How To Calculate Iron ore:coal:Air:DRI:Flue gas:Char for sponge iron makingin this video we know how to calculate specific iron ore, coal, air requirement f...
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The iron also can be produced from its ore by the direct reduction of iron ore by a reducing agent which is coal based or may be a gaseous reducing agent, which is called direct reduced iron (DRI) or sponge iron. DRI is a good substitute of scrap for making steel in electric arc furnace, basic oxygen furnace, etc. and there has been a rapid ...
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DRI (containing 9094% total iron) is an excellent feed stock for electric furnaces used by mini steel plants, allowing them to use lower grades of scrap for the rest of
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Sponge Iron Plant—WHR in Rotary Kiln Directly Reduced Iron (DRI) Production. Here, directly reduced iron (DRI) is produced in a rotary kiln of 36 m diameter and approximately 85 m length installed at an incline. The capacity of the kiln depends on metallization degree and usually does not exceed 225,000300,000 t/year (Fig. 2). It ...
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HOW TO CALCULATE CARBON FOR SPONGE IRON MAKINGIn this video we know how to calculate carbon /ton, DRI and how to calculate coal quantity for kiln inlet and o...
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Direct reduced iron (DRI), also called sponge iron, is produced by the reduction of iron ore (in the form of lumps, pellets or fines) with a reducing gas produced from natural gas or coal. This process is called direct reduction. ... Phase concentrations are converted to Femet, Metn and Ctot. The data from wet chemistry, those calculated with ...
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Coal is a combustible black or brownishblack sedimentary rock, formed as rock strata called coal is mostly carbon with variable amounts of other elements, chiefly hydrogen, sulfur, oxygen, and nitrogen. Coal is a type of fossil fuel, formed when dead plant matter decays into peat and is converted into coal by the heat and pressure of deep burial over millions of years.
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Sponge iron units of the country are facing an acute coal shortage, said an industry official. "Of the 450 direct reduced iron (DRI) units that produce sponge iron in the country, 105 are ...
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Coalbased sponge iron/DRI also has limitations in use due to its high sulphur and phosphorus content, and low carbon and metallization. ... The conversion of iron ore fines (size: −1 to + mm) to iron carbide takes place in a circulating fluid bed reactor, where the preheated ore reacts with the reducing constituents of the natural gas ...
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Abstract 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 Nomenclature hr heat transfer coefficient from outer surface of rotary kiln to outside atmosphere, kJ/h m 2 D diameter, m L length, m m mass flow rate, kg/h T temperature, °C Q heat load, kJ/h Cp
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The employed fuels are natural gas and/or coal. The energy consumption is in the order of GJ/tDRI that is equivalent to 300 m 3 of natural gas per ton of reduced iron. The CO 2 emissions are quantified in the range t of CO 2 per ton of steel. As a function of the employed reducing reactors, the systems are of four main types:
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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. ... The crucial factor in this reduction process is the controlled combustion of coal and its conversion ...
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India is the largest producer of sponge iron or direct reduced iron (DRI) in the world. ... Sponge iron, Coal, Rotary kiln, Modelling, ... Conversion of hematite to magnetite (Fe 3 O 4
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Overview of DR processes Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing gas to produce Direct Reduced Iron (also known as sponge iron). DRI is often compacted to reduce its porosity and to convert it to Hot Briquetted Iron (HBI) for sale or storage (Indian Bureau of Mines ...
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The reduced iron along with coal and lime is fed to a gasifiermelter, which completes the reduction process and produces pig iron or hot metal of the same quality as a blast furnace. The reducing gases generated by the gasifiermelter are recycled to reduce the iron ore in the prereduction step.
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Again a lot of coal fines and coke breeze are also produced during coal mining and coking of coal respectively. Utilization of iron ore and coal fines for extracting metal is of vital concern for resource conservation and pollution control. The other option is to convert the iron ore and coal/coke fines into composite pellets/briquettes.
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Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change. Raw material mixiron ore, dolomite and coal are fed to one end of rotary Kiln as well as some fine coal also fed from discharge end and product sponge iron along with char is taken out from the other ...
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There are different types of raw materials used for sponge iron making and steel products Like Coal, Iron Ore, and Dolomite Iron ore and decoking coal are the main raw materials to produce sponge iron. They are charged into the rotary kiln in the required proportion together with some dolomite used as a desulfurizing agent.
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Sponge Iron Making Process(Coal Based) KruppRenn Process : ... Sponge Iron Ferro Alloys 9 In Midrex process reform gasses entering the reduction furnace at around 800 ... continuously convert iron ore fines into a highly reduced product, usually in the form of briquettes. The first of the reactor preheats the ore and reduction is started in the
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The sponge iron is melted into the actual crude steel. This process will be discussed in more detail in the next section. In the directreduced iron (DRI) process, the iron ores are reduced directly to sponge iron by gaseous reducing agents! Electrosteel process. In the electric steel process, the sponge iron obtained from the direct reduced ...
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Sponge iron production process. DRI unit; ... and it is taken into the rotary cooler in which the product get cools down and is separated from the coal char. Some of the basic reactions that may be included in the process are ... After CO reacts with the oxygen it is converted into O2 and it automatically generates heat.
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Direct reduced iron (DRI), also called sponge iron due to its porous nature, is produced in reactors that directly reduce (remove) the oxygen from the iron oxides in iron ore. Unlike the chemical reactions that happen in the blast furnace, the DRI process is done without having to melt the iron ore. This direct reduction process is how the ...
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DRI production. Direct reduction of iron is the removal of oxygen from iron ore or other iron bearing materials in the solid state, without melting, as in the blast furnace. The reducing agents are carbon monoxide and hydrogen, coming from reformed natural gas, syngas or coal. Iron ore is used mostly in pellet and/or lumpy form.
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In 2019, DRI production hit a record million tons— percent more than the previous year, owing most of its increase to India, , and Algeria. In 2021, DRI production reached million tons, up by percent from 2019. While growing output in India—the world leader in DRI production—was due to productivity growth in coal ...
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visit to spong iron division direct reduction iron basic concepts
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In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, India producing 57% of its crude steel in electric arc furnaces (2016).
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Direct reduced iron (DRI), also called sponge iron, [1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by a reducing gas or elemental...
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Raw material utilization and waste generation for the DRI suggest that tonnes of ore, tonnes of noncoking coal and tonnes of dolomite are needed to produce 1 tonne of sponge iron and ...
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sponge iron sector, which is dominated by smallsized coalbased direct reduction of iron (DRI)based plants. India is one of the unique countries in the world where coalbased DRI route contributes to nearly 20% of the total steel capacity in the country. The prominence of DRI route in the country is
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