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Sponge iron manufacturing process

  • 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

  • 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.

  • 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

  • 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.

  • Sponge Iron - an overview ScienceDirect Topics

    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. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H

  • 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

  • The reasons for the success of Sponge Iron Industry in

    Jul 28, 2017· Additionally, EAF steel production grew in line with crude steel, this translated to improvement in sponge iron manufacturing, which grew by 49% between 2006-11. In addition, as sponge iron is used as an alternative to scrap iron (EAF process), the demand for sponge iron is also dependent on prices and availability of ferrous scrap.


    In the year 1908 use of tunnel kiln started for iron oxide reduction. This process was invented by E.Sieurin as Hoganas process [3]. In 1954, more kilns came in operation in SWEDEN and USA. Presently it is more popular in China for sponge iron production from beneficiated iron ore fines cakes. In this process, the material passes through

  • Sponge Iron Production Process - Arij Trading

    Market share: About 23% of sponge iron total production. 4) Tunnel furnace process . This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction

  • 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.


    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

  • What is Sponge Iron? (with pictures) - Info Bloom

    Feb 04, 2021· Malcolm Tatum Date: February 04, 2021 Sponge iron is created from iron ore.. Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.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.


    process uses coking coal. The DRI process doesnt 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

  • 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 - 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 &


    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

  • sponge iron manufacturing process j info

    TMT Bars Manufacturing Process - JSW Neosteel. Better production process ensures sponge is free from dust caused during material handling Key Statistics Second largest coal based sponge iron producer in the country Also referred as direct reduced iron, metallized iron or hot briquetted iron, sponge iron is the core material used in the iron and steel industry for the production of steel.

  • 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 Production Process - Arij Trading

    In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace. Input iron ore: In the Midrex or HYL process, it is


    The Rotary Kiln process is a well-established process for production of coal based sponge iron. Rotary kiln of certain dia and length is provided for reduction of Iron Ore into sponge iron using non-coking coal as reductant and Dolomite as sulphur scavenger; however the Diameter and Length are to be designed based on the Plant Capacities.

  • Sponge Iron - an overview ScienceDirect Topics

    Sponge iron Removing oxygen from the ore by a natural process produces a relatively small percentage of steels in the world. This process uses less energy and is a natural chemical reaction method. The process involves heating the naturally occurring iron oxide in the presence of carbon, which produces sponge iron.

  • US20030110889A1 - Method for producing sponge iron, and

    A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m 2 /g or more, and the content of the powdered

  • Hybrit: worlds first production plant for fossil-free

    Mar 24, 2021· The goal is to expand sponge iron production to a full industrial scale of 2.7 million t by 2030 to be able to supply SSAB, among others, with feedstock for fossil-free steel. The choice of Gällivare for establishing of the plant was based on a joint assessment of industrial synergies, where proximity to iron ore, logistics, an electricity


    The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, the departing oxygen causes micro pores in the ore body making it porous. The final product, when observed under a microscope, resembles a honeycomb structure looking spongy in texture, hence the name sponge iron.


    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

  • 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.

  • 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.

  • Agni Steels Sponge Iron Manufacturing Process - YouTube

    Nov 02, 2017· Right from the selection of high grade iron ore and coal, we use only the finest raw material for production. Sponge Iron (DRI) is the main constituent in pr

  • Project Report on sponge iron reduction plant

    Detailed Project Report (DPR) on sponge iron reduction plant Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.

  • SPONGE IRON Rashmi Group

    The production process followed at Rashmi Metaliks makes the Sponge Iron unique and superior than its competitors. Iron ore (Red Hematite) is extracted from the mines and taken to the Direct Reduced Iron (DRI) Plant where it is charged with different sizes of Coal (Carbon) by conveyor from different stock houses into the Rotary Kiln.

  • 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.

  • 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.

  • (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

  • 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.

  • Powder metallurgy - Wikipedia

    Sponge iron process. The longest established of these processes is the sponge iron process, the leading example of a family of processes involving solid state reduction of an oxide. In the process, selected magnetite (Fe 3 O 4) ore is mixed with coke and lime and placed in a silicon carbide retort. The filled retort is then heated in a kiln

  • Agni Steels Sponge Iron Manufacturing Process - YouTube

    Nov 02, 2017· Right from the selection of high grade iron ore and coal, we use only the finest raw material for production. Sponge Iron (DRI) is the main constituent in pr


    Process for production of sponge iron by direct reduction of iron ore wherein iron ore admixed with a carbonaceous reducing agent is passed through a rotary kiln countercurrent to a gas stream, and wherein granular coking high volatile coal is injected co-current to said gas stream as a solid reducing agent by means of oxygen containing gases through an inlet pipe, and said solid reducing

  • A Thesis Submitted for Partial Fulfillment of the Degree

    following advantages sponge iron production is rising. Pelletized iron ore or natural "lump" ore are used in direct reduction process. Exceptionally in the fluidized bed process sized iron

  • (PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to

    Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate

  • 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.

  • 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

  • Steelmaking in Induction Furnace IspatGuru

    May 24, 2018· Steelmaking in Induction Furnace. satyendra; May 24, 2018; 0 Comments ; carburizer, control system, Ferro alloys, Induction furnace, induction heating, scrap, slag, Sponge iron, steelmaking,; Steelmaking in Induction Furnace. Coreless induction furnaces have been used in the ferrous industry for over 50 years and are now one of the most popular means of melting and holding

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