make sponge iron from coal and iron ore process

Our Process | UMCIL

The mining of the Sanje Hill iron ore initially through the mountaintop mining and then open pit mining for the sub-surface deposit. The SL/RN coal-based direct reduction process for the conversion of iron oxide ore with coal around 1000 degrees …

Sponge Iron

Sponge iron is a highly processed form of iron ore that contains metallic iron in the range of 83-88% obtained by direct reduction through reaction with carbon in the form of coal at approx. 1100 degree Celsius. Due to high porosity, the resulting iron is called sponge iron. Sponge iron is also referred to as direct reduced iron or metalized iron.

The Steel Making Industry

The HISmelt process, named after the HISmelt Corporation of Australia, is another cokeless iron melting process being tested. In this process, ore fines and coal are manipulated to melt iron ore. In 1993, the process could produce eight tons of iron ore per hour using ore directly in the smelter.

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

2015-9-1 · 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 industries.

Energy Audit Methodology of Sponge Iron …

2014-7-14 · Most 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 (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary

SPONGE IRON PLANT

2018-9-24 · The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production can be classified into:-

Coal Base DRI Operation: Process Description and flow diagram of Coal …

 · Most 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 mix-iron 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 end.

Sponge Iron | Vandana Global

Sponge iron is formed through the reduction of iron ore to metallic iron through reaction with carbon in the form of coal, etc. at approx. 1100 degree Celsius. Over the years, the shortage of expensive melting scrap has made sponge iron a significant raw …

SPONGE IRON PLANT

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN

SPONGE IRON – Lloyd''s Metals

Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a ''select'' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished ...

IKEA Hong Kong

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Sponge iron from magnetite

2021-10-13 · Sponge iron from magnetite - A novel process developed in India. New Delhi [India], October 12 (ANI/PNN): With India eyeing record steel exports in FY22, the Indian steel industry is quickly becoming hot property. Along with it Sponge Iron, one of the essential raw materials used in steel productions, is bound to have a growing domestic demand.

Sponge Iron

Sponge iron, also known as direct reduced iron, is produced from the direct reduction of iron ore. The level of metallization shows the quality of sponge iron. Sree Metaliks Limited is one of the leading sponge iron manufacturers in India, built on a strong foundation of a dedicated and experienced team of experts and professionals.

Sponge iron from magnetite

2021-10-12 · Using only 10-15 per cent coal against an equal Proportion of Iron ore and Coal. Complete smokeless operation. Eco-friendly Process. The highest degree of Iron recovery. The minimum cost of ...

US5238487A

A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt. The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace.

SPONGE-IRON

Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & physical characteristics.

The Making of Iron & Steel

2020-8-3 · The BOS process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal (and scrap is used for temperature control). The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process, the EAF requires

Sponge iron Manufacturing process

2021-12-31 · Sponge iron is a metal product that is produced by a direct reduction of iron ore in solid-state. Sponge iron is a good alternative to waste and is mainly used in the manufacture of steel via secondary routes. The process of making sponge iron occurs by …

Sponge Iron | Manufacturer of Sponge Iron

Sponge iron is formed through the reduction of iron ore to metallic iron through reaction with carbon in the form of coal, etc. at approx. 1100 degree Celsius. Sponge iron is also referred to as direct reduced iron, metalized iron, or hot briquetted iron.

Iron ore | BHP

With 5 mines, 4 processing hubs and 2 port facilities, our Pilbara iron ore business is all connected by more than 1,000 kilometres of rail infrastructure. At each mining hub ore from the mines is crushed, beneficiated (where necessary) and blended to create high-grade hematite lump and fines products.

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

2012-6-1 · 1. Introduction. Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535 °C) by utilizing hydrocarbon gases or carbonaceous fuels as coal.The reduced product having high degree of metallization exhibits a ''honeycomb structure'', due to which it is named as sponge iron.

SPONGE IRON INDUSTRY

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. It is not possible to ascertain the exact

US5238487A

A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt. The gas ...

Difference Between Sponge Iron and Pig Iron | Compare the Difference Between Similar Terms

 · Sponge iron is a form of iron that we can produce directly from iron ore through a reduction process whereas pig iron is a form of iron that we can produce by melting iron ore along with charcoal and limestone under very high pressure. Hence, the key difference between sponge iron and pig iron is that we can produce sponge iron by direct ...

Difference Between Iron Ore and Iron | Compare the Difference Between Similar Terms

 · Iron ores make up nearly 5% of the earth''s crust, and when we consider both the crust as well as inner core, iron and its ores make up about 35% of the mass of the earth. Iron is extracted from its ore through removal of oxygen, which is a process called its reduction.

Development of energy conservations scenarios for sponge iron industry using process integration …

 · In sponge iron process variation in temperature of iron ore, coal, dolomite, sponge iron, and waste gas is in the range from 1,020 C to 30 C. Though specific heats of these materials vary considerably with change in temperature, in the present work these variations are taken as negligible.

Ironmaking in Rotary Hearth Furnace – IspatGuru

2017-5-17 · The Comet process, developed by the Centre de Recherches Metallurgiques (CRM), Belgium is a coal-based system that produces sponge iron from ore fines and limestone in a rotary hearth furnace. The Comet direct reduction process produces low gangue and low sulphur DRI from iron ore and coal fines.

Sponge iron production process and plant

1997-5-30 · A process for producing sponge iron from particulate iron-oxide-containing material, wherein the iron-oxide-containing material in a reduction zone is reduced to a sponge iron by a means of reducing gas and the gas forming during reduction is withdrawn as top gas, said process comprising: ... such as coal, ore, ...

The Direct Reduction of Iron Ore

The iron ore from which iron and steel are made is an oxide, that is, a chemi­ cal compound of iron (Fe) and oxy­ gen (0). Common forms of ore are hematite (Fe20a) and magnetite (Fea04)'' For the ore to be made into iron the oxygen atoms must be separated from the iron atoms by the process known as reduction. The separation

OPERATIONAL ASPECTS OF SPONGE IRON …

2012-1-10 · 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 ...

Direct reduced iron

Process Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to remove the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.), in order to convert the ore to metallic iron, without melting it (below 1,200 C (2,190 F)).

sponge iron process: 2010

 · Mean Particle Size: In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.

Development of energy conservations scenarios for …

2011-1-16 · In sponge iron process variation in temperature of iron ore, coal, dolomite, sponge iron, and waste gas is in the range from 1,020°C to 30°C. Though specific heats of these materials vary considerably with change in temperature, in the present work these variations are taken as negligible.

Al Buraq Steel Industry L.L.C

Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. It is a substitute for scrap and is mainly used in making steel through the secondary route. The process of sponge iron making aims to remove the oxygen from iron ore. The quality of sponge iron is primarily ascertained by the percentage of ...

SPONGE IRON – Lloyd''s Metals

Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a ''select'' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the

Tata Sponge Iron Limited, Keonjhar

The process of sponge iron manufacturing involves removal of oxygen from iron ore. When that happens, the departing oxygen causes micro pores in the ore body, turning it porous. When the eventual product is observed under a microscope, it resembles a honeycomb structure, which looks spongy in texture.

Vale restarts licensing process for Apolo iron ore project

 · Stock image. Brazilian miner Vale has restarted the process of acquiring environmental licenses for its Apolo iron ore project in the state of Minas Gerais following a major revision of the ...

Sponge Iron from Magnetite

2021-9-10 · Sponge iron produced by this process employed a coal fired Rotary Kiln with the input charge consisting of equal quantities of iron ore and coal. WATCH | Click on Zee Business Live TV Streaming Below:

MGM

The basic raw materials for the production of sponge iron are iron ore, non coking coal and dolomite. Iron Ore: Iron ore is the source of iron and available in oxide form namely hematite(Fe2O3). As only oxygen can be removed from the iron ore during the process of making sponge iron iron,ores rich in iron content of 65percent and above is ...

Energy integration of sponge iron production process

2012-10-19 · The residence time of iron ore inside the kiln is about 10 hours. During this time iron ore is reduced optimally. Hot sponge iron along with semi burnt coal exits the kiln at the discharge end. The product stream at 1000ºC consists of Fe (4.513 tph), Char (0.601 tph) and Ash (2.40 tph). This discharged material enters the rotary cooler where ...

How is Iron Refined from Ore? (with pictures)

To purify and strengthen iron, materials like coke are mixed in with it to remove oxygen. To coax the oxygen atoms away from the ore requires heat and an alternate atomic partner for the oxygen to bond to.Carbon fills this role nicely, and is readily available in the form of everyday charcoal, or coke, a form of carbon made from coal.