This is because DRI is produced by removing O2 from iron ore. It is also known as sponge iron since its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is around 10,000 times greater than the internal surface area of solid iron. DRI is produced in many forms.
WhatsApp: +86 18838072829Monthly average prices of sponge iron, specifically pelletbased DRI (PDRI), experienced a slowdown. ... the conversion spread from sponge iron to billets had increased by 9% mom in Raipur ...
WhatsApp: +86 18838072829I. Introduction Mill scale is an iron oxide waste generated during steelmaking process, casting and rolling. The mill scale contains very high percentage of iron which is generated during making of steel towards production of various long and flat products.
WhatsApp: +86 18838072829the reduction process, it is often termed as direct reduced iron (DRI). It is seen that the growth of sponge iron industry in last few years is unremarkable and today India is the largest producer of sponge iron as it covers 16% of global output. According to Sponge Iron Manufacturers Association [1], India has produced around 23 million
WhatsApp: +86 18838072829Pig iron Direct reduced iron Figure 1: Iron production, 2000, 2010, 2019 Source: (WSA, 2020) India is the country with the largest DRI production, reaching 34 Mt in 2019, accounting for around a third of global DRI (WSA, 2020). The majority of Indian DRI is produced via the coalbased route, using rotary kilns, making partly use of domestic coal.
WhatsApp: +86 18838072829Sponge 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 ...
WhatsApp: +86 18838072829The pilot plant has a size of 100 cubic meters. At a later stage, a fullscale hydrogen gas storage facility measuring 100,000 to 120,000 cubic meters may be required, in which case it will be able to store up to 100 GWh of electricity converted to hydrogen gas, which is sufficient to supply a fullsized sponge iron factory for three to four days.
WhatsApp: +86 18838072829Direct reduced iron (DRI) also referred to as sponge iron is produced by reducing iron ore directly into iron through the use of a reducing gas, such as natural gas or coal, or even by the use of elemental carbon, such as carbon dioxide. Moreover, the production of highgrade steel, awareness of CO2 emission control, and increasing ...
WhatsApp: +86 18838072829The product from this process is called DRI or sponge iron or hot briquette iron (HBI), which is a highly metalized solid that still contains gangue minerals, and hence needs further purification . The direct reduction method was adopted by Delta Steel Plant in Nigeria, while they were still in operation [ 26 ].
WhatsApp: +86 18838072829Renewable biomass is a potent, CO2 neutral substitute to fossil coal and coke in iron making. However, there has been relatively little work on the utilization of biomass for the production of directly reduced iron (DRI). The aim of the present work is to characterize Acacia nilotica (W1), Albizia lebbeck (W2), and Leucaena leucocephala (W3) biomass and to reduce iron ore pellets primarily ...
WhatsApp: +86 18838072829Most 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 ...
WhatsApp: +86 18838072829Overview 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 ...
WhatsApp: +86 18838072829High metallization cuts coal usage. DRI and HBI are usually made from highgrade iron ore pellets typically reduced by gas to provide a highlymetallized raw material for both electric arc furnaces and traditional blast furnaces. According to USbased DRI technologist Midrex Technologies, HBI, which is metallized beyond 90%, needs only to be ...
WhatsApp: +86 18838072829DRI 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.
WhatsApp: +86 18838072829Sponge 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 ...
WhatsApp: +86 18838072829Direct 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 ...
WhatsApp: +86 18838072829India 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
WhatsApp: +86 18838072829HOW 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...
WhatsApp: +86 18838072829Again 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.
WhatsApp: +86 18838072829The basic model of DRI production plant parameters are shown in table 8. In these facilities, the main function of feedcoal is to act as a reducing agent and react with the ore; some energy required for the kiln reactions also comes from the coal. Total coal demand for DRI production is 853 kg/ton DRI sponge iron. Table 8. DRI coalbased ...
WhatsApp: +86 18838072829Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) into iron by a reducing gas or elemental carbon produced from natural gas or ores are suitable for direct reduction. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting ...
WhatsApp: +86 18838072829The 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 ...
WhatsApp: +86 18838072829Direct reduced iron is iron ore in the form of lumps, fines or pellets that have had the oxygen removed by using hydrogen and carbon monoxide. Typical sources of carbon monoxide are natural gas, coal gas, and coal. Other energy inputs into the production process often include oil and electricity. Since much of the energy used is in the form of ...
WhatsApp: +86 18838072829The power consumption ranges from 45130 Kw/tonne direct reduced iron. The amount of char generation on an average is tonne/tonne of direct reduced iron and electrostatic precipitator dust is ...
WhatsApp: +86 18838072829The 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.
WhatsApp: +86 18838072829Direct 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 ...
WhatsApp: +86 18838072829Raw 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 ...
WhatsApp: +86 18838072829associated with iron ore as oxide removed from the particle is known as percentage reduction whereas the percent of iron as part of whole iron existing as metallic iron is called as degree of metallization in sponge iron technology. Sponge Iron Making Process(Coal Based) KruppRenn Process : The KruppRenn process was developed in 1930.
WhatsApp: +86 18838072829Coal 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 ...
WhatsApp: +86 18838072829Iron ore is preheated and fed into a reduction shaft, where it is converted to direct reduced iron (DRI) and further compacted to hot briquetted iron (HBI). Hydrogen generated in an electrolysis unit is preheated in a condenser before being supplied to the shaft where it acts as the reducing agent.
WhatsApp: +86 18838072829In 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).
WhatsApp: +86 18838072829Coalbased 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 ...
WhatsApp: +86 18838072829To reach a reduction degree of the hot DRI product of 95%, t of iron oxide input material containing input materials per ton of DRI are required for the DRNG as well as the DRH 2 process. Based on NG which contains approximately 95% methane, the simulation results in an NG demand of approximately 259 m 3 STP t −1 DRI for the reference case.
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