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. Study on accretion formation on dri kiln during spong iron. Dri is also known as sponge iron, it is a solidstate direct reduction process fig. Setting up of modalities for normative coal requirement in. Sponge iron units do not use the pollution control equipment. Pdf design modifications for energy conservation of sponge iron. Lloyds metals manufactures sponge iron directreduced iron by reducing gas elemental carbon produced from natural gascoal. Major plant facilities 1 raw material preparation system raw material system mainly consist vibro feeder, crusher and screen. Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 8388% obtained by direct reduction without melting it. Get sponge iron at best price with product specifications.
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. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. Information is just for reference not intended for trading purpose or to address your particular requirement. This preheating of raw material by using flue gas results reduction of coal consumption. It decreases coal consumption as coal is the only source of energy in this plant. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. Sponge iron manufacturing plant, detailed project report. Pdf operation of coalbased sponge iron rotary kiln to reduce. Manufacturing process the proposed plant uses the coal based process in which iron oxide in pelletiron ore will be reduced with non coking coal in a rotary kiln to make sponge iron. Raw material preparation plant direct reduction plant raw material preparation plant the basic raw materials for the production of sponge iron are iron ore, non coking coal and dolomite. Sponge iron plants cerana foundation, oct 2006 7 raigarh windroses at 0830 hrs raigarh windroses at 1730 hrs sponge iron plant air emissions air emissions from sponge iron plants see annex 2 include highly toxic heavy metals, which may be released in three ways. Thus, deposition of fly ash in the environment surrounding sponge iron plant leads to accumulation of heavy metals in the soil. Seml was one of the first companies to install a sponge iron plant in the siltara, raipur area. The process of sponge iron making aims to remove the oxygen from iron ore.
Study on accretion formation on dri kiln during spong iron production. Dri or sponge iron refers to porous iron produced by the. Sponge iron is fed into the electric furnace for steel production or into foundries for the manufacture of wrought iron. Detailed project report suraj products limited village barpali, po. Pdf waste heat recovery steam generator in sponge iron. When unutilized energy of the process is properly integrated, energy demand from outside sources can be reduced. Hematite pellet reduction with syngas, scientia iranica, 162c, 108124, 2009. In the present work, several challenges faced in sponge iron production have. It is used as a raw material for manufacturing steel. For energy integration in sponge iron process pinch technology is applied on the actual data of plant. Pdf dissolution of heavy metals from esp dust of a. One of the major challenges for sponge iron plant is the accretion formation.
Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. Iron sponge basics november 2017 one of the oldest technologies for the removal of hydrogen sulfide h 2 s from gas is the use of iron sponge. Today about 20 per cent of the sponge iron produced worldwide is made in india1. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. A typical sponge iron plant has been investigated to.
The direct reduction process uses pelletized iron ore or natural lump ore. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. Sponge iron process for manned space exploration final project report june 2005 executive summary redox cycling of an ironrich contact mass has been investigated and applied with. Installation of preheating furnace in the sponge iron plant can save 30647. Recovery and utilization of waste heat in a coal based. 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. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Material balance in a rotary kiln sponge iron plant.
Direct reduced iron dri production plant nippon steel engineering co. Productivity increment of coal based sponge iron plant using. In all coalbased dr processes using rotary kilns, sized. Subsequently unido came forward in bringing slrn technology of sponge iron making to our country with lurgi germany in1979. To push up further growth, dri industry was delicensed in 1985 baring certain location restrictions much before the delicensing and deregulation of indian economy in 1991. A chemicalphysical process, originally developed to remove h 2 s from natural and coal gas streams, iron sponge has been in use for over 140 years and more recently to remove h 2. Since 2002, india has been the largest producer of sponge iron, also called direct reduced iron dri, in the world. Schematic flow sheet of coal based direct reduction process 1. Sponge iron manufacture is highly sensitive to raw material characteristics. For a coal based dri plant with waste heat recovery boiler, power plant and having arrangement for selling surplus electricity, the gate in energy would be coal. Recovery and utilization of waste heat in a coal based sponge iron process. Specificationsponge iron is sold in two sizes lumps.
India production volume of sponge iron 2011 to 2019. Sponge iron production by direct reduction of iron oxide. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The sponge iron is also known as direct reduced iron, hot briquettes iron or metalized iron. Steel exchange india limited is having a sponge iron manufacturing unit in technical collaboration with world renowned ms mannesmann demag of germany codir process. Simulation of rotary kiln used in sponge iron process using ann.
A simplified flow diagram of sponge iron making in rotary kilns is given in fig51. The content includes facts, views, and opinions are of individuals and not that of the website or its management. The top countries of suppliers are china, india, from which the percentage of sponge iron plant supply is 99%, 1% respectively. Modeling of rotary kiln for sponge iron processing using.
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. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. With stress being placed upon expanding steel capacity, particularly in many areas lacking capital and coking coal. Development of energy conservations scenarios for sponge. Power has become an essential commodity all over world today, with rapid development in infrastructure and other aspects, power has become the most sought out commodity. Processes that produce iron by reduction of iron ore in solid state below the melting point. The production volume of sponge iron in india accounted for more than 30 million metric tons at the end of fiscal year 2018. This humble beginning has grown tremendously to 22 million tons of installed capacity today. Dissolution of heavy metals from esp dust of a coal based sponge iron plant by fungal leaching article pdf available april 2012 with 651 reads how we measure reads. If you continue browsing the site, you agree to the use of cookies on this website. Iron ore is the source of iron and available in oxide form namely hematitefe2o3. 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. A wide variety of sponge iron plant options are available to you, there are 579 suppliers who sells sponge iron plant on, mainly located in asia. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds.
Setting up of modalities for normative coal requirement in respect of cement and sponge iron industries 2. Due to high porosity, the resulting iron is called sponge iron. This is to certify that the thesis entitled design of waste heat recovery system in a sponge iron plant being submitted by saurav kumar sahu as an academic project in the department of chemical. With an installed capacity of 2x350tpd and can able to produce sponge iron of 0. A demonstration sponge iron plant of 30000tpa capacity was set up with liberal assistance from unido, govt. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route, which has shown a phenomenal growth in india. Commercial production of sponge iron in india commenced in 19801. Sponge iron india limited was the first plant to be set up in the country in 1980 in paloncha district of andhra pradesh with a capacity of. The third coal based dri plant was set up by tatas in 1985based on their own technology. Through this paper an attempt has been made to identify the root causes and broader. The quality of sponge iron is primarily ascertained by the percentage of metallization removal of oxygen, which is the ratio of metallic iron to the total iron present in the product. Sponge iron, power plant, steel plant 970 saraikelakharsawan sponge iron, power plant, steel plant.
Then in 1983, odisha sponge iron limited set up indias second coal based dri plant. Globally conventional fuels are going to be exhausted. Steel360 has taken due care and caution in compilation of content for its web site. 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. The slrn process also uses rotary kiln for reducing iron ore. Abstractin the present study, estimation of actual output parameters is carried out for a sponge iron production process by designing a multilayer perceptron. Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. Iron ore crushing is not required since sized material has to be purchased. Fundoodata also provides email ids of ceomd, cio, cfo, hr, sales, marketing head, admin head, purchase head of these companies. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes choudhury, 2014. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Sponge iron or direct reduced iron is produced by reducing iron ore in the form of. With the domestic steel industry picking up during the past year and prices moving up in leaps and bounds, india has emerged as the worlds largest producer of sponge iron or direct reduced iron, accounting for around 16 per cent of the global output. Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from the other end.
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