Sponge iron making pdf files

A thesis submitted for partial fulfillment of the degree. One of the major challenges for sponge iron plant is the accretion formation. The iron sponge process, a technology used for removing hydrogen sulphide h 2 s from biogas, can potentially use various biodegradable wastes as the supporting material for the h 2 s adsorption media, providing improved flexibility and costeffectiveness. Ferrous metallurgy is the metallurgy of iron and its alloys. The reduction of rolling mill scale to sponge iron powder is a new way to take advantage of a cheap byproduct of the steelmaking industry, yielding sponge iron that can be reused to the electric furnace as metallic charge for steelmaking to obtain a product with a lower residual content and improved properties8,10. Sponge iron is a metallic mass with honeycomb structure. Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. There is fluctuation in the quality of sponge iron. The process of sponge iron making aims to remove the oxygen from iron ore. In indian recycling firmament, the association could boast of a variegated history of growth within a short span of less than a decade. Tin the irons tip by touching a bit of solder to it before starting. Production of sponge iron powder by reduction of rolling.

West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Sponge iron production by direct reduction of iron oxide. Designing iron sponge process for h2s removal student. The main function of making sponge iron in the kiln is to convert iron ore into sp onge iron by using iron ore, coal and dolomite. Contact verified sponge iron manufacturers, sponge iron suppliers, sponge iron exporters wholesalers, producers, retailers and traders in india. In this study, ground garden waste, digested garden waste, and spent tobacco were evaluated as supporting. Sponge iron process, rotary kiln, ann topologies, optimum input parameters. Pig iron crude steel coils lime ferroalloys there are two routes for making steel. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. It has topped in total number of cites and citable documents.

Pdf operation of coalbased sponge iron rotary kiln to reduce. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. The ironsponge process generally uses a single vessel to contain the hydrated ferric oxide wood shavings. The eru has observed the following general pattern of sponge iron use in different regions of the country depending on the differential between the delivered costs of heavy melting scrap and sponge iron borne by the producers in the regional clusters. Since last few years, sponge iron has emerged as an alternate raw material for steel making. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron. Sponge with a drycleaning solvent or take to drycleaner as soon as possible.

Recovery and utilization of waste heat in a coal based sponge iron process vivek kumar, shabina khanam. 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. Only 20% to 30% of sponge iron can be used in the furnace charge when feeding is done in batches. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Wash follow the iron removal procedure in paragraph above. Sponge iron production by direct reduction of iron oxide chatterjee on. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india. The high fe content of sponge iron ore specification of 7880 % is the standard set by us. In fact it is believed that iron makes up about 5% by weight of the. Modeling of rotary kiln for sponge iron processing using. All students, freshers can attemp or download metallurgical engineering physical metallurgy quiz questions with answers as pdf files. In the present work, several challenges faced in sponge iron production have. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore.

Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Green steel making gas based technology for sponge iron industry by welspun maxsteel ltd worldwide, there is an increasing emphasis on environmental issues. The latter process is based on atomization of a stream of liquid. I have come to understand that this is a fixed bed adsorber column design but i cannot. This is to certify that the thesis entitled design of waste heat recovery system in a sponge iron plant being submitted by saurav kumar sahu as an academic project in the department of.

Designing iron sponge process for h2s removal posted in student. Find here information of sponge iron selling companies for your buy requirements. Sponge iron definition is iron in porous form or containing many voids. Integrated steel plant tmt bar manufacturing plants. Sponge irondirected reduced iron dri hot briquetted iron hbi and cold briquetted iron cbi for steel making by bureau of indian standards.

This process is applied to gases with low h2s concentrations 300 ppm operating at low to. Keep a damp sponge or rag handy and swab the irons tip frequently to keep it clean. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Energy survey of the coal based sponge iron industry. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. Shyam steel has best quality steel manufacturing integrated steel plants located in west bengal. Geologists recognise various types of iron ore, classified chiefly according to iron fe.

Hydrogen sulfide removal from biogas by biobased iron sponge. We are a leading importer and supplier of high quality gas based sponge iron in india. Raw material in production of iron and steel in hindi duration. Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. In fact it is believed that iron makes up about 5% by weight of the earths crust. This was a simple method used from the iron age to medieval times where iron. Sponge iron manufacture is highly sensitive to raw material characteristics. The quality of sponge iron is primarily ascertained by the percentage of metallization removal of oxygen, which is the ratio of metallic iron to the total iron present in the product.

Mrai, material recycling association of india, metal. If you continue browsing the site, you agree to the use of cookies on this website. We ensure no fines, no lumpiness and conform to all safety standards of industries producing dri sponge iron. In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to know and speak the laws that govern them. Over the years, the coal based route has emerged as a key contributor and accounted for 76% of total sponge iron production in the country 20. Sponge iron process for manned space exploration final project report june 2005 executive summary redox cycling of an ironrich contact mass has been investigated and applied with terrestrial hydrogen production from hydrocarbon and biomass sources. Optimization of operating parameters for sponge iron production. Directly reduced iron directly reduced iron is a product of. Study on accretion formation on dri kiln during spong iron. A drawing of an ironsponge unit showing typical provisions for internal and external design requirements was presented in figure 73. I am tasked with designing the equipment for the iron sponge oxide process for the removal of hydrogen sulphide from natural gas.

Hi all, i am a final year student in australia and am trying to complete my design project. Iron sponge unit design procedures hydrocarbon compression. 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 in india. It is produced by direct reduction of iron ore in the presence of coal and air. Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. A thesis submitted for partial fulfillment of the degree award of master of technology in chemical engineering by. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Recovery and utilization of waste heat in a coal based. The indian government has recognized sponge iron as a vital sector for growth of indian steel industries. Coal based spongeiron is a metallic product produced through direct reduction of iron ore in the solid state.

Sponge iron, also called direct reduced iron, is the product created when iron ore is reduced to metallic iron, usually with some kind of carbon charcoal, etc, at temperatures below the melting point of iron. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. Sponge iron or dri direct reduced iron is relatively uniform in composition, and virtually free from tramp elements. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder.

Section 2 creating a growing and sustainable iron and. This energy efficient feedstock is created by dspl using the dri process and our plants have an installed capacity of 2. Pdf production of sponge iron powder by reduction of. Received 1 october 2011 received in revised form 26 january 2012 accepted 7 march 2012. Instead of touching solder to the irons tip, try to heat the target component and melt the solder against the component. Green steel making gas based technology for sponge. Ralf coal injector used in sponge iron division kiln12tph ton per hourrotary air lock feeder.

This type of iron can be produced in several different types of furnaces, including. Some of these technologies are particularly suited to south africa, as they would lead to the replacement of imported coking coal and high grade iron ore lump with thermal coal and iron ore fines, both of which are abundant in south africa. All students, freshers can attemp or download metallurgical engineering physical metallurgy quiz questions with answers as pdf files and ebooks. Processes that produce iron by reduction of iron ore in solid state below the. Sg32 safety guideline for coal based dri ministry of steel. Ptrcentage consumption of bot metal, scrap and sponge lroa for world crude. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. The substitution of scrap by sponge iron has some limitations depending on the furnace operating conditions. Iron very rarely occurs in the earths surface as a metal.

Department of chemical engineering, national institute of technology, rourkela769008, orissa, india a r t i c l e i n f o article history. The proportion of sponge iron in the charge can however be increased to 4050% by providing continuous feeding arrangements. It is widely distributed, combined with oxygen as iron oxides. Sponge iron definition of sponge iron by merriamwebster. Energy balance in a rotary kiln sponge based iron making. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. Our high and consistent quality sponge iron facilitates steel makers to maintain high quality and reduce dependency on scrap. Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. The iron sponge process uses the chemical reaction of ferric oxide with h2s to sweeten gas streams.