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Sponge Iron Process Animation

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India

The production volume of coal based sponge iron in India accounted for more than 24 million metric tons at the end of fiscal year 2018 This production volume was estimated to reach 26 million metric tons by fiscal year 2019 India was the world's second largest steel producing nation in the year 2018

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AN INVESTIGATION FOR GENERATION OF ENERGY

2 COAL BASED SPONGE IRON PLANT A CONVENTIONAL PROCESS The process flow diagram of conventional coal based sponge iron plant is shown in figure 1 The operating data shown in figure 1 is taken from a typical Indian coal based sponge iron plant where iron ore feed coal and dolomite are fed to the rotary kiln

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sponge iron pptx

The substitution of scrap by sponge iron has some limitations depending on the furnace operating conditions Only 20% to 30% of sponge iron can be used in the furnace charge when feeding is done in batches The proportion of sponge iron in the charge can however be increased to 40-50% by providing continuous feeding arrangements

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sponge iron process 2011

During the process of manufacture of sponge iron coal injection plays a very vital role in maintaining the product quality Due to highly endothermic nature of Boudouard reaction heat has to be continuously supplied in entire reduction zone of rotary kiln Generally the length of

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Profitability analysis of power generation using waste

These studies utilized the waste heat available in sponge iron process for producing power However the authors did not check whether power generation using waste heat is profitable or not The present paper focuses on this aspect of heat recovery through detailed profitability analysis 2 Sponge iron process

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What process causes the mass of a drying sponge to

A sponge gets its oxygen from the water The oxygen moves from the water to the sponge by a process called diffusion Diffusion is when molecules of a substance move from an area where they are highly concentrated (where there are a lot of oxygen molecules) to an area where they are less concentrated (where there are not a lot of oxygen molecules)

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Melting behaviour of sponge iron in

Two varieties of sponge iron were melted in an induction furnace to investigate (i) isothermal dissolution behaviour of single particle in basic and acid slags and (ii) the isothermal melting rate with different amounts of additions of sponge iron Sponge iron used in these experiments was produced from two different processes

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Biochar in the Hgans sponge iron process

Hgans Sponge Iron process is one of the major production processes used for iron powders Here a solid-state reduction of iron ore concentrate with a mixture of coke anthracite and limestone is used to produce sponge iron units that are processed further to saleable iron powder products

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prcess critical parameters for sponge iron kiln

Mining News prcess critical parameters for sponge iron kiln Print prcess critical parameters for sponge iron kiln Posted at December 12 2012[ 4 6 - 3180 Ratings] sponge iron process During the process of manufacture of sponge iron

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Bessemer process

The basic process the Thomas-Gilchrist process remained in use longer especially in Continental Europe where iron ores were of high phosphorus content and the open-hearth process was not able to remove all phosphorus almost all inexpensive construction steel in Germany was produced with this method in the 1950s and 1960s

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Sponge Iron – Prakash Industries Limited

Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it Due to high porosity the resulting iron is called sponge iron It is used as a raw material for manufacturing steel

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tunnel kiln process

Sponge iron production in tunnel kiln – Aramico Company Sponge iron production in tunnel kiln Introduction Sponge iron production by tunnel kiln method was developed from 1911 as Hgans method in Sweden After many modifications now this process is a sufficient and effective method for sponge iron production

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How sponge is made

Sponge manufacturing produces no harmful byproducts and little waste Sponge material that is lost in trimming such as when an uneven end is cut off the large block is ground up and recycled It can be thrown in the mixer at the beginning of the process and become part of a new sponge

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iron ore silicon carbide dri process

What is claimed is 1 A process for making iron sponge from iron ores containing at least 95% by weight of iron oxide comprising pulverizing the iron ore to extremely fine grain size mixing the pulverized iron ore with fine-grained silicon carbide pelletizing the so obtained mixture and subjecting the same to direct reduction

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MIDREX Processes

1 Characteristics of reduced iron The MIDREX process produces direct reduced iron (hereinafter referred to as DRI ) The process reduces iron ore using a reforming gas made from natural gas The DRI is used mainly as the raw material for electric arc furnaces (EAFs) as a clean iron source substitute for scrap iron

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Sponge iron's dirty growth

In the years to come India's expanding steel production will be largely driven by sponge iron But its manufacturing process based on coal is () In the years to come India's expanding steel production will be largely driven by sponge iron L'quipe d'animation

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Plant Details

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 preferred We source iron ore from our group company from Barbil mineral rich area of Odisha state

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ORISSA SPONGE IRON AND STEEL LTD

Coal acts as the reductant to romove oxygen from iron ore The process of reduction causes micro pores in the ore body turning it porous Directly reduced iron looks like sponge in texture due to pores and hence is called sponge iron Iron Ore after due reduction inside the kiln is discharged to a rotary cooler of 3 5 mtr

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Development of energy conservations scenarios for

When unutilized energy of the process is properly integrated energy demand from outside sources can be reduced It decreases coal consumption as coal is the only source of energy in this plant For energy integration in sponge iron process pinch technology is applied on the actual data of plant

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Iron

Iron - Manufacturing process related to the specified manufacture(s) December 2013 update addition of new processes description and some modifications Related manufacture(s) Description of manufacturing process M-1 Iron Powders (Iron Powder made by sponge iron process atomization processes (gas and water) and electrolysis)

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Simulation of Rotary Kiln Used in Sponge Iron Process

Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN Anil K Poonia and Shabina Khanam Abstract—In the present study estimation of actual output parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A

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

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Sponge Iron Plants

The company has the world's largest coal-based sponge iron manufacturing facility at Raigarh The plant uses direct reduced iron (DRI) process method of production and utilises ten indigenously developed rotary kilns (6 kilns of 300 tonnes per day and 4 kilns of 500 tonnes per day)

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Seriously creative digital learning

At Sponge we do this in a seriously creative way We work with global brands to challenge the norm push the boundaries of creativity and bring learning to life By delivering custom elearning that motivates inspires and that people love to do you can solve even your biggest challenges through your people and deliver the results your business needs to see

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ENERGY INTEGRATION IN SPONGE IRON PLANT USING

Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively Presently there are 118 large and small sponge iron plants in India- 115 of them are coal based while only 3 are natural gas based The advantages of sponge iron are

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The HBI direct reduction process

The direct reduction process HBI is the product of reducing iron ore with natural gas This is called the direct reduction process and is an environmentally-friendly production process a DRI plant uses natural gas which is more environmentally sound than coke

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Iron processing

18-10-2019Iron processing use of a smelting process to turn the ore into a form from which products can be fashioned Included in this article also is a discussion of the mining of iron and of its preparation for smelting Iron (Fe) is a relatively dense metal with a silvery white appearance and distinctive

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SulfaTreat Process

It uses a patented proprietary mixture of ferric oxide and triferric oxide to react with H2O to sweeten gas streams In SulfaTreat process the iron oxides are supported on the surface of an inert inorganic substrate forming a granular material while in the iron sponge process the

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Flow of materials in rotary kilns used for sponge iron

Abstract The present work identifies the basic features of burden movement in a rotary kiln The cold model study was conducted with iron ore as the feed material to determine the influence of length to diameter ratio (L/D) of a rotary kiln on the filling degree hold-up and residence time of the charge

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tunnel kiln process for sponge iron making

Get Price tunnel process of sponge iron making in Process Get Price process making sponge iron rotary kiln animation Tunnel Kiln Process For Sponge Iron Making Rotary Kiln Tunnel Kiln Process For Sponge Iron Making Rotary kiln is the key equipment in Tunnel Kiln Process For

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Process analytics in the Iron and Steel Industry

Process analytics in the Iron and Steel Industry Steel is and will remain the most important engineering and construction material in the modern world With an actual steel production of over 100 million tons per month the global iron and steel industry is a very dynamic industrial sector

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Sponge Iron (DRI)

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 It is Coal Fuel based DRI Coal based Sponge-iron 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

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Energy Audit Methodology of Sponge Iron Manufacturing

2 Description of Sponge Iron Manufacturing Process 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

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