WEBSep 13, 2023 · This makes decarbonizing iron and steel sector difficult until the coal or fossil fuels can be replaced. The other way to manufacture iron is the direct reduced iron (DRI) or sponge iron method. In this, iron is extracted using reducing agents like coal or gas, and steel is produced thereafter through an electric arc or induction furnace.
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WEBNov 10, 2023 · During the last four decades, a new route of ironmaking has rapidly developed for Direct Reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as ...
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WEBDec 1, 2023 · Usually, Iron Ore is manufactured and converted into Pellets. These are oval lumps of iron ore that are hardened using fuel. This process of converting iron ore into pellets is known as Pelletization. Iron Ore Pellets are then used in the production of steel. Pellets are usually preferred instead of raw Iron Ore because it allows for maximum ...
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WEBApr 26, 2023 · Raw 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 tonnes of solid wastes [2, 5].This implies that for every 10 tonnes of sponge iron produced, almost 2 tonnes of solid wastes are .
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WEBJan 1, 2014 · Coalbased sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coalbased sponge iron plants use mostly thermal ...
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WEBMay 27, 2022 · The H 2 molecules react with the iron ore (iron oxide) directly in its solid state, converting it into Direct Reduced Iron (DRI), or 'sponge iron' (almost pure iron). Instead of climatedamaging CO 2, this generates harmless water, which is then further used in the integrated process.
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WEBIn the years to come, India's expanding steel production will be largely driven by sponge iron. Sponge iron, also known as direct reduced iron(DRI), is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. Sponge iron gives a cheaper way of producing steel which has a .
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WEBDec 1, 2018 · Iron 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.
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WEBApr 1, 2021 · Direct reduction (DR) processes produce different types of reduced solid iron, such as sponge iron (DRI) or hot briquetted iron (HBI). ... The remaining 18 % of direct reduced iron is produced through coalbased reducing agents in rotary kilns ... The DRI is converted into liquid steel in an EAF operating at 1650 °C with efficiency of 60 % ...
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WEBMar 12, 2024 · About sponge iron. 1. About: i) It is made from directly changing iron ore (in any form whatsoever) to iron by a cutback gas or carbon, produced from natural gas or coal. Sponge iron is also called direct reduced iron (DRI). ii) Direct reduction processes can be divided roughly into two egories: gasbased, and coalbased.
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WEBOct 9, 2023 · The chemical composition of direct reduction iron requires that the metallization ratio be 92–96%, FeO content 3–15%, gangue content 1–4%, phosphorus content less than %, sulfur content less than %, and content of each of the nonferrous metal impurities Cr, Ni, Cu, and Pb less than %. Other indiors, .
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WEBIt is Coal Fuel based DRI. Coal based Spongeiron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron (DRI). Iron Ore Pellet is used for reduction. After reduction of iron ore pellet the product resembles sponge because of pores left behind after removal of oxygen.
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WEBDirectreduced iron (DRI), also called sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. Unlike the conventional process, the process does not require coking coal; the coke ovens in a steel plant are expensive and polluting units. Direct ...
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WEBJun 22, 2022 · Directreduced iron and its more transportable sister hotbriquetted iron have dallied in the wings of mainstream steelmaking as highquality and lowresidue furnace inputs for nearly 60 years. Suddenly the two have swept center stage for holding the key to steel decarbonization.
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WEBSep 1, 2020 · 1. Introduction. According to the Ministry of Steel Policy 2017 declared by the Indian government, the requirement of lowgrade iron ore is about 800 million tons for the production of 300 million tons of steel by 2030 [1].To meet this targeted steel demand, shifting the focus towards the utilization of banded iron ore such as banded hematite .
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WEBNov 1, 2012 · A typical sponge iron industry (using DRI methodology) with 100 t per day capacity produces 25 t per day dolochar, thereby generating 9000 t waste material per annum [1, 2]. A negligible portion ...
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WEBDec 1, 2015 · The iron also can be produced from its ore by the direct reduction of iron ore by a reducing agent which is coal based or may be a gaseous reducing agent, which is called direct reduced iron (DRI) or sponge iron. DRI is a good substitute of scrap for making steel in electric arc furnace, basic oxygen furnace, etc. and there has been a .
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WEBIt contains abundant iron, such as Fe 2 O 3 and Fe 3 O 4, and nonferrous metals, such as zinc, lead and copper. In order to try and recycle this material as a source of Fe units, preparation of direct reduction iron (DRI) using pyrite cinder was investigated by coalbased grate rotary kiln process. This process includes chloridizing and ...
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WEBSponge iron produced using the non coking coal is called coal based sponge iron / DRI. For producing the sponge iron through this process requires high grade of iron ore and non coking coal. ... In this process route, iron oxides are converted to the DRI / HBI by using natural gas in a vertical shaft furnace. For steel producers, it is a ...
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WEBJul 16, 2023 · A sponge iron plant, also known as a directreduced iron (DRI) plant, is a facility where iron ore is converted into a metallic iron product known as sponge iron. This process is called direct reduction because it does not involve the use of coke or coal, which are typically used in traditional ironmaking processes such as blast furnaces.
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WEBSep 23, 2011 · The document discusses the production of direct reduced iron (DRI) using a rotary hearth furnace (RHF). DRI is produced by reducing iron ore to a purity of 9097% iron through a process using reducing gases like hydrogen and carbon monoxide at high temperatures below iron's melting point. In an RHF, iron ore and carbon pellets are .
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WEBMar 16, 2020 · What is sponge iron. Sponge iron, also name as direct reduced iron (DRI), is the resulting product (with a metallization degree greater than 82 percent) of solid state reduction of iron ores or agglomerates (generally of high grade), the principal constituents of which are Metallic iron, residual iron oxides carbon' and impurities such as .
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WEBNov 1, 2012 · Raw 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 ...
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WEBMay 13, 2022 · For that reason, experts see it as a bridging technology towards the direct reduction of primary steel, in which only hydrogen is used instead of coal or coke. In this process, iron ore is first reduced using hydrogen. The H 2 molecules react with the iron ore (iron oxide) directly in its solid state, converting it into Direct Reduced Iron (DRI ...
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WEBSep 8, 2020 · Benefits of sponge iron –. The content of sulfur in sponge iron is less. The direct reduced iron method can use poor quality coal that is unsuitable for ordinary iron production. Sponge Iron is a substitute for steel scrap for the manufacturing of steel through the EAF/IF courses. Sponge Iron acts as a superior feedstock for the electric ...
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WEBDec 1, 2007 · Complete conversion of the iron oxide in the heated reactor ... (as iron ore) is commonplace, that of sponge iron ('DRI' from metal works) requires some precaution. Due to the presence of fine metal particles and the great porosity of the material, there is a possibility that spontaneous oxidation with air could create a selfsustaining ...
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WEBCoal is a combustible black or brownishblack sedimentary rock, formed as rock strata called coal is mostly carbon with variable amounts of other elements, chiefly hydrogen, sulfur, oxygen, and nitrogen. Coal is a type of fossil fuel, formed when dead plant matter decays into peat which is converted into coal by the heat and pressure of deep .
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WEBThe production volume of coalbased sponge iron in India accounted for more than million metric tons at the end of 2022. It reflected an increase from the previous year's more than ...
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WEBNov 5, 2022 · The theoretical formula used by operators for conversion of Fe (T) from Fe (M) is. Derivation of the formula: Let us assume the ore having a having a Fe of %. Fe 2 O 3 % in the ore is. (The molar ratio of Fe 2 O 3 to Fe is, as the molecular weight of Fe 2 O 3, and Fe are and respectfully. The molar ratio is.
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WEBJun 21, 2021 · As POWER has reported, test operations to make hydrogenreduced sponge iron in the Lulea pilot plant began in August last year. They wrapped up on March 24. The process involved producing hydrogen ...
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WEBJan 1, 2010 · using iron ore fines and noncoking coal in a rotary kiln. Tata Sponge Iron Limited (TSIL) operates three large. industrial rotary kilns for producing DRI through the. TISCO direct reduction (TDR ...
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WEBNov 15, 2022 · Sponge iron is produced by reducing iron ore pellets in a directreduction process, whereas pig iron is produced by melting iron ore with a highcarbon fuel in a blast furnace.
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WEBThe name of the product is due to its form of porous spherical (pellet) with a spongelike appearance. Sponge Iron has a high grade of iron, which is more used today due to the shortage of iron scrap and its high price and its making environmental problems. Sponge iron grade: The grade and amount of iron in sponge iron is between 84% to 95%.
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WEBDec 1, 2000 · DirectReduction Iron (DRI) technology makes it possible to assess lowgrade iron ores and convert them into scrap at facilities that have electric arc furnaces. The reductant used was coke with ...
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