Part 3A Iron Sponge Basics November 2017 One of the oldest technologies for the removal of hydrogen sulfide H 2 S from gas is the use of Iron Sponge A chemical physical process originally developed to remove H 2 S from natural and coal gas streams iron sponge has been in use for over 140 years and more recently to remove H 2
The standard SL/RN process has been used for over 40 years to produce direct reduced iron DRI from lump ores or iron ore pellets However with the decreasing availability of lump ores the ability to process fine grained ores and concentrates is becoming increasingly important The SL/ RN process cannot be used to treat iron ore concentrates
Figure 1 illustrates that more than % C at the flat bath stage does not give significantly lower nitrogen at tap round markers in Figure 1; these results are from an EAF steelmaking process
Impurities are removed by the subsequent electric steel process The sponge iron is melted into the actual crude steel This process will be discussed in more detail in the next section In the direct reduced iron DRI process the iron ores are reduced directly to sponge iron by gaseous reducing agents Electro steel process In the electric
The so called Stelco Lurgi/Republic Steel National Lead SL/RN process is a widely used coal based DRI making process which uses a rotary kiln The process uses lump ore pellets beach sand or ilmenite ore and solid carbon to produce hot or cold DRI The process operates at high temperature and atmospheric pressure
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 re oxidation
Sponge iron means porous iron produced by direct reduction reduction DR process is a solid state reaction process solid solid or solid gas reaction by which removable oxygen is removed from the iron ore using coal or reformed natural gas as reductants below the melting and fusion point of the lump ore or agglomerates of fine ore []
Sponge Iron vs Pig Iron are two popular raw materials used in manufacturing Sponge Iron also known as Direct Reduced Iron DRI is produced by reducing iron ore in the form of lumps/pellets using non coking coal in a rotary kiln The Pig Iron manufacturing process involves a complex process that begins with mining iron ore and preparing
Iron sponge process An example of a hydrogen sulfide scavenger process is the iron sponge process also called the dry box process which is the oldest and still the most widely used batch process for sweetening of natural gas and natural gas liquids Anerousis and Whitman 1984 The process was implemented during the 19th century and
process with solid carbon as reductant little carbon dissolves in the sponge iron The carbon content of DRI produced at the plant considered in this work is
1 Dr Hassan Z Harraz hharraz2006 Autum 2023 Iron Ore is more Integral to the Global Economy than any Other Commodity Except Perhaps Oil Christopher LaFemina mining analyst at Barclays Capital In 2011 the Financial Times quoted Hassan Harraz 2023 IRONMAKING By DR Process A REVIEW OF IRONMAKING BY
Smelting Reduction Figure 2 The smelt reduction vessel SRV is the core technology component of the Hismelt process Source RioTinto While years of ironmaking technology innovations have optimized blast furnace productivity two alternative processes—smelting reduction and direct iron reduction— are growing in adoption The
Sponge Iron Industry Download as a PDF or view online for free The document outlines the DRI process and inputs/outputs identifying particulate matter SO2 NOx and CO as main pollutants It discusses regulatory air pollution standards and water usage at DRI plants In summary it analyzes pollution sources from coal based DRI
The iron sponge process generally uses a single vessel to contain the hydrated ferric oxide wood shavings A drawing of an iron sponge unit showing typical provisions for internal and external design requirements was presented in Figure 7 3
The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln It describes the chemical and physical composition of iron ore coal and dolomite that are fed into the kiln It then outlines the rotary kiln process which involves preheating and combustion zones use of primary and secondary air coal injection
These processes operate with different feedstocks The BF BOF pathway converts raw iron ore to pig iron and then to steel HM while EAF converts both steel scrap and sponge iron to steel HM DRI converts raw iron ore to sponge iron a porous permeable and highly reactive product that requires treatment with EAF before selling to market
The iron and steel industry is responsible for a portion of 7 10% of the global CO2 emissions it has to reduce its CO2 emissions drastically during the next 30 years The EU target is a reduction of CO2 emissions by 80% until 2050 which can The MIDREX® process is highly flexible regarding the source of energy and iron oxide feedstock
The iron ore is reduced to sponge iron inside the rotary kiln The coal enters from both ends of the rotary kiln; one end is known as the feed side and the other is the injection side The iron ore dolomite and coal nearly 50% of the total coal required enter from the feed end of the rotary kiln and coal balance in some cases raw
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 the interest in sponge iron as a hydrogen production process has grown again although the technology still has some major technical and economic challenges to
sponge iron production by direct reduction slrn 18 03 2019· slrn process of sponge iron making Direct Reduction Process Know More In a DR process iron ore pellets and/or lump iron ores are reduced by a Typical examples of the coal based process include the SL/RN and ACCAR processes DR processes accounting for about % of world DRI
The question whether sponge iron is at all interesting economically requires consideration t 0 20 of a number of factors; besides the type of re ductant and iron bearing material the geography and further processing of the sponge iron have to be taken into account In any case the sponge iron produced must compete in price with con
The principal burden material used for production of DRI in the SL/RN process is iron oxide either as sintered pellets or lump iron ore A wide range of fuels and reductants such as lignitite
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