Energy Conservation in Sponge Iron Production Process …
Many investigators [1]-[4] considered the manufacturing process of sponge iron and recommended improvement in that. It is found that during the operation in the coal based sponge iron plant, an incredible amount of heat is generated and a significant part of this heat associated with the waste gas, remains unutilized.
Coal based Direct Reduction Rotary Kiln Process …
The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital …
How much hydrogen is in green steel? | npj Materials …
Hydrogen-based reduction of iron ores is the key technology for future sustainable ironmaking, to mitigate the CO2 burden from the steel industry, accounting for ~7–8% of all global emissions.
Analyses of Different Modifications Proposed for the Sponge Iron …
Prasad et al. (2013) designed a gas carrying duct and rotary drier for utilization of waste heat in a sponge iron plant, which reduced the load on the kiln by 13.15% in comparison to the existing one to produce 1 tonne DRI. Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury ...
The production process of sponge iron in rotary kilns …
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, …
production of steel & iron ore requirements
For producing one tonne of crude steel, 1.6 tonnes of iron ore consumption has been assumed. If we add iron ore requirements of RINL of about 5.00MT (3.13 MT x 1.6 tonnes), the total iron ore requirements from non-captive mines work out to 58.31MT or about 60MT. Out of the total requirements of about 60 MT, NMDC supplied about 24 …
Raw materials used in making Iron and steel
The basic raw materials for making iron and steel are: Iron ore. Iron ore is one of the basic among other raw materials used in the production of iron. It is described as any mineral substance that contains enough iron which makes its smelting a viable proposition, i.e. an iron content of less than 20%. Ores vary considerably in form and ...
How much hydrogen will be needed to replace coal in making …
So each tonne of 'new' steel has typically required about 6 MWh in the process of getting from iron ore to a finished steel product, such as coil used for making the exteriors of cars. The coal energy needed for steel-making is therefore. 1.35 billion tonnes of steel times 6 MWh = about 8,000 Terawatt hours (TWh) = as a comparison, …
sbm/sbm iron ore required for tonne of sponge iron.md at …
Contribute to changjiangsx/sbm development by creating an account on GitHub.
Development of energy conservations scenarios for sponge iron …
Cost of sponge iron production varies with different inputs such as iron ore, coal, dolomite, fuel, maintenance, depreciation, power, etc. Costs of these inputs, taken directly from the plant, for 1 tonne production of sponge iron are drawn in Fig. 4, which shows that a significant component of total cost, i.e., 31.8% is due to coal.
ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …
OF IRON PROCESS (SPONGE IRON PLANTS) THE ENERGY AND ... small-sized coal-based direct reduction of iron (DRI)-based plants. India is one of the unique countries in the world ... To meet the DRI production target of 80 million tonne by 2030–31 as envisaged under the National Steel Policy (2017), whilst improving the industry's energy and ...
A review of ironmaking by direct reduction …
DRI (also known as sponge iron) is an important advancement in the ironmaking industry due to its high productivity and strong adaptability to raw materials …
Energy integration of sponge iron production process
I. INTRODUCTION Sponge iron is a metallic mass with honeycomb structure. It is a form of iron produced from direction reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. Sponge iron is produced primarily both by using non-coking coal and natural gas as reductant ...
TMT Steel bar Manufacturing Process | Shyam Steel
The manufacturing process of TMT Bar involves series of processes like rolling, water quenching, heat treatment, cooling at various stages of manufacturing. The Thermo Mechanical Treatment involves 3 essential steps that are: Quenching. Self Tempering. Atmospheric cooling. The quality of TMT Bar depends on three major factors.
EXERGY AND ITS EFFICIENCY ESTIMATIONS FOR …
calculated as 925.90 MJ and 41.74% per tonne of sponge iron, respectively. Exergy destroyed and exergy efficiency increase with the introduction of post-combustion in reduction zone.
From Ore to Iron with Smelting and Direct Iron Reduction
Smelting Reduction. Figure 2: The smelt reduction vessel (SRV) is the core technology component of the Hismelt process. Source: RioTinto While years of ironmaking technology innovations have optimized blast furnace productivity, two alternative processes—smelting reduction and direct iron reduction— are growing in adoption. The …
Sponge Iron | SpringerLink
1. Less capital cost: The capital cost per tonne of installed capacity, in case of coal-based plants, is 1.8–2 times as high as in the gas-based plants.. 2. High productivity: The throughput rates for gas-based sponge iron plants are much higher than in coal-based plants.The productivity for gas-based plants can be as high as 11 t/m 3 /day as against …
Direct Reduced Iron (DRI) | International Iron Metallics …
Direct Reduced Iron (DRI) is the product of the direct reduction of iron ore in the solid state by carbon monoxide and hydrogen derived from natural gas or coal. ... 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).
The perspective of hydrogen direct reduction of iron
Industrial-scale hydrogen-ironmaking, also known as direct reduction of iron (DRI) using hydrogen, is a process that aims to produce iron without the use of fossil fuels ( Chevrier, 2020; van Vuuren et al., 2022; Tang et al., 2020; Wang et al., 2021; Ledari et al., 2023 ). This process has the potential to significantly reduce carbon dioxide ...
A review of the sponge iron process for the storage and …
Even with a limited amount of heat integration, the sponge iron process demonstrated a higher energy efficiency for chemical storage than that of alternatives, including liquid H 2, synthetic liquid fuels made from CO 2 and H 2, MgH 2 slurry, and the methylcyclohexane–toluene–hydrogen (MTH) system. Such gains make the technology …
Sponge Iron Production Process
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.
Energy survey of the coal based sponge iron industry
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. The required data are obtained by measurements or taken from production industries. The process efficiency is about 51.31%.
ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR …
OF IRON PROCESS (SPONGE IRON PLANTS) THE ENERGY AND ... small-sized coal-based direct reduction of iron (DRI)-based plants. India is one of the unique countries in …
Production of Iron in the Blast Furnace | SpringerLink
The Iron Age began when the humans, probably by chance, discovered iron sponge when they were heating iron ores that were easily reduced. ... paid to achieve both an incomplete combustion and a reductant environment in the furnace favoring the formation of the sponge iron, which after the forging process had the following …
Sponge Iron | SpringerLink
Xu Kuangdi. 1 Accesses. Download reference work entry PDF. Sponge iron adopts direct reduction ironmaking method to obtain iron with sponge-like pores inside. …
Chapter 1 Review of Sponge Iron Making Process …
metallic iron is called as degree of metallization in sponge iron technology. Sponge Iron Making Process(Coal Based) Krupp-Renn Process : The Krupp-Renn process was …
Analyses of Different Modifications Proposed for the Sponge Iron …
In the present work, an effort is made for best utilization of waste heat to reduce energy requirements in sponge iron plants. For this purpose, based on the principles of process integration, three design modifications, scheme-1, scheme-2, and scheme-3, are proposed and applied on actual data of two sponge iron plants being …
Sponge Iron | SpringerLink
Based on C/Fe ratio of 0.42–0.44, the coal input in the process varies between 1.10 and 1.20 tonne per tonne of sponge iron, depending on the ash content of …
Recovery and utilization of waste heat in a coal based sponge iron process
The waste gas enters into this exchanger with a velocity of 7 kg/s and is cooled from 214.5 °C to 115.18 °C and consequently, heating the air flowing at 5 kg/s from 30 °C to 170 °C. The overall heat transfer coefficient is estimated to be 52.56 W/m 2 K. Preheating of air up to 170 °C reduces the coal consumption.
Profitability analysis of power generation using waste heat of sponge …
It is used as prime source in steel making process. It is found in the literature that required amount of energy for rotary kiln is in the range from 14.63 GJ to 20.9 GJ per tonne of sponge iron [2]. Although, during the operation enormous amount of heat is generated, which remains unutilized in the process.