 sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.


Feb 14, 2017· Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials.


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


Sponge Iron - an overview ScienceDirect Topics. Direct reduction iron or sponge iron is an old method for producing hydrogen (Milne et al., 2006; Peña et al., 2010; Biljetina and Tarman, 1981) that was replaced by more efficient and economic processes.Recently, the interest in sponge iron as a hydrogen production process has grown again, although the still has some major …


Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are assigned individual number and henceforth each stream


Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process. Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe ...


Such coal based sponge iron is mainly used by induction furnace steel producers leading to technical deficiencies in the steel making process. Further, energy consumption wise, the coal based sponge iron plants are not efficient which can be improved by co-generation using kiln off gas. CONSIDERATIONS IN SETTING UP COAL BASED SPONGE IRON PLANTS


The efficiency of the coal based sponge iron process is defined as the energy needed for the reduction reactions compared to the energy added to the system. Due to chemical reactions and combustion the heat generated inside the kiln is 64.98 Gcal/h and the heat value of coal input is 118.6 Gcal/h resulting in a thermal efficiency of the process ...


Jul 02, 2018· Sponge iron, also known as direct reduced iron (DRI) and used widely in the steel making process, resembles a honeycomb in its structure. As India has adequate coal deposits and its utilization for steel plants is considered to be of prime importance, production of coal-based sponge iron is considered as a viable option (Agrawal et al. 2000).In DRI production, …


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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.


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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.


This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln. In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace.


Gas-based sponge iron is not subjected for magnetic separation, as no contamination with nonmagnetic is possible either it can be cooled indirectly or briquetted in hot condition to get hot briquetted iron (HBI) B. Solid Reducant or Coal Based Technologies This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.


Mar 16, 2013· Major DRI production processes are either natural gas based or coal based. Feed material for the DR process is either sized iron ore of size ranging from 10 mm to 30 mm or iron ore pellets of size ranging from 8 mm to 20 mm produced in an iron ore pellet plant. The gas based process uses a shaft furnace for the reduction reaction.


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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.


The contribution of coal based sponge iron to the total production in India has remained above 60 per cent since 2004-05. The contribution of coal based sponge iron has been on the rise. From about 8 MT in 2004-05, contributing 63 per cent to the total production, it has grown to


Objective: A typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal and air as well as increase the productivity of sponge iron by applying heat integration using simulation process.Methods: In the present work, utilized waste heat to preheat the feed coal and air, heat integration process using modified pinch approach is applied and …


Sponge iron, also called direct reduced iron, is a vital constituent in steel making process. Sponge iron is made either by using coal or natural gas. It is coal based sponge iron that is still the primary method of obtaining sponge iron in India. This is because India has a shortage of natural gas while there is an abundance of coal in the ...


Dec 10, 2012· Investment and operational costs of the process are reported to be $344.4 and $183.1 per ton of steel, based on a scrap cost of $120/t-scrap (US DOE, 2003. p. 4/4.) Commercial. Waste Heat Recovery for Rotary Kiln Direct Reduction. The coal consumption is about 800 kg/t DRI.


Orissa Sponge Iron & Steel Ltd. (OSIL) was promoted in the year 1979. It was the first 100,000 TPA commercial scale coal based Sponge Iron Plant in our Country and one of the first few in the World. The Plant went into commercial production in 1984 with process technology from Allis Chalmers Corporation of U.S.A. using 80% coal and 20% oil.


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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:


Dec 06, 2007· What is the process for producing sponge iron in coal based rotary kiln process quantitatively? Wiki User. ∙ 11:24:12. See Answer. Best Answer. Copy.


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 remove 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)).


Oct 24, 2013· Coal gasification-based sponge iron plant of Jindal Steel & 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 route.