The proposed plant uses the coal based process in which iron oxide in pellet iron ore will be reduced with non coking coal in a rotary kiln to make sponge iron. Recovery and utilization of waste heat in a coal based sponge iron. Energy audit methodology of sponge iron manufacturing. Sponge iron produced by this plant is of high grade which contains 80% fe, 12% feo and 8% gangue material. The main function of making sponge iron in the kiln is to convert iron ore into sp onge iron by using iron ore, coal and dolomite. 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. The first gasbased sponge iron plant was started up at hazira in guajarat in 1990 by essar steel ltd. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. A typical sponge iron plant has been investigated to find out the potential areas where energy is being wasted. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. Today about 20 per cent of the sponge iron produced worldwide is made in india1. A thesis submitted for partial fulfillment of the degree. I lardl and sponge iron is utilised in eastern asia and australia.
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. Processes that produce iron by reduction of iron ore in solid state below the melting point. Raw material preparation, combustion optimization, optimum utilization of unused raw material and coal fines, primary, secondary and submerged air system for enhancing higher yield. Among the three gasbased sponge iron producers, essar steel setup the worlds largest hotbriquelted iron hbi plant. Sponge iron production by direct reduction of iron oxide. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron.
This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Download free pdf ebooks with advances in rotary kiln sponge iron plant free pdf free ipad and nook in pdf format for free download. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 c. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. Power has become an essential commodity all over world today, with rapid development in infrastructure and other aspects, power has become the most sought out commodity. 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.
As the manufacture of sponge iron is very sensitive to the physical and chemical characteristics of raw materials, a well designed raw material preparation plant with crushingscreening facility for iron ore and coal to control the size of input materials to the kiln is a prime requiste. Coal india limited auction of coal linkages in the sponge iron subsector tranche ii pre bid presentation this presentation is for ease of understanding of the scheme by the bidders. Pdf stabilization of integrated sponge iron plant waste. Imo confirm that hot briquetted iron hbi can be handled and shipped without special precautions. Pdf energy audit methodology of sponge iron manufacturing.
The main function of making sponge iron in the kiln is to convert iron ore into. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. There is a plan to install 4x100 tpd dri kilns for production of 1,20,000 tpa sponge iron. From the mid 1970s until today, after extensive pilot testing of the technology, a number of industrial plants for the hot briquetting of direct reduced iron went into operation. Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. All cpps and units other than sponge iron will participate in the auction of their particular subsectors.
Based on the types of reductant used, dr processes can be broadly classified into two groups. Major plant facilities 1 raw material preparation system raw material system mainly consist vibro feeder, crusher and screen. Recovery and utilization of waste heat in a coal based. Plants that use electric arc furnaces can be sited closer to the market. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Sponge iron plants cerana foundation, oct 2006 7 raigarh windroses at 0830 hrs raigarh windroses at 1730 hrs sponge iron plant air emissions air emissions from sponge iron plants see annex 2 include highly toxic heavy metals, which may be released in three ways. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr processes.
Jay iron and steel is a dedicated industry of jpm group that manufactures sponge iron using coal fired rotary kilns method in its plant that has a capacity to manufacture 60, 000 mt per annum of sponge irondirectly reduced iron dri. Direct reduced iron dri production plant nippon steel engineering co. Hematite pellet reduction with syngas, scientia iranica, 162c, 108124, 2009. The sponge iron produced by the company is well demanded in the market for its quality and grade. What are the base line data that an audit team should collect while conducting detailed energy audit. A typical sponge iron plant has been investigated to. Integrated steel plant tmt bar manufacturing plants. Direct reduction iron plant will have the following recommended. Sponge iron dri plant the company has two coal based rotary kiln, 1 x 200tpd and 1 x 500tpd to produce around 255000 tpa high grade sponge iron under direct reduced iron technology. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Stabilization of integrated sponge iron plant waste dump through ecological restoration approacha field study conference paper pdf available october 2014 with 80 reads how we measure reads. The following factors have been considered for selection of site for the existing plant. Therefore, it becomes imperative to select an ore with a high fe content and a low.
Schematic flow sheet of coal based direct reduction process 1. Globally conventional fuels are going to be exhausted. Iron ore crushing is not required since sized material has to be purchased. Unlike in the conventional steel melting processes, the gangue content of iron ore cannot be separated as a slag.
Where market size permits, some degree of product specialisation is practised. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. Pdf on jan 1, 2014, avijit choudhury and others published energy audit. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron. This product is known as direct reduced iron dri or sponge iron. Ispatind was set up as nippon denro ispat limited in may 1984 by founding chairman mr m l mittal. This is to certify that the thesis entitled energy integration in sponge iron plant using heat of waste gas being submitted by annavajhala mrudula as an academic project in the department of chemical. Get sponge iron at best price with product specifications. In case of any discrepancies between this presentation and the scheme document, the provisions of the scheme document will prevail. Heat of formation values converted into kcalkgmole.
The reduction is carried out in a rotary kiln which is inclined and rotates at a predetermined range of speeds at a. 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. Also, on page 724, the eia states that the company will provide employment to all land oustees as per the government norms, which is a very vague statement. Employment opportunities as well as the reservation in employment in public sector. It has topped in total number of cites and citable documents. One of the major challenges for sponge iron plant is the accretion formation.
Jsw steel ltd sponge iron plant na address geetapuram plot no taluka village sponge iron plant pen dolvi capital investment in lakhs scale city 60866 large raigad pincode person name designation 402107 vitthal. A thesis submitted for partial fulfillment of the degree award of master of technology in chemical engineering by. Char has good amount of fixed carbon 28 % 35% and moderate gcv 2720 2780 kcalkg. The direct reduction process uses pelletized iron ore or natural lump ore. Pdf waste heat recovery steam generator in sponge iron. Thus there is a great need to create facility for washing of coal around the coal mines. The main function of making sponge iron in the kiln is to convert iron ore into sp onge iron by using iron. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. Study on accretion formation on dri kiln during spong iron. 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. Waghchaure general manager telephone number fax number email 2143277501 2143277542 vitthal. This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant. Plant energy performance pep is the measure of whether a plant is now using more or.
Iron ore is the source of iron and available in oxide form namely hematitefe2o3. For a coal based dri plant with waste heat recovery boiler, power plant and having arrangement for selling surplus electricity, the gate in energy would be coal. The entire process of making sponge iron is associated with various safety hazards. Sponge private limited is an existing plant operating 2 x 100 tpd sponge iron plant in taraimal village, ghargoda tehsil, raigarh district. Specifications of iron ore consumed by major sponge iron plants in the country are presented in table. Best tmt bar manufacturing plants india in the direct reduced iron dri plant, production of sponge iron using a solid reductant involves reducing iron ore lumpspellets with a carbonaceous material such as coal. Modeling of rotary kiln for sponge iron processing using.
The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Sponge iron units do not use the pollution control equipment. Sponge iron, power plant, steel plant 970 saraikelakharsawan sponge iron, power plant, steel plant. In sponge iron making, iron ore is reduced in solid state.
Material balance in a rotary kiln sponge iron plant. If you continue browsing the site, you agree to the use of cookies on this website. In the present work, several challenges faced in sponge iron production have. 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. In the public sector, one sponge iron plant is being operated by the national mineral development corporation nmdc at paloncha, khammam district, telangana state, in which 194 employees are working. After separation of sponge iron in the magnetic screenpulley, the remains arecollected as char.
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. Optimization of operating parameters for sponge iron production. Since 2002, india has been the largest producer of sponge iron, also called direct reduced iron dri, in the world. The company have operations in iron, steel, mining, energy and infrastructure. Recovery and utilization of waste heat in a coal based sponge iron process.
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