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Sponge iron manufacturing process by pcpradhan

  • OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION

    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 Audit Methodology of Sponge Iron Manufacturing

    2. Description of Sponge Iron Manufacturing Process . Most of the plants in India use DRI processa solid state direct reduction process by which iron ore is reduced to sponge without phase change (Figure 1).Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end.

  • Sponge iron Manufacturing process - Azerbaijan Simurgh

    Sponge iron is a metal product that is produced by a direct reduction of iron ore in solid-state. Sponge iron is a good alternative to waste and is mainly used in the manufacture of steel via secondary routes. The process of making sponge iron occurs by removing oxygen from the iron ore.

  • Iron - Manufacturing process related to the specified

    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

  • M/s Bravo Sponge Iron Pvt. Ltd. - Welcome to Environment

    BSIPL started manufacturing sponge iron in the year of 2003 under the management of Bhalotia Group, Jamshedpur. In June 2015, it has been taken over by Shakambhari Ispat Group who is having a vast experience in the line of steel manufacturing. The Admin and Correspondence office is at Diamond Prestige, 41A, AJC Bose Road, 8th

  • Sponge Iron Prakash Industries Limited

    Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel through electrical arc

  • How sponge is made - material, manufacture, making, used

    Sponge manufacturing produces no harmful byproducts and little waste. Sponge material that is lost in trimming, such as when an uneven end is cut off the large block, is ground up and recycled. It can be thrown in the mixer at the beginning of the process, and become part of a new sponge.

  • Misra Group Ceramics & Sponge Iron Manufacturing (DRI)

    The pilot project that was setup for 0.1 million Tons P.A capacity under the guidance of Prof. G.G Roy Dept of Metallurgy IIT Khargapur, has been successful and has exceeded all the expectations with the technological breakthrough in the process of Iron ore reduction or Sponge iron manufacturing through a tunnel kiln instead of the conventional

  • DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

    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 plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln.

  • Sponge Iron Iron Steelmaking

    Sponge iron is the product created when iron ore is reduced to metallic iron, in the presence of coal, at temperatures below the melting point of iron. The external shape of the ore is retained with 30% reduction in weight due to oxide reduction resulting in change in

  • Sponge Iron - an overview ScienceDirect Topics

    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 meltergasifier vessel.

  • Effluent and Emission Standards for Sponge Iron Plant

    Sep 01, 2018· The location of Sponge Iron Plant should be at least 500 m away from National Highway and State Highway. The radial distance between two Sponge Iron Plants should be 5 km for plants having capacity 1000 TPD or more. Sponge Iron Plants can be established in designated industrial areas/Estates as notified by State Government.

  • THE KRUPP SPONGE IRON PROCESS PRODUCTION AND

    Sponge 'iron process might well be scaled up to a commercial operation, a full-scale test was car-ried out in a production kiln of 4.6 m diameter and 110 m length, which had been modified to suit the conditions encountered in processing rich iron ores. This test furnished proof that the test results are reproducible on a production scale.

  • Energy Audit Methodology of Sponge Iron Manufacturing

    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

  • SPONGE IRON PLANT

    The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production

  • Sponge Iron - an overview ScienceDirect Topics

    Direct reduction iron or sponge iron is an old method for producing hydrogen (Milne et al., 2006; Peña et al., 2010; Biljetina and Tarman, 1981) that was replaced by more efficient and economic processes.Recently, the interest in sponge iron as a hydrogen production process has grown again, although the technology still has some major technical and economic challenges to overcome (Milne

  • Sponge iron making process - SlideShare

    Nov 09, 2014· Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE Iron = 65-67 % SiO2 + Al2O3 = 2-3 % CaO + MgO = 0,5-1 % Sulphur = 0,02 % max Phosphorus = 0,04 % max Chemical Composition Size

  • Biochar in the Höganäs sponge iron process techno

    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 adapted, using the principle of bio-oil recycle.

  • Sponge iron Manufacturing process - Azerbaijan Simurgh

    The process of making sponge iron occurs by removing oxygen from the iron ore. The quality of sponge iron is mainly determined by the percentage of metallization (removal of oxygen). This parameter is equal to the ratio of metal iron to total iron in the product. Sponge iron itself is not used but can be processed

  • US5238487A - Process for the production of pig iron and

    A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt. The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace.

  • PRODUCTION OF IRON AND STEEL POWDERS

    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

  • (PDF) i) Direct Reduced Iron: Production

    Mar 30, 2016· This product is known as direct reduced iron (DRI) or sponge iron. Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as

  • Detailed Project Report

    3.5.1 Manufacturing Process of Sponge Iron (DRI) 31 3.5.2 Manufacturing process of Pig Iron through Mini Blast Furnace 37 3.5.3 Process and Process Flow diagram of Iron Ore and other Mineral Ore Beneficaiton Plant 42 3.5.4 Process and Process Flow diagram of Coal Washery 49

  • Energy Audit Methodology of Sponge Iron Manufacturing

    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.

  • Sponge Iron Manufacturer India

    Sponge Iron Manufacturers Association. The Sponge Iron Manufacturers Association (SIMA) established in 1992 is an all India apex body of Indian sponge iron industry. It is the voice of the indian iron ore based sponge iron & steel industry, at both domestic and global forums.

  • Accretion Control in Sponge Iron Production Kiln using

    2 KILN BASED SPONGE IRON PRODUCTION PROCESS Rotary kilns are found in many processes that involve processing of solids. This study focuses on sponge iron kiln based process. The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of non-coking coal [Patra et al, (2005)]. The

  • Sponge Iron Industry - SlideShare

    Nov 17, 2012· Pollution from the sponge iron industries is the core reason whycommunities rise in arms against this industry. 26 27. Various CSE Reports of 2008 inform us1. In Odisha, women from the Bonai Vana Suraksha Committee marched up to the District Collector with samples of soil, water and grain to protest against sponge iron plants.2.

  • SPONGE-IRON - Shakambhari Group

    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 fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical &

  • Direct reduced iron - Wikipedia

    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) into iron by a reducing gas or elemental carbon produced from natural gas or coal.Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting

  • Sponge Iron Plant - Entrepreneur India

    The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant.

  • Coal Base DRI Operation: Process Description and flow

    Aug 07, 2016· Sponge iron produced by the process will be the high grade which contains 80% Fe, 12% FeO and 8% gangue material. After separation of sponge iron in the magnetic screen/pulley, the remains are collected as char. Char has good amount of fixed carbon (25% - 30%) and moderate GCV (2500 - 2600 Kcal/Kg).

  • Sponge Iron - Manufacturing Plant, Detailed Project Report

    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. Sponge Iron is the iron ore reduced in solid state by a direct reduction process

  • (PDF) New Concept of Hot Metal Production using Rotary

    [Show full abstract] technology for production of sponge iron in Indonesia due to direct utilization of bituminous coal. Besides rotary kiln based process, some blast furnaces are also installed

  • A Thesis Submitted for Partial Fulfillment of the Degree

    million tons of steel by 2020. The requirement of Sponge Iron as metallic will be 30 million tons. Projection for metallic requirement in Year 2010-11 we require Melting Scrap 14 million and DRI 18 million But availability of scrap is not likely to reach 11 million. So there is a huge requirement of sponge iron production.

  • Energy Audit Methodology of Sponge Iron Manufacturing

    Jul 14, 2014· 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. Substantial amount of un-reacted carbon

  • sponge iron process

    Jul 29, 2010· In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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.

  • CA2052659C - Process for the production of pig iron and

    A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt. The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace.

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