sponge iron manufacturing process pdf

De-centralised hydrogen production by an integrated ...

2018-12-10 · Iron sponge Figure 1: Flow sheet of the 2-step process for hydrogen production from bio mass. 1. step: reduction of iron oxide to iron sponge by the use of gasified bio mass; 2. step: pure hydrogen production by oxidation of iron sponge with steam 323 Clean Technology 2008,, ISBN 978-1-4200-8502-0

Production of Sponge Iron Powder by Reduction of a By ...

2020-1-27 · Key Words: Powder production, Sponge iron, Solid by-product. 1. Introduction Mill scale is a steelmaking by-product from the rolling mill in the steel hot rolling process. Mill scale contains both iron in elemental form and three types of iron oxides: wustite (FeO), hematite (α-Fe 2 O 3) and magnetite (Fe 3 O

1A Manufacturing Process for Iron and Steel

2019-6-13 · The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and basic oxygen furnace (denoted BF and BOF hereinafter, respectively), which is presently the most commonly used method (51% of world steel production).

A Thesis On PREPARATION AND CHARACTERIZATION …

2020-9-21 · 1.2 Development of DRI process And IS Values of Sponge Iron 5 1.2.1 Coal-based Process 5 1.2.2 Gas-based Process 7 1.3 Direct Reduced Iron 9 1.3.1 Type of DRI Processes 10 1.4 Sponge Iron 11 1.4.1 Concept of Sponge Iron 11 1.4.2 Kinetics of Iron Ore Reduction 13 1.4.3 The Reduction Mechanism for Porous Iron Ores 14

Sponge Iron Process for Manned Space Exploration

2021-4-15 · Sponge iron process for manned space exploration Final project report June 2005 1 Introduction Reduction of oxidised iron species is a well-established technology utilised in iron metal production. The basic principle applied in this process is to reduce the iron oxides with

MIDREX Processes

2011-1-6 · The process reduces iron ore using a reforming gas made from natural gas. The DRI is used mainly as the raw material for electric arc furnaces (EAFs), as a clean iron source substitute for scrap iron. Pores are left behind in the DRI after oxygen has been removed. These pores, if filled with water, for example, can cause the iron to reoxidize with

Control of Pollution in the Iron and Steel Industry

2017-1-16 · Lungen H. B. and Steffen R. (1998). Comparison of Production Costs for Hot Metal and Sponge Iron. Cokemaking International, Vol. 10, 1, pp. 28-34.[This article shows the current state of development of the ore reduction processes, and a comprehensive discussion of new processes of direct reduction iron(DRI)].

(PDF) Energy Audit Methodology of Sponge Iron ...

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 (kWth/kWe) of sponge iron plants ranges from

PRODUCTION OF IRON AND STEEL POWDERS

1997-5-6 · 2. PRODUCTION OF IRON AND STEEL POWDERS 8 2.3 The Höganäs Sponge Iron Process The Höganäs sponge iron process, is essentially a chemical process in which finely divided iron ore is being reduced with coke breeze yielding a spongy mass of solid metallic iron, which can readily be comminuted to iron powder. The iron ore used at

Production of sponge iron powder by reduction of …

2020-7-27 · metallic iron (Fe) and three types of iron oxides: wustite (FeO), hematite (α-Fe 2 O 3) and magnetite (Fe 3 O 4). It also contains traces of non-ferrous metals, alkaline compounds and oils from the rolling process. A study is made of the reduction of mill scale to sponge iron using coke at different temperatures and times. The reduced samples are

OPERATIONAL ASPECTS OF SPONGE IRON …

2012-1-10 · 1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge ...

Energy integration of sponge iron production process

2012-10-19 · SPONGE IRON PLANT The process flow sheet of a typical coal-based sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd. In this process screened iron ore (6.5tph), coal (3.529tph) and dolomite (0.2tph) are charged into the rotary kiln.

THE OPTIMUM METHOD FOR CONVERTING SPONGE …

2012-1-11 · SPONGE IRON TO STEEL IN ARC FURNACES G. POST Lurgi Chemie and Huttentechnik , Frankfurt, West Germany A bstract Four different process techniques for the melting of sponge iron in arc furnaces are judged by eva-luating operating results from a great number of arc furnaces up to 200 tons tap weight. Taking the power

SPONGE IRON PRODUCTION FLOW CHART Raw …

2016-8-10 · 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 Lumps Magnetic Separation Lumps Bunker Despatch …

Energy Audit Methodology of Sponge Iron …

2014-9-15 · sponge iron manufacturing process or kiln operation with a view to finding out major energy sav-ing potential of the unit. In the research work we find that it is the incomplete reaction of coal that causes the major energy inefficiency in the process…

Manufacturing Process Of Sponge Iron

Sponge iron manufacturing process pdf - WordPress . Sponge iron manufacturing process pdf The major Raw Materials required for production of Sponge Iron by the rotary kiln.

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron …

2017-8-4 · 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 assigned individual number and henceforth each stream

SPONGE IRON PLANT

2018-9-24 · MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid. Most solid reduction process use non-coking coal as reducing agent due to abundantly available non-coking coal. The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore.

Iron and Steel Manufacturing

Iron and Steel Manufacturing Industry Description and Practices Steel is manufactured by the chemical reduction of iron ore, using an integrated steel manufac-turing process or a direct reduction process. In the conventional integrated steel manufacturing process, the iron from the blast furnace is con-verted to steel in a basic oxygen furnace ...

BILLET MANUFACTURING PROCESS FLOW CHART …

2016-8-10 · BILLET MANUFACTURING PROCESS FLOW CHART Sponge Iron Stock Yard [email protected] Heavy Melting Scraps Stock Yard Quality Control Confirmation on it''s grade Quality report to Melting/ Production Incharges Final Product (Billets) Final product reconfirmed and colour coded with paint as per grade Stocking the Billets as per Grade

Energy Conservation in Sponge Iron Production Process ...

A waste heat recovery system was designed to integrate the heat of stack gas in the sponge iron process by considering a case study of typical Indian sponge iron process. After complex reduction and combustion the process stack gas exits the sponge iron plant at substantially higher temperature ranges (200-250ᵒC) which carries a lot of sensible heat that directly goes to the …

No. 11.7 HBI – Hot Briquetting of Direct Reduced Iron ...

2020-3-17 · During direct reduction, oxygen is removed from iron ore in solid state. This procedure results in a spongy structure of the product, thus "Sponge Iron", with a high porosity. De-pending on the raw material and the reduction process applied, apparent product density is approx. 2 g/cm³ associated with a very high specific surface area. The ...

(PDF) Different processes of Sponge Iron production – A …

2013-2-22 · Different processes of Sponge Iron production – A Review February 2013 Conference: International Conference on Advances in chemical Engineering (ACE-2013) February 22- 24, 2013

FS 7 How bread is made

2017-1-31 · Sponge and Dough Process – this is a two-step bread making process; in the first step a sponge is made and allowed to ferment for a period of time, and in the second step the sponge is added to the rest of the ingredients to produce the final dough. Ferment Dough Process – this process is a variation of the sponge and dough method and is ...

Iron

2014-1-14 · Sponge iron powder . The Höganäs process is a direct reduction method for production of sponge iron powder using magnetite ore (Fe3O4) and carbon as raw materials. The reduction process takes place in a gas fired tunnel kiln at around 1200°C for 60 hours producing a sponge iron cake that is crushed, milled and

basic sponge iron manufacturing process ppt

iron and steel manufacturing process.ppt. iron and steel manufacturing process.ppt - Free download as Powerpoint Presentation (. ppt), PDF File (.pdf), Text file (.txt) or view presentation This technique produces 97.0 percent pure iron, which is called, solid Sponge Iron. Read More

SPONGE IRON INDUSTRY

2020-5-1 · Indian Sponge Iron Industry 1. Introduction 1.1 An Introduction to the sector Sponge iron is an intermediate product used for the manufacture of steel.Also referred to as Direct Reduced Iron (DRI) or Hot Briquetted Iron (HBI) in its compacted form, sponge iron is not a …

The Making of Iron & Steel

2020-8-3 · The BOS process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal (and scrap is used for temperature control). The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process, the EAF requires

Direct Reduced Iron (DRI) Production Plant

2021-2-17 · from the DRI production plant) will be reduced by 50 - 100 kg.) 3. Increase in the productivity of blast furnaces The productivity of a blast furnace increased with charging DRI with large metallic iron content to it. (When 100 kg of DRI is used for the production of 1 ton of molten iron, the production of molten iron increases by 10 - 15 %.) 4.

Biochar in the Höganäs sponge iron process – techno ...

2018-6-18 · production plant integrated with sponge iron production in Höganäs. In this study, a steady-state process model was developed, where state-of-the-art research and development in biochar production for increased biochar yield was applied and …

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

2011-5-13 · process uses coking coal. The DRI process doesn‟t require coking coal and therefore is advantageous. In the present work waste heat recovery system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron ...