Pdf an optimization problem is concerned to find the optimal. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of iron coking 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. We offer various range of products for steel, cement, mini steel, foundries, power, and many other industries. It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary steelmaking and continuous casting. It is a substitute for scrap and is mainly used in making steel through the secondary route. Lloyds metals manufactures sponge iron directreduced iron by reducing gas elemental carbon produced from natural gascoal. Sponge iron production in rotary kiln kindle edition by sarangi, a. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes choudhury, 2014. Sponge iron definition is iron in porous form or containing many voids. Sponge iron definition of sponge iron by merriamwebster. Modeling of rotary kiln for sponge iron processing using. This type of iron can be produced in several different types of furnaces, including coke or charcoal ovens, blast.
Sponge iron is a better substitute of steel scrap for steelmaking. In the secondary route of steel making steel is produced using sponge iron. Sponge iron is a metallic mass with honeycomb structure. 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. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. In the first stage iron ore is melted in a blast furnace to produce hot metal, and in second stage this hot metal is moved to a steel making shop to produce steel in a basic oxygen furnace. Production of sponge iron powder by reduction of rolling mill scale m. Pig iron is divided into steel making pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. Its members account for more than 80% of production and international trade in orebased metallics. With such dimension of notion we in our sponge iron manufacturing process through 4 kilns 1 350t and 3 500t laid up the best dri making process in india. Iron ore lumps shows lower degree of reduction than the corresponding fired pellets small.
Apart from these wastes, coke fines are generated during the coke. Sponge iron dri is the main constituent in production of billets. Apr 23, 2020 sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. Whether youre building a robot or working with arduino, knowing how to solder will come in handy. Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. The reduction of rolling mill scale to sponge iron.
Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden. The refining of iron to make steel is where the carbon content of hot metal is lowered, usually to. If you continue browsing the site, you agree to the use of cookies on this website. The indian government has recognized sponge iron as a vital sector for growth of indian steel industries.
In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to. Today with a production of nearly 19 million tones, it is the largest. Naik manager of construction and special projects tata iron and steel company ltd. In 2011 the financial times has speculated that iron ore is more integral to the global economy than any other commodity, except perhaps oil. This product is known as direct reduced iron dri or sponge iron. Agni steels sponge iron manufacturing process youtube. In this tutorial, we outline the basics of soldering irons, soldering stations, types of solder, desoldering and safety tips. Green steel making gas based technology for sponge iron. It was postulated in the nineteenth century that both indirect and direct reduction were taking place inside an iron blast furnace. 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. Nov 17, 2012 sponge iron units do not use the pollution control equipment. This authoritative account covers the entire spectrum from iron ore to finished steel.
Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. Direct reduced iron dri production plant nippon steel engineering co. 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. The former process is based on reduction of iron ore, yielding a highly porous sponge iron which subsequently is comminuted to powder. With the availability of raw materials, high demand of sponge iron and less payback period, sponge iron industry has emerged as a profitable venture. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize sponge iron production from ore coal composite pellets in tunnel kiln. At present, there are 18 sponge iron plants coalbased in orissa. Compared to the bos process, the eaf requires less chemical reaction for refining. Growth in indian dri sponge iron production unused dri production capacity in egypt higher capacity utilisation by nucor 5 mt new dri capacity scheduled to come on stream in algeria with no domestic pellet supply short term supplyside issues. Creating a growing and sustainable iron and steel value chain in south africa.
In addition, an ammeter can be calibrated to use as a new device called sponge iron meter for ensuring ideal sponge iron feeding rate for continuously feeding into a pool of liquid iron. Sponge iron which is produced in power form can be made into pellets, which is an economic and useful substitute for the scrap metal sometimes used by steel manufacturers. Annual sponge iron production for sample sponge iron plants. The product of these early smelting process was a sponge mass of coalesced granules of nearly. Energy balance in a rotary kiln sponge based iron making. Learning how to solder w proper soldering techniques is a fundamental skill every maker should master. Production of direct reduced iron in rotary hearth furnace slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising.
Study on accretion formation on dri kiln during spong iron. Solving all your pdf problems in one place and yes, free. The latter process is based on atomization of a stream of liquid. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india, and more. Simulation of rotary kiln used in sponge iron process. A drawing of an iron sponge unit showing typical provisions for internal and external design requirements was presented in figure 73. Expired lifetime application number us363339a inventor cecil a mann. Co therefore, cannot act as a reducing agent in the lower part of the furnace. Iron sponge unit design procedures hydrocarbon compression. Sponge iron dri has gained great prominence in india as a substitute of steel scrap partially or fully in steel making in electric arc furnace and induction furnace.
This production of steel has come thro both conventional blast furnace route, electric arcinduction furnace route and thro new iron making technology corex. The amount of time and resources required to produce sponge iron is minimal, so it is possible to manufacture large amounts quickly, a fact that only adds to. This standard has been formulated by amalgamating is 10812. Pdf production of sponge iron powder by reduction of.
The xrd patterns were identified using powder diffraction files pdf. The small amount of ingredients called for by this recipe would blend better in a smaller bowl. This growth will create more than 14,000 jobs, excluding potentially more jobs from new. Use features like bookmarks, note taking and highlighting while reading sponge iron production in rotary kiln. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Rio tintoioc strike and suspension of production at anglo americans minas rio project. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. The performance of rotary kiln is affected by temperature profile.
In historic times, sponge iron was produced in shallow hearths, which used charcoal as reductant fuel. Sponge iron process for manned space exploration final project report june 2005 executive summary redox cycling of an iron rich contact mass has been investigated and applied with terrestrial hydrogen production from hydrocarbon and biomass sources. 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 material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Since last few years, sponge iron has emerged as an alternate raw material for steel making. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work was conducted in it. A thesis submitted for partial fulfillment of the degree award of master of technology in chemical engineering by. However, the sharp drop in gas prices due to the marcellus shale development has led to resurgence in interest in gas based dri production. Rise of the coalbased sponge iron sector in india and some issues in conservation of resources. One of the major challenges for sponge iron plant is the accretion formation.
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. A thesis submitted for partial fulfillment of the degree award of. Technical aspects of manufacture of sponge iron we have produced 55 million tons plus of steel in our country in the year 2008. Directreduced iron dri, also called sponge iron, 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. Green steel making gas based technology for sponge iron industry by welspun maxsteel ltd worldwide, there is an increasing emphasis on environmental issues. Production of sponge iron powder by reduction of a byproduct of the steelmaking. Sponge iron production by direct reduction of iron oxide. Energy survey of the coal based sponge iron industry.
The material of the air tube is astm a297 hk 40, a member of the heatresistant cast alloy family h series steels widely used for enhanced hightemperature properties. In sponge iron industry rotary kiln is the primary equipment, which is used to reduce iron ore to metallic iron i. Integrated steel plants of less than one million tonne. The technology of melting sponge iron is presently in an evaluationary state as the characteristics of dri differ appreciably from iron and steel scrap as well as pig iron. Production of sponge iron powder by reduction of rolling mill. Sarangi, b download it once and read it on your kindle device, pc, phones or tablets. Capacity and production of sponge iron in india has grown at a frenetic pace in the last half decade. Nonblast furnace iron making technology total materia article.
As with dri, hbi is produced in controlled metallization ranges around 94% and. Chinese smelting took advantage of phosphorusrich iron ores with a lower melting point and. Selvakumar, in reference module in materials science and materials engineering, 2017. Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. The performance of rotary kiln significantly affects the production capacities of these industries. The reducing gas is a mixture majority of hydrogen h2 and carbon monoxide co which acts as reducing agent.
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. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize 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 is a metallic product produced through direct reduction of iron ore in the solid state. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route.
The physicochemical fundamental concepts of chemical equilibrium, activitycomposition relationships. 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. A thesis submitted for partial fulfillment of the degree. Since 1911 the hoganas corporation has continuously manufactured sponge iron, although the early use for this product was as a feedstock for steel making. Briquettes are compressed, cut and cooled to make hbi, typically for merchant sale over long distances. Corex is the first commercially operating alternative to the blast furnace for hot metal production, and hismelt is the worlds first commercial smelting process for making iron straight from the ore. Iron ore is the raw material used to make pig iron, which is one of the main raw materials to make steel98% of the mined iron ore is used to make steel.
The iron sponge process generally uses a single vessel to contain the hydrated ferric oxide wood shavings. The mini steel plant comprises of steel melting using induction furnace or electric furnace to melt scrap. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Coal based sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue.
This was a simple method used from the iron age to medieval times where iron ore and charcoal were placed in a small furnace. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Midrex is an innovative ironmaking process, developed for the production of directreduced iron dri from iron ores and primarily natural gas. In the primary route of steel making iron ore is used as raw material. Although iron ore fines are used for making pellet after beneficiation. Sponge iron is then taken to a product bin for dispatch.
Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. Iron fe is a relatively dense metal with a silvery white appearance and distinctive.
The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic iron nickel. The indian sponge iron industry some issues in conservation. Direct reduction process an overview sciencedirect topics. Mill scale is an iron oxide waste generated during steelmaking process, casting and rolling. Reduction of iron oxides and ores by carbon is a key metallurgical reaction. The product sponge iron being hydroscopic in nature, it is.
Sulphur removal in ironmaking and oxygen steelmaking. The indian sponge iron industry, which was started as late as in 1980s has come a long way. An investigation on the cracking of air tubes of rotary. Abstract the author tries to foresee the future of sponge iron making in india and forecasts that the metallur. Hytemp iron hot dri is discharged continuously from the reactor at 700 c to a pneumatic transport system. Cost effectiveness batch size 30 tons daily production 30 x 10 batches 300 tons. The coal base dri rotary kiln used for the production of sponge iron with. Ferrous metallurgy is the metallurgy of iron and its alloys. The process of sponge iron making aims to remove the oxygen from iron ore. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting.
Sponge iron feeding plays an important role in electric steel making. Torralba4 rolling mill scale is a solid byproduct of the steelmaking industry that. Sponge iron is used as feedstock and a recognized alternative to steel scraps in iron and steel making processes. Processes that produce iron by reduction of iron ore in solid state below the melting point. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Energiron dri is safe to transport and store under normal established procedures. Green steel making gas based technology for sponge.
Pdf operation of coalbased sponge iron rotary kiln to reduce. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. Right from the selection of high grade iron ore and coal, we use only the finest raw material for production. 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. Production of direct reduced iron in rotary hearth furnace.
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