A good way to do this is to attach a magnet to the outside of the dish. Coal based sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. Nov 17, 2012 sponge iron units do not use the pollution control equipment. 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. Green steel making gas based technology for sponge iron industry by welspun maxsteel ltd worldwide, there is an increasing emphasis on environmental issues. This energy efficient feedstock is created by dspl using the dri process and our plants have an installed capacity of 2. At present, india is largest producer of sponge iron with a largest number of coal based sponge iron plant of total capacity around 12. Ralf coal injector used in sponge iron division kiln12tph ton per hourrotary air lock feeder kiln duration. The sponge iron we make available is used for the production of various steel and iron based products like bars, pipes and tubes. 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. Sponge iron brushing magnetic separation entering secondary reduction furnace becoming powder lump crushing magnetic separation sieving classifying mixing packingfinished iron powder product. Sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. 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. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore.
Take some scrap paper and tear it into small strips, place in jar and cover with warm water. Geologists recognise various types of iron ore, classified chiefly according to iron fe. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron ore in the form of lumps, pellets, or fines to iron by a reducing gas or elemental carbon produced from natural gas or coal. We also manufacture high grade sponge iron in the brand name of rexon strips limited. Since last few years, sponge iron has emerged as an alternate raw material for steel making.
The high fe content of sponge iron ore specification of 7880 % is the standard set by us. Spongeironproductioninrotarytn786312020 adobe acrobat reader dcdownload adobe. This process is applied to gases with low h2s concentrations 300 ppm operating at low to. In this study, ground garden waste, digested garden waste, and spent tobacco were evaluated as supporting.
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. Sponge iron production by direct reduction of iron oxide. Today with a production of nearly 19 million tones, it is the largest. A thesis submitted for partial fulfillment of the degree award of. Nov 09, 2014 making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The indian sponge iron industry some issues in conservation. Before you chase any further symptoms go to help check for updates in word s menu bar. Sponge iron manufacture is highly sensitive to raw material characteristics. 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. Note there are 2 vowel letters and 4 consonant letters in the word sponge. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces.
Apr 23, 2020 sometimes known as directreduced iron, sponge iron is a product that is produced using iron ore. Simulation of rotary kiln used in sponge iron process. Pig iron is divided into steel making 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. 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. 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. Several grades of treated wood chips are available, based on iron oxide content. Green steel making gas based technology for sponge. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the. Iron very rarely occurs in the earths surface as a metal. The newly formed metallic sponge is then crushed and pressed.
Green steel making gas based technology for sponge iron. 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. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. Ironically, india is the worlds top producer of sponge iron, but producers there are grappling with high production costs and suffering from the more aggressive iranian exporters. Clean dry cellulose sponge iron how to begin the activity. Pdf word cant be simpler ms word is one of the most used text processing applications and the pdf format is the most used format to publish documents using the free pdf24 creator you can continue to use word or any other text processor to write your. The indian government has recognized sponge iron as a vital sector for growth of indian steel industries. The volume in bushels can be determined from the following equation once the bed dimensions of diameter and height are known. The process of sponge iron making aims to remove the oxygen from iron ore. It is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when air pollution is a concern the unqualified term coke usually refers to the product derived. Sponge iron definition is iron in porous form or containing many voids. Study on accretion formation on dri kiln during spong iron. Sponge iron is then taken to a product bin for dispatch.
A series in which the amount of coke in the charge was varied, other components remaining constant. Sponge iron units do not use the pollution control equipment. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. The process of pelletization helps converting iron ore fines into uniform size iron ore pellets that can be fed in the blast furnaces or in the dri kiln dri. Directly reduced iron directly reduced iron is a product of. While china primarily buys raw iron ore, the islamic republic is also boosting exports to india of sponge iron. The crushed titanium sponge is then melted in an electrode vacuum arc furnace at extremely high temperatures.
Tata steel proposed to do this by introducing an innovative technology for making sponge iron tisco direct reduction tdr, developed by its research and development division. Make sure that all staples, paper clips and other materials have been removed. Sponge iron is used as feedstock and a recognized alternative to steel scraps in iron and steel making processes. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Sponge iron is a better substitute of steel scrap for steelmaking through the eafif routes. 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. 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. This gave an overview of the environmental aspects and highlighted the main environmentally related issues involved in the process of producing liquid steel from iron ore by the direct reduction route. It is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when air pollution is a concern. Sponge iron definition of sponge iron by merriamwebster.
In the year 1908 use of tunnel kiln started for iron oxide reduction. Reduced iron powder sponge iron powder metal powder. Orgwhat is a adobe portable document format adobedownload. Capacity and production of sponge iron in india has grown at a frenetic pace in the last half decade.
The latter process is based on atomization of a stream of liquid. Most of these have died down but some of them have reemerged in slightly different form. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. The fundamental sponge iron reaction principle could also be utilised with a number of different applications in space missions. We are offering sponge iron sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. The chips are contained in a vessel, and sour gas flows through the bed and reacts with the ferric oxide. Sponge iron production flow chart raw material feeding to kiln iron ore, coal, dolamite rotary kiln conversion of raw iron ore into sponge iron cooler sponge iron cooling below 100deg by external water cooling intermediate bin desired quality for blending screening in product house. Figure 73 shows a typical vessel for the iron sponge process. A series in which both limestone and coke were varied in the charge.
How many words can you make out of sponge word maker online. Aug 05, 2017 the iron sponge process uses the chemical reaction of ferric oxide with h2s to sweeten gas streams. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. 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. This type of iron can be produced in several different types of furnaces, including. Product capacity the plant commissioned by tata sponge was initially designed to facilitate a production capacity of 90,000 tpa, which was enhanced to 1,20,000 tpa. Adobe acrobat reader dc install for all versions read ebook online at mdeddirectory. S is 19th, p is 16th, o is 15th, n is 14th, g is 7th, e is 5th, letter of alphabet series. Iron sponge unit design procedures hydrocarbon compression. One of the major challenges for sponge iron plant is the accretion formation. We ensure no fines, no lumpiness and conform to all safety standards of industries producing dri sponge iron.
It can be seen from table 1 above that while production of crude steel in the if units registered an average annual growth of 11. Sponge iron article about sponge iron by the free dictionary. Dec 19, 2017 india is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Pdf production of sponge iron powder by reduction of. 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. It is widely distributed, combined with oxygen as iron oxides.
This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. Because each batch, called an ingot, can weigh as much as 12000 pounds, the melted titanium is allowed to harden and solidify in the furnace rather. Spongeironproductioninrotarytn786312020 adobe acrobat. Cut the screen material so that it is smaller than the bottom of the pan. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. In 1954, more kilns came in operation in sweden and usa. Surface regolith with a high iron content being widely available on moon and mars provides a feasible resource for the process contact. The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge.
Shellair tube used in sponge iron kilnsatswirllerrotary kilnwhrbespsiddri plant sponge iron duration. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. Presently it is more popular in china for sponge iron production from beneficiated iron ore fines cakes. Mar 09, 2017 ralf coal injector used in sponge iron division kiln12tph ton per hourrotary air lock feeder kiln duration. The iron sponge process uses the chemical reaction of ferric oxide with h2s to sweeten gas streams. The value of dri is measured by comparing its cost and properties. More than 100 dr processes have been invented and operated since 1920. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. Coke is a grey, hard, and porous fuel with a high carbon content and few impurities, made by heating coal or oil in the absence of aira destructive distillation process. If you continue browsing the site, you agree to the use of cookies on this website. Hydrogen sulfide removal from biogas by biobased iron sponge. Coal based spongeiron is a metallic product produced through direct reduction of iron ore in the solid state.
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