material balance of gas based sponge iron

material balance of gas based sponge iron

Energy survey of the coal based sponge iron industry ...

2015-9-1  The computation points out that 4.2%, 1.12%, 43.5% and 3.6% energy is lost through streams of sponge iron, char, waste gas and volatile matter, respectively. It is clear from this figure that significant amount of heat is also lost with waste gas. (2) Hot sponge iron is being cooled with water in rotary cooler.

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ENERGY INTEGRATION IN SPONGE IRON PLANT USING

2012-5-12  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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Heat and Mass Transfer in Reduction Zone of Sponge Iron ...

The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation. Simultaneous mass and energy balances along the reactor lead to a set of ordinary differential equation which includes kinetic equations.

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION

2012-1-10  material 1cooliei)rum (water cooling) gas, g'.7 eirtuttitiol, coal or lignite 77 screening 4-5 os. -5 ,•• magnetic separation lime,coke,ash -5 nt • 7,1 a t/on _..waste lime and ash i 75ppcreening 3 to 5 rt.m --4/- flowsheet of a commercial krupp sponge iron plant for processing of ore fines or concentrates final product sponge iron figure i

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sponge iron process

2010-7-29  The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

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Figure 10:E x-CCGT Energybalanced iagram

2017-9-8  c. Ideal Mass balance condition To produce 1 kg of Sponge Iron in ideal condition i.e. with no excess air (flue gas without O 2 CO). Input: 0.64 kg coal, 1.43 kg Iron Ore, 5.20 Kg of Air Output: 6.206 Kg flue gas, 0.064 Kg (Ash of Coal), 1 kg sponge iron.

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SPONGE IRON PRODUCTION FROM ORE -COAL

2014-9-2  SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE PELLETS IN TUNNEL KILN . S.C.Khattoi. 1* , G. G. Roy2 1 Project Engineering Consultancy, Keonjhar, Odisha, India 2 . Indian Institute of Technology, Kharagpur – 721302, India. Abstract: Today India stands as the largest producer of coal based sponge iron through

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M/s Bravo Sponge Iron Pvt. Ltd. - Welcome to Environment

2018-11-16  Bravo Sponge Iron Pvt. Ltd. is planning for expansion project in their existing unit with following proposed unit. The Plant configuration for proposed unit is given as below: SL Particulars of facilities Capacity 1 Pellet Plant (2 X 0.85 MTPA) with grinding Facilities 5600 TPD 2 Producer Gas Plant(12X 4000 Nm3 /hr) Coal Base 48000 Nm3/hr

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Sponge iron industry needs quick actions for survival ...

2013-10-24  On the initiative of SIMA, the Ministry of Steel has initiated another survey by JPC with active participation of SIMA. As per the available information with SIMA, there are more than 330 sponge iron plants including three gas based plants covering a capacity of about 37.30 MTPA (Gas Based - 9.60 MTPA, Coal Based - 27.70 MTPA).

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Chapter 4 – Material Balances Note

2013-8-28  General Procedure for Solving Material Balance Calculations 1). Choose a basis of calculation. 2). Draw and completely label the flowchart. The flowchart is fully labeled if the composition and flowrate (or amount) of each process stream can be expressed in terms of the labeled quantities.

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Sponge Iron Process for Manned Space Exploration

2021-4-15  Sponge Iron Process for Manned Space Exploration Ariadna Contract No. 18461/04/NL/MV ... Based on thermodynamic considerations, conversion ... cycle (oxidation of iron contact mass, reduction of gas phase) is generally endothermic. The

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M/s Bravo Sponge Iron Pvt. Ltd. - Welcome to Environment

2018-11-16  1.7 MTPA Iron Ore Pellet Plant with grinding Unit 48000 Nm3/hr Producer Gas Plant 350 TPD Sponge Iron Plant 7 MW of Power Plant on WHRB of 350 TPD Kiln Revision from 600TPD to 1000 TPD Rolling Mill. Material Balance 13 05 Raw materials

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sponge iron process

2010-7-29  The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

Read More
Accretion Control in Sponge Iron Production Kiln using ...

Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the accumulation of semi-molten material

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Sponge Iron Iron Steelmaking

2017-7-31  Sponge iron is the product created when iron ore is reduced to metallic iron, in the presence of coal, at temperatures below the melting point of iron. The external shape of the ore is retained with 30% reduction in weight due to oxide reduction resulting in change in true density from 4.4 gm/cc to 7.8 gm/cc in this product

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Heat and Mass Transfer in Reduction Zone of Sponge Iron ...

Numerical prediction is performed on reduction zone of iron ore reactor which is a part of counter current gas-solid reactor for producing sponge iron. The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation.

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SPONGE IRON PRODUCTION BY DIRECT REDUCTION OF IRON

The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production.

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MIDREX Processes - KOBELCO

2011-1-6  by a sealing gas, allowing the continuous charging of raw material and discharging of DRI. The reaction occurring in the shaft furnace is the well-known reduction reaction of iron, described as follows: Fe 2O 3 + 3CO → 2Fe + 3CO 2 Fe 2O 3 + 3H 2 → 2Fe + 3H 2O The exhaust gas (top gas) emitted from the top of

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Sponge iron industry needs quick actions for survival ...

2013-10-24  From 2003, coal based sponge iron route dominated because of limited availability of natural gas and fast growing demand of metallics. In fact, no gas based sponge iron/HBI plant came up after 1994 (19 years). During 2003-2008, there had been a rapid growth of coal based sponge iron plants.

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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.

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M/s Bravo Sponge Iron Pvt. Ltd. - Welcome to Environment

2018-11-16  1.7 MTPA Iron Ore Pellet Plant with grinding Unit 48000 Nm3/hr Producer Gas Plant 350 TPD Sponge Iron Plant 7 MW of Power Plant on WHRB of 350 TPD Kiln Revision from 600TPD to 1000 TPD Rolling Mill. Material Balance 13 05 Raw materials

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Accretion Control in Sponge Iron Production Kiln using ...

Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the accumulation of semi-molten material

Read More
Heat and Mass Transfer in Reduction Zone of Sponge Iron ...

Numerical prediction is performed on reduction zone of iron ore reactor which is a part of counter current gas-solid reactor for producing sponge iron. The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation.

Read More
SPONGE IRON PRODUCTION FROM ORE -COAL

2014-9-2  SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE PELLETS IN TUNNEL KILN . S.C.Khattoi. 1* , G. G. Roy2 1 Project Engineering Consultancy, Keonjhar, Odisha, India 2 . Indian Institute of Technology, Kharagpur – 721302, India. Abstract: Today India stands as the largest producer of coal based sponge iron through

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2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

2015-5-17  called sponge iron. The performance of rotary kiln significantly affects the production capacities of these industries. The performance of rotary kiln is affected by temperature profile inside the kiln, distributions of gas (air)-solid flow, particle size of raw material

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SPONGE IRON PRODUCTION BY DIRECT REDUCTION OF IRON

The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production.

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Direct Reduced Iron and its Production Processes – IspatGuru

2013-3-16  Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as to prevent its re-oxidation.

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Final Iron Steel - Bureau of Energy Efficiency

2017-9-8  Figure 9: Ex-Coal/Lignite/Oil/Gas based Thermal Power Plant Energy balance diagram 194 Figure 10: Ex-CCGT Energy balance diagram 195 Figure 11: Product Mix diagram 197 Figure 12: Ex-GtG Boundary boundary for Sponge Iron Sub-sector 198 Figure 13: Figure 14: Ex

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Figure 10:E x-CCGT Energybalanced iagram

2017-9-8  Iron ore 1.43 Kg Sponge iron 1 Kg. Coal 0.64 Kg. Char 0.064 Kg. Air 5.20 Kg. Flue Gas 6.20 kg. Total Input 7.270 Kg Total Output Heat Supplied = 2058-251 Kcal (Excess heat) In Heat balance of ideal kiln (100% coal used as reducing agent and no coal is

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Modelling and optimization of a rotary kiln direct ...

2014-8-5  Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3. Kiln temperature distribution for the base case The feed material (bed) enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard.

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