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 ...
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 ...
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 ...
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 [].
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.
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
The present work investigates the design modifications which can lead to efficient energy integration in coalbased sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coalbased sponge iron plant, a tremendous amount of heat is generated and a ...
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 ...
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
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
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 ...
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 ...
In chemical industry: Benzene. .from the carbonization (heating) of coal, which produces coke, combustible gas, and a number of byproducts, including benzene. Carbonization of coal to produce illuminating gas dates back in England to the very early years of the 19th century. The process is still employed in some countries, but more use is..
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 ...
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)).
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
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 ...
Coal based: 9293: : ... The principle of the water gas shift reactor (or also called sponge iron process) is not new (see [2, 3] and the references therein). This reaction involves a redox reaction, in which the carbon within the carbon monoxide is oxidised and the hydrogen within the water is reduced.
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.
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.
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 ...
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.
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 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. ...
In coalbased DRI process, accretion formation inside the rotary kiln is a genuine complex problem. Accretion formation in a rotary kiln of 100 tpd DRI plant has been investigated. ... Metallic iron Fe (m) in sponge iron varied between 84 and 62%. Approximately 300 ton of accretion was generated for a running of 25 days. Table 1 Iron ore ...
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.
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.
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.
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