Conducting complete energy audit both process and utility of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at. For this purpose a case study of typical sponge iron production process is considered. Coal based sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. Sponge iron plant manufacturers and sponge iron equipment. Sponge iron is produced in a powdered form so, it acts as a good raw. The material bed in tunnel kiln being stationary, it.
Complete process of sponge iron kilns a thesis submitted for partial fulfillment of the degree have been able to complete my 33 schematic of optimised rotary kiln sponge iron making process get price and support online. Sponge iron also replaces ferrous scrap as coolent in l. Fe total content of 90%min is required for steel making requirement. Nov 09, 2014 making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Ashokas sponge iron plants manufacturing capabilities.
The reduction is carried out in a rotary kiln of a predetermined temperature and controlled atmospheric pressure. However, rotary kiln process suffers from serious limitations like low productivity and pollution. Production of sponge iron page 1 unt digital library. Characteristics of reduced iron the midrex process produces direct reduced iron hereinafter referred to as dri. In the subsequent oxidation step, the iron ore is reoxidised by water vapour yielding an hydrogen rich fuel gas. One of the major challenges for sponge iron plant is the accretion formation. Sponge iron dri is the main constituent in production of billets. Processes that produce iron by reduction of iron ore in solid state below the.
Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route, which has shown a phenomenal growth in india. This product is known as direct reduced iron dri or sponge iron. Energy audit methodology of sponge iron manufacturing. Number of dri processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world.
It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant. A thesis submitted for partial fulfillment of the degree. Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. Tunnel kiln furnace are evolving as an alternative to rotary kiln process. Sponge iron is produced in a powdered form so, it acts as a good raw material that can very well mixed with other metals in the production of different types of iron based or ferro alleys. Nov 17, 2012 sponge iron units do not use the pollution control equipment. Pdf operation of coalbased sponge iron rotary kiln to reduce. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron. Agni steels sponge iron manufacturing process youtube.
Iron sponge process an overview sciencedirect topics. Sponge iron or direct reduced iron is produced by reducing iron ore in the form of lumpspellets using noncoking coal in a rotary kiln. The latter process is based on atomization of a stream of liquid. Pdf energy audit methodology of sponge iron manufacturing. The process reduces iron ore using a reforming gas made from natural gas. Few selected ores are suitable for direct reduction process. India production volume of sponge iron 2011 to 2019. Description of sponge iron manufacturing process most of the plants in india use dri processa solid state direct reduction process by which iron ore is reduced to sponge without phase change figure 1.
Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work was conducted in it. Designing iron sponge process for h2s removal posted in student. The sponge iron is a substitute for scrap in the electric arc furnace upto 80%, which can be easily manufactured from indigenously available raw materials at very competitive price. Lloyds metals manufactures sponge iron directreduced iron by reducing gaselemental carbon produced from natural gascoal. Sponge iron is then taken to a product bin for dispatch. I have come to understand that this is a fixed bed adsorber column design but i cannot find much.
Raw material mixiron ore, dolomite and coal are fed to one end of. Energy audit methodology of sponge iron manufacturing units. Hydrogen production by steamiron process sciencedirect. This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln. Sizing of the raw materials also play vital role in sponge iron manufacturing process. Steel exchange india limited is having a sponge iron manufacturing unit in technical collaboration with world renowned ms mannesmann demag of germany codir process. The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. Sponge iron production by direct reduction of iron oxide. Selvakumar, in reference module in materials science and materials engineering, 2017. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of. In this method, heat coal as a reducing agent is mixed with iron ore and sponge iron is produced in a horizontal furnace. Now a days,sponge iron is a household name in steel making process. The principal burden material used for production of steel making grade dri in the sponge iron making process is iron oxide lump. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production.
Direct reduced iron dri, also called sponge iron,1 is produced from the direct reductionof iron ore in the form of lumps, pellets, or fines to. Fe metallic content in sponge iron depends on the effective control of process parameters. There are different methods to manufacture sponge iron but in india largely coal based process are carried out. In the research work we find that it is the incomplete reaction of coal that causes the major energy inefficiency in the process. The former process is based on reduction of iron ore, yielding a highly porous sponge iron which subsequently is comminuted to powder. Nov 02, 2017 right from the selection of high grade iron ore and coal, we use only the finest raw material for production. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of iron coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished. In the present work, several challenges faced in sponge iron production have. The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source. Coal based spongeiron is a metallic product produced through direct reduction of iron ore in the solid state. Direct reduced iron dri production plant nippon steel engineering co. With an installed capacity of 2x350tpd and can able to produce sponge iron of 0.
Hi all, i am a final year student in australia and am trying to complete my design project. Jun 10, 1997 the present invention concerns a process for manufacturing sponge iron with low sulphur content. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of ironcoking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in. Sponge iron is a valuable source of iron for the production of highquality steel. Study on accretion formation on dri kiln during spong iron. The process was implemented during the 19th century and. Exceptionally in the fluidized bed process sized iron ore particles are used.
Further, the average heat to power ratio kwthkwe of sponge iron plants ranges from. He has wide experience in productivity enhancement, energy conservation, cost effectiveness etc. Modeling of rotary kiln for sponge iron processing using. Sponge iron production flow chart raw material feeding to. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. Due to high porosity, the resulting iron is called sponge iron.
With the direct reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages than scrap metal smelting for steel making. Jul 29, 2010 the fe total content in sponge iron purely depends on fe con tent in iron ore and the degree of reduction achieved in the process. Seml was one of the first companies to install a sponge iron plant in the siltara, raipur area. A particle of sponge iron has the same size and shape as the particle of ore from which it was. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore.
This is one of the best book for a metallurgist who works in sponge iron indusrtrythe book contains data mass balance and heat balance which never seen in any other books of sponge iron. Sponge iron is produced using noncoking coal by the process of reduction of iron are in a rotary kiln. It is used as a raw material for manufacturing steel. Processes that produce iron by reduction of iron ore in solid state below the melting. A thesis submitted for partial fulfillment of the degree award of. Sponge iron plants cerana foundation, oct 2006 6 visible air pollution from point and area sources from sponge iron plants around raigarh solid waste dumps at sponge iron plants 3. Our sponge manufacturing process begins with dissolving wood pulp sourced from fsc certified paper mills. Sponge iron india ltd company, directors and contact. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of ironcoking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished. Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 8388% obtained by direct reduction without melting it. The required size of iron ore, mps mean particle size, its physical properties like t. The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. The value of dri is measured by comparing its cost and properties.
Schematic flow sheet of coal based direct reduction process 1. The fe total content in sponge iron purely depends on fe con tent in iron ore and the degree of reduction achieved in the process. Get sponge iron at best price with product specifications. The product of direct reduction processes known as sponge iron is used mainly as high quality melting stock for steelmaking. Sponge iron production from orecoal composite pellets in. If you continue browsing the site, you agree to the use of cookies on this website. The history of sponge iron production says that the need for development and commercialization of sponge iron manufacturing process arose in late 50s when electric arc furnaces eafs engaged in manufacturing steel started facing problems of availability of scrap of desired quality, the traditional source of their iron metallics. This site gives information on the work experience and the services provided by him. Lloyds metals manufactures sponge iron directreduced iron by reducing gas elemental carbon produced from natural gascoal. There is fluctuation in the quality of sponge iron. It is used as a raw material for manufacturing steel through electrical arc furnace and the induction furnace routes. Sponge iron manufacturing plant, detailed project report.
We shall discuss in detail all technical aspects of coal base sponge iron making with particular reference to control of important process parameters to achieve quality sponge iron in this august gathering. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. Sponge iron is a better substitute of steel scrap for steelmaking through the eafif routes. Aug 11, 2017 india is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. The dri is used mainly as the raw material for electric arc furnaces eafs, as a clean iron source substitute for scrap iron. This type of iron can be produced in several different types of furnaces, including coke or charcoal ovens, blast. Chari is engaged in quality and process control in cement manufacturing units in india. Raw material general the major raw materials required for. In the present work waste heat recovery system is designed to integrate the heat of waste gas in the sponge iron process. Documented data meteorology the meteorology of the area is summarized. Sponge technology sponge manufacturing our process. Ppt for rotary kiln process of making sponge iron rotary sponge iron manufacturing process pdf wordpress. Designing iron sponge process for h2s removal student. An example of a hydrogen sulfide scavenger process is the iron sponge process also called the dry box process, which is the oldest and still the most widely used batch process for sweetening of natural gas and natural gas liquids anerousis and whitman, 1984.
Since 1911 the hoganas corporation has continuously manufactured sponge iron, although the early use for this product was as a feedstock for steel making. Process for manufacturing sponge iron with low sulphur. Sponge iron is the iron ore reduced in solid state by a direct reduction process. The material bed in tunnel kiln being stationary, it does not require high strength and thermal stability of the raw material. Sponge iron units do not use the pollution control equipment. I am tasked with designing the equipment for the iron sponge oxide process for the removal of hydrogen sulphide from natural gas. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. The major raw materials required for production of sponge iron by the rotary kiln process are. With such dimension of notion we in our sponge iron manufacturing process through 4 kilns 1 350t and 3 500t laid up the best dri making process in india. We are the largest producer of sponge iron using non coking coal as a reductant and and are having the largest coal based plant in the world.
West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. Schematic of optimised rotary kiln sponge iron making process. Production prereduits dri et hbi par procedes midrex hyl charbon. The production volume of sponge iron in india accounted for more than 30 million metric tons at the end of fiscal year 2018.
Directors of sponge iron india ltd are sanjay mangal, narsing rao singayapally, rana som. This ar ticle is a firsthand description of the production and utilization of sponge iron from a new process, the hyl process, in mexico. Producing sponge iron and then working it was the earliest method used to obtain iron in the. Larsen introduction sponge iron is the product formed by the reduction of iron oxide to metallic iron at a temperature below the fusion point of the constituents of the charge.
For the purposes of the present invention sponge iron is a ferrous matter obtained by a reduction operation so called direct, from iron oxide. Chemicals used throughout the production process are reclaimed and reused to reduce the environmental impact of sponge manufacturing. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces.
573 657 651 1648 1014 952 1042 1338 313 462 99 569 830 1370 855 1225 625 1065 1138 279 1582 621 295 282 1479 1236 952 185 705 477 1095 1342