Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H2 and CO.
Coalbased sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation
Iron ore or pellets, reductant ( noncoking coal or natural gas) and limestone/dolomite are the main raw materials for DR technology. For the successful operations, the process of DR technology has specified the characteristics of the raw materials to be used in the process. The principal raw materials used in DR/sponge iron processes are ...
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 ... Engineering, Environmental Science. 2011; During the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and significant part of this heat ...
During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as ...
Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H 2 and CO. Although DRI production is more energy efficient than pig iron production from BF, additional processing (typically EAF) is needed to upgrade DRI sponge iron for market.
The major difference between the gas and coal based DRI processes is the incorporation of coal in the later. In fact in coal used by sponge iron produces in India contains as high as 40% ash.
Coalbased sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln. In combination ...
The present paper proposes two energy integration options, Option1 and Option2, to compare power generation and preheating scheme in sponge iron accounts power generation whereas in Option2 preheating of feed material, slinger coal and kiln air is considered. These options utilize heat of waste gas that exits the after burning chamber of the process, which is available from ...
On sponge ironmaking in coalbased rotary kilns, there are studies on process modeling (Gaurav and Khanam, 2016), ... Switching from coal to NG as the feedstock leads to a 58% reduction in the GHG emissions of the coalbased DRI process plants (including electricity use). On a life cycle basis, GHG emissions from the NG reformer DRI process ...
Given that the EAF process's primary inputs are scrap iron, coalbased sponge iron, and gasbased sponge iron, three scenarios are defined in Table 5, and their impacts are assessed. Scenario 1: 90% gasbased sponge iron is used alongside 10% scrap iron (which is the actual modus operandi of the factory).
Coalbased sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln.
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 ...
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
Process. Direct reduction processes can be divided roughly into two categories: gasbased, and coalbased. 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)).
Broadly two types of technologies are used for producing sponge iron, for coal based plants, coa l . ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of .
Sponge Iron Making Process(Coal Based) KruppRenn Process : The KruppRenn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of ore and reducing agent like coke breeze or bituminous coal fines are fed into rotary kiln continuously. The ...
Looking forward to the need of developing coalbased sponge iron technology in India, a country having no significant resources of either coking coal or natural gas, the Research and Development ...
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 coalbased sponge iron is considered as a viable option (Agrawal et al. 2000).In DRI production, India deserves special attention ...
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. Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and ...
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 ...
Sponge iron is a type of iron produced by coal based or gasbased reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...
A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency.
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