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coal based sponge iron plant pdf

SPONGE IRON PLANT

The major quality requirements of coal for Sponge iron production are- 1) Non-coking characteristics 2) Low ash content 3) Low sulphur content 4) Good reactivity 5) High ash fusion temperature 6) Medium volatile matter 1). Non-coking character:- Non-coking coal is required in sponge iron

COAL BASED SPONGE IRON PLANT

Title: COAL BASED SPONGE IRON PLANT Author: bf Created Date: 11/9/2009 1:20:49 PM

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to ...

Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE

(DRI). Sponge iron is produced primarily both by using non-coking coal and natural gas as reductant and therefore classified as coal based and gas based process respectively. Due to a promising availability of coal, the coal based sponge iron plants share the major amount of its production.

SPONGE IRON INDUSTRY

West Bengal the average capacity of a sponge iron plant is 0.0731 MTPA20. In terms of numbers, medium scale plants account for 53 per cent of the total plants in India followed by small scale (34 per cent)(see Table 1.2: Number of coal based sponge iron plants). Large-scale plants account for only 13 per cent of the total.

EDITORIAL - Sponge Iron Manufacturer India

Then in 1983, Odisha Sponge Iron Limited set up India’s second coal based DRI plant. The third coal based DRI plant was set up by Tatas in 1985based on their own technology. To push up further growth, DRI industry was de-licensed in 1985 baring certain location restrictions much before the de-licensing and deregulation of Indian economy in 1991.

Direct Reduced Iron Industry in India — Problems and Prospects

objective of earning higher profits by sponge iron sales. PROBLEMS OF COAL BASED PLANTS About 75% of the sponge iron capacity in India is coal based. While setting up the plants, it has been assumed that iron ore and coal are available easily as India has the fourth largest reserves of iron ore and non-coking coal is available in plenty.

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge ...

A Thesis Submitted for Partial Fulfillment of the Degree ...

requirement of sponge iron production. Today India produce 13.9 million tons of sponge iron, out of which 4.2 million ton is gas based and remaining 9.7 million ton is coal based. India has a proven reserve of 410 million ton of high grade iron ore, another 440 million ton of high grade iron

(PDF) i) Direct Reduced Iron: Production

Mar 30, 2016 · decades, a new route of ironmakin g has rapidly developed for direct reduction (DR) of iron ore to. metallic iron by using noncoking coal/n atural gas. This product is known as direct reduced iron ...

COAL BASED SPONGE IRON PLANT

Title: COAL BASED SPONGE IRON PLANT Author: bf Created Date: 11/9/2009 1:20:49 PM

Health-related quality-of-life of coal-based sponge iron ...

Sep 04, 2014 · A cross-sectional study was conducted among coal-based sponge iron plant workers in Barjora block (Bankura district, West Bengal, India) as shown in figure 1. Participants who gave written informed consent to participate in the study were included, and those who were absent from work on the dates of the survey were excluded.

Direct Reduced Iron Industry in India — Problems and Prospects

objective of earning higher profits by sponge iron sales. PROBLEMS OF COAL BASED PLANTS About 75% of the sponge iron capacity in India is coal based. While setting up the plants, it has been assumed that iron ore and coal are available easily as India has the fourth largest reserves of iron ore and non-coking coal is available in plenty.

Sponge Iron Industry: An Analysis

based sponge iron plant in a single location in India. It is used mainly for internal consumption. Ispat industries also has a sponge iron making capacity of 1.6 million tonnes. Outlook: Sponge iron can be used along with normal coal in the electric arc furnace and

Sponge Iron Factories - Sanhati

Till date, as per official figures, about 7000 workers have been employed in 33 large coal­ based sponge iron units in West Bengal. Of these about 10% are hired against daily wage from nearby localities. Around Rs. 10­12 crores are required to produce 100 metric tons per day,

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION

1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge ...

Productivity Increment of Coal based Sponge Iron Plant ...

Objective: A typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal and air as well as increase the productivity of sponge iron by applying heat integration using simulation process.Methods: In the present work, utilized waste heat to preheat the feed coal and air, heat integration process using modified pinch approach is applied and to increase ...

Development of energy conservations scenarios for sponge ...

Jan 16, 2011 · Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coal-based sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.

(PDF) How Can Indian Railways Service the Steel Sector ...

There are two types of sponge iron making: gas based and coal based. While iron ore is the primary solid raw material for gas based sponge iron, iron ore, thermal coal and fluxes constitute the solid raw material for coal based sponge iron. The iron ore requirement for a gas based plant would be about 1.6 times the output.

SPONGE IRON – Lloyd's Metals

Sponge iron is also known as Direct Reduced Iron (DRI). Direct reduction, is an alternative route of iron making has been developed to overcome some of these difficulties of conventional blast furnaces. DRI is successfully manufactured through either gas or coal-based technology. Iron ore is reduced in solid state at 800-1050 c either by ...

Recovery and utilization of waste heat in a coal based ...

Jun 01, 2012 · Sponge iron is produced primarily both by using non-coking coal and natural gas as reductant and therefore classified as coal based and gas based process respectively. Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production [2] .

Sponge iron - Installation of coal based gasifier in ...

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ARTICLE How and why to value coal-based power plants in 2020

7 Coking coal is used in steel industry whereas non-coking coal is used in sponge iron industry. 8 Includes various pre-project activities based on coal to chemicals initiatives undertaken by the government. 9 Includes coking coal production and imports.

Respiratory health status and its predictors: a cross ...

Mar 20, 2015 · Thus, the sector depends mostly on coal-based sponge iron and nearly 80% of the total coal-based sponge iron plants are located in India. 1 About 60% of this production comes from small-scale industries in the unorganised sector with poor pollution control facilities. 1 During the past decade, these sponge iron plants have rapidly grown in the ...

MINISTRY OF STEEL, Direct Reduction GOVT. OF INDIA Plant ...

SAFETY GUIDELINES FOR IRON & STEEL SECTOR MINISTRY OF STEEL, Direct Reduction GOVT. OF INDIA Plant (Coal Based) Doc. No: SG/32 Rev no. : 00 Effective Date: -- 1. OBJECTIVE: The main function of making Sponge Iron in the Kiln is to convert Iron ore into sponge iron by using Iron ore, coal and dolomite / limestone. The Sponge Iron is processed

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are

Open Access Research Health-related quality-of-life of ...

Sponge iron or direct reduced iron (DRI) is a transitional material used in the production of steel. Either coal or natural gas is used in sponge iron production. In India, non-coking coal is easily available. Thus, the sector depends mostly on coal-based sponge iron and nearly 80% of the total coal-based sponge iron

Energy survey of the coal based sponge iron industry ...

Sep 01, 2015 · In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and dolomite, is fed to the rotary kiln (RK).A separate conveyor collects different size fractions of coal (Stream no. 5) for injection into the kiln with the help of pressurized air (Stream no. 4) from discharge end side.

DRI UPDATE - Sponge Iron Manufacturer India

MICRO INTEGRATED STEEL PLANT 4 Coal Crusher Iron Ore Crusher Sponge Iron (DRI) Kiln MET Coke Cold Briquette Mn Fines Briquette Fluxesi.e. Dolomite, Quartz, Lime stone, etc. Blast Furnace Induction Furnace WHR Boiler AFBC Boiler Power STEAM Generation DOLO-CHAR FLUE GAS POWER SPONGE IRON PIG IRON C C M Rolling Mill FINISHED Products Mill Scale ...

New Technologies for the Steel Industry

continuing improvement in coal-based direct reduction (DR) systems, including ... The term “sponge iron” ... SOURCE Institute for Iron and Steel Studies plant would have many of the indicated oper-ations; a nonintegrated plant would have only a few. A nonintegrated steel plant might have

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing ...

523-1 Designing of an Intelligent Fuzzy Logic System for Accretion Prevention in Sponge Iron SL/RN Rotary Kiln Based 100TPD Dri Process By Tawanda Mushiri and talon garikayi Industrial and Process Furnaces: Principles, Design and Operation

(PDF) How Can Indian Railways Service the Steel Sector ...

There are two types of sponge iron making: gas based and coal based. While iron ore is the primary solid raw material for gas based sponge iron, iron ore, thermal coal and fluxes constitute the solid raw material for coal based sponge iron. The iron ore requirement for a gas based plant would be about 1.6 times the output.

Sponge Iron Plant - Entrepreneur India

The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant. The sponge iron is also known as Direct Reduced ...

SPONGE IRON – Lloyd's Metals

Sponge iron is also known as Direct Reduced Iron (DRI). Direct reduction, is an alternative route of iron making has been developed to overcome some of these difficulties of conventional blast furnaces. DRI is successfully manufactured through either gas or coal-based technology. Iron ore is reduced in solid state at 800-1050 c either by ...

SPOTLIGHT - SAIMM

Theperformance ofIscor'sfour-kiln plant, whichwillbe the largest coal-based plant in the world producing sponge iron, will undoubtedly bewatched with great interest bysteelmakers throughout theworld. Thetechnical andeconomic reasons forIscor'sdecision toinstall the 100percentcoal-based rotary-kiln direct-reduction process aredescribed ...

Open Access Research Respiratory health status and its ...

Sponge iron or direct-reduced iron is a transi-tional material used in the production of steel. Either coal or natural gas is used in sponge iron production. In India, non-coking coal is easily available. Thus, the sector depends mostly on coal-based sponge iron and nearly 80% of the total coal-based sponge iron plants are located in India.1

Coal based Direct Reduction Rotary Kiln Process – IspatGuru

Feb 14, 2017 · The reduced product having high degree of metallization shows a ‘honeycomb structure’, due to which it is often called sponge iron. Coal based DRI plants are flexible with respect to plant location since non-coking coal is widely distributed in large deposits and is easy to transport.

Case History on “Repair of Kiln Shell” At Ankit Metals ...

The working of Ankit Metals & Power Limited which is primarily a Coal–based Sponge Iron plant is mentioned below: 1. This type of plant generally utilizes non coking coal as a reducing agent along with the lumpy rich grade Iron ore. 2. The reduction is carried out in an inclined horizontal rotary Kiln, which rotates at a predetermined