In fact, we were the first player in the State to pioneer and successfully set up the first coal-based DRI plant in Raniganj, West Bengal in 1999. ... The process includes warming the normally occurring iron oxide in the …
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, 2011). Depending on …
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 reaction) by which removable oxygen is removed from the iron ore, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or …
The principles of circular economy (CE) in systems thinking (ST) have been proposed in this paper as a measure towards augmenting the sustainability of coal …
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 …
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.: Health-related quality-of-life of coal-based sponge iron plant workers in Barjora, India: a ...
Because this process does not use natural gas, a lower-carbon- content product (around 0.4%) is expected. Similar to the gas-based HYL process, in the coal-based process, the furnace top gas is cooled and cleaned, and its CO 2 is removed and then recycled into a reducing gas circuit. Reducing gas is produced in a coal gasifier …
Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in …
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 ...
The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coal-based sponge iron plant, …
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
a Process flow diagram of a typical coal based sponge iron plant. b Schematic of enclosed section of Fig. 1a as an available in plant-B Flow chart showing iteration steps Heat exchanger networks ...
sponge iron sector, which is dominated by small-sized coal-based direct reduction of iron (DRI)-based plants. India is one of the unique countries in the world where coal-based …
On sponge iron-making in coal-based rotary kilns, there are studies on process modeling (Gaurav and Khanam, 2016), ... Switching from coal to NG as the feedstock leads to a 58% reduction in the GHG emissions of the coal-based DRI process plants (including electricity use). On a life cycle basis, GHG emissions from the NG …
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. ... The quantity of coal feed is adjusted to get the required degree of production and to sustain the process. Adjustment of coal quantity can be done from the ends of the reactor ...
Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of Pollution Sources of air pollution and its control Air pollutants include particulate matter (dust) and ...
This study summarises our findings from a survey of coal-based direct reduced iron (DRI) plants in India. DRI process is a method to produce iron from iron ore without melting it. The National Steel Policy, 2017 projects that by 2030, of the 80 million tonnes per annum (MTPA) of DRI production, 70 per cent will be coal-based. The study reports ...
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 reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & physical characteristics.
Thus, large ΔT is preferred for operation (Linnhoff et al. 1982) when gas streams are involved in heat exchange. Due to above fact, ∆Tmin as 50°C is considered for heat integration in all cases. In sponge iron process variation in temperature of iron ore, coal, dolomite, sponge iron, and waste gas is in the range from 1,020°C to 30°C.
The temperature profiles of the gas and charge in a coal-fired rotary sponge iron kiln affect both the iron ore reduction process and accretion formation.
Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coal-based DR process and (2) gas-based DR process. Details of DR processes,...
The conventional rotary kiln-based sponge iron (SI) production process in India, which contributed to the manufacture of 33.88 million tons of SI in 2022 was depicted in Fig. 1 (Ministry of Steel, 2023).The SI production system of 100 ton per day (TPD) capacity comprised an inclined rotary kiln (3°), a rotary cooler, an after burning chamber …
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.
Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...
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 and find ways to increase the efficiency.
5.1.2. Increase use of gases in coal- based route DRI production There is a need to substitute part of coal by bio gas/ syn gas/ natural gas/green hydrogen in the existing coal based DRI route to save about 40 MTPA installed capacity which has been set up with huge investment, provide large number of direct and indirect employment and plays very
The present work is an attempt to conserve energy in coal based sponge iron industry incorporating certain design modifications without disturbing the process technology. A typical sponge iron plant has been investigated to find out the potential …
Gas-based direct reduction ironmaking processes are mostly shaft furnace process, vessel process, fluidization process, and iron carbide process. Shaft Furnace Process It is the process in which high-temperature reducing gas and solid reductant are used to reduce iron ore in order to produce sponge iron.
sponge iron sector, which is dominated by small-sized coal-based direct reduction of iron (DRI)-based plants. India is one of the unique countries in the world where coal-based DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is
Coal-based sponge iron process. The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking coal are fed to the kiln at controlled rates without pre-mixing and the charge moves through the kiln depending upon the rotation speed and inclination of the kiln. In combination ...
