Sponge Iron Plant Process

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron …

2017-8-4 · Sponge Iron Production Process Process description 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. Different streams in the PFD are assigned individual number and henceforth each stream

Accretion Control in Sponge Iron Production Kiln using ...

processing plant determines the type of control strategy to be implemented. Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the

What is Sponge Iron? (with pictures)

Malcolm Tatum Sponge iron is created from iron ore. Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process …

Status of Sponge Iron Plant in Orissa

2018-9-17 · 3 Raw Material for sponge iron plant Coal: Non-coking coal having certain important parameters is being used for the direct reduction of iron ore . Important factors determining coal quality are: • Chemical properties such as fixed carbon, ash content, volatile matter, etc.: & • Physical properties viz, reactivity and ash fusion temperature. In Orissa scenario, all most all the sponge iron ...

Project Report on SPONGE IRON REDUCTION PLANT ...

2020-11-10 · SPONGE IRON REDUCTION PLANT - Project Report - Manufacturing Process - Cost - Investment Required. Report includes feasibility report, profitability analysis, raw materials, break even points, formulations and formula and much more.

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

2011-5-13 · process uses coking coal. The DRI process doesn‟t require coking coal and therefore is advantageous. In the present work waste heat recovery system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron ...

Sponge Iron

Energy Audit Methodology of Sponge Iron Manufacturing Units U…

Sponge Iron Plant | Sponge Iron Plant Equipment | Turnkey ...

Sponge Iron Plant Process Equipment. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off 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 1200 °C).

SPONGE IRON INDUSTRY

2020-5-1 · The average sponge iron plant size in India is 0.0886 MTPA implying the dominance of medium scale plants in the country 18. The average plant size in Chhattisgarh is 0.1026 MTPA and that in Jharkhand is 0.0641 MTPA19. Odisha has plants with 0.0971 MTPA capacity on an average while in West Bengal the average capacity of a sponge iron plant is 0 ...

ENERGY INTEGRATION IN SPONGE IRON PLANT USING …

2012-5-12 · Direct-reduced 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.

Energy Audit Methodology of Sponge Iron …

2014-9-15 · 2. Description of Sponge Iron Manufacturing Process 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 (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from ...

Sponge Iron Division – Trimula Industries

Sponge Iron Division – Trimula Industries. This plant is based on SL/RN process. Rated capacity of this plant 0.21mtpa. In addition to producing DRI, the system is equipped with waste heat recovery boiler from where we can generate 16 MW/hr power from waste gas. We are also having down word expansion where with our own power we operate ...

Sponge Iron

Direct reduction iron or sponge iron is an old method for producing hydrogen (Milne et al., 2006; Peña et al., 2010; Biljetina and Tarman, 1981) that was replaced by more efficient and economic processes.Recently, the interest in sponge iron as a hydrogen production process has grown again, although the technology still has some major technical and economic challenges to …

SPONGE IRON PLANT – INDUSTRIAL PROJECT CONSULTANT

sponge iron plant Introduction DRI (Direct Reduced Iron) is a type of Iron formed by reduction of Iron Oxides to it''s metallic form in process below the melting point of both Iron & its oxides.

Sponge iron production process and plant

Sponge iron production process and plant . United States Patent 5997609 . Abstract: In a process for producing sponge iron from particulate iron oxide-containing material, the iron oxide-containing material in a reduction zone is reduced to sponge iron by means of reducing gas and the gas forming during reduction is withdrawn as top gas. ...

Sponge Iron

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H ...

OPERATIONAL ASPECTS OF SPONGE IRON …

2012-1-10 · 1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge ...

World''s First Hydrogen-Reduced Sponge Iron Produced

2021-6-23 · World''s First Hydrogen-Reduced Sponge Iron Produced. 23.06.2021 Editor: Ahlam Rais. Under the Hybrit initiative, SSAB, LKAB and Vattenfall have produced the world''s first hydrogen-reduced sponge iron at a pilot plant in Luleå, Sweden. The technological breakthrough aims to eliminate carbon dioxide emissions from the steelmaking process.

Process Plant Equipment

Being amongst the largest companies, we are engaged in manufacturing, supplying and exporting an extensive range of Process Plant Equipment. The offered products are manufactured using high grade raw materials and are preferred for their sturdiness and better operational life. Our range of products includes Cement Plant Equipment, Sponge Iron ...

FUTURE OF SPONGE IRON IN INDIA AND PLANT …

2012-1-10 · priately called the Malza-Bharati Process of producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the

Energy integration of sponge iron production process

2012-10-19 · SPONGE IRON PLANT The process flow sheet of a typical coal-based sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd. In this process screened iron ore (6.5tph), coal (3.529tph) and dolomite (0.2tph) are charged into the rotary kiln.

Sponge Iron

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. Sponge Iron is the iron ore reduced in solid state by a direct reduction process using natural gas or non-cooking coal as reductant.

Project Proponent M/s BRGD Sponge and Iron Pvt. Ltd.

2018-1-18 · 5.1 SPONGE IRON PLANT There is a plan to install 4x100 TPD DRI kilns for production of 1,20,000 TPA sponge iron. Manufacturing Process The proposed plant uses the coal based process in which iron oxide in pellet/iron ore will be reduced with non coking coal in a rotary kiln to make sponge iron.

TMT Bar Manufacturing Plants and Process with Latest ...

Best TMT Bar Manufacturing Plants India – In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is …

Development of energy conservations scenarios for …

2011-1-16 · Coal based sponge iron plant: a conventional process. 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 sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.

Sponge Iron Plant

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. It is the iron ore reduced in solid state by a direct reduction process using …

Sponge Iron Plants Equipment

Sponge Iron. TGS is one of the largest manufacturers of sponge iron plant equipments in the country with the largest market share in supply of the 500 TPD Sponge Iron Plants in India.With years of experience, the Company has supplied a large range of equipments for sponge iron plants of different capacities viz. 50 TPD, 100 TPS, 350 TPS, and 500 TPD.

Sponge Iron

MANUFACTURING PROCESS. In the DRI plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. The reduction is carried out in a rotary Kiln (which is inclined and rotates at a pre-determined range of speed) at a stipulated temperature ( 850 °C – 1050°C).

Sponge Iron (DRI) | The Hira Group

In Energy conservation process in DRI plant we catch Process resultant fuel gases which is at high temperatures of around 950°C from the sponge iron kiln; constituting significant amount of heat energy. With WHRB, a modern Technology, We produces around 0.5 million TPA of Sponge Iron. Thus we have achieved about 85% recovery of waste heat from ...

SPONGE IRON PLANT

2018-9-24 · sponge iron, originating from Iron Ore, namely, silica and alumina and the sulphur and phosphorous contents adversely affect the economics in subsequent steel making operation. Therefore, the ore should be high in iron content and low in gangue, Physical Specification – Size - 5-20 mm Oversize - < 5 % max

ORISSA SPONGE IRON AND STEEL LTD.

2017-7-24 · The process of reduction causes micro pores in the ore body turning it porous. Directly reduced iron looks like sponge in texture due to pores and hence is called sponge iron. Iron Ore after due reduction inside the kiln is discharged to a rotary cooler of 3.5 mtr.