Directreduced iron (DRI), also called sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. Unlike the conventional process, the process does not require coking coal; the coke ovens in a steel plant are expensive and polluting units. Direct ...
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Abstract 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 Nomenclature hr heat transfer coefficient from outer surface of rotary kiln to outside atmosphere, kJ/h m 2 D diameter, m L length, m m mass flow rate, kg/h T temperature, °C Q heat load, kJ/h Cp
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Sponge iron produced using the non coking coal is called coal based sponge iron / DRI. For producing the sponge iron through this process requires high grade of iron ore and non coking coal. ... 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 ...
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Figure Thermal energy consumption across sample sponge iron plants. Figure shows the steel production across different plants. The steel production ranges from 30,000 tons to Mt. This may be due to the export of SI and scrap utilization in the steel melting shops (SMS). Sign in to download fullsize image Figure
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Direct reduced iron (DRI), also called sponge iron due to its porous nature, is produced in reactors that directly reduce (remove) the oxygen from the iron oxides in iron ore. Unlike the chemical reactions that happen in the blast furnace, the DRI process is done without having to melt the iron ore. This direct reduction process is how the ...
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admin Sponge iron, also called direct reduced iron (DRI), is made from directly changing iron ore (in any form whatsoever) to iron by a cutback gas or carbon, produced from natural gas or coal. It is one of the many raw materials used in sponge iron. Specifications WHY IS IT CALLED SPONGE IRON?
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A consortium of European companies, research institutes, and universities have launched the world's first demonstration of a fully.. While using lowcarbon hydrogen is not a viable economic ...
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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 iron by a reducing gas or elemental...
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In 2019, DRI production hit a record million tons— percent more than the previous year, owing most of its increase to India, , and Algeria. In 2021, DRI production reached million tons, up by percent from 2019. While growing output in India—the world leader in DRI production—was due to productivity growth in coal ...
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associated with iron ore as oxide removed from the particle is known as percentage reduction whereas the percent of iron as part of whole iron existing as metallic iron is called as degree of metallization in sponge iron technology. Sponge Iron Making Process(Coal Based) KruppRenn Process : The KruppRenn process was developed in 1930.
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Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change. Raw material mixiron ore, dolomite and coal are fed to one end of rotary Kiln as well as some fine coal also fed from discharge end and product sponge iron along with char is taken out from the other ...
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Pig iron Direct reduced iron Figure 1: Iron production, 2000, 2010, 2019 Source: (WSA, 2020) India is the country with the largest DRI production, reaching 34 Mt in 2019, accounting for around a third of global DRI (WSA, 2020). The majority of Indian DRI is produced via the coalbased route, using rotary kilns, making partly use of domestic coal.
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Raw material utilization and waste generation for the DRI suggest that tonnes of ore, tonnes of noncoking coal and tonnes of dolomite are needed to produce 1 tonne of sponge iron and ...
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The pilot plant has a size of 100 cubic meters. At a later stage, a fullscale hydrogen gas storage facility measuring 100,000 to 120,000 cubic meters may be required, in which case it will be able to store up to 100 GWh of electricity converted to hydrogen gas, which is sufficient to supply a fullsized sponge iron factory for three to four days.
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A new route for making steel from iron ore based on the use of hydrogen to reduce iron oxides is presented, detailed and analyzed. The main advantage of this steelmaking route is the dramatic reduction (90% off) in CO2 emissions compared to those of the current standard blastfurnace route. The first process of the route is the production of hydrogen by water electrolysis using CO2lean ...
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There are different types of raw materials used for sponge iron making and steel products Like Coal, Iron Ore, and Dolomite Iron ore and decoking coal are the main raw materials to produce sponge iron. They are charged into the rotary kiln in the required proportion together with some dolomite used as a desulfurizing agent.
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Direct reduced iron (DRI), also called sponge iron, is produced by the reduction of iron ore (in the form of lumps, pellets or fines) with a reducing gas produced from natural gas or coal. This process is called direct reduction. ... Phase concentrations are converted to Femet, Metn and Ctot. The data from wet chemistry, those calculated with ...
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DRI production. Direct reduction of iron is the removal of oxygen from iron ore or other iron bearing materials in the solid state, without melting, as in the blast furnace. The reducing agents are carbon monoxide and hydrogen, coming from reformed natural gas, syngas or coal. Iron ore is used mostly in pellet and/or lumpy form.
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Again a lot of coal fines and coke breeze are also produced during coal mining and coking of coal respectively. Utilization of iron ore and coal fines for extracting metal is of vital concern for resource conservation and pollution control. The other option is to convert the iron ore and coal/coke fines into composite pellets/briquettes.
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especially at the present situation where the sponge iron market is highly depressed. SPONGE IRON QUALITY The rotary kiln sponge iron has lower metallisation (about 85 — 88% on the average) and low carbon content (%) compared to gas based sponge iron (Metallisation of 92 — 94% and carbon content of — 2%).
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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 as sponge iron). DRI is often compacted to reduce its porosity and to convert it to Hot Briquetted Iron (HBI) for sale or storage (Indian Bureau of Mines ...
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HOW TO CALCULATE COAL REQUIREMENT FOR DRI MAKINGin this video we know how to find coal requirement for specific iron ore feed in side the sponge iron kiln an...
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The main raw materials for the production of DRI by the rotary kiln process are (i) sized graded iron ore or iron ore pellets, (ii) noncoking coal, and (iii) dolomite in small quantities to scavenge the sulphur. Iron ore of the right quality is the basic input for the coal based direct reduction process.
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I. Introduction Mill scale is an iron oxide waste generated during steelmaking process, casting and rolling. The mill scale contains very high percentage of iron which is generated during making of steel towards production of various long and flat products.
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High metallization cuts coal usage. DRI and HBI are usually made from highgrade iron ore pellets typically reduced by gas to provide a highlymetallized raw material for both electric arc furnaces and traditional blast furnaces. According to USbased DRI technologist Midrex Technologies, HBI, which is metallized beyond 90%, needs only to be ...
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The appearance of iron ore is completely changed when it gets converted to sponge iron of its composition. The hematite iron ore is ... is called DRI /sponge iron and the weight of the product becomes lighter due to removal of O 2 ... The hot reduced sponge iron along with semiburnt coal, discharged from kiln is cooled in watercooled ...
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Direct reduced iron is iron ore in the form of lumps, fines or pellets that have had the oxygen removed by using hydrogen and carbon monoxide. Typical sources of carbon monoxide are natural gas, coal gas, and coal. Other energy inputs into the production process often include oil and electricity. Since much of the energy used is in the form of ...
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iron. and reheating Emissions varies based on how electricity is generated ( coal or nuclear) BFBOF route: 1,600 2,000 kg CO. 2 /ton HRC Limited potential to reduce further (mature technology) Capture / reuse if possible EAF (scrap) route : 500600 kg CO. 2 / ton HRC EAF can be misleading: scrap / OBM were previously converted from ...
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HOW TO CALCULATE CARBON FOR SPONGE IRON MAKINGIn this video we know how to calculate carbon /ton, DRI and how to calculate coal quantity for kiln inlet and o...
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This is because DRI is produced by removing O2 from iron ore. 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. DRI is produced in many forms.
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Sponge Iron is a form of direct reduced iron that is produced from the reduction of iron ore in the form of lumps, pellets, or fines using a reducing gas such as hydrogen, natural gas, or coal. There are three main types of Sponge Iron: DRI (Direct Reduced Iron): It is produced in lump or pellet form and is often used as a feedstock in the ...
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The product from this process is called DRI or sponge iron or hot briquette iron (HBI), which is a highly metalized solid that still contains gangue minerals, and hence needs further purification . The direct reduction method was adopted by Delta Steel Plant in Nigeria, while they were still in operation [ 26 ].
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The various advantages of iron ore pellets are given below. Iron ore pellet is a kind of agglomerated fines which has better tumbling index when compared with the iron ore and it can be used as a substitute for the iron ore lumps both in the BF and for DRI production. Pellets have good reducibility since they have high porosity (25 % to 30 %).
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Sponge iron production process. DRI unit; ... and it is taken into the rotary cooler in which the product get cools down and is separated from the coal char. Some of the basic reactions that may be included in the process are ... After CO reacts with the oxygen it is converted into O2 and it automatically generates heat.
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