The employed fuels are natural gas and/or coal. The energy consumption is in the order of 10.4 GJ/t-DRI that is equivalent to 300 m 3 of natural gas per ton of reduced iron. The CO 2 emissions are quantified in the range 0.77–0.92 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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1. Less capital cost: The capital cost per tonne of installed capacity, in case of coal-based plants, is 1.8–2 times as high as in the gas-based plants.. 2. High productivity: The throughput rates for gas-based sponge iron plants are much higher than in coal-based plants.The productivity for gas-based plants can be as high as 11 t/m 3 /day as against …
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The unavailability of the required quantity of recyclable steel in India has made the industries depend on sponge iron (SI) for steel manufacturing. However, …
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microstructure to the melted sponge iron (Supplementary Fig. 2). Figure 2a shows the hydrogen desorption spectra of the samples during continuous heating at a ramping rate of 1000°C/h.
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The induction furnace for melting sponge iron is required to have a large ratio of cross sectional area to volume so that the heat transfer is high and to keep the slag hot and fluid. ... For every 1 % slag formed at 1500 deg C energy loss is 10 kWh per ton. The sponge iron charge in the furnace is characterized by (i) high porosity, (ii) low ...
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Sponge iron adopts direct reduction ironmaking method to obtain iron with sponge-like pores inside. Sponge iron is produced by low-temperature reduction of iron …
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From a technical perspective, the challenge of decarbonization involves two processes: chemical reduction for iron ore refining (process emission), commonly with metallurgical coal and coke, and from the high-temperature heat sourced needed to operate blast furnace (BF) and other production reactor. 5 Unlike the power sector, there are …
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Steel making contributes 6% of global CO2 emission (including associated power emissions). Blast furnaces dominate global production, have long capital lives, and resist adoption of decarbonization technology. Deep decarbonization and net-zero production will require both asset replacement from BF to DRI+EAF and development …
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Sponge iron powder The Höganäs process is a direct reduction method for production of sponge iron powder using magnetite ore (Fe3O4) and carbon as raw materials.
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It is one of the important raw materials used in production of iron and steel. Dolomite contains theoretically 54.35 % of CaCO3 and 45.65 % of MgCO3 or 30.41 % of CaO, 21.86 % of MgO, and 47.73 % of CO2.
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Coal is a major raw material for sponge iron making as 1.75 tonnes of local coal is required for making one tonne of sponge iron. ... shortage and inadequate quantity offered in e-auctions to ...
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Raw Materials used in Making iron. The basic raw materials for making iron and steel are: Iron ore. Iron ore is one of the basic among other raw materials used in the production of iron. It is described as any mineral substance that contains enough iron which makes its smelting a viable proposition, i.e. an iron content of less than 20%.
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DRI (also known as sponge iron) is an important advancement in the ironmaking industry due to its high productivity and strong adaptability to raw materials (Guo et al., 2017). ... DR processes emit only one-third of the CO2 per ton of steel of a BF â€" BOF route. In the HYL III process for example carbon dioxide emissions range from …
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India is the world's largest producer of sponge iron, accounting for 13 per cent of the global production 8. Sponge iron is produced using either coal or natural gas. Since coal is available in India, the sector largely depends on coal based sponge iron which contributes about 80 per cent of the total capacity in the country9.
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requirements EAF Units 14.82 23.71 Sponge Iron Units 18.50 29.60 Total: 53.31 Note: Assuming no scrap is being used. For producing one tonne of crude steel, 1.6 tonnes of iron ore consumption has been assumed. If we add iron ore requirements of RINL of about 5.00MT (3.13 MT x 1.6 tonnes), the total iron ore requirements from non-captive …
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This study reviews the different DR processes used to produce Direct Reduced Iron, providing an analysis on the quality requirements of iron-bearing ores for …
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sponge iron production plant at Chandrapur, Maharastra. The OSIL process uses a rotary kiln of 3.5mtr diameter and 84mtr long. The output of this plant is 300 tons per day. The …
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The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel Company of Canada, Lurgi Chemie, Republic Steel Company and National Lead Corporation in 1964), which works on direct reduction of ore.This process is adopted by worldwide conventional sponge iron …
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However, one must examine the presence of undesirable elements such as sodium, potassium, lead, zinc, etc. in the waste. Blue dust, a pure form of iron oxide with very little gangue and rejects of sponge iron plant have also been utilized in sinter making. The iron oxide fines containing small amount of pellet fines have also been used to ...
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Sponge iron provides the base feedstock for all iron-based, self-lubricating bearings and still accounts for around 30% of iron powder usage in PM structural parts. Solid state reduction is also used for the production of refractory metal powders, using hydrogen as the reducing agent, and for the production of specialist iron powders by the ...
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Sponge iron is the metallic form of iron produced from direct reduction of iron oxide below the fusion temperature of iron ore (1535ºC) utilizing hydrocarbon gases or carbonaceous fuels such as coal. With the availability of raw materials, high demand of sponge iron and less payback period, sponge iron industry has emerged as a profitable ...
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In book: Encyclopedia of Iron, Steel, and Their Alloys (pp.pp 1082-1108) Chapter: i) Direct Reduced Iron: Production; Publisher: CRC Press, Taylor and Francis Group, New York.
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metallic iron is called as degree of metallization in sponge iron technology. Sponge Iron Making Process(Coal Based) Krupp-Renn Process : The Krupp-Renn process was developed in 1930. In this process high silica ore and lime stone is treated. In this process a mixture of -6.4mm ore and
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Sponge iron adopts direct reduction ironmaking method to obtain iron with sponge-like pores inside. Sponge iron is produced by low-temperature reduction of iron ore in a rotary furnace, shaft furnace, or reactor. ... Silica content is the main factor that determines the amount of steelmaking slag, and it is generally required to be no more …
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The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As …
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Among other expenses of pig-steel production, maintenance and capital charges would be about the same as for electric-furnace pig-iron production. The labor cost per ton of product would be a little lower for pig steel. The electrode consumption per long ton of pig iron has been reduced to 6.7 lb.
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Steelmaking in Induction Furnace. satyendra; May 24, 2018; 1 Comment ; carburizer, control system, Ferro alloys, Induction furnace, induction heating, scrap, slag, Sponge iron, steelmaking,; Steelmaking in Induction Furnace. Coreless induction furnaces have been used in the ferrous industry for over 50 years and are now one of …
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for Steel Making [MTD 30: Sponge Iron and Smelting Reduction] IS 15774:2007 (Amalgamating IS 10812:1992, IS 13839:1993 and IS 13905: 1993) ... General requirements for the supply of metallurgical materials (second revision) ... 3.5 Metallic Iron — Itis the aggregate quantity of iron, either free or combined with carbon (as cementite)
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The conventional rotary kiln-based sponge iron (SI) production process in India, which contributed to the manufacture of 33.88 million tons of SI in 2022 was depicted in Fig. 1 (Ministry of Steel, 2023).The SI production system of 100 ton per day (TPD) capacity comprised an inclined rotary kiln (3°), a rotary cooler, an after burning chamber …
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