A novel process for stationary hydrogen production: the ...

The reformer sponge iron cycle (RESC) is discussed as a new process for stationary hydrogen production. The RESC is based on the sponge iron reaction process in combination with a reformer unit. The sponge iron reaction process is a cyclic process for water splitting, whereby a syngas is consumed. The syngas reacts with iron oxide (magnetite, Fe 3O 4) to produce a …

Production of Sponge Iron Powder by Reduction of a By ...

2020-1-27 · Key Words: Powder production, Sponge iron, Solid by-product. 1. Introduction Mill scale is a steelmaking by-product from the rolling mill in the steel hot rolling process. Mill scale contains both iron in elemental form and three types of iron oxides: wustite (FeO), hematite (α-Fe 2 O 3) and magnetite (Fe 3 O

Sponge Iron

Four sponge iron (SI1, SI2, SI3, and SI4) plants with different installed capacity and sponge iron (SI) production have been considered for studies based on the baseline methodology. Figure 3.3.18 shows the annual SI production across sample plants. The production varies from 0.06 (SI1) to 0.2 Mt (SI4).

Powder Production Technologies

The sponge iron process. The longest established of these processes is the sponge iron process, the leading example of a family of processes involving solid state reduction of an oxide. In the process, selected magnetite (Fe3O4) ore is mixed with coke and lime …

World''s First Hydrogen-Reduced Sponge Iron Produced

2021-6-23 · Stockholm/Sweden – The Hybrit pilot plant in Luleå, Sweden has completed test production of sponge iron and demonstrates that it is possible to use fossil-free hydrogen gas to reduce iron ore instead of using coal and coke to remove the oxygen.Production has been continuous and of good quality. Around 100 tons have been made so far.This is the first time ever that hydrogen made with …

Production Process

2016-5-19 · Production Process Ingots To manufacture Mild Steel Ingots the company purchase M.S. Scrap from open market, imported Scrap from actual importer, Sponge Iron from the manufacturers and these materials, once reach the plant the quality is tested and after getting satisfied, unload the material in the stock yard.

Iron Sponge Process

Maurice I. Stewart Jr. PhD, PE, in Surface Production Operations (Third Edition), Volume 2, 2014 9.4.2.1 Application. The iron sponge process is economically applied to gases containing small amounts of H 2 S (< 300 ppm) operating at low to moderate pressures in the range of 50-500 psig (344.7-3447 kPa). This process does not remove CO 2.

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

2011-5-13 · process uses coking coal. The DRI process doesn‟t require coking coal and therefore is advantageous. In the present work waste heat recovery system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron ...

Energy integration of sponge iron production process

2012-10-19 · 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. In this process screened iron ore (6.5tph), coal (3.529tph) and dolomite (0.2tph) are charged into the rotary kiln.

SPONGE IRON

2010-9-21 · Iron ore (haematite) and non-coking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln ...

Energy Audit Methodology of Sponge Iron …

2014-9-15 · sponge iron manufacturing process or kiln operation with a view to finding out major energy sav-ing potential of the unit. In the research work we find that it is the incomplete reaction of coal that causes the major energy inefficiency in the process. Substantial amount of un-reacted carbon

(PDF) Different processes of Sponge Iron production – A …

2013-2-22 · 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters.

Sponge iron Manufacturing process

2021-9-2 · Sponge iron is a metal product that is produced by a direct reduction of iron ore in solid-state. Sponge iron is a good alternative to waste and is mainly used in the manufacture of steel via secondary routes. The process of making sponge iron occurs by removing oxygen from the iron ore.

Which process is better for Sponge Iron Production? HYL ...

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 ...

Sponge iron production process and plant

Sponge iron production process and plant . United States Patent 5997609 . Abstract: In a process for producing sponge iron from particulate iron oxide-containing material, the iron oxide-containing material in a reduction zone is reduced to sponge iron by means of reducing gas and the gas forming during reduction is withdrawn as top gas. ...

Sponge Iron

manufacturing process In the DRI plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. The reduction is carried out in a rotary Kiln (which is inclined and rotates at a pre-determined range of speed) at a stipulated temperature ( 850 °C – 1050°C).

The HBI direct reduction process

2016-11-3 · The direct reduction process. HBI is the product of reducing iron ore with natural gas. This is called the direct reduction process and is an environmentally-friendly production process; a DRI plant uses natural gas which is more environmentally sound than coke. The reduction process …

THE KRUPP SPONGE IRON PROCESS PRODUCTION AND …

2020-5-6 · Sponge ''iron process might well be scaled up to a commercial operation, a full-scale test was car-ried out in a production kiln of 4.6 m diameter and 110 m length, which had been modified to suit the conditions encountered in processing rich iron ores. This test furnished proof that the test results are reproducible on a production scale.

SPONGE IRON PLANT

2018-9-24 · The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production …

Production of sponge iron powder by reduction of …

2020-7-27 · The sponge iron obtained subsequently passes into a rotary cooler where it is cooled with water11-15. There is another process, known as the "Höganäs process", in which high purity ore is placed together with coke and lime in ceramic containers which are in turn placed in a reduction furnace where the process takes place16.

SPONGE IRON PRODUCTION FROM ORE -COAL …

2014-9-2 · In the year 1908 use of tunnel kiln started for iron oxide reduction. This process was invented by E.Sieurin as Hoganas process [3]. In 1954, more kilns came in operation in SWEDEN and USA. Presently it is more popular in China for sponge iron production from beneficiated iron ore fines cakes. In this process, the material passes through

Energy Audit Methodology of Sponge Iron Manufacturing ...

2014-10-14 · Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.

Energy Audit Methodology of Sponge Iron Manufacturing ...

Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kWth/kWe) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.

THE KRUPP SPONGE IRON PROCESS PRODUCTION AND …

2012-1-5 · Sponge ''iron process might well be scaled up to a commercial operation, a full-scale test was car-ried out in a production kiln of 4.6 m diameter and 110 m length, which had been modified to suit the conditions encountered in processing rich iron ores. This test furnished proof that the test results are reproducible on a production scale.

Energy integration of sponge iron production process

Sponge Iron Production Process - Arij Trading

The Making of Iron & Steel

2020-8-3 · The BOS process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal (and scrap is used for temperature control). The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process, the EAF requires

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron …

2017-8-4 · Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are assigned individual number and henceforth each stream

Process for the production of pig iron and sponge iron ...

A similar sponge iron production process is known from U.S. Pat. No. 4,260,412, in which top gas of a reducing shaft furnace prepared by carbon dioxide removal is used for producing fresh reducing gas. The gas producer is a fluidized bed gasifier, to which are supplied the prepared top gas, coal and lime, as well as oxygen and optionally water ...

Energy Conservation in Sponge Iron Production Process ...

A waste heat recovery system was designed to integrate the heat of stack gas in the sponge iron process by considering a case study of typical Indian sponge iron process. After complex reduction and combustion the process stack gas exits the sponge iron plant at substantially higher temperature ranges (200-250ᵒC) which carries a lot of sensible heat that directly goes to the atmosphere ...

Sponge Iron Production Process

2021-9-9 · Sponge iron production process discussed herein are selected from known methods of which the references are available and referable. We look at the 4 different methods of producing sponge iron: Midrex process. HYL process (4th generation) or Energiron. SL / RN process. Tunnel furnace process.