Jan 16, 2011· Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coal-based sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.
Waste Heat based Power Plants utilizing Coke Oven / Sponge Iron / Cement Kiln / Glass Furnace and other waste gases DISTRIBUTED POWER PLANTS Diesel / Gas Engine and Renewable Energy based Power Generation along with storage for communities and off-grid areas
10 Application Solutions Guide — Refinery Process GLOBAL REFINERY LANDSCAPE Figure 1.4: In-process refinery end products and finished marketable refinery end products diagram API for valves The oil and gas industry does not use a universal API specification for valves like they have on pumps and
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 (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.
Mar 08, 2021· Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solid-state with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gas-based DRI) or coal (coal-based DRI) called syngas, a mixture of H2 and CO.
Jun 21, 2018· Direct reduced iron (DRI) process. In addition to the process route via the blast furnace process, there is another option for extracting crude steel from iron ores using the so-called direct reduced iron (DRI) process (secondary route).The starting point for the efforts to find an alternative to the blast furnace process was the relatively high process expenditure.
below the melting point of iron using reducing gases produced from coal or natural gas. The natural gas based process called MIDREX NGTM process is the most widely used technology for the production of sponge iron. In this process, natural gas is initially reformed to obtain reducing gases, a mixture of H 2 and CO. This gaseous mixture is then
This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln. In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace.
For producing the sponge iron through this process requires high grade of iron ore and non coking coal. Gas Based DRI / HBI In this process route, iron oxides are converted to the DRI / HBI by using natural gas in a vertical shaft furnace.
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
Jul 06, 2015· This process is usually installed in a two-tower configuration, as shown in Fig. 5.The slightly sour gas is flowed through both towers in series. The H 2 S content is monitored in the gas between the two towers. When the concentration of H 2 S starts to increase in this gas, it is an indication that the SulfaTreat chemical in the first tower is consumed.
Jul 29, 2010· The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making. Size Distribution:
Dec 01, 2008· The Midrex ™ Direct Reduction process is based upon a low pressure, moving bed shaft furnace where the reducing gas moves counter-current to the lump iron oxide ore or iron oxide pellet solids in the bed. The reducing gas (from 10-20% CO and 80-90% H2) isproduced fromnatural gasusing Midrex's CO2 reforming process and their proprietary…
SAFETY GUIDELINES FOR IRON & STEEL SECTOR MINISTRY OF STEEL, GOVT. OF INDIA Direct Reduction Plant ( Gas Based) Doc. No: SG/33 Rev no. : 00 Effective Date: -- 1. OBJECTIVE : The entire process of making Sponge Iron by coal based DRI process is associated with various Safety hazards like Fire, Explosion, Radiation, Burns hit /
Process Flow Diagram of Sponge Iron Plant/ Direct Reduction Iron Plant is given below: 4.0 PROCESS HAZARD ANALYSIS & NECESSARY RISK CONTROL MEASURES S.No. Equipment Hazards Risk Control Measures 1) Belt Conveyors a. Rotating parts of conveyor system, like head pulley, tail pulley, snub pulley, coupling guards etc. b. Moving
reduced iron (DRI). This is produced in the direct reduction process, in which prepared iron ore pellets are reduced from oxygen in their solid state by a heat and reduction gas, consisting of carbon monoxide and hydrogen, or even by coal [6]. The direct reduced iron which results is a porous product, so called sponge iron.
sponge iron manufacturing facility to pre-heat raw material(s) before feeding it into the furnace(s) / ... process (e.g. based on specific energy consumption specified by the manufacturer) was procured commercially. Project participants are required to demonstrate through the ... schemes and diagrams
To produce 1 kg of Sponge Iron in ideal condition i.e. with no excess air (flue gas without O 2 & CO). Input: 0.64 kg coal, 1.43 kg Iron Ore, 5.20 Kg of Air Output: 6.206 Kg flue gas, 0.064 Kg (Ash of Coal), 1 kg sponge iron.
The process operates continuously and only requires a periodical inspection and cleaning of some internal components to ensure optimum efficiency and performance. Dry Scrubbing Catalyst (DSC) Process. The DSC process is based on the property of iron sponge to convert to iron pyrite in the presence of hydrogen sulfide.
Apr 09, 2017· Midrex Process for Direct Reduction of Iron Ore. Midrex is an ironmaking process, developed for the production of direct reduced iron (DRI). It is a gas-based shaft furnace process is a solid state reduction process which reduces iron ore pellets or lump ore into DRI without their melting using reducing gas generally formed from natural gas.
All the gas based plants in operation use natural gas as reductant. ... MANUFACTURING PROCESS. Sponge iron production using coal involves reducing iron ore with coal. The reduction is carried out in a rotary kiln at a pre-determined temperature and controlled atmosphere . ... Sponge iron is taken to a storage bin for dispatch. The char which is ...
process, causing movement in the form of twisting and bending. Metallurgical Considerations and Process Requirements Nitriding is a ferritic thermochemical method of diffusing nascent nitrogen into the surface of steels and cast irons. This diffusion process is based on the solubility of nitrogen in iron, as shown in the iron-nitrogen
Process. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to remove the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.), in order to convert the ore to metallic iron, without melting it (below 1,200 °C (2,190 °F)).
Of the various direct reduction processes converting iron ores to sponge iron, the Midrex and HYL processes are generally used for gas based reduction and SL/RN process is the most common coal ...
A process for regenerating a reducing gas mixture from direct reduction furnaces for the production of sponge iron characterized by the steps of providing an arc heater having spaced electrodes and an arc chamber communicating with a gas reformation chamber, striking an electric arc between the electrodes, introducing an arc gas comprising a gaseous mixture of CO, CO2, H2, and H2O to provide ...
The COREX process is a two-stage process, as is shown in Figure 1.1.40.In the first step, iron ore is reduced to sponge iron in a shaft furnace by means of reducing gas. In the second step, the reduced iron is melted in the melter–gasifier vessel.
The Fischer-Tropsch process is a catalytic chemical reaction in which carbon monoxide (CO) and hydrogen (H 2) in the syngas are converted into hydrocarbons of various molecular weights according to the following equation: (2n+1) H 2 + n CO → C n H (2n+2) + n H 2 O. Where n is an integer. Thus, for n=1, the reaction represents the formation of ...
A process for producing chromium iron alloys suitable for steel making directly from chromite ore wherein fines of chromite ore with additions of carbon fines, and accelerant and a binder are agglomerated and the dry agglomerates are fed into a reaction vessel with natural gas as a reducing agent at elevated temperatures adequate for reduction for thereby producing a chromium iron alloy ...