SPONGE IRON PRODUCTION FROM ORE -COAL …
With composite agglomerate, the internal coal used is 5% to 6% of iron fines weight. The internal coal has ash of 6.0% and VM 9.0%. The additional silica and alumina in the …
Sponge Iron Manufacturer in India | Vandana Global
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 Ore Pellet is used for reduction. After the reduction of iron ore pellet, the product resembles a sponge because of pores left behind after the ...
(PDF) Study on reduction of iron ore concentrate in rotary kiln …
The pellets are a mixture of magnetite iron El-Hussiny et al. (2015) examined Baharia concentrate and coal as a reductant in the iron ore using hydrogen as a reducing agent ratio of Fixed Carbon/Iron (FC/Fe) from 0.22 and studied its kinetic reduction rate to yield to 0.52 and reduction temperature of reduction control through a thin layer of ...
Sponge Iron
Use of self-reducing pellets (SRP) cold-embedded with reactive carbonaceous materials or pressed iron ore-carbon composites is targeting primarily at the lowering of the thermal …
A review of ironmaking by direct reduction processes: …
The authors found out that the reducibility of iron increased to 99.95% at a reduction temperature of 1323K. The results also showed that the biomass derived syngas had an iron pellet reduction efficiency similar to that of natural gas, but presenting a possibility of an ironmaking process with no net CO2 emissions.
Reduction Efficiency of Iron Ore–Coal Composite Pellets in …
Reduction Efficiency of Iron Ore–Coal Composite Pellets in Tunnel Kiln For Sponge Iron Production. February 2015. Transactions of the Indian Institute of Metals. …
A study on the accretion formation in DRI kilns and …
Thus, due to this porous structure, DRI is often called sponge iron. Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced product having high degree of metallization exhibits a „honeycomb ...
Sponge Iron Production and Uses | UPSC
Reduction: The pellets are fed into a rotary kiln or vertical shaft furnace where they are heated to around 1000°C to 1200°C in the presence of a reducing gas (CO and H2). Sponge Iron Formation: In the kiln, the iron oxides are reduced to metallic iron, forming sponge iron with a high porosity.
(PDF) METCON POWER CONSULTANT & ENGINEERS Direct Reduced Iron …
Unloading of DRI / SPONGE IRON (pellets / sponge iron of 2 to 8 mm. size): After Completion of cooling process, DRI (pellets / sponge iron of 2 to 8 mm. size) are ready to leave the Tunnel Kiln.
The production process of sponge iron in rotary kilns …
achieved. Sponge iron is produced using non-crushing coal through the iron ore reduction process in a rotary kiln. Regeneration takes place at a predetermined …
Conversion of Sponge Iron From Low Grade Iron …
The shrinkage behaviour of the pellets containing mill scale is given in the figure 3 DOI: 10.9790/1684-1305064954 53 | Page Conversion of sponge iron from low grade iron ore and mill scale …
(PDF) Modeling of Rotary Kiln for Sponge Iron …
Sponge iron, also called Direct-reduced iron (DRI),[2] is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. The reducing gas is a …
STUDY ON REDUCTION OF IRON ORE CONCENTRATE …
A direct reduced iron (DRI) was prepared using iron concentrate pellets and a coal as a reductant through three stages, namely, the first: iron concentrate pellets were dried by slow heating at ...
Cold bonded ore–coal composite pellets for sponge
Abstract. Cold bonded ore–coal composite pellets developed on a laboratory scale (Part 1 of this two part paper) were tested in a rotary kiln sponge iron plant. This plant had a 12 m length ...
(PDF) Reduction and Swelling of Fired Hematite Iron Ore Pellets …
Swelling Behavior of Fired Hematite Iron Ore Pellets during Reduction The swelling index values of fired Zenith hematite iron ore pellets (batch A), reduced nonisothermally in Ananta coal particles of size 6 þ 16 mesh at final tem- peratures of 850, 900, 950, and 1000 C, have been plotted against soak time in Figure 2.
Pressure Measurement and Control in Rotary Kilns at TATA Sponge Iron …
Pressure fluctuations inside a coal-fired rotary kiln for production of sponge iron affect the temperature distribution as well as the rate of reduction of iron oxides. The fluctuations can be ...
(PDF) Operation of Coal-Based Sponge Iron …
Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation. Conference: AISTech 2019 — Proceedings of the Iron & Steel...
Steel Exchange India Ltd
They enter the rotary kilns through a feed chute and are initially pre-heated with the liberation of heat from the volatiles from the coal in the first 1/3rd of the kiln. The reduction process begins after this where the iron oxides are reduced to metallic iron. The following chemical reactions take place inside the kiln. C + O2 = CO2 CO2 + C = 2CO
Sponge Iron | SpringerLink
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 …
Janki Corp Limited | JCL Ltd. | Steel Division
Sponge iron is produced by reducing iron ore in the form of pellets using non-coking coal in a rotary kiln. The coal acts as fuel as well as a reducing agent when oxygen is removed from the ore to produce the sponge like properties. Since the reduction takes place in the solid phase only, the output is called direct reduction.
Rungta Steel
For example, in the direct reduced iron (DRI) manufacturing process, the porosity of the iron pellets helps facilitate the reduction of oxygen in the kiln. This process is essential for producing high-quality DRI fem (ferrous metallics) with a grade of 80+. Moreover, the iron pellets have a mean particle size (MPS) of approximately 9.5-10 units.
Introduction to Iron ore Pellets and Pelletizing processes
Before transfer to the kiln, the green pellets are to be sufficiently hardened: 6: Process availability is higher: Process availability is lower: 7: ... – What will be the impact on pellets during reduction process in a coal base sponge iron kiln if -325 mesh is ~80% to 85%? Is there Fe loss in E.S.P. reducing sponge iron yield?
(PDF) i) Direct Reduced Iron: Production
Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR processes. Based on the types of reductant used, DR processes can be ...
Process flow diagram of the sponge iron plant.
In the conventional process, the sponge iron leaving the rotary kiln at 1,020 °C (Dey et al., 2015) is cooled to 110 °C for two reasons: (i) to prevent re-oxidation of the sponge iron when ...
An innovative process for direct reduction of cold-bound pellets …
Successfully developed an innovative process of direct reduction of cold-bound pellets from iron ore concentrate with a coal-based rotary kiln, in comparison with the traditional direct reduction of fired oxide pellets in coal-based rotary kilns, possesses such advantages as: shorter flowsheet, lower capital investment, greater economic profit, good …
THE EFFECT OF REDUCTION TIME AND SIZE …
The method used in this research was the direct reduction process using a pilot-scale rotary kiln with the variables related to residence time (1, 2 and 3 hours) for the pellets and to the diameter of the pellets (-12+8mm and -20+12mm). Meanwhile, the reduction temperature was fixed, i.e. 1100oC. The maximum metallization of sponge iron ...
(PDF) Optimization of sponge iron (direct reduced iron) …
Optimization of sponge iron (direct reduced iron) production with Box-Wilson experimental design by using iron pellets and lignite as reductant. CC BY 4.0. …
Review on Reduction Kinetics of Iron Ore–Coal Composite …
Reduction Efficiency of Iron Ore–Coal Composite Pellets in Tunnel Kiln For Sponge Iron Production. Article 13 February 2015. Introduction. Most iron is presently …
LECTURE NOTES ON Sponge Iron & Ferro Alloys
The term direct reduction of iron ore originates from the fact that the iron oxide(Fe 2 O 3 ... It can use large iron ore and pellets c) The length of the kiln is 125mtr inside diameter is 6mtr. d) This process uses lumpy ore, coal and recycled char. ... Sponge Iron & Ferro Alloys 9 In Midrex process reform gasses entering the reduction furnace ...
Cold bonded ore–coal composite pellets for sponge
These composite pellets were tested in the laboratory and found to reduce very quickly, compared with lump iron ore. Composite pellets were also tested in an 8 t/day rotary kiln sponge iron plant ...