sponge iron gas based process diagram

Top informations

MINISTRY OF STEEL, Direct Reduction GOVT OF INDIA Plant ,

Process Flow Diagram of Sponge Iron Plant/ Direct Reduction Iron Plant is given below: 40 PROCESS HAZARD ANALYSIS & NECESSARY RISK CONTROL MEASURES SNo Equipment Hazards Risk Control Measures 1) Belt Conveyors a Rotating parts of conveyor system, like head pulley, tail pulley, snub pulley, coupling guards etc b Moving...

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

A schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in Fig 1 The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material The kiln is around 80 m long with 4 m internal diameter with nine different ports of secondary air In...

Development of energy conservations scenarios for sponge ,

Jan 16, 2011· 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...

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 008% to 020%The carbon content in gas based processes can be controllrd to a level of 15% to 20% based on requirement for steel making Size Distribution:...

Steam Reforming of Methane on Sponge Iron: Influence of ,

Sponge iron or direct reduced iron (DRI) is produced by , and 82% of it is produced with gas-based technologies, mostly by Midrex and Energiron pro- , Based on this diagram....

Sponge Iron Manufacturer India

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...

Direct reduced iron process - tec-science

Jun 21, 2018· Direct reduced iron (DRI) process In addition to the process route via the blast furnace process, there is another option for extracting crude steel from iron ores using the so-called direct reduced iron (DRI) process (secondary route)The starting point for the efforts to find an alternative to the blast furnace process was the relatively high process expenditure...

Syngas - Wikipedia

Syngas, or synthesis gas, is a fuel gas mixture consisting primarily of hydrogen, carbon monoxide, and very often some carbon dioxideThe name comes from its use as intermediates in creating synthetic natural gas (SNG) and for producing ammonia or methanolSyngas is usually a product of coal gasification and the main application is electricity generation...

71 Annexure I: Thermal Power Station Table 15: Auxiliary ,

Balance diagrams a The DCs shall submit the Heat Mass Balance Diagrams showing the complete cycle b Water Balance Diagram shall also be submitted 7 Fuel Mix Normalisation in Gas based Thermal Power Plant Due to change in fuel mix ie, % of consumption of Gas and Oil/other fuel in , Sponge Iron Sub-Sector 11 The entire sub-sector is ....

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...

Direct reduced iron - Wikipedia

Process Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based In both cases, the objective of the process is to remove the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc), in order to convert the ore to metallic iron, without melting it (below 1,200 °C (2,190 °F))...

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron ,

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 ,...

Steelmaking based on inductive melting - Home | ABP Induction

reduced iron (DRI) This is produced in the direct reduction process, in which prepared iron ore pellets are reduced from oxygen in their solid state by a heat and reduction gas, consisting of carbon monoxide and hydrogen, or even by coal [6] The direct reduced iron which results is a porous product, so called sponge iron...

Direct reduced iron process - tec-science

Jun 21, 2018· Direct reduced iron (DRI) process In addition to the process route via the blast furnace process, there is another option for extracting crude steel from iron ores using the so-called direct reduced iron (DRI) process (secondary route)The starting point for the efforts to find an alternative to the blast furnace process was the relatively high process expenditure...

An Introduction to Nitriding - ASM International

process, causing movement in the form of twisting and bending Metallurgical Considerations and Process Requirements Nitriding is a ferritic thermochemical method of diffusing nascent nitrogen into the surface of steels and cast irons This diffusion process is based on the solubility of nitrogen in iron, as shown in the iron-nitrogen...

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 008% to 020%The carbon content in gas based processes can be controllrd to a level of 15% to 20% based on requirement for steel making Size Distribution:...

Green Hydrogen‐Based Direct Reduction for Low‐Carbon ,

May 13, 2020· The equilibrium line in the diagram is based on a projection of the reduction equilibria (M, W) of magnetite (Fe 3 O 4) to wustite (FeO) and wustite (FeO) to metallic iron (Fe) This projection is dependent on the characteristic reduction temperature in the shaft furnace ( ϑ BG ) and the initial reduction gas composition...

(PDF) COMPARISON OF DIFFERENT COAL BASED DIRECT REDUCTION ,

Of the various direct reduction processes converting iron ores to sponge iron, the Midrex and HYL processes are generally used for gas based reduction and SL/RN process is the most common coal ....

Biogas Desulfurization

The process operates continuously and only requires a periodical inspection and cleaning of some internal components to ensure optimum efficiency and performance Dry Scrubbing Catalyst (DSC) Process The DSC process is based on the property of iron sponge to convert to iron pyrite in the presence of hydrogen sulfide...

Development of energy conservations scenarios for sponge ,

Jan 16, 2011· 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...

Sponge Iron Production Process - Arij Trading

This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace...

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...

GOVERNMENT OF KARNATAKA DEPARTMENT OF TECHNICAL ,

Gas based processes: Midrex process- equipment, production of reducing gas, reduction of iron ore, cooling of end product; HYL process – process technique, production of reducing gas UNIT III: CHARACTERSTICS AND USES OF SPONGE IRON (CO3) 08 Hrs...

Midrex Process for Direct Reduction of Iron Ore – IspatGuru

Apr 09, 2017· Midrex Process for Direct Reduction of Iron Ore Midrex is an ironmaking process, developed for the production of direct reduced iron (DRI) It is a gas-based shaft furnace process is a solid state reduction process which reduces iron ore pellets or lump ore into DRI without their melting using reducing gas generally formed from natural gas...

Synthesis of Spongy Iron Powder from Maghemite in Pure ,

below the melting point of iron using reducing gases produced from coal or natural gas The natural gas based process called MIDREX NGTM process is the most widely used technology for the production of sponge iron In this process, natural gas is initially reformed to obtain reducing gases, a mixture of H 2 and CO This gaseous mixture is then...

aessoft – Aravinthraajan Energy Systems Private Limited

Waste Heat based Power Plants utilizing Coke Oven / Sponge Iron / Cement Kiln / Glass Furnace and other waste gases DISTRIBUTED POWER PLANTS Diesel / Gas Engine and Renewable Energy based Power Generation along with storage for communities and off-grid areas...

Sponge Iron - an overview | ScienceDirect Topics

The COREX process is a two-stage process, as is shown in Figure 1140In the first step, iron ore is reduced to sponge iron in a shaft furnace by means of reducing gas In the second step, the reduced iron is melted in the melter–gasifier vessel...

SAFETY GUIDELINES FOR IRON & STEEL SECTOR

SAFETY GUIDELINES FOR IRON & STEEL SECTOR MINISTRY OF STEEL, GOVT OF INDIA Direct Reduction Plant ( Gas Based) Doc No: SG/33 Rev no : 00 Effective Date: -- 1 OBJECTIVE : The entire process of making Sponge Iron by coal based DRI process is associated with various Safety hazards like Fire, Explosion, Radiation, Burns hit /...

Direct Reduced Iron (DRI) | International Iron Metallics ,

Direct Reduced Iron (DRI) is the product of the direct reduction of iron ore in the solid state by carbon monoxide and hydrogen derived from natural gas or coal See more information about the production of DRI Most gas-based direct reduction plants are part of integrated steel mini-mills, located adjacent to the electric arc furnace (EAF ....

Low-carbon production of iron and steel: Technology ,

Mar 09, 2021· 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 H 2 and CO...