The process of sponge iron making aims to remove the oxygen from iron ore. Sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. For this purpose a case study of typical sponge iron production process is considered. Find here information of sponge iron plant selling companies for your buy requirements. Armed with strength to go global, incorporated reaffirmed focus to develop and produce best quality of product with inventive approach open for flexible solution sowing the seed of multiple yields. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Oct 31, 2017 list of oil refineries and steel plants industries in india pdf general awareness for banking and other competitive exams like rrb, cds, lic ao, rbi, ssc, upsc, fci, uiic, oicl, sbi clerks and po requires knowledge on many different subjects, one such subject is oil refineries and steel plants industries in india.
It is widely distributed, combined with oxygen as iron oxides. Heat and mass transfer in reduction zone of sponge iron reactor. Tslpl is a pioneer in india for using hot metal in electric arc furnace, which later became an industry norm. Sponge iron industry needs quick actions for survival the. They are single largest dominant player in terms of market share of the sponge iron producers. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. This is mainly due to variation in capacity, raw material composition, and vintage of the plant. Jspl is a leading player in steel, power, mining, oil and gas and infrastructure in india. Sponge iron or direct reduced iron is produced by reducing iron. Four different applications of the sponge iron reaction have been considered within this initial study. Sponge iron production by direct reduction of iron oxide. Raw material preparation plant direct reduction plant raw material preparation plant the basic raw materials for the production of sponge iron are iron ore, non coking coal and dolomite. Brochure hbi hot briquettin g of direct reduced iron.
Jspl has acquired the development rights for 20 billion tonnes of ei mutun iron ore reserves in bolivia, south america. Sponge iron plants cerana foundation, oct 2006 2 contents sections 1. Gas consumption for each unit of sponge iron production in direct reduction process in kilo calories over ton. The company have operations in iron, steel, mining, energy and infrastructure. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting.
Iron ore the quality requirement of sized ore for sponge iron production can be classified into. Human health effects of sponge iron plant pollutants 8 5. Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near future. Pdf energy survey of the coal based sponge iron industry. Direct reduction of ferrous oxides to form an ironrich alternative.
Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. Sponge iron produced by this plant is of high grade which contains 80% fe, 12% feo and 8% gangue material. Directly reduced iron looks like sponge in texture due to pores and hence is called sponge iron. Sponge iron industry needs quick actions for survival. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material.
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. Direct reduced iron dri production plant nippon steel engineering co. Dhruvdesh metasteel pvt ltd koppal kspcb koppal expansion of sponge iron to steel and sponge iron plant of dmpl is located in hirebaganal more detailed. Reduction degree of process was evaluated as a function of time and the. The company produces steel and power through backward integration from its own captive coal and iron ore mines in terms of tonnage, it is the third largest steel producer in india. We surya engineering works sew gears manufacturers, suppliers and exporters of 100 tpd sponge iron plant kiln and cooler in various domestic as well as international regions for sponge iron plant that have running capacities of. This procedure results in a spongy structure of the product, thus sponge iron, with a high porosity. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr. This product is known as direct reduced iron dri or sponge iron. List of oil refineries and steel plants industries in india pdf. Schematic of optimised rotary kiln sponge iron making process. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron.
Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. Iron ore is the source of iron and available in oxide form namely hematitefe2o3. Iron sponge is a highly porous, coarsely powdered or granular form of iron metal with numerous applications in catalysis, gas purification, and alloy production. The former process is based on reduction of iron ore, yielding a highly porous sponge iron which subsequently is comminuted to powder. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. Table 2 characteristics of iron ore for coalbased process.
One of the major challenges for sponge iron plant is the accretion formation. Sponge iron plants cerana foundation, oct 2006 6 visible air pollution from point and area sources from sponge iron plants around raigarh solid waste dumps at sponge iron plants 3. Additional technical, research and safety msds information is available. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. If the inline pdf is not rendering correctly, you can download the pdf file here. Ico files icons download 2430 free ico files icons here. Iron ore crushing is not required since sized material has to be purchased.
It is noteworthy that many iron ore mine owners are operating sponge iron plants too. Tata steel long products limited tata sponge iron limited. The use of preheating technology in the rotary kilns has made it capable of producing at 175% of its installed capacity. The rapid growth of sponge iron industry was fuelled due to rise in steel making capacity through if eaf route to meet the fast growing demand of steel in the country, high price of steel melting scrap and its restricted availability. Download fulltext pdf stabilization of integrated sponge iron plant waste dump through ecological restoration approacha field study conference paper pdf available october 2014 with 80 reads. Sponge iron product quality in direct reduced iron dri plant can be increased by rising reduction gas temperature and composition of. Indus technical and financial consultant limited 205,samata colony, raipurc. Contact verified sponge iron plant manufacturers, sponge iron plant suppliers, sponge iron plant exporters wholesalers, producers, retailers and traders in india. Phase 1 eafy green vegetables l endive, lettuce, spinach, swiss chard, and watercress.
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. Oct 25, 20 nmdc is the prime source of iron ore for sponge iron producers as they have almost 100% reserves of sponge iron grade, particularly drclo in bailadila sector. An imbalance between the solubility of iron in soil and the demand for iron by the plant are the primary causes of iron. Sponge iron manufacture is highly sensitive to raw material characteristics.
Whenever possible, try to select organic and nongmo varieties. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 c. Strength and granulometry are the two important physical requirements. Wed like to understand how you use our websites in order to improve them. Char has good amount of fixed carbon 28 % 35% and moderate gcv 2720 2780 kcalkg.
It has two integrated steel plants, located at dolvi and kalmeshwar in. List of oil refineries and steel plants industries in india pdf general awareness for banking and other competitive exams like rrb, cds, lic ao, rbi, ssc, upsc, fci, uiic, oicl, sbi clerks and po requires knowledge on many different subjects, one such subject is oil refineries and steel plants industries in india. Specificationsponge iron is sold in two sizes lumps. Major plant facilities 1 raw material preparation system raw material system mainly consist vibro feeder, crusher and screen. A thesis submitted for partial fulfillment of the degree. In this study, production of sponge iron by direct reduction of oxides and the effect of.
This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Modeling of rotary kiln for sponge iron processing using. Pdf stabilization of integrated sponge iron plant waste. Detailed project report suraj products limited village barpali, po. Ispatind was set up as nippon denro ispat limited in may 1984 by founding chairman mr m l mittal. A thesis submitted for partial fulfillment of the degree award of. In fact it is believed that iron makes up about 5% by weight of the earths crust.
A survey is made on a typical coal based indian sponge iron plant of capacity 500 td in order to identify the largest. The sponge iron produced in the existing plant will be utilized in the proposed project to manufacture steel products. The offered products are manufactured using high grade raw materials and are preferred for. Foods for each phase of the plant paradox program here is a handy, ata glance chart of the foods you should aim to eat in each phase of the program. Study on accretion formation on dri kiln during spong iron. The impact of improvement in iran iron and steel production. Process plant equipment being amongst the largest companies, we are engaged in manufacturing, supplying and exporting an extensive range of process plant equipment. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. For a plant of 100 td capacity, increase in annual earnings will be more than rs.
The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge. List of oil refineries and steel plants industries in. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. Sponge iron or direct reduced iron is produced by reducing iron ore in the form of lumpspellets using noncoking coal in a rotary kiln. The latter process is based on atomization of a stream of liquid. Get sponge iron at best price with product specifications. Sponge iron is the product created when iron ore is reduced to metallic iron, usually with some kind of carbon charcoal, etc, at temperatures below the melting point of iron. Iron very rarely occurs in the earths surface as a metal. For better visualization of the process the longitudinal section of coal based sponge iron plant is presented in fig. In the present work a system is designed to integrate the heat of waste gas in the sponge iron process.
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. Sponge iron units do not use the pollution control equipment. Energy audit methodology of sponge iron manufacturing. Effect of amount of carbon on the reduction efficiency of iron ore. During 20032008, there had been a rapid growth of coal based sponge iron plants.
Find details of companies offering sponge iron plant at best price. They have also installed 33 mw captive power plant. Nov 17, 2012 sponge iron units do not use the pollution control equipment. The sponge iron we make available is used for the production of various steel and iron based products like bars, pipes and tubes. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron. Iron ore after due reduction inside the kiln is discharged to a rotary cooler of 3. Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. Process plant equipment sponge iron plant equipment. Seml was one of the first companies to install a sponge iron plant in the siltara, raipur area. The effective volume of the kiln inside the refractory lining should be about 2 cu. Documented data meteorology the meteorology of the area is summarized below. Energy audit methodology of sponge iron manufacturing units. All the plants are existing in vidarbha region of maharashtra.
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