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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CPP shall be set up in the existing Sponge Iron Plant Area utilizing the surplus land, out of total 30 Acres now available with the Plant. 2.2 Brief description about nature of the project Anindita Steel Limited proposes to Captive Power Plant (CPP) of 15 MW based on WHRB and FBC in the existing 4x100 TPD Sponge Iron Plant. The water requirement of
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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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Table II shows the growth of coal based as well as gas based Sponge Iron industries in India. ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of .
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Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information. ... Low Capex and gestation period compared to Gas based DRI plant; It can be produced with non-coking coal and poor quality of coal that is available in abundance;
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Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...
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The OSIL stands for Orissa Sponge Iron Limited. This plant was set up in the year 1983 at Palaspanga, keonjhar, Odisha. It is based on the ACCAR technology with under bed injection …
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In the present work a 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 …
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Sponge iron is produced by direct reduction of iron ore (DRI. process) and is popular because of use of non-coking coal. The conventional blast furnace. coking coal. advantageous. in the …
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Some H 2 can be introduced in a natural gas-based plant as a substitute for part of the natural gas, or the DR plant can be based on H 2. ... In case of pure hydrogen as reducing gas for production of sponge iron, the …
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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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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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Sponge Iron Manufacturers Association of India 1. urrent Indian DRI Scenario Indian Direct Reduced Iron (DRI) Industry, within a span of 42 years since its inception, has been ... natural gas based DRI plant came up after 1994 (29 years) due to non-availability of natural gas. India is only country in the world making DRI from coal gasification.
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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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In addition, the installed steel production capacity in India is 155 MTPA, and the installed iron capacity is 136 MTPA, of which coal-based DRI plants contribute 37 MTPA (Joint Plant Committee 2023). Coupled with the fact that the type of coal and iron ore utilised for DRI production has an impact on the emission footprint, it is necessary to ...
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The direct carbon dioxide (CO 2) emissions from the iron and steel sector are nearly 7 % of the global CO 2 emissions from energy use. India is the world's second-largest producer of steel and the largest sponge iron producer. India produces one-third of the global sponge iron, mostly from rotary kilns using coal as an energy source, resulting in higher …
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2. Overview of DR processes Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing gas to produce Direct Reduced Iron (also known as sponge iron).
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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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During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as...
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Kumar and Khanam [6] suggested that 21.6 t/h waste gas generated during sponge iron production process. ... During the operation in coal-based sponge iron plant, a tremendous amount of heat is ...
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During the operation in coal-based sponge iron plant, a tremendous amount of heat is generated and a significant part of this heat, associated with the waste gas, remains unutilized.
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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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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. 4 | P a g e Introduction of Jindal Steel and Power Ltd JSPL is an industrial powerhouse with a dominant presence in steel, power, mining and infrastructure sectors. Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified Jindal Group conglomerate. In terms of tonnage, it is the third largest steel producer in India. The company …
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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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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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Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . ... Char generated in the plant is stored separately for use as fuel in the power plant. Waste gas system – The kiln waste gases at temperature of around 850 deg ...
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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 represent their interest. ... Gas Based DRI / HBI. In this process route, iron oxides are converted to the DRI ...
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The Indian Government has recognized sponge iron as a vital sector for growth of Indian steel industries. At present, India is largest producer of sponge iron with a largest number of coal based sponge iron plant of total capacity around 12.8 million ton. Sponge iron manufacturing units looked profitable since beginning of the nineties.
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