Expansion of existing Sponge Iron Plant capacity DRI Kilns 2x 100 TPD to 3x100 TPD and installation of WHRB based Power Plant 6 MW and AFBC based power plant 6 MW; Fig Sponge Iron Unit Process flow 19 Figure Manufacturing Flow Diagram of 22 Figure Schematic diagram showing process flow diagram of
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
Sometimes this process accomplished with some secondary operations like sizing coining infiltration hot forging etc 1 Powder production Almost all iron powders for the production of PM components are produced either using the sponge iron process or by water atomization
It is produced by direct reduction of iron ore in solid state either by reducing gas or non coking coal at 1000 1050 °C The resulting iron is highly porous in nature and hence the name sponge iron Sponge iron is richer in iron than pig iron which has a
The major Raw Materials required for production of Sponge Iron by the rotary kiln process are sized graded Iron Ore and Non Coking coal Limestone in small quantities is also required to scavenge the sulphur IRON ORE The quality requirement of Sized ore for sponge iron production can be classified into
Brief description of sponge iron plant process 40 Technological options for coal based plants 42 Status of Sponge Iron Plants in India 67 Questionnaire Survey 67 Identified stakeholders for consultations 67 Questionnaire Survey Analysis 68 General outlook of green house emission measures and practice
Direct Reduction of Iron Process Sponge Iron Plants New Delhi The Energy and Resources Institute Published by The Energy and Resources Institute TERI Darbari Seth Block IHC Complex Lodhi Road New Delhi 110003 iii ENERGY EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT REDUCTION OF IRON PROCESS
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 process is adopted by worldwide conventional sponge iron industries
Sponge iron is produced by low temperature reduction of iron ore in a rotary furnace shaft furnace or reactor Since the reduction temperature is lower than the melting temperature of the ore the iron ore still maintains the shape of the ore after solid state reduction and has a porous and low density sponge like structure hence the name
Direct Reduced Iron Production I ndia continued its streak as the number one DRI producer worldwide producing a record Mt of DRI Mt in rotary kilns and Mt by gas based processes an % increase overall According to the Sponge Iron Manufacturers Association SIMA of India rotary kilns saw an 18% increase in
Review of Sponge Iron Making Process Historical Development Sponge iron was the main source of iron for many centuries before the blast furnace technology of iron making got developed During that time sponge iron was developed in shallow hearths using charcoal which worked both as reductant and fuel
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
IRON SAND BRIQUETTE IN THE SPONGE IRON MAKING Name Fiqri Sanubari Ekaputra SRN 2713 100 092 Major Materials and Metallurgical Engineering Advisor Sungging Pintowantoro Co Advisor Fakhreza Abdul ABSTRACT
The Iron making is necessarily a reduction process as far as the chemical theory is concerned where reduction of the iron ores takes place to produce metallic iron • Iron ores Generally in Oxides Hematite Fe 2 O 3 Magnetite Fe 3 O 4 Mass number Density=/cc Atomic number 26 = 1538° C = 2861° C Fe Iron Latin
Prasad et al [7] suggested that by applying process integration in sponge iron process which reduces coal and water consumption by % and % respectively resulting releases minimum waste
The process flow diagram PFD of sponge iron production process shown in Fig 1 consists of a number of equipment namely rotary kiln rotary cooler DSC ABC WHRB ESP wet scrapper and chimney As the aim of the present work is to correlate input and output parameters of the sponge iron process using
TATA Sponge employs coal fired rotary kilns to produce sponge iron Iron ore coal and dolomite are charged from one end of rotary kiln schematic diagram in Fig 1 and the coal for combustion is fired from the other kiln is slightly inclined so that material flows in forward direction
Key points include The DRI plant uses iron ore coal and dolomite as raw materials which are fed into a rotary kiln and reduced to sponge iron through chemical reactions The sponge iron is then cooled in a rotary cooler before being separated into lumps and fines in the Product Separation Building using magnetic separation and screening
Pig iron and sponge iron are both intermediate products in the iron and steel manufacturing process but they differ in their composition and production methods Pig iron is produced by smelting iron ore in a blast furnace which results in a high carbon content around 3 4% and impurities such as sulfur and phosphorus
hydrogen from different hydrocarbon species The reformer sponge iron cycle RESC an innovative process combining a sponge iron reactor with a hydrocarbon reformer and a partial off gas feedback loop was investigated as means of providing an on site hydrogen production capacity from a feedstock of hydrocarbons produced with ISRU technology
Direct Reduced Iron / Sponge Iron Process DRI The process of reduction takes place inside the rotary kiln which is mounted on tyres and supported by support rollers The transverse motion of the kiln is controlled with the help of hydro thruster and thrust rollers The kiln is rotated at the rate of rpm with the help
Sponge Iron SIPL is operating 4 x 100 TPD Direct Reduced Iron Rotary Kilns for production of 2000 TPA Sponge Iron at Purulia using the proven German SL/RN technology 5 to 18 mm size by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln Sponge iron is rich in Metallic
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