One of the major challenges for sponge iron plant is the accretion formation. If you continue browsing the site, you agree to the use of cookies on this website. Plant energy performance pep is the measure of whether a plant is now using more or. The company have operations in iron, steel, mining, energy and infrastructure. 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.
Direct reduction iron plant will have the following recommended. Specifications of iron ore consumed by major sponge iron plants in the country are presented in table. What are the base line data that an audit team should collect while conducting detailed energy audit. Since 2002, india has been the largest producer of sponge iron, also called direct reduced iron dri, in the world. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. 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. A thesis submitted for partial fulfillment of the degree. 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. In the present work, several challenges faced in sponge iron production have. Optimization of operating parameters for sponge iron production. 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. Globally conventional fuels are going to be exhausted. Integrated steel plant tmt bar manufacturing plants. Energy audit methodology of sponge iron manufacturing. Among the three gasbased sponge iron producers, essar steel setup the worlds largest hotbriquelted iron hbi plant. 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. Today about 20 per cent of the sponge iron produced worldwide is made in india1. Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. The following factors have been considered for selection of site for the existing plant.
Based on the types of reductant used, dr processes can be broadly classified into two groups. In sponge iron making, iron ore is reduced in solid state. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Pig iron and refined iron ore pellets briquetted iron can also be used, and because his t method is economic at lower volumes these operations are called mini mills. A typical sponge iron plant has been investigated to.
Thus there is a great need to create facility for washing of coal around the coal mines. Pdf waste heat recovery steam generator in sponge iron. A thesis submitted for partial fulfillment of the degree award of master of technology in chemical engineering by. Waghchaure general manager telephone number fax number email 2143277501 2143277542 vitthal. 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. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Major plant facilities 1 raw material preparation system raw material system mainly consist vibro feeder, crusher and screen. 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. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 c. Imo confirm that hot briquetted iron hbi can be handled and shipped without special precautions. The main function of making sponge iron in the kiln is to convert iron ore into sp onge iron by using iron. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr processes. 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. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron.
Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. 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. This product is known as direct reduced iron dri or sponge iron. Sponge iron process, rotary kiln, ann topologies, optimum input parameters. Ispatind was set up as nippon denro ispat limited in may 1984 by founding chairman mr m l mittal. Get sponge iron at best price with product specifications. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. Sponge iron units do not use the pollution control equipment.
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. This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant. Pdf energy audit methodology of sponge iron manufacturing. Study on accretion formation on dri kiln during spong iron. 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.
Sponge iron produced by this plant is of high grade which contains 80% fe, 12% feo and 8% gangue material. All cpps and units other than sponge iron will participate in the auction of their particular subsectors. Iron ore of size 5 mm to 20 mm is being used for the production of sponge iron. Modeling of rotary kiln for sponge iron processing using. Schematic flow sheet of coal based direct reduction process 1. The reduction is carried out in a rotary kiln which is inclined and rotates at a predetermined range of speeds at a. 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. The entire process of making sponge iron is associated with various safety hazards. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron. Employment opportunities as well as the reservation in employment in public sector.
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. There is a plan to install 4x100 tpd dri kilns for production of 1,20,000 tpa sponge iron. Processes that produce iron by reduction of iron ore in solid state below the melting point. Pdf stabilization of integrated sponge iron plant waste. I lardl and sponge iron is utilised in eastern asia and australia. Iron ore is the source of iron and available in oxide form namely hematitefe2o3. Pdf operation of coalbased sponge iron rotary kiln to reduce. Sponge iron, power plant, steel plant 970 saraikelakharsawan sponge iron, power plant, steel plant. The direct reduction process uses pelletized iron ore or natural lump ore. Hematite pellet reduction with syngas, scientia iranica, 162c, 108124, 2009. 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. 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.
Recovery and utilization of waste heat in a coal based sponge iron. After separation of sponge iron in the magnetic screenpulley, the remains arecollected as char. Download free pdf ebooks with advances in rotary kiln sponge iron plant free pdf free ipad and nook in pdf format for free download. Recovery and utilization of waste heat in a coal based.
Direct reduced iron dri production plant nippon steel engineering co. Iron ore crushing is not required since sized material has to be purchased. Therefore, it becomes imperative to select an ore with a high fe content and a low. 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. It has topped in total number of cites and citable documents. 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. 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. 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. The first gasbased sponge iron plant was started up at hazira in guajarat in 1990 by essar steel ltd. Pdf on jan 1, 2014, avijit choudhury and others published energy audit.
Sponge iron production by direct reduction of iron oxide. Unlike in the conventional steel melting processes, the gangue content of iron ore cannot be separated as a slag. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The sponge iron produced by the company is well demanded in the market for its quality and grade.
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. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. The main function of making sponge iron in the kiln is to convert iron ore into. 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.
Where market size permits, some degree of product specialisation is practised. Char has good amount of fixed carbon 28 % 35% and moderate gcv 2720 2780 kcalkg. 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. Sponge private limited is an existing plant operating 2 x 100 tpd sponge iron plant in taraimal village, ghargoda tehsil, raigarh district. Recovery and utilization of waste heat in a coal based sponge iron process. Plants that use electric arc furnaces can be sited closer to the market. A typical sponge iron plant has been investigated to find out the potential areas where energy is being wasted. 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. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Raw material preparation, combustion optimization, optimum utilization of unused raw material and coal fines, primary, secondary and submerged air system for enhancing higher yield. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material.
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