Sponge iron plant pdf merge

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. We are a leading supplier and exporter of high quality sponge iron in india. Our high and consistent quality sponge iron facilitates steel makers to maintain high quality and reduce dependency on scrap. The top countries of suppliers are china, india, from which the percentage of sponge iron plant supply is 99%, 1% respectively. Iron ore is the source of iron and available in oxide form namely hematitefe2o3. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 c. The gangue material in sponge iron, originating from iron ore, namely, silica and alumina and the sulphur and phosphorous contents adversely affect the economics in subsequent steel making operation. Coal based sponge iron plant using magnetite ore mine. Today about 20 per cent of the sponge iron produced worldwide is made in india1.

A wide variety of sponge iron options are available to you, there are 4,168 suppliers who sells sponge iron on, mainly located in asia. Contact verified sponge iron plant manufacturers, sponge iron plant suppliers, sponge iron plant exporters wholesalers, producers, retailers and traders in india. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. A thesis submitted for partial fulfillment of the degree. We surya engineering works sew gears manufacturers, suppliers and exporters of 100 tpd sponge iron plant kiln and cooler in various domestic as well as international regions for sponge iron plant that have running capacities of. 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. Armed with strength to go global, incorporated reaffirmed focus to develop and produce best quality of product with inventive approach open for flexible solution sowing the seed of multiple yields. 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. Osil has also been allotted a coal block at new patrapara, talcher in 2004 along with a group of six other industries. Recovery and utilization of waste heat in a coal based sponge. Sponge iron industry needs quick actions for survival the. Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near future. Process plant equipment sponge iron plant equipment. Documented data meteorology the meteorology of the area is summarized below.

We are a consulting firm providing services to the clients for the establishment of plants from steel and power sector in india and abroad. Limestone, in small quantities, is also required to scavenge the sulphur. The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge. Indus technical and financial consultant limited 205,samata colony, raipurc. In fact, no gas based sponge ironhbi plant came up after 1994 19 years. We, at industrial technical consultant itc in raipur, started in the year 2000. The equipment support provided for the plants include kilncooler tyre, kilncooler support roller.

Pdf waste heat recovery steam generator in sponge iron. This product is known as direct reduced iron dri or sponge iron. Four different applications of the sponge iron reaction have been considered within this initial study. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the. Since 2002, india has been the largest producer of sponge iron, also called direct reduced iron dri, in the world. Thus, deposition of fly ash in the environment surrounding sponge iron plant leads to accumulation of heavy metals in the soil. Globally conventional fuels are going to be exhausted. According to sponge iron manufacturers association 1, india has produced around 23 million tonnes of sponge iron in the. Sponge iron produced by this plant is of high grade which contains 80% fe, 12% feo and 8% gangue material. 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 material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Manufacturing process the proposed plant uses the coal based process in which iron oxide in pelletiron ore will be reduced with non coking coal in a rotary kiln to make sponge iron. Char has good amount of fixed carbon 28 % 35% and moderate gcv 2720 2780 kcalkg. Detailed project report suraj products limited village barpali, po. The sponge iron produced in the existing plant will be utilized in the proposed project to manufacture steel products. For this purpose a case study of typical sponge iron production process is. 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. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore.

Sponge iron in hyderabad, telangana sponge iron price in. The process technology developed by allis chalmers corporation, usa based on pilot plant studies known as accar process was used initially. 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. Nov 17, 2012 sponge iron units do not use the pollution control equipment. The rotary kiln is slightly inclined at an angle 2. A typical sponge iron plant has been investigated to.

A wide variety of sponge iron plant options are available to you, there are 579 suppliers who sells sponge iron plant on, mainly located in asia. 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. Recovery and utilization of waste heat in a coal based sponge iron process. Use of high ash indigenous coal not only raises the coal requirement to 1. The effective volume of the kiln inside the refractory lining should be about 2 cu. Pipe and ms billets bars at village samkhiyali, taluka.

In this backdrop trfi took the first step to set up a coal based sponge iron plant in india. The offered products are manufactured using high grade raw materials and are preferred for their sturdiness and better operational life. Study on accretion formation on dri kiln during spong iron. Sponge iron plant offered are designed and developed so as to meet the demands of turnkey projects in different functional capacities including for 100 tpd, 300 tpd, 500 tpd plants and others for the sponge iron industry sector. For this purpose a case study of typical sponge iron production process is considered. Get sponge iron at best price with product specifications. Siil was the first sponge iron plant in the country which was set up at paloncha in andhra pradesh in 1990 with an initial capacity of 0. It is a substitute for scrap and is mainly used in making steel through the secondary route. We are a consulting firm providing services to the clients for the establishment of plants from steel and power sector in india and abroad on consultancy as well as on turnkey basis. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag.

We have a team of experienced engineers for plant operations and project implementation. This high requirement is mainly due to the fines generated in handling the purchased ore from the source to the plant. Sponge iron units do not use the pollution control equipment. Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. Detailed project report for suraj product limited for capacity increase by modernization of mini blast furnace, installation of ferro alloys, induction furnace with ccm, rerolling mill, iron power through t unnel kiln, coal washery, ore beneficiation, cold briquetting, brick making and captive power plant. During 20032008, there had been a rapid growth of coal based sponge. Iron ore the quality requirement of sized ore for sponge iron production can be classified into. Sponge iron plantdrihenan dajia mining machinery co.

The company also commissioned a sponge iron plant of 8,80,000 tonnes per annum capacity for essar steel at hazira. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. After separation of sponge iron in the magnetic screenpulley, the remains arecollected as char. The sponge iron we make available is used for the production of various steel and iron based products like bars, pipes and tubes. It is an acknowledged fact that the plant availability in indian sponge iron sector has been under strain due to inconsistent supply of raw materials like iron ore and noncoking coal, both quantitatively and qualitatively.

Energy audit methodology of sponge iron manufacturing. Simulation of rotary kiln used in sponge iron process. Four different applications of the sponge iron reaction have been considered within this. 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. Since coal was adequately available in india, production of coalbased sponge iron plants was considered as a feasible option. General the major raw materials required for production of sponge iron by the rotary kiln process are.

Therefore, the ore should be high in iron content and low in gangue. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr. The quality of sponge iron is primarily ascertained by the percentage of metallization removal of oxygen, which is the ratio of metallic iron to the total iron present in the product. Process plant equipment being amongst the largest companies, we are engaged in manufacturing, supplying and exporting an extensive range of process plant equipment. This process used 80% coal and 20% oil, which subsequently became uneconomical due to increase in crude prices. One of the major challenges for sponge iron plant is the accretion formation. Sponge iron plants cerana foundation, oct 2006 6 visible air pollution from point and area sources from sponge iron plants around raigarh solid waste dumps at sponge iron plants 3. The indian sponge iron industry has come a long way but instead of resting on its laurels it is looking steady and subsequently focusing on broadening its scope of growth. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. This results in a spongy mass, sometimes called a bloom, consisting of a. Sponge iron division masvingo trading as simbi, the sponge iron manufacturing facility at masvingo was commissioned in december 2004 for the purposes of supporting the steel plant at redcliff. The process of sponge iron making aims to remove the oxygen from iron ore. Oct 25, 20 sponge iron industry needs quick actions for survival presently this important segment of indias steel industry is passing through its worst crisis and urgent steps are needed for its survival.

Find here information of sponge iron plant selling companies for your buy requirements. Dri, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 8001200 c. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. Osil has been allotted an iron ore mines containing sufficient reserve of high grade ore in 2004 at a distance of 35 kms from its plant site to take care of its present and future ore requirements. Most of it is produced primarily through the coal based method of production. A thesis submitted for partial fulfillment of the degree award of. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. Sponge iron industry needs quick actions for survival. Sponge iron industry needs quick actions for survival presently this important segment of indias steel industry is passing through its worst crisis and urgent steps are needed for its survival. Recovery and utilization of waste heat in a coal based. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Find details of companies offering sponge iron plant at best price. Sponge iron manufacture is highly sensitive to raw material characteristics.