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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 …
Abstract. 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 …
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 ...
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 ...
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 …
Sponge iron is iron ore reduced directly in solid state using coal gasses, natural gasses or coke coal as reductants and is known as Directly Reduced Iron (DRI). It is a recognized alternative to Steel Scrap as a raw material for the manufacture of steel products. The process of making sponge iron aims at reducing oxygen levels in the raw iron ore.
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 coal-based sponge iron is considered as a viable option (Agrawal et al. …
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
Sponge iron is the final product of coal fired rotary kilns. The schematic diagram in Fig. 1 describes the unit processes ... Fig. 1 Schematic flow sheet of coal based direct reduction process[1]
Different processes of coal-based and gas-based are discussed in detail. Forms of sponge iron, characteristics of sponge iron and re-oxidation of sponge iron …
The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel Company of Canada, Lurgi Chemie, Republic Steel Company and National Lead ...
This process is one of the oldest direct reduction methods, and its structure is based on a horizontal cement kiln. In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in …
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 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 ...
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 …
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 ...
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 …
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 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
Coal based Sponge-iron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron (DRI). Iron Ore Pellet is used for reduction. ... Coal based DRI process is mainly preferred on account of better non contaminated Iron (Fe) for steel making instead of facing crisis of ...
Sponge Iron Making Process(Coal Based) Krupp-Renn Process : The Krupp-Renn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of -6.4mm ore and reducing agent like coke breeze or bituminous coal fines are fed into rotary kiln continuously. ...
The process flow diagram (PFD) of a typical coal-based sponge iron plant is shown in Fig. 1a. Different streams in PFD are assigned individual numbers and henceforth each stream will be …
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.
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 ...
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 …
be leached into the soil from this process. 3 Wastes from Coal Based DRI Process The Sponge Iron production is critically air polluting in nature emitting high concen-tration of particulate matter from point sources and from several secondary sources. The three main types of wastes generated are solid wastes, liquid wastes, and gaseous emissions.
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 …
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, …
In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.