While coalbased DRIEAF is common in India, a majority of DRIEAF steelmaking entails the reforming of natural gas to generate a mixture of carbon monoxide and hydrogen—the first step toward producing gray or blue hydrogen. Both carbon monoxide and hydrogen are used to reduce iron ore in a furnace, which then yields solid iron, steam, and CO₂.
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In coalbased DRI plants rotary kiln is used for the reduction of iron ore. Accretion rings formations inside the kiln adversely affect the performance of plant in terms of low production and inferior quality, which frequently lead to shut down. About 70% of the coalbased DRI rotatory kiln shut down is due to the accretion formation [ 1 ].
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DRI processes can reduce CO 2 emissions by using natural gas instead of coal due to the replacement of carbon reductant by hydrogen from the methane. Many complementary gasification processes have been developed in order to synthesize the reducing atmospheres.
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The coalbased DR process is more popular in India and China. Different types of reactors, such as shaft furnaces, fluidized beds, rotary kilns, and rotary hearth furnaces, have been used in different variations of the processe to achieve the metallization required.
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It is widely understood that manmade climate change is chiefly caused by greenhouse gas emissions, especially carbon dioxide (CO 2 ), and that the consequences of global warming will be profound, widespread, and destructive. 1 Nonetheless, global emissions have risen more or less continuously for the past 25 years and have increased each of the...
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Based on production process, the direct reduced iron (DRI) market is bifurcated into coal based and gas based. The gas based segment held a larger market share of the global direct reduced iron ...
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Coal based DRI making process. Iron Ore and noncoking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite which acts as a desulphurized. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to ...
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What is hydrogenbased reduction? Direct reduction of iron is the chemical removal (reduction) of oxygen from iron ore in its solid form. The iron used in the steelmaking process is currently chemically reduced from iron ore through the use of fossil resources natural gas or coal. This process is known as Direct Reduced Ironmaking (DRI).
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Emissions from DRI vary with the source of fuel, with coalbased DRI in India, producing around t CO 2 /t steel and natural gasbased DRI producing around t CO 2 /t steel. Of all the current commercially available technologies, scrap based EAF steel making is the greenest with emissions of around t CO 2 /t steel on average ...
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ResearchGate | Find and share research
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At present, fossil fuels are the steel sector's bloodstream: 27 EJ (10 18 J) of coal, 3 EJ of gas and 5 EJ (1400 TWh) of electricity are consumed annually for the production of the mostly widely ...
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efficiency. Both coal and gasbased DRI plants are operational in India. However, the share of coalbased DRI production is quite substantial and in comparison to gasbased production, this route is energy and carbonintensive. To meet the DRI production target of 80 million tonne by 203031 as envisaged under the
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DRI: This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H 2 and CO. Although DRI production is more energy efficient than pig iron production from BF ...
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From 2016, worldwide DRI output has grown by almost Mt, or nearly 64%, primarily driven by the increase in coalbased DRI in India, new gasbased plants in , and rampup of new gasbased capacity in Algeria, Egypt, USA, and Russia. The reduced effects of the global COVID19 pandemic, an % jump in coalbased production in India,
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gasbased fluidized bed processes (the Finmet / Finored process being the only commercial scale one in operation) accounting for % of 2019 DRI production; coal based rotary kiln furnaces (mainly in India) accounting for 24% of 2019 production. Generic illustrations of the types of process are shown in the graphics below.
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Another case study of a CGP based DRI plant in Angul of Odisha, India which is the first CGP based DRI plant in India with a maximum steel producing annual capacity of about using syngas ...
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Coalbased DRI key to Indian steel industry's higher emissions intensity Aug 12, 2023 India's merchant pig iron production seen rising 15% in FY24 Aug 11, 2023 ...
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In coalbased DRI plants rotary kiln is used for the reduction of iron ore. Accretion rings formations inside the kiln adversely affect the performance of plant in terms of low production and inferior quality, which frequently lead to shut down. About 70% of the coalbased DRI rotatory kiln shut down is due to the accretion formation [1]. Lit
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The decarbonization pathways projected by this study revealed that coalbased DRI production had a lower carbon abatement cost than gasbased DRI production and can account for 45% of the iron and steel's total carbon reduction under the HCN scenario. Therefore, China could adapt its resource endowment, taking coal as the foundation of ...
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TERI proposes to undertake the following activities in collaboration with SIMA (Sponge Iron Manufacturers Association ) in the coalbased DRI production process: Detailed mapping of DRI production units and shortlisting 23 prominent coalbased DRI manufacturing clusters representing domestic production ranges, existing and proposed capacity, operating practices etc. Explore possibilities ...
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Scrapbased EAF operations present the most CO 2 friendly route (Figure 3) even when including electricity contributions (assuming 65 kg CO 2 /Te DRI and about a 15% scrap charge in the BOF). However, the beneficial continuous recycling in the EAF will render prime scrap sources fewandfarbetween long term (Figure 4), necessitating greater use of Ore Based Metallics (OBMs DRI/HBI and Pig ...
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Direct reduced iron to electric arc furnace (DRIEAF) production is 5% and growing, it appears to have better decarbonization potential to move towards netzero.
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and since the inception of first DRI plant in 1957 in Mexico, there has been a continuous growth of this industry in last three decades. This is evident from the steep rise in world DRI production during the past three decades. India, entered the sponge iron industry only in 1980, when the coal based DRI plant of Sponge Iron India Limited (SIIL)
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2
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well over half of the global DRI. From, worldwide DRI output increased by Mt, or nearly 49%, primarily driven by the increase in coalbased DRI in India, the high capacity utilization of existing and new gasbased plants in , and the ramp up of new capacity, such as Tosyali Holding's MIDREX® Plant in Algeria.
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The broad interest shown by the steel industry in coalbased direct reduction is a result of: (1) the need for a scrap supplement, (a) due to the steadily increasing electric arc furnace capacity in the USA, direct reduced iron (DRI) is required as a substitute in times of scrap shortages, and (b) due to the decreasing quantities of quality ...
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Direct Reduced Iron (DRI) manufacturing, a growing technology in ironmaking, offers the potential to reduce emissions. India, as the largest manufacturer of DRI, is characterized by technological diversity, while simultaneously dominated by coalbased DRI processes.
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Thereafter, other coal based DRI plants like PI Tata I Steel, Bihar Sponge Iron Ltd, Odisha Sponge iron Ltd etc were set up. Major growth in coal based sector from 200304 to 200809. In early 90's three gas based DRI plants were set up in the west coast due to the availability of natural gas at that time.
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Coal based DRI plants are flexible with respect to plant location since noncoking coal is widely distributed in large deposits and is easy to transport. Most plants employ reduction process which is carried out in rotary kilns. These plants use wide variety of raw materials and noncoking coal.
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Another way to make primary steel is through what is termed Direct Reduced Iron (DRI), when iron ore is mixed with a fuel and a reductant to reduce the oxygen content. ... Worldwide, natural gas is the fuel typically used while in India 82% of DRI is produced in coalbased rotary kilns with the remainder being produced via gasbased routes ...
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Hydrogenbased DRI was produced at a commercial scale in Trinidad and Tobago using a fluidized bed reactor process as long ago as the early 2000s. Now the process needs to be finetuned and accompanied by a truly fossilfree energy source.
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Sponge iron produced using the non coking coal is called coal based sponge iron / DRI. 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. For steel ...
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Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coalbased DR process and (2) gasbased DR process. Details of DR processes, reoxidation,...
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