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 ...
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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).
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process of HYLSA. These contribute over 80% of world sponge iron production today. Out of the coal based technologies SL/RN technology of Lurgi , West Germany has been the most successful one. Little success has been achieved by other coal based technologies namely CODIR technology of Krupp Industriatechnik now Mannesmann Demag,, DRC
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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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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. ...
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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 ...
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Recovery and utilization of waste heat in a coal based sponge iron process (PDF) Recovery and utilization of waste heat in a coal based sponge iron process | Vivek kumar bir98bir no longer supports Internet Explorer.
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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 ...
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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 ...
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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 ...
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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 ...
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Making of mild steel in the induction furnace was first experimented during early 1980s and it gained popularity when the production of sponge iron utilizing coal based process of rotary kilns became popular. Induction furnace is a type of electric melting furnace which uses electric current to melt metal.
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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 ...
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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 ...
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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 ...
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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.
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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 ...
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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.
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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
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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.
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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 ...
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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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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).
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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.
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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.
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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 ...
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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 ...
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2. Overview of DR processes. Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing. gas to produce Direct Reduced Iron (also known ...
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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 .
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A material supplier from Belgium would like to produce limestone powder for his custome...
India is rich in various mineral resources and it is an important mineral processing market
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