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Additionally, the reference values are determined based on the specific type of coal being utilized, which are obtained through data analysis of various coal types used in the sponge iron plant. The selected bandwidth for this analysis is set at 15%, while the reference value is set at 20% of the input feed side FC.
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A typical sponge iron plant has been investigated to find out the potential. ... At present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the remaining 115 plants are coal based. Among all the available options, rotary kilns have been widely used as a reactor in coal based ...
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The first gas based sponge iron plant, with a capacity of 1.52 MTPA, was set up by Essar Steel Limited in Hazira, Gujarat in 19905. Today, India has an installed capacity of 36.7 MTPA of sponge iron6. Leading states in sponge iron production are Odisha, Chhattisgarh, West Bengal and Jharkhand. Odisha occupies the top position
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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:
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4.1 Brief description of sponge iron plant process 40 4.2 Technological options for coal based plants 42 5.0 Status of Sponge Iron Plants in India 67 5.1 Questionnaire Survey 67 ... in oil and gas feed, 1000 10000 GT of CO– 2. in saline formation and 3200 GT in coal beds worldwide. Canada serving as a storage site for world's
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3 Table I: Global Scenario of DRI Production Country Direct Reduced Iron Production (Thousand Tonnes) India 20336 Iran 14551 Mexico 5976
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section of coal based sponge iron plant is presented in Fig. 2. In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and
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Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...
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This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas.
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The plant is based on usage of natural gas based process to produce Sponge Iron. The availability of Natural Gas is becoming very scarce in India & the prices are also increasing. It is apprehended that it may no longer be viable to operate this plant with Natural Gas leading to closure of the plant and loss of employment of people.
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This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas.
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The generated steam can be used for steam turbine to generate power. Figure 2 – Energy Intensity in Iron Plant (50% of total produced heat only used) II. EXPERT REVIEW Department of Chemical Engineering, National Institute of Technology, Rourkela Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900° C.
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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.
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In early 90's three gas based DRI plants were set up in the west coast due to the availability of natural gas at that time. No Greenfield natural gas based DRI/HBI plant came up after 1994 (26 years) due to non-availability of natural gas. Subsequently, one syn gas based plant and one corex based plant were set up.
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It is the voice of the indian iron ore based sponge iron & steel industry, at both domestic and global forums. As a not-for-profit society, SIMA has been mandated to communicate the viewpoints of its constituents & al stakeholders and …
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Sponge Iron Plant Process Equipment. Direct reduction processes can be divided roughly into two categories: gas-based, and coal-based. In both cases, the objective of the process is to drive off the oxygen contained in various forms of iron ore (sized ore, concentrates, pellets, mill scale, furnace dust, etc.), in order to convert the ore to metallic iron, without melting it (below 1200 °C).
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Direct reduced iron (DRI) is also known as sponge iron (Hasambeigi et al. 2014). This high porous material has a metallization degree in the range 85–95% with a carbon content in the range 0.5–4% depending on …
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Sponge Iron production gas based; KEY PERFORMANCE INDICATORS. ... Various energy losses occurs in sponge iron plant during the production process. Waste heat in off-gases formed in rotary kiln forms the major share of heat loss. Waste heat recovery (WHR) has been identified as one of the viable options towards maximizing the utilization of heat ...
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We are a leading manufacturer of Coal / Gas based DRI Plant. Approx. Rs 12 Lakh / Number Get Latest Price. We manufacture Sponge Iron Plant on turn …
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Manufacturer of Coal & Gas based DRI Plant - Rotary Kiln for Making Sponge Iron, Sponge Iron Plant, Gas Based HYL DRI Plant and Coal Based DRI Plant offered by Remso Control Technologies Private Limited, Greater Noida, Uttar Pradesh.
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modifications based on the actual data of sponge iron plant are suggested. II. DESCRIPTION OF CONVECTIONAL COAL BASED SPONGE IRON PLANT The process flow sheet of a typical coal-based sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd.
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We manufacture Sponge Iron Plant on turn-key basis of different functional capacities i.e. 100 TPD, 300 TPD, 500 TPD plants.The equipment support provided for the plants include Kiln/cooler tyre, Kiln/cooler support roller, Kiln/cooler support roller shaft, Kiln/cooler support roller assembly with bearing housing, Kiln/cooler girth gear, Kiln/cooler pinions, Kiln/cooler pinion shaft, Kiln ...
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On sponge iron-making in coal-based rotary kilns, there are studies on process modeling (Gaurav and Khanam, 2016), ... Similarly, direct plant GHG emissions for the lean gas case are 1.8% (9 kgCO 2 e/t-DRI) lower than that of …
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SAFETY GUIDELINES FOR IRON & STEEL SECTOR MINISTRY OF STEEL, GOVT. OF INDIA Direct Reduction Plant ( Gas Based) Doc. No: SG/33 Rev no. : 00 Effective Date: -- 1. OBJECTIVE : The entire process of making Sponge Iron by coal based DRI process is associated with various Safety hazards like Fire, Explosion, Radiation, Burns hit /
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Sponge Iron is iron ore reduced directly in solid state using coal gas, natrual gas or coal as reductants and is also known as Directly Reduced Iron (DRI).
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India is the largest producer of direct reduction of iron (DRI), popularly known as sponge iron and accounted for about 39.3% of the global production in 2020. India's growing economy will …
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The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coal-based sponge iron plant, a tremendous amount of …
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Gas based process is simple to operate and involves three major steps namely (i) iron ore reduction, (ii) gas preheating, and (iii) natural gas reforming. Presently the gas based process is also available in which the reforming of natural gas is not needed.
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MAJOR PLANT FACILITIES 1- RAW MATERIAL PREPARATION SYSTEM - 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
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1985-1995, apart from few coal based plants, 3 large gas based plants with an aggregate capacity of 6.10 million tonnes per annum were commissioned. From 2003, coal based sponge iron route dominated because of limited availability of natural gas and fast growing demand of metallics. In fact, no new gas based sponge iron/HBI plant came since last 19
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