Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coalbased 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.
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.
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 ...
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
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 ...
Sponge iron is produced primarily both by using noncoking coal and natural gas as reductant and therefore classified as coalbased and gasbased process, respectively. High purity sponge iron powder is currently manufactured from high purity iron ore following the basic steps of magnetic separation and milling, primary reduction process ...
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. ... The modified PFD for sponge iron process based on HEN is shown in Fig. 4 where grey lines shows the ducts to carry waste gas from chimney to exchanger1 (shown through G
Yes, sponge iron making is a primary or can be a primar metallurgical process base on the Chemistry information that is provided. What process causes the mass of the drying sponge to change ...
Coal gasificationbased 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.
Smelting reduction (SR) processes are the latest development in pig iron production. The SR process emerged during the 1990s. In SR processes, iron ore and coal are added directly to a metalslag phase where the ore is reduced. The SR process combines the gasification of coal with the smelting reduction of iron ore.
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 ...
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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 ...
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 ...
Jun 23, 2023. Around percent of the sponge iron produced in India in 2022 was under coal based process route. This was due to numerous coal based units present in the mineral rich states. The ...
Fig 3 Process flow diagram for coal based sponge iron The hot reduced sponge iron along with semiburnt coal, discharged from kiln is cooled in watercooled cylindrical rotary cooler to a temperature of 100200°C. The discharge from cooler consisting of sponge iron, char other contaminations are passed on through
This is a coalbased reduction technology, applicable to both steel mill waste and iron ore fines, with coal as a Creductant agent. The reduced iron can be fed to a BF or directly into a melting process. If exposed to air for a long time, the metallic iron reoxidizes into iron oxide, deteriorating its quality.
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.
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.
therefore classified as coal based and gas based process respectively. Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production [5]. At present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the ...
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 ...
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 ...
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 ...
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
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
However, for coalbased DR the reductant is generated from noncoking coal and rotary kilns, rotary hearth furnaces and multihearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 6575% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
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 ...
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.
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 [].
Recovery and utilization of waste heat in a coal based sponge iron process. by Vivek Kumar. 2012, Chemical Engineering and Processing: Process Intensification. See Full PDF Download PDF. Create a free account. Access 47 million research papers for free; Keep uptodate with the latest research;
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