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 ...
WhatsApp: +86 18203695377
Coalbased sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln.
WhatsApp: +86 18203695377
Market share: About 23% of sponge iron total production. 4) Tunnel furnace process . This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction temperature, and reduction is performed on Silicon Carbide (SiC) Crucibles in a tunnel furnace.
WhatsApp: +86 18203695377
Broadly two types of technologies are used for producing sponge iron, for coal based plants, coa l . ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of .
WhatsApp: +86 18203695377
SIPL is operating 4 x 100 TPD Direct Reduced Iron Rotary Kilns for production of 2000 TPA Sponge Iron at Purulia, using the proven German SL/RN technology. Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and ...
WhatsApp: +86 18203695377
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
WhatsApp: +86 18203695377
The efficiency of the coal based sponge iron process is defined as the energy needed for the reduction reactions compared to the energy added to the system. Due to chemical reactions and combustion the heat generated inside the kiln is Gcal/h and the heat value of coal input is Gcal/h resulting in a thermal efficiency of the process ...
WhatsApp: +86 18203695377
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. ... Coal based process. In a coal based process, the reactor for the reduction reaction is a rotary ...
WhatsApp: +86 18203695377
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 ...
WhatsApp: +86 18203695377
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.
WhatsApp: +86 18203695377
Recovery and utilization of waste heat in a coal based sponge iron process. by Vivek Kumar. 2012, Chemical Engineering and Processing: Process Intensification. See Full PDF Download PDF. Create a free account. Access 47 million research papers for free; Keep uptodate with the latest research;
WhatsApp: +86 18203695377
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 coal based sponge iron plant where iron ore, feed coal and dolomite are fed to the rotary kiln. A separate conveyor collects different size fractions of coal for injection into the kiln
WhatsApp: +86 18203695377
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.
WhatsApp: +86 18203695377
Making of mild steel in the induction furnace was first experimented during early 1980s and it gained popularity when the production of sponge iron utilizing coal based process of rotary kilns became popular. Induction furnace is a type of electric melting furnace which uses electric current to melt metal.
WhatsApp: +86 18203695377
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.
WhatsApp: +86 18203695377
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
WhatsApp: +86 18203695377
However, for coalbased DR the reductant is generated from noncoking coal and rotary kilns, rotary hearth furnaces and multihearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 6575% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
WhatsApp: +86 18203695377
VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coalbased sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore
WhatsApp: +86 18203695377
sponge iron sector, which is dominated by smallsized coalbased direct reduction of iron (DRI)based plants. India is one of the unique countries in the world where coalbased DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is
WhatsApp: +86 18203695377
This paper presents an approach to find the best modification in the coalbased sponge iron process with an aim to integrate energy in it. For this purpose, a few energy conservation cases are ...
WhatsApp: +86 18203695377
Yes, sponge iron making is a primary or can be a primar metallurgical process base on the Chemistry information that is provided. What process causes the mass of the drying sponge to change ...
WhatsApp: +86 18203695377
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.
WhatsApp: +86 18203695377
Recovery and utilization of waste heat in a coal based sponge iron process (PDF) Recovery and utilization of waste heat in a coal based sponge iron process | Vivek kumar bir98bir no longer supports Internet Explorer.
WhatsApp: +86 18203695377
Coal Based Sponge Iron / DRI. ... For producing the sponge iron through this process requires high grade of iron ore and non coking coal. Gas Based DRI / HBI. 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 preferred metallic, energy efficient and ...
WhatsApp: +86 18203695377
process of HYLSA. These contribute over 80% of world sponge iron production today. Out of the coal based technologies SL/RN technology of Lurgi , West Germany has been the most successful one. Little success has been achieved by other coal based technologies namely CODIR technology of Krupp Industriatechnik now Mannesmann Demag,, DRC
WhatsApp: +86 18203695377
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 ...
WhatsApp: +86 18203695377
Coalbased sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and noncoking coal are fed to the kiln at controlled rates without premixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln. In combination ...
WhatsApp: +86 18203695377
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 ...
WhatsApp: +86 18203695377
therefore classified as coal based and gas based process respectively. Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production [5]. At present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the ...
WhatsApp: +86 18203695377
Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H2 and CO.
WhatsApp: +86 18203695377
Given that the EAF process's primary inputs are scrap iron, coalbased sponge iron, and gasbased sponge iron, three scenarios are defined in Table 5, and their impacts are assessed. Scenario 1: 90% gasbased sponge iron is used alongside 10% scrap iron (which is the actual modus operandi of the factory).
WhatsApp: +86 18203695377
يرغب أحد موردي المواد من بلجيكا في إنتاج مسحوق الحجر الجيري لملابسه...
الهند غنية بالموارد المعدنية المختلفة وهي سوق مهم لمعالجة المعادن
Copyright © 2023 GMC Co., Ltd. SiteMap
