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Direct Reduced Iron ( DRI ) Plant

The plant is integrated by addition of captive power plant and long term iron ore coal supplies The DRI plant comprises of 4 kilns each of 100 TPD capacity The rated annual production of sponge iron is 1 28 000 tonnes The Raw materials are iron ore coal dolomite Get price

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FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN DATA A N NAIK Manager of Construction and Special Projects Tata Iron and Steel Company Ltd Jamshedpur Abstract The author tries to foresee the future of Sponge Iron Making in India and forecasts that the metallur-Get price

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Steel making today and tomorrow

Reduction occurs in a solid state at a lower temperature than in the blast furnace process and produces an intermediate product sponge iron or direct reduced iron (DRI) with water vapour emitted from the top of the furnace Water vapour can be condensed and scrubbed before reuse in the plant Get price

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SPONGE IRON PLANT

The major Raw Materials required for production of Sponge Iron by the rotary kiln process are sized graded Iron Ore and Non-Coking coal Limestone in small quantities is also required to scavenge the sulphur IRON ORE The quality requirement of Sized ore for sponge iron Get price

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PRODUCTION OF IRON AND STEEL POWDERS

Hgans sponge-iron process and the water-atomizing process The former process is based on reduction of iron ore yielding a highly porous sponge-iron which subsequently is comminuted to powder The latter process is based on atomization of a stream of liquid iron (or steel) by means of a jet of pressurized water Both processes will be Get price

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AN INVESTIGATION FOR GENERATION OF ENERGY

2 COAL BASED SPONGE IRON PLANT A CONVENTIONAL PROCESS The process flow diagram of conventional coal based sponge iron plant is shown in figure 1 The operating data shown in figure 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 Get price

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Iron Sponge Process

8 5 1 Iron sponge process An example of a hydrogen sulfide scavenger process is the iron sponge process (also called the dry box process) which is the oldest and still the most widely used batch process for sweetening of natural gas and natural gas liquids (Anerousis and Whitman 1984) The process was implemented during the 19th century and Get price

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Sponge Iron Plant

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 – 1050C) Get price

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coal based sponge iron process in south africa

tunnel kiln process sponge iron in south africa sponge iron by tunnel process in south africa CARBON RECOVERY FROM SPONGE IRON PLANT DUST sponge iron by tunnel process in south africa India is the world's largest Sponge Iron producer and mostly uses the Coal based process The downside of this industry is that it generates significant amou Get price

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status of sponge iron plant Orissa

sponge iron plants in cluster is because of the easily availability of raw materials communication facility in those area Similarly in Keonjhar district maximum number of sponge iron plants is found to be mushroomed at Badbil-Joda area (12) Jharsuguda district contain 10% (13) sponge iron plant of state followed by sambalpur 9% (10) Get price

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status of sponge iron plant Orissa

sponge iron plants in cluster is because of the easily availability of raw materials communication facility in those area Similarly in Keonjhar district maximum number of sponge iron plants is found to be mushroomed at Badbil-Joda area (12) Jharsuguda district contain 10% (13) sponge iron plant of state followed by sambalpur 9% (10) Get price

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Direct reduced iron

Process Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a 'select' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled magnetically separated screened and size wise in Get price

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FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN DATA A N NAIK Manager of Construction and Special Projects Tata Iron and Steel Company Ltd Jamshedpur Abstract The author tries to foresee the future of Sponge Iron Making in India and forecasts that the metallur-Get price

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Is pig iron and sponge iron the same or not?

Mar 07 2019No They aren't The source of both pig iron and sponge iron are iron ore In case of pig iron the ore is reduced and melt in the blast furnace and the preliminary product is liquid iron which solidifies to pig iron On the other hand sponge irGet price

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Difference Between Sponge Iron and Pig Iron

Apr 30 2011That is the production process of sponge iron is a liquid state process whereas it is a solid state process for pig iron Summary – Sponge Iron vs Pig Iron Both sponge iron and pig iron are two basic forms of iron that we can obtain via processing natural iron ore The key difference between sponge iron and pig iron is that we can produce Get price

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Energy Audit Methodology of Sponge Iron Manufacturing

Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side Further the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25 1) to (31 1) This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant Get price

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coal based sponge iron process in south africa

tunnel kiln process sponge iron in south africa sponge iron by tunnel process in south africa CARBON RECOVERY FROM SPONGE IRON PLANT DUST sponge iron by tunnel process in south africa India is the world's largest Sponge Iron producer and mostly uses the Coal based process The downside of this industry is that it generates significant amou Get price

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CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

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 Get price

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SPONGE IRON PLANT FEASIBILITY STUDY IN KALIMANTAN

the local iron ore raw materials are still many impurities which would lead to lower levels of iron in the material standard so that the standard product manufacture sponge iron will be difficult to achieve if there are impurities in the raw materials The following are steps in the process for the processing of iron ore to sponge iron Get price

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Make Sponge Iron From Coal And Iron Ore Process

Make Sponge Iron From Coal And Iron Ore Process We are a large-scale manufacturer specializing in producing various mining machines including different types of sand and gravel equipment milling equipment mineral processing equipment and building materials equipment Get price

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Direct Reduced Iron (DRI)

Some of the sponge iron plants are captive to steel mills but there is a significant domestic merchant market India producing 57% of its crude steel in electric arc furnaces (2016) At integrated mini-mills DRI can be hot charged to the EAF at temperatures in the region of 650 C Get price

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Risk appraisal study Sponge iron plants Raigarh District

Risk appraisal Sponge iron plants Cerana Foundation Oct 2006 6 Visible air pollution from point and area sources from sponge iron plants around Raigarh Solid waste dumps at sponge iron plants 3 Documented data Meteorology The meteorology of the area is summarized below The area has hot summers and cool winters Get price

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US5238487A

A process for producing pig iron is described which contains a reducing shaft furnace 1 and a melting gasifier 2 The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace Get price

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Energy Audit Methodology of Sponge Iron Manufacturing

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 Get price

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sponge iron process 2010

Jul 29 2010The Fe total content in sponge iron purely depends on Fe con tent in iron ore and the degree of reduction achieved in the process Fe total content of 90%min is required for steel making requirement Fe metallic Fe metallic content in sponge iron depends on the effective control of process Get price

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What is Sponge Iron? (with pictures)

Oct 10 2019Sometimes 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 that is created by the use of a reducing gas that emits from coal or a Get price

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Sour gas sweetening

Iron sponge (Iron Oxide) Iron sponge consists of wood chips that have been impregnated with a hydrated form of iron oxide The material is placed in a pressure vessel through which the sour gas is flowed Because this is a batch process usually two vessels are installed—one in service and the other on standby Fluor Solvent Process Get price

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CHAIRMAN'S MESSAGE

Sponge Iron industry comes under Iron Steel sector with sectoral energy reduction target of 1 56 mMTOE(million metric tones of oil equivalent) For a coal based DRI plant with waste heat recovery boiler power plant and having arrangement for selling surplus electricity the Get price

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Recovery and utilization of waste heat in a coal based

Recovery and utilization of waste heat in a coal based sponge iron process of coal of 264 535million tonnes the coal based sponge iron plants share the major amount of its production [2] At present there are 118 large and small sponge iron plants operating in India amongGet price

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Sponge Iron Process for Manned Space Exploration

Sponge iron process for manned space exploration Final project report June 2005 Executive Summary REDOX cycling of an iron-rich contact mass has been investigated and applied with terrestrial hydrogen production from hydrocarbon and biomass sources The governingGet price

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STEEL / SPONGE IRON CAPTIVE POWER PLANT PROFILE

Boiler design and engineering for sponge iron waste heat recovery boilers Boiler design and engineering for BFG / coke oven gas / oil fired boilers Power plant engineering for sponge iron steel plants Trouble shooting and revamping of boiler and power plant machinery Plant Piping design and Get price

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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 Get price

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Electrosteel Castings Ltd

In 2005 Electrosteel has successfully developed an Industrial estate in Haldia as a major supplement to its process integration objective with the establishment of a coke oven a sponge iron unit and a power plant Captive Coke Oven Plant and Sponge Iron plant Electrosteel installed a 2 80 000 TPA Coke Oven Plant and Sponge Iron unit (2 x 100 Get price

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Sponge Iron (DRI)

In Energy conservation process in DRI plant we catch Process resultant fuel gases which is at high temperatures of around 950C 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 Get price

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