coal based sponge iron process

LowCarbon Production of Iron Steel: Technology Options ... Columbia

LowCarbon Production of Iron Steel: Technology Options ... Columbia

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.

Direct Reduced Iron: Most Efficient Technologies for Greenhouse ...

Direct Reduced Iron: Most Efficient Technologies for Greenhouse ...

Direct reduced iron (DRI) is also known as sponge iron (Hasambeigi et al. 2014 ). This high porous material has a metallization degree in the range 8595% with a carbon content in the range % depending on the processing route. During the process, the iron oxides are reduced at the solid state.

PDF Direct Reduced Iron Industry in India — Problems and Prospects

PDF Direct Reduced Iron Industry in India — Problems and Prospects

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 cogeneration using kiln off gas. CONSIDERATIONS IN SETTING UP COAL BASED SPONGE IRON PLANTS

Comparative life cycle assessment of natural gas and coalbased ...

Comparative life cycle assessment of natural gas and coalbased ...

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 ...

(PDF) i) Direct Reduced Iron: Production ResearchGate

(PDF) i) Direct Reduced Iron: Production ResearchGate

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 ...

Computational fluid dynamics analysis of sponge iron rotary kiln

Computational fluid dynamics analysis of sponge iron rotary kiln

Simulation of rotary kiln for sponge iron process is based on combustion of coal particles and reduction of iron ore. The heat transfer inside the kiln is done through radiation. The model equations used for computation of desired parameters, such as temperature profile and % metallization, are tabulated in Table 3.

(PDF) Energy survey of the coal based sponge iron industry ResearchGate

(PDF) Energy survey of the coal based sponge iron industry ResearchGate

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. The required data are ...

Direct Reduced Iron and its Production Processes IspatGuru

Direct Reduced Iron and its Production Processes IspatGuru

It is also known as sponge iron since its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is around 10,000 times greater than the internal surface area of solid iron. ... Coal based process. In a coal based process, the reactor for the reduction reaction is a rotary ...

PDF Rotary Kiln Process (ACCAR / SL RN / Krupp CODIR) ResearchGate

PDF Rotary Kiln Process (ACCAR / SL RN / Krupp CODIR) ResearchGate

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.

Sponge Iron Manufacturer India

Sponge Iron Manufacturer India

Coal Based Sponge Iron / DRI. ... For producing the sponge iron through this process requires high grade of iron ore and non coking coal. Gas Based DRI / HBI. In this process route, iron oxides are converted to the DRI / HBI by using natural gas in a vertical shaft furnace. For steel producers, it is a preferred metallic, energy efficient and ...

Sponge Iron | SpringerLink

Sponge Iron | SpringerLink

Sponge iron means porous iron produced by direct reduction reduction (DR) process is a solidstate reaction process ( solidsolid or solidgas 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 [].

Shabina Khanam IIT Roorkee

Shabina Khanam IIT Roorkee

Apart from these research publications, an article entitled "PROCESS INTEGRATION OF COAL BASED SPONGE IRON PLANT" has been published in DRI UPDATE Magazine, November 2020, Sponge Iron Manufacturing Association (SIMA), New Delhi. It is circulated to all sponge iron fraternity of the world through SIMA.

SPONGEIRON Shakambhari Group

SPONGEIRON Shakambhari Group

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 ...

PDF LECTURE NOTES ON Sponge Iron Ferro Alloys Kalinga Institute of ...

PDF LECTURE NOTES ON Sponge Iron Ferro Alloys Kalinga Institute 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 ...

Direct reduction : a review of commercial processes US EPA

Direct reduction : a review of commercial processes US EPA

Coalbased direct reduction systems have been discussed previously in the section, "Solid Reductant Systems." ... Meyer, G. and U. Bongers, "Reduction by Solid Fuels with the Krupp Sponge Iron Process", 2nd Latin American Seminar on Direct Reduction, Porto Alegre, Brazil, May 49, 1975. 38. Staff, "Krupp Waste Recovery Process", Metal Bulletin ...

Energy survey of the coal based sponge iron industry

Energy survey of the coal based sponge iron industry

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 Gcal/h and the heat value of coal input is Gcal/h resulting in a thermal efficiency of the process ...

PDF Safety Guideline for Coal Based DRI Ministry of Steel

PDF Safety Guideline for Coal Based DRI Ministry of Steel

SAFETY GUIDELINES FOR IRON STEEL SECTOR MINISTRY OF STEEL, Direct Reduction GOVT. OF INDIA Plant (Coal Based) Doc. No: SG/32 Rev no. : 00 Effective Date: 1. OBJECTIVE: The main function of making Sponge Iron in the Kiln is to convert Iron ore into sponge iron by using Iron ore, coal and dolomite / limestone. The Sponge Iron is processed

Mathematical Modelling of Sponge Iron Production in a Rotary Kiln

Mathematical Modelling of Sponge Iron Production in a Rotary Kiln

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 ...

Sustainability Enhancement of the Coal Based Direct Reduction of Iron ...

Sustainability Enhancement of the Coal Based Direct Reduction of Iron ...

After the reduction process, a mixture of sponge iron and char is discharged from the kiln into the cooler where cooling takes. Water is sprayed at the cooler shell to indirectly cool the material from about 1000 ℃ to 120 ℃. ... Kaltenthaler, E.: Healthrelated qualityoflife of coalbased sponge iron plant workers in Barjora, India: a ...

PDF Mathematical Modelling of Sponge Iron Production in a Rotary Kiln

PDF Mathematical Modelling of Sponge Iron Production in a Rotary Kiln

VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coalbased sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore

TSLP | Sponge Iron | TATA Steel Long Product Limited

TSLP | Sponge Iron | TATA Steel Long Product Limited

Coal based DRI making process. Iron Ore and noncoking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite which acts as a desulphurized. ... The process of sponge iron making aims to remove the oxygen from iron ore and when the same occurs ...

Production cost of sponge iron Input parameters Unit ... ResearchGate

Production cost of sponge iron Input parameters Unit ... ResearchGate

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 ...

Recovery and utilization of waste heat in a coal based sponge iron process

Recovery and utilization of waste heat in a coal based sponge iron process

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 ...

Coal based Direct Reduction Rotary Kiln Process IspatGuru

Coal based Direct Reduction Rotary Kiln Process IspatGuru

Coal based direct reduction process is based on the solid reducing agent which is noncoking coal. The reaction takes place at high temp (1000 deg C to 1100 deg C). Coal plays a dual role in the kiln. Part of coal is used as fuel to supply the desired heat so as to take the raw materials to the desired temperature.

Recovery and utilization of waste heat in a coal based sponge iron process

Recovery and utilization of waste heat in a coal based sponge iron process

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.

CDM: CDMHome

CDM: CDMHome

Increasing pellatisation capacity of the country based on large iron ore deposits with high proportion of fines,'blue dust. Long term policy in respect of allotment and pricing of natural gas and coal to sponge iron industry. Coal authorities should pay special attention for production Of superior grade noncoking coal to cater to the needs of ...

PDF Recovery and Utilization of Waste Heat in a Coal Based Sponge

PDF Recovery and Utilization of Waste Heat in a Coal Based Sponge

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

PDF Energy Survey of the Coal Based Sponge Iron Industry

PDF Energy Survey of the Coal Based Sponge Iron Industry

The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel ... In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no ...