The companys core competency lies in the production of world class iron ore sized, iron ore finesexport quality, drisponge iron m. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. Free rulebook and reference downloads for the ironsworn rpg. Simulation of rotary kiln used in sponge iron process. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic iron nickel.
The indian sponge iron industry, which was started as late as in 1980s has come a long way. Techno economic feasibility report of ms bravo sponge iron. Dspl is the leading manufacturer of sponge iron in eastern region of india. How to make a fillable pdf using pdf escape 2017 in this video, janet shows you step by step process to create a fillable editable pdf using the free form pdf form filler. This was a simple method used from the iron age to medieval times where iron ore and charcoal were placed in a small furnace. Rotary cooler the product is conveyed to the product separation and storage building the product is sponge iron and char place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. If you continue browsing the site, you agree to the use of cookies on this website. Growth in indian dri sponge iron production unused dri production capacity in egypt higher capacity utilisation by nucor 5 mt new dri capacity scheduled to come on stream in algeria with no domestic. This process is applied to gases with low h2s concentrations 300 ppm operating at low to moderate pressures 50500 psig. With such dimension of notion we in our sponge iron manufacturing process through 4 kilns 1 350t and 3 500t laid up the best dri making process of india. 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. Energy balance in a rotary kiln sponge based iron making. The average melting time of sail sponge iron is higher than that of nml sponge iron in acidic slag at 0c.
It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary steelmaking and continuous casting. Pig iron is divided into steel making pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. Techno economic feasibility report of ms bravo sponge iron pvt ltd. Study on accretion formation on dri kiln during spong iron. Only 20% to 30% of sponge iron can be used in the furnace charge when feeding is done in batches.
Pig iron is usually remelted and suitably treated to make. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route. In the midrex or hyl process, it is generally recommended to use high quality cooked pellets with a maximum of about 30% iron ore lumps. Growth in the sponge iron production can be attributed. Pdf design modifications for energy conservation of sponge iron. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. It may allow one to convert or create basic pdf s but creating a form fill pdf is something that only actual pdf programs have. Coal based sponge iron is a metallic product produced through direct reduction of iron ore in the solid state.
The final product can be in the form of fines, lumps, briquettes or pellets. Pig iron is usually remelted and suitably treated to make castings. Green steel making gas based technology for sponge iron. The product, hot briquette iron hereinafter referred to. Selvakumar, in reference module in materials science and materials engineering, 2017.
The product is pig iron, used in foundries to make a variety of castings such as car engine blocks, and parts for light and heavy machinery. Sponge iron when briquetted in hot condition at elevated temperature is called hot. This authoritative account covers the entire spectrum from iron ore to finished steel. How to clean a sponge tips for sanitizing kitchen sponge. Nov 09, 2014 making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. A drawing of an iron sponge unit showing typical provisions for internal and external design requirements was presented in figure 73. Annual sponge iron production for sample sponge iron plants. Production of sponge iron powder by reduction of rolling mill. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. You can easily insert, delete and modify the texts, images and pages in your pdf, annotate your files with a variety of markup tools, or convert pdf. Pdf during the operation in the coal based sponge iron plant, a tremendous amount of. Hotbriquetted iron hbi is a compacted form of dri designed for ease of shipping.
Sponge iron uses noncoking coal, and iron ore fines palletized form or directly. One of the major challenges for sponge iron plant is the accretion formation. We are the largest producer of sponge iron using non coking coal as a reductant and and are having the largest coal based plant in the world. Unlike in the conventional steel melting processes, the gangue content of iron ore cannot be separated as a slag. Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. Sponge iron is the metallic form of iron produced from reduction of iron oxide below. You can then choose to select a file or scan a document. The history of sponge iron production says that the need for development and commercialization of sponge iron manufacturing process arose in late 50s when electric arc furnaces eafs engaged in manufacturing steel started facing problems of availability of scrap of desired quality, the traditional source of their iron metallic s. Green steel making gas based technology for sponge iron industry by welspun maxsteel ltd worldwide, there is an increasing emphasis on environmental issues.
T, burla person involved name designation and email. Sponge iron, also called direct reduced 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. Direct reduction process an overview sciencedirect topics. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize sponge iron direct reduced iron dri finesbriquettes for steel making, is 839. It is a substitute for scrap and is mainly used in making steel through the secondary route. How to save fillable form data in pdfs trevor bekolay september 23, 2010, 2.
It begins by tracing the history of iron and steel production, right from the earlier days to todays world of. We shall discuss in detail all technical aspects of coal base sponge iron making with particular reference to control of important process parameters to achieve quality sponge iron. Therefore, it becomes imperative to select an ore with a high fe content and a low gangue content, to optimize yield during steel making. The process of sponge iron making aims to remove the oxygen from iron ore. Being able to create interactive and fillable pdf forms is important since pdf has become the most widely used format for business documentation. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. Green steel making gas based technology for sponge. We are the leading manufacturer of directreduced iron dri, also called sponge iron, which is produced from direct reduction of iron ore in the form of lumps.
It is produced by direct reduction of iron ore in the presence of coal and air. In addition to offering great pdf creation tools, pdfelement also acts as a powerful pdf editor, allowing you to edit and convert pdfs without hassle. Directreduced iron dri, also called sponge iron, is produced from direct reduction of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue.
Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Study on accretion formation on dri kiln during spong iron production. The former process is based on reduction of iron ore, yielding a highly porous sponge iron. Sponge iron feeding plays an important role in electric steel making. 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.
Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. Within acrobat, click on the tools tab and select prepare form. Since last few years, sponge iron has emerged as an alternate raw material for steel making. The advantages of sponge iron use with growing scarcity of scrap, a replacement could be found in the form of dri. Energy survey of the coal based sponge iron industry. Acrobat analyzes your document and adds form fields automatically. With the direct reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages than scrap metal smelting for steel making. A thesis submitted for partial fulfillment of the degree award of.
Waste management of solid wastes consists of generation, prevention, characterization, monitoring, treatment, handling, reuse and residual disposition. It is seen that the growth of sponge iron industry in last few years is unremarkable and today india is the largest producer of sponge iron as it covers 16% of global output. The iron sponge process generally uses a single vessel to contain the hydrated ferric oxide wood shavings. Its members account for more than 80% of production and international trade in orebased metallics. In sponge iron industry rotary kiln is the primary equipment, which is used to reduce iron ore to metallic iron i. Sponge iron production flow chart raw material feeding to. Are you looking for the best pdf fillable form creator on the market. The xrd patterns were identified using powder diffraction files pdf. The amount of sponge iron in the charge mix varies from 090% depending on its availability and economics of production. Start free trial whether its a scan or a simple form made with microsoft word, excel, or any other application, adobe acrobat gives you a simple way to make it smarter with signature fields, calculations, and much more. This standard has been formulated by amalgamating is 10812. Sponge iron is a better substitute of steel scrap for steelmaking.
To create a fillable pdf, start by launching adobe acrobat on your computer. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize apr 01, 2014 demonstrates how to make a pdf form fillable. Modelling and optimization of a rotary kiln direct. Direct reduced iron dri production plant nippon steel engineering co. The coal base dri rotary kiln used for the production of sponge iron with increased.
The conventional route for making steel consists of sinteringpelletization plants. O rukni in purliya district of west bengal global experts 4 the various types of induction furnaces used for steel making are medium frequency and high frequency. If you have acrobat pro you can print to pdf or flatten the form, providing it does not. Modeling of rotary kiln for sponge iron processing using. In this method, heat coal as a reducing agent is mixed with iron ore and sponge iron is produced in a horizontal furnace. It clearly indicates that the acidic slag facilitates melting, as melting time of nml sponge iron is reduced from 7. To create a fillable pdf form, a powerful pdf form creator is needed. Pdf production of sponge iron through tunnel kiln process. 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. Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron. Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden.
Such tumbling of prices hits at the economic viability of the sponge iron 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. The substitution of scrap by sponge iron has some limitations depending on the furnace operating conditions. 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.
Latex seems more like a writing program with basic programming in it. How to create a fillable pdf with pictures wikihow. In this paper the direct reduction of iron ore to sponge iron is used as an example. 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. It has been observed during the year 200607 the prices of sponge iron went down upto rs. Sponge iron can be used in steel units where dri more. Since 1911 the hoganas corporation has continuously manufactured sponge iron, although the early use for this product was as a feedstock for steel making. Simulation of rotary kiln used in sponge iron process using ann. Sponge iron is used as feedstock and a recognized alternative to steel scraps in iron and steel making. In addition, an ammeter can be calibrated to use as a new device called sponge iron meter for ensuring ideal sponge iron feeding rate for continuously feeding into a pool of liquid iron. Ferrous metallurgy is the metallurgy of iron and its alloys. The latter process is based on atomization of a stream of liquid. Feb 29, 2008 this authoritative account covers the entire spectrum from iron ore to finished steel. This product is known as direct reduced iron dri or sponge iron.
The iron sponge process uses the chemical reaction of ferric oxide with h2s to sweeten gas streams. India is the worlds largest producer of sponge iron, most of which is produced primarily through the coal based method of production. The pdf form creator breathes new life into old forms and paper documents by turning them into digital, fillable pdfs. Sponge iron production by direct reduction of iron oxide. Sponge iron is then taken to a product bin for dispatch. Mild steel, stainless steel and low and high alloy steel can be made from these furnaces. In sponge iron making, iron ore is reduced in solid state.
The model incorporates a large number of variables, covering, among others. Once adobe is open, click tool and select open under prepare form. A fillable pdf form is a fillable pdf form so when you you save it you are saving the form field data in the fillable pdf form. The carbon and oxygen combine together to form carbon monoxide which is used. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. The reduction of rolling mill scale to sponge iron powder is a new way to take advantage of a cheap byproduct of the steelmaking industry, yielding sponge iron that can be reused to the electric furnace as metallic charge for steelmaking to obtain a product with a lower residual content and improved properties8,10. Sponge iron is a high quality metallic product produced from iron ore, pallets etc. The history of sponge iron production says that the need for development and commercialization of sponge iron manufacturing process arose in late 50s when electric arc furnaces eafs engaged in manufacturing steel started facing problems of availability of scrap of desired quality, the traditional source of their iron metallic. Depending on its content of volatile matter, the coal is part ly blown into the kiln from the discharge end and or partly fed. Directly reduced iron directly reduced iron is a product of iron. Mix 34 cup of bleach in one gallon of water and soak the sponge for five minutes, then rinse and thats it. Sponge iron is a valuable source of iron for the production of highquality steel. If you have acrobat pro you can print to pdf or flatten the form, providing it does not have security restrictions preventing these methods.
We shall discuss in detail all technical aspects of coal base sponge iron making with particular reference to control of important process parameters to achieve quality sponge iron in this august gathering. Iron sponge unit design procedures hydrocarbon compression. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Sponge iron is a metallic mass with honeycomb structure. A thesis submitted for partial fulfillment of the degree award. The proportion of sponge iron in the charge can however be increased to 4050% by providing continuous feeding arrangements. The indian government has recognized sponge iron as a vital sector for growth of indian steel industries.
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