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. 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. This will help sponge iron and sponge iron based steel plants to have additional working capital at their disposal, which in turn will help to improve capacity utilization. Sponge iron is the iron ore reduced in solid state by a direct reduction process using natural gas or noncooking coal as reductant. Designing iron sponge process for h2s removal posted in student. Nov 17, 2012 sponge iron units do not use the pollution control equipment. Reduced iron dri or hot briquetted iron hbi in its compacted form, sponge iron is not a new route to steel production. With an installed capacity of 2x350tpd and can able to produce sponge iron of 0. Use features like bookmarks, note taking and highlighting while reading sponge iron production by direct reduction of iron oxide. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Fe2o3 has deformed as fe by using strong reductant like h2 or co gas and the entire reduction process takes place in solid state only.
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. Iron sponge dry media of iron oxide on wood chips does best using warm wet gas with oxygen 4000 scfm treating 300 ppmv h2s. Sponge iron production inrotarytn786312020 adobe acrobat reader dcdownload adobe acrobat reader dc ebook pdf. Iron ore crushing is not required since sized material has to be purchased. Nucor louisiana dri production has been constrained by plantequipment issues captive supply to own minimills iranian exports are growing. Sponge iron production by direct reduction of iron oxide ebook. Iron ore prices in the context of the economics of sponge iron and steel production september 2008 steel and natural resources strategy research 3368, sectord, pocketiii, vasant kunj, new delhi110 070, india snrsr research and beyond. The trials yielded adequate data for designing a commercial prototype, or for industrial production of sponge iron. I have come to understand that this is a fixed bed adsorber column design but i cannot find much. The key difference between sponge iron and pig iron is that we can produce sponge iron by direct reduction of iron ore through reducing agents whereas the production of pig iron is by melting iron ore with charcoal and limestone at very high pressures sponge iron and pig iron are different forms of iron that we can produce from iron ores that occurs naturally. The indian sponge iron industry some issues in conservation. This process is applied to gases with low h2s concentrations 300 ppm operating at low to. H2s treatment of landfill gas at the roosevelt landfill.
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. In this method, thermal coal is mixed with iron ore as a reducing agent. Iron ore is the basic raw material for production of metallic iron. 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. We would like to acknowledge the support of our colleagues, ms sneha kashyap and. The iron sponge process involves passing sour gas through an absorption tower containing redwood chips coated with hydrated ferric oxide the iron sponge. One of the major challenges for sponge iron plant is the accretion formation. Sponge iron production flow chart raw material feeding to. Production for sale of pig iron in 201112 prov, was 5. The reformer sponge iron cycle resc, an innovative process combining a sponge iron reactor with a hydrocarbon reformer and a partial offgas feedback loop, was investigated as means of providing an onsite hydrogen production capacity from a feedstock of hydrocarbons produced with isru technology. It has topped in total number of cites and citable documents. Sponge iron process, rotary kiln, ann topologies, optimum input parameters. Extract more sponge iron to boost steel production, jobs. Difference between sponge iron and pig iron compare the.
Sipl is operating 4 x 100 tpd direct reduced iron rotary kilns for production of 2000 tpa sponge iron at purulia, using the proven german slrn technology. The hoganas process is a direct reduction method for production of sponge iron powder using magnetite ore fe3o4 and carbon as raw materials. Or in other words, to produce 1 kg of pure sponge iron the. 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. All raw materi als listed above, pig iron, ferro alloy, sponge iron, iron scrap, iron ore, and coal, are among best prospects for u.
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. 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. Brief history of iron production according to most historians, the first iron used by man was of meteoritic origin. Available weekly, monthly, quarterly sponge iron and pellet sponge news with market updates. The new iron age part 2 balancing global metallics supply and demand duration. In application, the sit is used in the reformer sponge iron cycle resc in combination with a. Presently it is more popular in china for sponge iron production from beneficiated iron ore fines cakes. Optimization of operating parameters for sponge iron production. Ptrcentage consumption of bot metal, scrap and sponge lroa for world crude.
This process is the oldest direct reduction method. For the production of primary iron, this route is recognized as an alternate route to. Nagesh and others published methods of titanium sponge production find, read and cite all the research you need on researchgate. The amount of sponge iron in the charge mix varies from 090% depending on its.
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. Integrated steel plant tmt bar manufacturing plants. A particle of sponge iron has the same size and shape as the particle of ore from which it was. Get sponge iron at best price with product specifications. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. India is one of the countries where use of sponge iron contributes a large share in annual crude steel production. 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. Sponge iron production by direct reduction of iron oxide kindle edition by chatterjee, amit. The reduction is carried out in a rotary kiln which is inclined and rotates at a predetermined range of speeds at a. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder.
Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. Sponge iron manufacture is highly sensitive to raw material characteristics. Larsen introduction sponge iron is the product formed by the reduction of iron oxide to metallic iron at a temperature below the fusion point of the constituents of the charge. Therefore, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. Of the total domestic consumption of iron ore, about 98% accounts for pig iron and sponge iron. She has authored a book titled international relations, 2nd edition, for phi learning, new delhi. For current and future scenario of sponge iron market especially west bengal and chhattisgarh, visit our site. Sponge iron during the early 90s, the sponge iron industry had been specially promoted so as to provide an alternative to steel melting scrap, which was increasingly becoming scarce. Sponge iron units do not use the pollution control equipment. Study on accretion formation on dri kiln during spong iron.
A thesis submitted for partial fulfillment of the degree award of. Hi all, i am a final year student in australia and am trying to complete my design project. Hot briquetted iron is a form of dri which is briquetted at elevated temperature to form dense briquettes which can be. In the year 1908 use of tunnel kiln started for iron oxide reduction. Recovery and utilization of waste heat in a coal based sponge. The companys core competency lies in the production of world class iron ore sized, iron ore finesexport quality, drisponge iron m. Coal is another main raw material for process of sponge iron and both. The production of sponge iron direct reduced iron dri during the period 199192 to 200203 was as under. Most of sponge iron plants in india are coal based and are concentrated in the central eastern belt of the country including odisha because of the easy availability of iron and coal in this belt 12.
Download it once and read it on your kindle device, pc, phones or tablets. Key suppliers iron ore is primarily supplied f rom australia and brazil. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Iron sponge is a highly porous, coarsely powdered or granular form of iron metal with numerous applications in catalysis, gas purification, and alloy production. With acrobat reader dc you can do more than just open and view pdf files its easy to add annotations to documents using a complete set of commenting tools. Production of sponge iron powder by reduction of rolling mill. The requirement of sponge iron as metallic will be 30 million tons.
Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. In the present work, several challenges faced in sponge iron production have. Shyam steel has best quality steel manufacturing integrated steel plants located in west bengal. 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. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of ironcoking 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 finished.
Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. Natural gas generates the required reduction temperature, and reduction is performed on silicon carbide sic crucibles in a tunnel furnace. There is fluctuation in the quality of sponge iron. Sponge iron is a valuable source of iron for the production of highquality steel. Production of sponge iron by reduction of iron oxides from roasted pyrite concentrate from ok tedi mine, western province, papua new guinea. The sponge iron is a substitute for scrap in the electric arc furnace upto 80%, which can be easily manufactured from indigenously available raw materials at very competitive price.
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. Pdf operation of coalbased sponge iron rotary kiln to reduce. For this purpose a case study of typical sponge iron production process is considered. 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. The figures in the bracket indicate the weight of the reactants and products. Modeling of rotary kiln for sponge iron processing using. The latter process is based on atomization of a stream of liquid. So there is a huge requirement of sponge iron production. In january 2007, the economic research unit of jpc had conducted a techno. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. Recovery and utilization of waste heat in a coal based. The reduction of rolling mill scale to sponge iron powder is a new way to take advantage of a cheap byproduct of the steelmaking industry, yielding sponge iron that can be reused to the electric furnace as metallic charge for steelmaking to obtain a product with a lower residual content and improved properties8,10.
Dspl is the leading manufacturer of sponge iron in eastern region of india. Alternatively dri grade pellets which are produced from iron ore fines can also be purchased and utilized instead of iron ore. Sponge iron production by direct reduction of iron oxide. According to sponge iron manufacturers association 1, india has produced around 23 million tonnes of sponge iron in the. Integrated steel plant tmt bar manufacturing plants shyam. India where the product is know as sponge iron about 20% of global production as a highly reduced form of iron, dri is very reactive and requires special measures for safe transportation and handling. 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. I am tasked with designing the equipment for the iron sponge oxide process for the removal of hydrogen sulphide from natural gas. 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 8001200 c. The main raw materials used for the production of sponge iron is iron ore which is purchased and transported from nmdc through railway wagons. The production volume of sponge iron in india accounted for more than 30 million metric tons at the end of fiscal year 2018.
India is the largest producer of sponge iron in the world with the coal based route accounting for 76% of total sponge iron production in the country 20. Pdf production of sponge iron through tunnel kiln process. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. Spongeironproductioninrotarytn786312020 adobe acrobat. Iron manufacturing process related to the specified. Best tmt bar manufacturing plants india in the direct reduced iron dri plant, production of sponge iron using a solid reductant involves reducing iron ore lumpspellets with a carbonaceous material such as coal. India production volume of sponge iron 2011 to 2019. The amount of sponge iron in the charge mix varies from 0.
Aug 05, 2017 the iron sponge process uses the chemical reaction of ferric oxide with h2s to sweeten gas streams. Designing iron sponge process for h2s removal student. 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. Or in other words, to produce 1 kg of pure sponge iron the stoichiometric requirements. Energy audit methodology of sponge iron manufacturing. 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 hydrogen sulfidebearing gas reacts with the hydrated ferric oxide to produce ferric sulfide and residual water. The basic raw materials for the production of sponge iron are iron ore, noncoking coal and dolomite. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. This product is known as direct reduced iron dri or sponge iron. With the direct reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages. The reduction process takes place in a gas fired tunnel kiln at around 1200c for 60 hours producing a sponge iron cake that is crushed, milled and. Production of sponge iron page 1 unt digital library.
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