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(3) Sponge Iron Process: As the name implies, the spongy iron is obtained by the reduction of lumpy iron ore or iron ore pellets from the oxide form into the metallic state. The iron content of the product so obtained varies from 90% to 94% and the balance represents the traces of gangue and residual iron .
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Jul 23, 2020· Malcolm Tatum Last Modified Date: July 23, 2020 . Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source.
Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as to prevent its re-oxidation.
Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. Spong ...
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 .
Jun 02, 2020· Malcolm Tatum Last Modified Date: July 23, 2020 . Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source.
Iron production by using the direct method has been promoted in order to produce iron effectively, low cost, and environmentally safe. The method was optimal requirements with respect to the feed materials especially iron ore, coal as well as a binder. In this study, the experiments were conducted on physical properties of iron ore briquette from Aceh (Indonesia) to analyze its suitability to ...
Dec 24, 2018· Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron .
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 ...
The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI).
Such coal based sponge iron making from iron ore, is popular both in India and China. However, in the world almost 80% of sponge iron is being produced by gas based DR process.
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. Hence the name sponge iron.
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 ...
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.
This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is 'directly reduced' in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces ...
Jul 29, 2010· IS 11092: 1991 Iron ore pellets for direct reduction process. IS 11093: 1991 Iron ore lumps for direct reduction process. IS 11284: 1985 Rotary tube test for iron bearing materials for the manufacture of sponge iron/direct reduced iron(DRI). IS 1285 : 1985 Various tests on raw materials to be used for coal based rotary kiln
Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) to iron by a reducing gas or elemental carbon produced from natural gas or coal.Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting ...
Such coal-based sponge iron making from iron ore is popular both in India and China. However, in the world, almost 80% of sponge iron is being produced by the gas-based DR process. Both the gas and coal based DRI technology are gaining importance due to comparatively less investment cost, flexibility in using raw materials like cheap iron ore ...
During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as ...
Now a days,sponge iron is a name in steel making process.There are different methods to manufacture sponge iron but in India largely coal based process are carried out.In this process ...
THE KRUPP SPONGE IRON PROCESS PRODUCTION AND UTILISATION OF METALLIZED MATERIALS DR. ING. GUNTHER MEYER Krupp Industrie—und Stahlbau, Essen DR. ING. UWE BONGERS Krupp Industrie—und Stahlbau, Essen Introduction a MEXT to ore, fuel is the most important factor governing the cost of producing primary iron. In the blast furnace process, coke with
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 .
Sponge iron produced using the non coking coal is called coal based sponge iron / DRI. For producing the sponge iron through this process requires high grade of iron ore and non coking coal. Gas Based DRI / HBI. In this process route iron oxides are converted to the DRI / HBI by using natural gas in a vertical shaft furnace. Get Price
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