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Material Balance Of Gas Based Sponge Iron

Energy survey of the coal based sponge iron industry ...

2015-9-1 · A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency. The required data are obtained by measurements or taken from production industries. The process efficiency is about 51.31%. The energy balances of the process show that ...

Energy Survey of the Coal-Based Sponge Iron Industry

Energy survey of the coal based sponge iron industry ... suggested that 21.6 t/h waste gas generated during sponge iron production process. ... a

Energy integration of sponge iron production process

2012-10-19 · Keywords- Sponge iron plant, Heat integration, Material and Energy balance I. INTRODUCTION Sponge iron is a metallic mass with honeycomb structure. It is a form of iron produced from direction reduction of iron oxide below the fusion temperature of iron ore (1535ºC) by utilizing hydrocarbon gases or carbonaceous fuels as coal.

SPONGE IRON PLANT

2018-9-24 · Raw material system mainly consist Vibro Feeder, Crusher and Screen. Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of

ENERGY INTEGRATION IN SPONGE IRON PLANT USING

2012-5-12 · Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively. Presently, there are 118 large and small sponge iron plants in India- 115 of them are coal based while only 3 are natural gas based. The advantages of sponge iron are:

Sponge Iron - an overview | ScienceDirect Topics

7.7.1 Iron Sponge Process. The iron sponge absorption is the earliest sulfur removal process and remains one of the widely used processes today. Iron sponge is very selective for H 2 S removal. In this process, the inlet gas is fed at the top of the fixed-bed reactor filled with hydrated ferric oxide (Fe 2 O 3 ).

Steam Reforming of Methane on Sponge Iron: Influence

2020-10-31 · Sponge iron or direct reduced iron (DRI) is produced by direct reduction processes. World production reached 87.1 million tons in 2017, and 82% of it is produced with gas-based technologies, mostly by Midrex and Energiron pro-cesses.1) Gas-based direct reduction processes are composed of a shaft furnace in which a mixture of heated reducing

Sponge Iron | SpringerLink

2020-3-3 · Processes that produce iron by reduction of iron ore in solid state are generally classified as direct reduction (DR) processes and the products also referred to as direct reduced iron (DRI) or sponge iron. Different processes of coal-based and gas-based are discussed in detail. Forms of sponge iron, characteristics of sponge iron and re ...

Development of energy conservations scenarios for

2011-1-16 · 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.

(PDF) i) Direct Reduced Iron: Production

2016-3-30 · decades, a new route of ironmakin g has rapidly developed for direct reduction (DR) of iron ore to. metallic iron by using noncoking coal/n atural gas.

Energy Survey of the Coal-Based Sponge Iron Industry

Energy survey of the coal based sponge iron industry ... suggested that 21.6 t/h waste gas generated during sponge iron production process. ... a

Energy integration of sponge iron production process

2012-10-19 · Keywords- Sponge iron plant, Heat integration, Material and Energy balance I. INTRODUCTION Sponge iron is a metallic mass with honeycomb structure. It is a form of iron produced from direction reduction of iron oxide below the fusion temperature of iron ore (1535ºC) by utilizing hydrocarbon gases or carbonaceous fuels as coal.

Sponge Iron | SpringerLink

2020-3-3 · Processes that produce iron by reduction of iron ore in solid state are generally classified as direct reduction (DR) processes and the products also referred to as direct reduced iron (DRI) or sponge iron. Different processes of coal-based and gas-based are discussed in detail. Forms of sponge iron, characteristics of sponge iron and re ...

Iron and Steel - Bureau of Energy Efficiency

2017-9-8 · Iron ore 1.43 Kg Sponge iron 1 Kg. Coal 0.64 Kg. Char 0.064 Kg. Air 5.20 Kg. Flue Gas 6.20 kg. Total Input 7.270 Kg Total Output Heat Supplied = 2058-251 Kcal (Excess heat) In Heat balance of ideal kiln (100% coal used as reducing agent and no coal is used as fuel) S.No Component Heat Value (Kcal)

Heat and Mass Transfer in Reduction Zone of Sponge Iron ...

Numerical prediction is performed on reduction zone of iron ore reactor which is a part of counter current gas-solid reactor for producing sponge iron. The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation.

A Thesis Submitted for Partial Fulfillment of the Degree ...

2012-5-29 · requirement of sponge iron production. Today India produce 13.9 million tons of sponge iron, out of which 4.2 million ton is gas based and remaining 9.7 million ton is coal based. India has a proven reserve of 410 million ton of high grade iron ore, another 440 million ton of high grade iron ore which will be established.

Development of energy conservations scenarios for

2011-1-16 · 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.

Iron & Steel Sector - beeindia.gov

2017-9-8 · Figure 9: Ex-Coal/Lignite/Oil/Gas based Thermal Power Plant Energy balance diagram 194 Figure 10: Ex-CCGT Energy balance diagram 195 Figure 11: Product Mix diagram 197 Figure 12: Ex-GtG Boundary boundary for Sponge Iron Sub-sector 198 Figure 13: Figure 14: Ex-GtG boundary for Cement Sector 202

Direct Reduced Iron (DRI) Production Plant

2021-2-17 · and coal gas refined in coal gasifiers, as well as widely-used natural gas, may be used as reducing gases. u NSENGI, Tenova-HYL and Danieli concluded a strategic alliance agreement for the joint development of DRI steel production plant and expansion of the market of DRI in September 2013. Direct Reduced Iron (DRI) Production Plant

MIDREX Processes - KOBELCO

2011-1-6 · by a sealing gas, allowing the continuous charging of raw material and discharging of DRI. The reaction occurring in the shaft furnace is the well-known reduction reaction of iron, described as follows: Fe 2O 3 + 3CO → 2Fe + 3CO 2 Fe 2O 3 + 3H 2 → 2Fe + 3H 2O The exhaust gas (top gas) emitted from the top of

Pre-feasibility Report

2016-12-2 · Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill along with 27 MW capacity Captive Power Plant at Village Jemua, P.O. – Mejia, Dist. – Bankura, West Bengal Pre-feasibility Report Page-7 Table 2.0 : Material Balance chart for the proposed DRI plant INPUT QTY (T) OUTPUT QTY (T)

Low-Carbon Production of Iron & Steel: Technology

2021-3-8 · Reducing gases are produced from natural gas (gas-based DRI) or coal (coal-based DRI) called syngas, a mixture of H2 and CO. Although DRI production is more energy efficient than pig iron production from BF, additional processing (typically EAF) is needed to upgrade DRI sponge iron for market. These processes operate with different feedstocks.

Sponge Iron - Manufacturing Plant, Detailed Project

The sponge iron is also known as Direct Reduced Iron (DRI), Hot briquetted Iron (HBI) or Metalized Iron. The term Hot Briquetted Iron (HBI) is generally used for gas based direct reduced iron made in briquette shape in hot condition just after it has been discharged from the shaft furnace. Direct Reduction (DR) is a metallurgical process of ...

Iron & Steel Sector - beeindia.gov

2017-9-8 · Figure 9: Ex-Coal/Lignite/Oil/Gas based Thermal Power Plant Energy balance diagram 194 Figure 10: Ex-CCGT Energy balance diagram 195 Figure 11: Product Mix diagram 197 Figure 12: Ex-GtG Boundary boundary for Sponge Iron Sub-sector 198 Figure 13: Figure 14: Ex-GtG boundary for Cement Sector 202

Direct Reduced Iron (DRI) Production Plant

2021-2-17 · and coal gas refined in coal gasifiers, as well as widely-used natural gas, may be used as reducing gases. u NSENGI, Tenova-HYL and Danieli concluded a strategic alliance agreement for the joint development of DRI steel production plant and expansion of the market of DRI in September 2013. Direct Reduced Iron (DRI) Production Plant

MIDREX Processes - KOBELCO

2011-1-6 · by a sealing gas, allowing the continuous charging of raw material and discharging of DRI. The reaction occurring in the shaft furnace is the well-known reduction reaction of iron, described as follows: Fe 2O 3 + 3CO → 2Fe + 3CO 2 Fe 2O 3 + 3H 2 → 2Fe + 3H 2O The exhaust gas (top gas) emitted from the top of

Process for regenerating a reducing gas mixture from

EXAMPLE An example of the process of this invention is as follows: For a sponge iron production rate of 100,000 MT/y using oil as the reforming hydrocarbon, heat and material balance calculations indicate that %12,000 kW of arc heaters (946 kWh/MT Fe) and 0.515 kg oil/s (146 kg of oil/MT Fe) are required to reform a top gas initially containing ...

ENVIRONMENTAL - ASPECTS OF THE DIRECT

2021-5-28 · liquid steel from iron ore by the direct reduction route. The report was examined at the meeting of experts and environmental management guidance for the direct reduction route to steel making was drafted (2). A period of two months was allowed for participants to submit additional material for inclusion in a revised

Sponge Iron Production by Direct Reduction of Iron Oxide ...

This book provides a fascinating study of the newly emanating field of direct reduction in which iron ore is ‘directly reduced’ in the solid state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron, which is subsequently melted in electric arc furnaces (sometimes in induction furnaces) to produce liquid steel.

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