The Box-Behnken design of the response surface methodology was used to optimize the phosphorus-recovery process with sponge iron (maximum phosphorus recovery rate was 83.17%), and the interaction ...

While HYL is a batch-type gas based process and uses a countercurrent shaft-furnace, the SL/RN process utilizes rotary kiln to reduce lump ore, pellets and sand iron with coal. Here we will discuss about some …

The advantages of the iron sponge process include: (1) providing complete removal of small to medium concentrations of hydrogen sulfide without removing carbon dioxide, (2) requiring relatively small investment, for small to moderate gas volumes, compared with other processes, (3) being equally effective at any operating pressure, and (4) being ...

sponge iron supply. There are about 107 sponge iron units in cluster and majority of industries located in Sundargarh District area and engaged in production of sponge iron. The major Energy consumption in sponge Iron cluster is of thermal energy which is derived from coal and electrical energy from which is used from grid.

As a new type of denitrification technology, iron-based autotrophic denitrification has the advantages of low cost and no secondary pollution, so it has a broad prospect and research potential (Kiskira et al. 2017).Many studies have been reported on iron-based autotrophic denitrification (Liu et al. 2020; Jokai et al. 2021).However, its application in practice …

Dolochar, a solid waste generated from sponge iron industry during the process of direct reduction of iron by rotary kiln, is explored as an adsorbent for phosphate removal in this study.

The result is Sponge Iron as pellets that are initially stuck together but are later magnetically separated. Each sponge iron is screened based on size and then prepared for dispatch. Sponge Iron – Where Is It Used? Sponge Iron plant manufacturers in India use sponge iron as a substitute for scrap in induction and electrical furnaces.

Direct Reduction is a process by which metallic iron is produced by the reduction of iron ore. Furthermore, it is produced from iron ore in the form of lumps, pellets, or fines. Advantages of Sponge Iron: Chemical Composition is uniform; It contains no undesirable impurities. It permits dilution with low-cost scrap.

Overview of Sponge Iron sector . 33 ; 3.3 Inventorization of Sponge Iron plants 34 4.0 . Process Description of Sponge Iron Plant ; 40 . 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

It is a gas-based shaft furnace process is a solid state reduction process which reduces iron ore pellets or lump ore into DRI without their melting using reducing gas generally formed from natural gas. The principle of the reduction process using reducing gas is shown in Fig 1. ... These advantages help in increasing the shaft furnace ...

In sponge iron process variation in temperature of iron ore, coal, dolomite, sponge iron, and waste gas is in the range from 1,020°C to 30°C. Though specific heats of these materials vary considerably with change in temperature, in the present work these variations are taken as negligible. The reason behind this assumption is that the present ...

VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coal-based sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore

The material balances of the sponge iron process, shown in Table 1, ... The combined effect of above two advantages gives an impact on the process of sponge iron making. Coal being the costliest raw materials for sponge iron making and if very high volatile material (VM) coals are used i.e. (fixed carbon) FC/VM ratio is 1 or less, it would be ...

The process of sponge iron manufacturing involves removal of oxygen from iron ore. When that happens, the departing oxygen causes micro pores in the ore body, turning it porous. ... Some of the inherent advantages of using Sponge Iron in comparison to Scrap are as under : More Volumetric Weight : Considerably higher (10-) than other types ...

1 Review of sponge iron making process 3-13 2 Thermodynamics of Sponge Iron making 14-18 3 Parameters of Sponge Iron making 19-25 4 Plant operating parameter 26-30 5 Environmental management in DRI 31-33 6 Production of Ferro-Alloys 34-37 . KIIT POLYTECHNIC Sponge Iron & Ferro Alloys 3 ...

Sponge iron (SI) can serve as an indirect electron donor to provide Fe(II) for the nitrate-dependent ferrous oxidation (NDFO) process, producing OH – and magnetite. The SI–NDFO system mainly uses Fe(OH) 2 as an electron donor, achieving a TN reduction rate of 0.42 mg–TN/(gVSS·h) for a period of at least 90 days. The enrichment of iron-oxidizing …

Let's delve more into understanding one of the crucial by-products of Iron – Sponge Iron. Sponge Iron gets its name from its unique physical characteristics. It has hole …

In the conventional process, the sponge iron leaving the rotary kiln at 1,020 °C (Dey et al., 2015) is cooled to 110 °C for two reasons: (i) to prevent re-oxidation of the sponge iron when ...

The advantages of DRI include: predictable chemistry, low tramp material content, carbon and y slag formation, lower capital and operating costs, relatively uninterrupted continuous iron making, EAF feed adjustment …

The advantages of sponge iron are: • Chemical composition is known exactly • Chemical composition is uniform • Contains no undesirable metallic impurities • Permits dilution with low …

In book: Encyclopedia of Iron, Steel, and Their Alloys (pp.pp 1082-1108) Chapter: i) Direct Reduced Iron: Production; Publisher: CRC Press, Taylor and Francis Group, New York.

The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln. It describes the chemical and physical composition of iron ore, coal, and dolomite that are fed into the kiln. It then outlines the rotary kiln process which involves preheating and combustion zones, use of primary and secondary air, coal injection ...

In the present work, an effort is made for best utilization of waste heat to reduce energy requirements in sponge iron plants. For this purpose, based on the principles of process integration, three design modifications, scheme-1, scheme-2, and scheme-3, are proposed and applied on actual data of two sponge iron plants being operated in India. Scheme-1 accounts …

The iron product has 6% carbon content. The product is stable and free from spontaneous combustion. In addition to the advantages of direct reduction iron, the product has high carbon content, and the smelting combustion releases heat that is used in the steelmaking process, which reduces electricity consumption during steelmaking.

Direct Reduced Iron (DRI) is the process of removing oxygen from iron ore or iron-bearing solids. Learn more about its types, advantages, and manufacturing process.

DRI (Direct Reduced iron), commonly known as Sponge Iron, is a metallic product produced through the direct reduction of iron ore (in the form of lumps, pellets, or fines) in the solid state. It is a substitute for scrap and therefore is mostly applicable in making steel through the …

The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI).

1.5.2 The Sponge Iron Process The sponge iron process is a process for producing sponge iron, which is porous iron [1]. The raw material used for producing sponge iron is magnetite ore concentrate (Fe 3 O 4), which is the material that will become reduced [1]. The reduction mixture consists of coke and anthracite [1]. Figure 1.1 shows the ...

Using sponge iron instead of iron scrap in steelmaking furnaces has many advantages include: Uniform chemical composition; Less inclusion and impurities; Less environmental problems Although iron powder could be produced in sponge iron tunnel kiln production line and it is the main raw material for powder metallurgy production lines. Process

`the quality requirements for the rotary kiln sponge iron process. The sponge iron fines generation is high and ranges from 15 — 30% depending upon the ore used due to high reduction degradation. This will not only reduce the sales realization of the product but also will lead to accretion formation in the kiln shortening the campaign life.