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.
5. Main features of Hismelt process • The method of solid injections using high speed lances ensure that the absorption efficiency in the melt is high and even ultra fines can be used directly. • The 'natural' 5 % to 6 % FeO level in the slag in conjunction with the metal carbon at 4 % creates conditions for strong partition of phosphorus from …
The OSIL stands for Orissa Sponge Iron Limited. This plant was set up in the year 1983 at Palaspanga, keonjhar, Odisha. It is based on the ACCAR technology with under bed …
4. Description of the process of producing sponge iron The most important raw materials required for the production of sponge iron are oxides in the form of iron ore / pellets, …
Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information. ... Highly engineered plant layout for minimal material handling and smooth material flow. Efficient plant and process design for maximum waste heat recovery.
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 …
Download scientific diagram | Process flow diagram of the sponge iron plant. from publication: Energy survey of the coal based sponge iron industry | A survey is made on a typical coal based ...
Page 12. ROTARY COOLER. The product is conveyed to the product separation and storage building. The product is Sponge iron and char. Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. Page 13. SCREENING. + 10 mm 3-10 mm - 3 mm.
a well-established. process. for production of coal based sponge iron. Rotary kiln of certain dia and length is provided for reduction of Iron Ore into sponge iron using non-coking coal as reductant and Dolomite as sulphur scavenger; however the Diameter and Length are to be designed based on the Plant Capacities.
Conventional sponge iron plant flow diagram Coal injector, Air: 2500m3/h, Injection coal:6.13 t/h, all at 300C Rotary Kiln (10200C) 8 shell air fan at 48000 m3/h, 300C Flue gas Fly ash Fines of iron ore 108.94 t/h Kiln Feeding Iron ore: 30 t/h Feed coal: 14.297 t/h Dolomite (Lime stone): 0.5 t/h All at 300C Rotary Cooler At 1200C Sponge iron:
Contexts in source publication. ... process flow diagram (PFD) of a conventional coal based sponge iron plant is shown in Fig. 1. Different streams in the PFD are assigned individual number and ...
Sponge Iron Plant 2x95TPD(62,700 TPA) 2x100 TPD & 2x500 TPD (3,96,000 TPA) 4,58,700 TPA. ... gangue constituents at every stage of the beneficiation process. The process flow sheet diagram is given as below . EXECUTIVE SUMMARY PECS, Nagpur 7 | P a g e ... Flow chart for Iron Ore Beneficiation Sponge Iron manufacturing Process
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 …
Process Flow Diagram of Sponge Iron Plant/ Direct Reduction Iron Plant is given below: 4.0 PROCESS HAZARD ANALYSIS & NECESSARY RISK CONTROL MEASURES S.No. Equipment Hazards Risk Control Measures 1) Belt Conveyors a. Rotating parts of conveyor system, like head pulley, tail pulley, snub pulley, coupling guards etc. b. Moving
mixed units, lumps iron as feed stock and abundant availability of non-coking coal. The process flow diagram of the sponge iron plant is as given in following Figure. Figure: Sponge Iron Manufacturing Process Iron Ore Beneficiation process. The iron ore input is iron ore fines (-) 10 mm. The iron ore material is received in underground feed hopper.
4.1 Brief description of sponge iron plant process 40 4.2 Technological options for coal based plants 42 5.0 Status of Sponge Iron Plants in India 67 5.1 Questionnaire Survey 67 5.2 Identified stakeholders for consultations 67 5.3 Questionnaire Survey Analysis 68 5.4 General outlook of green house emission measures and practice ...
Phase – I (Existing) 100 TPD of Sponge Iron Plant of 30000 MTPA capacity Phase – II (Existing) 100 TPD of Sponge Iron Plant of 30000 MTPA capacity ... FLOW SHEET OF MANUFACTURING PROCESS AS A WHOLE . Executive Summary Satyam Iron & Steel Co. Pvt. Ltd. 6 At the beginning, in tilted condition of the crucible, M. S. Scrap / pig iron …
Greenfield project for a DRI based Steel plant to produce Sponge Iron 198,000TPA; Mild Steel Billets 345,800TPA; Rerolled Steel Products through Hot Charging and through Reheating Furnace 342,144TPA; Ferro Alloys ... 3.5.8 Process and flow diagram of Brick making from waste ...
The OSIL stands for Orissa Sponge Iron Limited. This plant was set up in the year 1983 at Palaspanga, keonjhar, Odisha. It is based on the ACCAR technology with under bed injection of diesel from discharge end. Later on OSIL used coal as fuel. In the year 1995 OSIL supplied the technology to Llyods India for their sponge iron production plant
DRI production. Direct reduction of iron is the removal of oxygen from iron ore or other iron bearing materials in the solid state, i.e. 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.
BF-BOF operation relies almost entirely on coal products, emitting ~70% of CO2 in the integrated plant (BF iron making). Hot iron is then charged to BOF to make steel HM (BOF steel making). An integrated BF-BOF production plant also include process plants for coking, pelletizing, sinter, finishing, and associated power production.
Conventional sponge iron plant flow diagram Coal injector, Air: 2500m3/h, Injection coal:6.13 t/h, all at 300C Rotary Kiln (10200C) 8 shell air fan at 48000 m3/h, 300C Flue …
Throughout this period, a large amount of CO, iron and other semi-metallic elements are generated and enter the wet dust removal system in the form of flue gas. Under the treatment of the wet ...
Sponge iron means porous iron produced by direct reduction process.Direct reduction (DR) process is a solid-state reaction process (i.e. solid–solid or solid–gas …
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 …
BILLET MANUFACTURING PROCESS FLOW CHART Sponge Iron Stock Yard SUNVIK@ Heavy Melting Scraps Stock Yard Quality Control Confirmation on it's grade Quality report to Melting/ Production Incharges Final Product (Billets) Final product reconfirmed and colour coded with paint as per grade Stocking the Billets
Flow diagram is shown in Figure 1 0, including converter sludge pellets preparing, drying, preheating in the baking cup, and subsequent direct reduction in the preheated pellets with reductant of ...
Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively. Presently, there are 118 large and small sponge iron plants in India- 115 of them are coal based while only 3 are natural gas based. The advantages of sponge iron are:
Sponge iron production process discussed herein are selected from known methods of which the references are available and referable. We look at the 4 different methods of producing sponge iron: Midrex …
Sponge iron making process - Download as a PDF or view online for free ... CARBON RECOVERY FROM SPONGE IRON PLANT DUST. ... SECONDARY AIR Secondary air is introduced axially in the direction of the gas flow The air supplied to the length of the kiln is metered for close control of temperature and gas atmosphere in the …
Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR processes. Based on the types of reductant used, DR processes can be ...