Us4726839a process and an arrangement for the production of. India production volume of sponge iron 2011 to 2019 statista. Dri is also known as sponge iron, it is a solidstate direct reduction process fig. Details of dr processes, reoxidation, storage, transportation, and application of dri are discussed in this section. Sponge iron production by direct reduction of iron oxide. Processing techniques and productions of ductile iron. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. The requirement of sponge iron as metallic will be 30 million tons. This type of iron can be produced in several different types of furnaces, including coke or charcoal ovens, blast. The iron sponge process is economically applied to gases containing small amounts of h 2 s iron oxide reduction. While iron sponge is no longer used for treating large volumes of natural gas, it is still widely used for removing.
Sponge iron manufacture is highly sensitive to raw material characteristics. Tslpl is a pioneer in india for using hot metal in electric arc furnace, which later became an industry norm. Productivity increment of coal based sponge iron plant. Coal is another main raw material for process of sponge iron and both. The reduction of the iron ore pellets is described using. The production volume of coal based sponge iron in india accounted for more than 24 million metric tons at the end of fiscal year 2018. A survey is made on a typical coal based indian sponge iron plant of capacity 500 td in order to identify the largest energy losses and find ways to increase the efficiency.
Optimization of the iron ore direct reduction process through. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. Ironically, india is the worlds top producer of sponge iron, but producers there are grappling with high production costs and suffering from the more aggressive iranian exporters. Pdf energy survey of the coal based sponge iron industry. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. The sponge iron produced by this process is carbon free 1.
Iron sponge process an overview sciencedirect topics. What are the best books forabout sponge iron making. Phd, pe, in surface production operations third edition, volume 2, 2014. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Free download sponge iron production in rotary kiln book. Download and read free online sponge iron production by direct reduction. Nov 12 2012 sponge iron production in rotary kiln bidyapati sarangi this book comprehensively deals with the production of sponge iron in the rotary kiln or download a free kindle. This production volume was estimated to reach 26 million. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron ore in the form of lumps, pellets, or fines to iron by a reducing gas or elemental carbon produced from natural gas or coal. Oluwasegun abstractductile cast irons are materials having strength, impact toughness and ductility comparable to those of many grades of steel while exceeding by far those of standard gray irons. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. Over the years, the coal based route has emerged as a key contributor and accounted for 79% of total sponge iron production in the country.
Pdf word cant be simpler ms word is one of the most used text processing applications and the pdf format is the most used format to publish documents using the. India production volume of sponge iron 2011 to 2019. Dspl is the leading manufacturer of sponge iron in eastern region of india. Dec 19, 2017 india is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. Production of sponge iron through tunnel kiln process. The indian sponge iron industry some issues in conservation. The sponge iron reaction sir is a chemical process based on redox cycling of an iron based contact mass, the first cycle is a conversion step between iron metal fe and wuestite feo, the second cycle is a conversion step between wuestite feo and magnetite fe 3 o 4.
The process is dry, using no free liquids, and can be used for all natural gas applications where a batch process is suitable. Get sponge iron at best price with product specifications. Equation 6 and co, cannot exist above c in the presence of free. Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from the other end. With the direct reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages than scrap metal smelting for. Study on accretion formation on dri kiln during spong iron. Spongeironproductioninrotarytn786312020 adobe acrobat reader dcdownload adobe. Alternatively dri grade pellets which are produced from iron ore fines can also be purchased and utilized instead of iron ore. These following books are more useful for sponge iron making 1. Oct 08, 2019 the production volume of sponge iron in india accounted for more than 30 million metric tons at the end of fiscal year 2018. It can be seen from table 1 above that while production of crude steel in the if units registered an average annual growth of 11.
Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. Direct reduction process an overview sciencedirect topics. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route, which has shown a phenomenal growth in india. Sling coal is essential for creation of reducing environment in the free board of kiln. Iron ore is being fed to the ground hopper, from where it conveyed to the screen with the help of vibro feeder, where.
A thesis submitted for partial fulfillment of the degree. Sponge iron production flow chart raw material feeding to kiln iron ore, coal, dolamite rotary kiln conversion of raw iron ore into sponge iron cooler sponge iron cooling below 100deg by external water cooling intermediate bin desired quality for blending screening in product house. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. This more than proportionate rise in the production of sponge iron can be explained by a pronounced shift of if units to sponge iron in the charge mix away from scrap. Pdf on apr 1, 2010, swaren bedarkar and others published. The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge. In the present work, utilized waste heat to preheat the feed coal and air, heat integration process using modified pinch approach is applied and to increase. Sponge iron is produced by a direct reduction of iron oxide containing materials in a rotary kiln, the material discharged from the rotary kiln is separated into sponge iron and material which contains surplus carbon, the carboncontaining material is burnt in a fluidized bed reactor containing a circulating fluidized bed, and the heat generated by the combustion is recovered and utilized to.
Brief history of iron production according to most historians, the first iron used by man was of meteoritic origin. In order to be able to process sponge iron with high contents of acid gangue and a phosphorus content of more than 3% in an economic and operationally safe manner, the following measures are taken. Download it once and read it on your kindle device, pc, phones or tablets. Sponge iron is a valuable source of iron for the production of highquality steel. Sponge iron production by direct reduction of iron oxide kindle edition by chatterjee, amit. Us4676824a process for generating heat and producing sponge. The amount of sponge iron in the charge mix varies from 090% depending on its availability and economics of production. The basic raw materials for the production of sponge iron are iron ore, noncoking coal and dolomite. Production of sponge iron by reduction of iron oxides from roasted pyrite concentrate from ok tedi mine, western province, papua new guinea. Production of sponge iron by reduction of iron oxides from. The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform fe metallic of all grain size fraction of the product. In the year 1908 use of tunnel kiln started for iron oxide reduction. India, worlds largest producer of sponge iron 2018, has a host of coal based units located in the mineralrich states of the country. Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore.
This production volume was estimated to reach over 33 million metric. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron. Annual sponge iron production for sample sponge iron plants. A typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal and air as well as increase the productivity of sponge iron by applying heat integration using simulation process. With an installed capacity of 2x350tpd and can able to produce sponge iron of 0. Sponge iron or direct reduced iron is produced by reducing iron ore in the form of lumpspellets using noncoking coal in a rotary kiln. Seml was one of the first companies to install a sponge iron plant in the siltara, raipur area. Sponge iron production by direct reduction of iron oxide ebook.
Therefore, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. Iron sponge is a highly porous, coarsely powdered or granular form of iron metal with numerous applications in catalysis, gas purification, and alloy production. The main raw materials used for the production of sponge iron is iron ore which is purchased and transported from nmdc through railway wagons. With the direct reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages than scrap metal smelting for steel making. Sponge iron production by direct reduction of iron oxide by amit. Coal based sponge iron production in india 20112019 statista. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes choudhury, 2014.
Over the past 20 years to use of eaf for the production of. Projection for metallic requirement in year 201011 we require melting scrap 14 million and dri 18. Us4676824a process for generating heat and producing. In his discussion of electricfurnace production of pig iron and pig steel before the engineers society of western pennsylvania, dr. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr. In 1954, more kilns came in operation in sweden and usa. A process and an arrangement for the production of steel from sponge iron. This product is known as direct reduced iron dri or sponge iron. Sponge iron production by direct reduction of iron oxide by amit chatterjee 2. Direct reduction refers to solidstate processes which reduce iron oxides. Iron ore is being fed to the ground hopper, from where it conveyed to the screen with the help of vibro feeder, where oversize i. It is widely distributed, combined with oxygen as iron oxides.
Additional technical, research and safety msds information is available. Melting of a new carbon free waxed sponge iron in electric arc. Modeling of rotary kiln for sponge iron processing using. Sponge iron production by direct reduction of iron oxide kindle edition by. Apr 23, 2020 sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. Majority of the steel produced through induction furnace route is plain.
The sponge iron reaction sir is a chemical process based on redox cycling of an ironbased contact mass, the first cycle is a conversion step between iron metal fe and wuestite feo, the second cycle is a conversion step between wuestite feo and magnetite fe 3 o 4. In application, the sit is used in the reformer sponge iron cycle resc in combination with a steam reforming unit. Iron ore crushing is not required since sized material has to be purchased. Us4726839a process and an arrangement for the production. Use features like bookmarks, note taking and highlighting while reading sponge iron production by direct reduction of iron oxide.
The latter process is based on atomization of a stream of liquid. Iron very rarely occurs in the earths surface as a metal. Ironmaking and steelmakingtheory and practice and sponge iron production by direct reduction of iron oxide both published by phi learning, delhi as well as two other books entitled beyond the blast furnace and metallics for steelmakingproduction and use, besides a number of monographs on. The production volume of sponge iron in india accounted for more than 30 million metric tons at the end of fiscal year 2018. One of the major challenges for sponge iron plant is the accretion formation. Aug 25, 2014 these following books are more useful for sponge iron making 1. The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. While china primarily buys raw iron ore, the islamic republic is also boosting exports to india of sponge iron. Pdf production of sponge iron through tunnel kiln process.
So there is a huge requirement of sponge iron production. In fact it is believed that iron makes up about 5% by weight of the earths crust. Sponge iron production by direct reduction of iron oxide, amit. In january 2007, the economic research unit of jpc had conducted a techno. Projection for metallic requirement in year 201011 we require melting scrap 14 million and dri 18 million but availability of scrap is not likely to reach 11 million. Sponge iron article about sponge iron by the free dictionary. The direct reduction process uses pelletized iron ore or natural lump ore. This is one of the best book for a metallurgist who works in sponge iron indusrtrythe book contains data mass balance and heat balance which never seen in any other books of sponge iron.