Atomized iron powder sponge iron powder figure 2 photographs of atomized and sponge iron powders there are two major chemical reduction methods used in the production of friction grade iron powders, one uses carbon monoxide and the other uses hydrogen as the reducing agent. India was the largest producer of sponge iron in the world during the period 20032015 and was the 2nd largest producer in 2016 after iran. This volume was projected to reduce to almost 28 million metric. An oversized pdf file can be hard to send through email and may not upload onto certain file managers. Pdf energy audit methodology of sponge iron manufacturing. Key suppliers iron ore is primarily supplied f rom australia and brazil. The trials yielded adequate data for designing a commercial prototype, or for industrial production of sponge iron. Iron and steel production and sponge iron production in india. With the domestic steel industry picking up during the past year and prices moving up in leaps and bounds, india has emerged as the worlds largest producer of sponge iron or direct reduced iron, accounting for around 16 per cent of the global output. The eaf steel production grew 8% in the period as compared to a double digit growth in the production of sponge iron. Capacity expansion of sponge iron plant from 60,000 to 1,20,000 tpa, upgradation of cpp. The sponge iron industry is forced to use coal with ash content over 40%, fc less than 33%. Tata sponge iron limited bileipada, atpo joda, keonjhar, orissa, india 758034 communication on progress 2010 2 cop 2010 message from the managing director we at tata sponge iron limited believe that the promise of good business lies in being good and the primary purpose of a business is to improve the quality of life of.
Identity as used on label and list iron sponge label note. A pdf file is a portable document format file, developed by adobe systems. Roles of iron metal powders in semimetallic friction materia. An overview of steel sector global scenario domestic. Once youve done it, youll be able to easily send the logos you create to clients, make them available for download, or attach them to emails in a fo. Accretion control in sponge iron production kiln using. After three to four months, the iron sponge is spent.
The sponge iron industry is concerned about the problem of pollution and global warming. Iron manufacturing process related to the specified. In sponge iron industry rotary kiln is the primary equipment, which is used to reduce iron ore to metallic iron i. Read on to find out just how to combine multiple pdf files on macos and windows 10. The reasons for the success of sponge iron industry in. April 2018 international iron metallics association.
Iron sponge basics november 2017 one of the oldest technologies for the removal of hydrogen sulfide h 2 s from gas is the use of iron sponge. India was the largest producer of sponge iron in the world in 2019. Nucor louisiana dri production has been constrained by plantequipment issues captive supply to own minimills iranian exports are growing. If your scanner saves files as pdf portbale document format files, the potential exists to merge the individual files into one doc. Strategy paper on resource efficiency in steel sector through. Making a pdf file of a logo is surprisingly easy and is essential for most web designers. Increase in the productivity of blast furnaces the productivity of a blast furnace increased with charging dri with large metallic iron content to it. Sponge iron making is a process in which iron ore lumps typically 5mm18mm 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. Schematic of rotary kiln for the present work data of a typical industry of 527 tday production capacity is collected for 25 days. India has a proven reserve of 410 million ton of high grade iron ore, another 440 million ton of high grade iron.
The sponge iron production increased by 20% on a yoy basis in 2014 as the noncoking coal supplies improved. If your pdf reader is displaying an error instead of opening a pdf file, chances are that the file is c. Leading states in sponge iron production are odisha, chhattisgarh, west bengal and jharkhand. I paid for a pro membership specifically to enable this feature.
It also contains traces of nonferrous metals, alkaline compounds and oils from the rolling process. The basic raw materials for the production of sponge iron are iron ore, noncoking coal and dolomite. India production volume of sponge iron 2020 statista. Fluidizedbed technology for the production of iron products for steelmaking co 2 removal system. The data of temperature t1 to t12, at1 to at3 and mf1 and. The coal based route accounted for 79% of total sponge iron production in the country in 201617 prov. The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of noncoking coal patra et al, 2005. 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. There is some evidence that the bloomery method was also used in china, but china had developed blast furnaces to obtain pig iron by 500 bce. Pdf operation of coalbased sponge iron rotary kiln to.
The application and benefits of sponge iron pk steel. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting. This article explains what pdfs are, how to open one, all the different ways. Mar 15, 2021 the production volume of sponge iron in india accounted for more than 34 million metric tons at the end of the fiscal year 2019. This is causing a concern for the sponge iron industry as well as environment. Nucor louisiana dri production has been constrained by plantequipment issues captive supply to own minimills iranian exports arewere growing. Flow sheet of the 2step process for hydrogen production from bio mass. Sponge iron manufacture is highly sensitive to raw material characteristics. Webinar cost reduction innovations in coal based sponge.
Iron ore is being fed to the ground hopper, from where it conveyed to the screen with the help of vibro feeder, where. Techno economic feasibility report of ms bravo sponge iron. The procedure of sponge iron making aims to expel the oxygen from iron ore. One of the fun things about computers is playing with programs like paint. The reduction process takes place in a gas fired tunnel kiln at around 1200c for 60 hours producing a sponge iron cake that is crushed, milled and. Iron sponge dry media of iron oxide on wood chips does best using warm wet gas with oxygen 4000 scfm treating 300 ppmv h2s. Sponge iron is the metallic form of iron and scarp substitute produced from reduction of iron oxide below the fusion temperature of iron ore 15350c by utilizing hydrocarbon gases or carbonaceous fuels as coal. The performance of rotary kiln significantly affects the production capacities of these industries. Recovery and utilization of waste heat in a coal based sponge. Depending on the type of scanner you have, you might only be able to scan one page of a document at a time. Pdf file or convert a pdf file to docx, jpg, or other file format.
Production of sponge iron powder by reduction of rolling. Steel, government of india for longterm objectives of improving production. Environmental control measures in sponge iron industry. Energy balance in a rotary kiln sponge based iron making. Siil was the first sponge iron plant in the country which was set up at paloncha in andhra pradesh in 1990 with an initial capacity of 0. A study is made of the reduction of mill scale to sponge iron using coke at different temperatures and times. Eaf plant has a direct reduction facility that produces sponge iron from iron ore, for conversion into steel in the eaf process. Potential pollution problems met with in sponge iron production based on direct reduction, compiled from data of the environmental protection agency in the usa unepwgl. If an item is not applicable also known as iron sponge, not spent or information unavailable, the space must be so marked. The first gas based sponge iron plant, with a capacity of 1. H 2s removal from gas manufacturers name emergency telephone number connellygpm, inc. You can use the tools in paint to add something to a different document.
Modeling of rotary kiln for sponge iron processing using cfd. Techno economic feasibility report of ms bravo sponge. However, the sponge iron prices increased marginally by 2% yoy owing to demandsupply mismatch. Decentralised hydrogen production by an integrated biomass. Recently, the interest in sponge iron as a hydrogen production process has grown again, although the technology still has some major technical and economic challenges to overcome milne. Noncoking coal having certain important parameters is being used for the direct reduction of iron ore. The hoganas process is a direct reduction method for production of sponge iron powder using magnetite ore fe3o4 and carbon as raw materials. India was the largest producer of sponge iron in the world. With the availability of raw materials, high demand of sponge iron and less payback period, sponge iron industry has emerged as a profitable venture. Biljetina and tarman, 1981 that was replaced by more efficient and economic processes. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines.
Production of titanium metal powder by the hdh process x goso. Transcript of sponge iron manufacturing process pdf fdocuments. This study focuses on sponge iron kiln based process. Iron products are preparations of iron taken either by mouth or given by injection, to correct iron deficiency in humans. To combine pdf files into a single pdf document is easier than it looks. Since coal was adequately available in india, production of coalbased sponge iron plants was considered as a feasible option. India has a proven reserve of 410 million ton of high grade iron ore, another 440 million ton of high grade iron ore which will be established. Purulia, west bengal project proponent ms bravo sponge iron pvt.
Pdf is a hugely popular format for documents simply because it is independent of the hardware or application used to create that file. Production of sponge iron powder by reduction of rolling mill. Producing sponge iron and then working it was the earliest method used to obtain iron in the middle east, egypt, and europe, where it remained in use until at least the 16th century. Iron ore is being fed to the ground hopper, from where it conveyed to the screen with the help of vibro feeder, where oversize i. Hot briquetted iron hbi production plant in india univac quality policy. Measures in sponge iron indust with particular reference to tata sponge iron limited fig. In 1954, more kilns came in operation in sweden and usa. Sponge iron manufacturing process pdf the major raw materials required for production of sponge iron by the rotary kiln. The performance of rotary kiln is affected by temperature profile.
The coal based route accounted for 82% of total sponge iron production 37. H2s treatment of landfill gas at the roosevelt landfill. Mini and others producers data is updated monthly, averaging 9,405. By michelle rae uy 24 january 2020 knowing how to combine pdf files isnt reserved. The reasons for the success of sponge iron industry in india. Sponge iron is used as feedstock and a recognized alternative to steel scraps in iron and steel making processes. The paint program can help you make new image files, but it cannot open document or pdf file. When 100 kg of dri is used for the production of 1 ton of molten iron, the production of molten iron increases by 10 15 %. Most electronic documents such as software manuals, hardware manuals and ebooks come in the pdf portable document format file format. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. The coal based route accounted for 79% of total sponge iron production 30. Pdf on jan 1, 2014, avijit choudhury published energy audit methodology of sponge iron manufacturing units using dri process find, read and cite all the. Due to boom in steel market during 20002005, there is mushroom growth of coal based sponge iron plants and integrated steel plants in iron and coal rich states like. Furthermore, over the past two decades the government has actively pursued policies aimed at fostering downstream activities, such as iron ore beneficiation, for the purpose of this case study, a historical overview of the the rsa iron and steel industry is given, beginning in 1910 and continuing to the present.
All raw materi als listed above, pig iron, ferro alloy, sponge iron, iron scrap, iron ore, and coal, are among best prospects for u. Therefore, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. A thesis submitted for partial fulfillment of the degree. The sponge iron is also known as direct reduced iron, hot briquettes iron or metalized iron. This means it can be viewed across multiple devices, regardless of the underlying operating system. In the year 1908 use of tunnel kiln started for iron oxide reduction. Luckily, there are lots of free and paid tools that can compress a pdf file in just a few easy steps. As shown in the flow diagram, the hdh process is used to convert the titanium sponge to titanium powder. It is a substitute for scrap and therefore is mostly applicable in making steel through the secondary route. Simulation of rotary kiln used in sponge iron process using ann. World sponge iron production million tonnes data source. The production of sponge iron depends on metallization of iron ore.
Besides, specific energy consumption is also reduced drastically as the requirement of energy for production of steel through primary and secondary routes is 14 mjkg and 11. Presently it is more popular in china for sponge iron production from beneficiated iron ore fines cakes. Simulation of rotary kiln used in sponge iron process. Project feasibility report for expansion project chapter 01 2 of p a g e 2 salient features of the project the company has acquired 78. The reformer sponge iron cycle resc, an innovative process combining a sponge iron reactor with a hydrocarbon reformer and a partial offgas feedback loop, was investigated as means of providing an onsite hydrogen production capacity from a feedstock of hydrocarbons produced with isru technology. Jan 21, 2019 sponge iron is a metallic product produced through the direct reduction of iron ore in the strong state. A thesis submitted for partial fulfillment of the degree award of. The sponge iron in the country is produced through two routes, one is gasbased using iron ore pellets and other is coalbased using highgrade iron ore lumps.
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