material balance of gas based sponge iron

material balance of gas based sponge iron

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

2015-9-1 · A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency. The required data are obtained by measurements or taken from production industries. The process efficiency is about 51.31%. The energy balances of the process show that ...

Mass balance around main components of the plant on

During the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and significant part of this heat, associated with the waste gas, remains unutilized.

Energy integration of sponge iron production process

2012-10-19 · Keywords- Sponge iron plant, Heat integration, Material and Energy balance I. INTRODUCTION Sponge iron is a metallic mass with honeycomb structure. It is a form of iron produced from direction reduction of iron oxide below the fusion temperature of iron ore (1535ºC) by utilizing hydrocarbon gases or carbonaceous fuels as coal.

SPONGE IRON PLANT

2018-9-24 · Raw material system mainly consist Vibro Feeder, Crusher and Screen. Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of

Sponge Iron - an overview | ScienceDirect Topics

Unlike the iron sponge process, the SulfaTreat material is non-pyrophoric and has a higher capacity than iron sponge on a volumetric or mass basis. In the process, the inlet gas stream enters the unit through a small inlet separator to separate out any entrained liquid, salt water, and any liquid hydrocarbon in

(PDF) Energy survey of the coal based sponge iron industry

2015-4-20 · A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

2011-5-13 · (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.

Energy Audit Methodology of Sponge Iron Manufacturing ...

2014-10-14 · Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.

Synthesis of Spongy Iron Powder from Maghemite in

2016-11-29 · Sponge iron, also called direct reduced iron (DRI), is used as an alternative charge material to scrap for high quality steel production. It is produced by direct reduction of its oxides below the melting point of iron using reducing gases produced from coal or natural gas. The natural gas based process called MIDREX NGTM process is the most widely

Direct Reduced Iron (DRI) Production Plant

2021-2-17 · and coal gas refined in coal gasifiers, as well as widely-used natural gas, may be used as reducing gases. u NSENGI, Tenova-HYL and Danieli concluded a strategic alliance agreement for the joint development of DRI steel production plant and expansion of the market of DRI in September 2013. Direct Reduced Iron (DRI) Production Plant

SPONGE IRON PLANT

2018-9-24 · Raw material system mainly consist Vibro Feeder, Crusher and Screen. Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of

ENERGY INTEGRATION IN SPONGE IRON PLANT USING

2012-5-12 · 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:

Heat and Mass Transfer in Reduction Zone of Sponge Iron ...

Numerical prediction is performed on reduction zone of iron ore reactor which is a part of counter current gas-solid reactor for producing sponge iron. The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation.

Steam Reforming of Methane on Sponge Iron: Influence

Sponge iron or direct reduced iron (DRI) is produced by direct reduction processes. World production reached 87.1 million tons in 2017, and 82% of it is produced with gas-based technologies, mostly by Midrex and Energiron pro-cesses.1) Gas-based direct reduction processes are composed of a shaft furnace in which a mixture of heated reducing

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

2012-5-29 · 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

Biochar in the Höganäs sponge iron process – techno ...

2018-6-18 · natural gas, separating hydrogen gas from the syngas to replace current hydrogen produced from natural gas, and finally producing a biochar product, intended for utilization as a reducing agent in the sponge iron process (Pettersson et al. 2016). Experiments with utilizing biochar as a reducing agent for the sponge iron process have been

Development of energy conservations scenarios for

2011-1-16 · 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.

Synthesis of Spongy Iron Powder from Maghemite in

2016-11-29 · Sponge iron, also called direct reduced iron (DRI), is used as an alternative charge material to scrap for high quality steel production. It is produced by direct reduction of its oxides below the melting point of iron using reducing gases produced from coal or natural gas. The natural gas based process called MIDREX NGTM process is the most widely

Process for regenerating a reducing gas mixture from

EXAMPLE An example of the process of this invention is as follows: For a sponge iron production rate of 100,000 MT/y using oil as the reforming hydrocarbon, heat and material balance calculations indicate that %12,000 kW of arc heaters (946 kWh/MT Fe) and 0.515 kg oil/s (146 kg of oil/MT Fe) are required to reform a top gas initially containing ...

Pre-feasibility Report

2016-12-2 · Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill along with 27 MW capacity Captive Power Plant at Village Jemua, P.O. – Mejia, Dist. – Bankura, West Bengal Pre-feasibility Report Page-7 Table 2.0 : Material Balance chart for the proposed DRI plant INPUT QTY (T) OUTPUT QTY (T)

Steam Reforming of Methane on Sponge Iron: Influence

Sponge iron or direct reduced iron (DRI) is produced by direct reduction processes. World production reached 87.1 million tons in 2017, and 82% of it is produced with gas-based technologies, mostly by Midrex and Energiron pro-cesses.1) Gas-based direct reduction processes are composed of a shaft furnace in which a mixture of heated reducing

Biochar in the Höganäs sponge iron process – techno ...

2018-6-18 · natural gas, separating hydrogen gas from the syngas to replace current hydrogen produced from natural gas, and finally producing a biochar product, intended for utilization as a reducing agent in the sponge iron process (Pettersson et al. 2016). Experiments with utilizing biochar as a reducing agent for the sponge iron process have been

Iron and Steel - Bureau of Energy Efficiency

2017-9-8 · Iron ore 1.43 Kg Sponge iron 1 Kg. Coal 0.64 Kg. Char 0.064 Kg. Air 5.20 Kg. Flue Gas 6.20 kg. Total Input 7.270 Kg Total Output Heat Supplied = 2058-251 Kcal (Excess heat) In Heat balance of ideal kiln (100% coal used as reducing agent and no coal is

Synthesis of Spongy Iron Powder from Maghemite in

2016-11-29 · Sponge iron, also called direct reduced iron (DRI), is used as an alternative charge material to scrap for high quality steel production. It is produced by direct reduction of its oxides below the melting point of iron using reducing gases produced from coal or natural gas. The natural gas based process called MIDREX NGTM process is the most widely

Iron - Manufacturing process related to the specified ...

2014-1-14 · Sponge iron powder . The Höganäs process is a direct reduction method for production of sponge iron powder using magnetite ore (Fe3O4) and carbon as raw materials. The reduction process takes place in a gas fired tunnel kiln at around 1200°C for 60 hours producing a sponge iron cake that is crushed, milled and

Singhal Group of Industries

2019-8-11 · is manufacturing Coal-based Sponge Iron using 3 indigenously developed rotary kilns, with a capacity of 90000 TPA along with a Waste Heat Recovery Boiler (WHRB) with a generation capacity of 6 MW Power. The company has a coal based Power Plant of 6 MW and two Ferro Alloys Plant for production of Silico-manganese of 12 MVA i.e. 28500 TPA.

Iron & Steel Sector

2017-9-8 · Figure 9: Ex-Coal/Lignite/Oil/Gas based Thermal Power Plant Energy balance diagram 194 Figure 10: Ex-CCGT Energy balance diagram 195 Figure 11: Product Mix diagram 197 Figure 12: Ex-GtG Boundary boundary for Sponge Iron Sub-sector 198 Figure 13: Figure 14: Ex

Hydrogen Uses in Ironmaking - Energy

2018-8-28 · conversion of iron ore to iron. and re-heating Emissions varies based on how electricity is generated (e.g. coal or nuclear) BF-BOF route: 1,600 – 2,000 kg CO. 2 /ton HRC Limited potential to reduce further (mature technology) Capture / re-use if possible EAF (scrap) route : 500-600 kg CO. 2 /

ENVIRONMENTAL - ASPECTS OF THE DIRECT

2021-5-28 · liquid steel from iron ore by the direct reduction route. The report was examined at the meeting of experts and environmental management guidance for the direct reduction route to steel making was drafted (2). A period of two months was allowed for participants to submit additional material for inclusion in a revised

Chapter 3 Separation Processes (Unit operations)

2009-1-10 · 3.5.2. Absorption (or gas absorption) is the removal of a solute (component) from its gaseous mixture by means of a liquid which dissolves the solute gas. In most cases, the gas solute being absorbed is the less abundant component or has a very low content in the gas phase. Absorption is more commonly carried out in packed towers than in plate ...