make sponge iron from coal and iron ore process

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 800–1200 °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 ...

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 (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. Apart from this, primary

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 …

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

Malcolm Tatum 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.

Sponge Iron industry passing through difficult times

policy of iron ore by PSU mining companies for small and mid-sized industries who will find it difficult to have a captive mine. 4. Coal supplies should be made regular and the CESS in coal should be given input credit which will make the sponge iron industry competitive. 5. Consortium of maximum 10 sponge iron producers should be allowed

New Sponge Iron Rotary Kiln Design In Sponge Iron ...

Sep 10, 2020· In the newly designed sponge iron rotary kiln system, a coarse coal branch pipe and fine coal branch pipe are added at the kiln head. The original way of adding coal at the kiln head is changed to 50-70% coal is added together with fine iron ore and dolomite through the mixing mode at the kiln tail, and the remaining 30-50% coal is added ...

How to Manufacture Pig Iron: How Pig Iron is made?

(3) Sponge Iron Process: As the name implies, the spongy iron is obtained by the reduction of lumpy iron ore or iron ore pellets from the oxide form into the metallic state. The iron content of the product so obtained varies from 90% to 94% and the balance represents the traces of …

Low-Carbon Production of Iron & Steel: Technology Options ...

Mar 08, 2021· Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solid-state with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gas-based DRI) or coal (coal-based DRI) called syngas, a mixture of H2 and CO.

(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 ...

US4490168A - Process of making steel by melting sponge ...

Sponge iron produced by direct reduction is melted in an electric arc furnace, in which a pool of liquid metal is maintained. To ensure that liquid carbon-containing iron for forming the pool is available in adequate quantities and that the process can be carried out with the highest possible economy, the sponge iron is reacted in an electric arc furnace on a bath of liquid carbon-containing ...

The Making of Iron & Steel

The BOS process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal (and scrap is used for temperature control). The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process, the EAF requires

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 generally recommended to use high quality cooked pellets with a maximum of about 30% iron ore lumps.

Sponge Iron - HIRA - Godawari Power & Ispat Limited

With such dimension of notion WE in our Sponge Iron Manufacturing process through 4 Kilns (1 * 350T and 3 * 500T) laid up the best DRI making process of India. It is Coal Fuel based DRI. Coal based Sponge-iron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron ...

Green reduction of iron ore | Höganäs

Green reduction of iron ore. Fossil process coal used in our production is a challenge where we take the lead to become more renewable. The sponge iron plant is the only operation within the Group where we use fossil coke and anthracite to reduce iron ore into metallic iron. Today, the reduction process accounts for almost 70 percent of the ...

Steelmaking - Stahlinstitut VDEh

The sponge iron is mainly used for steel production in electric arc furnaces. Two steps are required with the smelting reduction method. First the ore is reduced to sponge iron and this is then converted to a blast-furnace-like form of hot metal through the use of coal and oxygen.

Non-coke smelting reduction of iron ores: Process ...

The COREX process is composed of two main reactors: the vertical shaft furnace for the gaseous reduction of iron ore to sponge iron, and the melter-gasifier for the gasification of coal and smelting of iron. The gasification process generates the reducing gas mixture (CO and Hsb2) for use in the reduction furnace and also produces heat for ...

WELSPUN STEEL LIMITED

Welspun sources its entire coal requirement from the imported coal by the China & South Africa. Iron Ore. In sponge iron making, iron ore is reduced in solid state. Unlike in the conventional steel melting processes, the gangue content of iron ore cannot be separated as a slag. Therefore, it becomes imperative to select an ore with a high Fe ...

SPONGE IRON – Properti Industri terpercaya

Sep 27, 2017· sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. The reducing gas is a mixture majority of hydrogen (H2) and carbon monoxide (CO) which acts as reducing agent. This process of directly reducing the iron ore in solid form by reducing gases is ...

Sponge iron making full process_Coal base DRI - YouTube

Dec 24, 2018· 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 ...

Coal Briquetting Process Used In Sponge Iron Plant Samac

Iron Ore Sponge Iron Anthracite Coal Briquette Making . 13 Sep 2016, The sponge iron manufacturer in Delhi India offers DRI products tunnel kiln process sponge iron in south africa. Prices / Quote Direct Reduced Iron Wikipedia

Science: Sponge Iron - TIME

It is called sponge iron, and the U.S. Bureau of Mines has decided to risk $500,000 in hurry-up development of the hitherto unpractical process by which it is made. To make sponge iron, ore is not smelted. It is mixed with pulverized coal (natural gas can also be …

Sponge iron making process - SlideShare

Nov 09, 2014· ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3 …

Extracting More Sponge Iron Is Imperative To Boost Steel ...

Sep 29, 2019· Such coal-based sponge iron making from iron ore is popular both in India and China. However, in the world, almost 80% of sponge iron is being produced by the gas-based DR process. Both the gas and coal based DRI technology are gaining importance due to comparatively less investment cost, flexibility in using raw materials like cheap iron ore ...

Sponge Iron – Prakash Industries Limited

Solid reduction process. 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 furnace and the induction ...

Youtube Tunnel Kiln Sponge Iron Process

Tunnel Kiln Process For Sponge Iron. Case group tunnel kiln iron ore plant. Dri tunnel kiln by case group - youtube history is finally created by case group in india indias first dri through tunnel kiln process india the largest producer of dri in the world has got a new technology to make dri from iron

HYBRIT first with hydrogen-reduced sponge iron

Jun 21, 2021· SSAB, LKAB and Vattenfall have produced the world's first hydrogen-reduced sponge iron at a pilot scale. The technological breakthrough in the HYBRIT initiative captures around 90% of emissions in conjunction with steelmaking and is a decisive step on the road to fossil-free steel, claims the Scandinavian steelmaker.

Ratio of coking coal and iron ore to make steel

Ratio of coking coal and iron ore to make steel Products. As a leading global manufacturer of crushing, grinding and mining equipments, we offer advanced, reasonable solutions for any size-reduction requirements including, Ratio of coking coal and iron ore to make steel, quarry, aggregate, and different kinds of minerals.

Iron Ore To Steel Process Flow Chart - Blog.lif.co.id

Oct 24, 2019· Iron ore to steel raw material for manufacturing the tmt bar are iron ore coal dolomite in this process raw materials are piled recovered and mixed in required proportion the iron ore experiences beneficiation procedure to raise the iron substance at this point metal fines are gathered to shape a mass of pellets and sinter to improve.

Sponge Iron - Sponge Iron Manufacturer & Supplier in India

India is the world's largest producer of sponge iron, most of which is produced primarily through the coal-based method of production. Its production is set to rise with upcoming capabilities. Sponge iron is known to be a metallic product manufactured through direct reduction of iron ore in the solid state.

SPONGE IRON – Lloyd's Metals

Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a 'select' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished ...

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 ...

Creating Iron | HowStuffWorks

The more advanced way to smelt iron is in a blast furnace. A blast furnace is charged with iron ore, charcoal or coke (coke is charcoal made from coal) and limestone (CaCO 3 ). Huge quantities of air blast in at the bottom of the furnace, and the calcium in the limestone combines with the silicates to form slag.

Apparatus for producing sponge iron or pig iron - Deutsche ...

I claim: 1. An apparatus for producing sponge iron from iron ore comprising: a melt-down gasifier or coal-to-gas plant, a shaft furnace having a top portion of a first cross section, an inlet in said top portion for introducing iron ore thereinto and an outlet for removing top gas therefrom; a base portion of a second cross section larger than said first cross section and having an outlet for ...

sponge iron process

Jul 29, 2010· The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making. Size Distribution:

Convert your sponge iron plant into a cast iron plant and ...

Schematic views of the existing rotary kiln for making sponge iron & the proposed addition of MAGMA for making pig iron are given below – Advantages of converting a sponge iron plant into a pig iron plant are – Any grade of iron ore (55-63% Fe) and any size of iron ore and coal (3-20 mm) can be used in MAGMA. South African / Australian ...

make sponge iron from coal and iron ore process

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