This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln. In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace.
The manufacture of sponge iron entails the de-oxidisation of iron ore through the direct reduction. Direct reduction is a process by which metallic iron is produced by the reduction of iron ore below the melting temperature of iron. The production technology of DRI has two distinct routes.
1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge ...
Dec 24, 2018· Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by ...
Iron Sponge Process. The iron sponge process uses the chemical reaction of ferric oxide with H2S to sweeten gas streams. This process is applied to gases with low H2S concentrations (300 ppm) operating at low to moderate pressures (50-500 psig).
Sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. It is a substitute for scrap and is mainly used in making steel through the secondary route.
Hot sponge iron from rotary kiln shall be smelted directly by continuously charging into smelting reduction furnace. The smelting furnace itself is equipped with stoves to preheat the hot blast ...
Sponge iron is a highly ferrous ore from the direct reduced iron process! In order to prevent excessive re-oxidation of the sponge iron in the ambient air, it must …
Mar 16, 2013· 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.
Iron Sponge Process. The iron sponge process uses the chemical reaction of ferric oxide with H2S to sweeten gas streams. This process is applied to gases with low H2S concentrations (300 ppm) operating at low to moderate pressures (50-500 psig).
The pilot project that was setup for 0.1 million Tons P.A capacity under the guidance of Prof. G.G Roy Dept of Metallurgy IIT Khargapur, has been successful and has exceeded all the expectations with the technological breakthrough in the process of Iron ore reduction or Sponge iron manufacturing through a tunnel kiln instead of the conventional ...
Sep 19, 2009· The iron-sponge process generally uses a single vessel to contain the hydrated ferric oxide wood shavings. A drawing of an iron-sponge unit showing typical provisions for internal and external design requirements was presented in Figure 7-3.
This product is known as direct reduced iron (DRI) or sponge iron. Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR ...
Jun 25, 2020· Although iron sponge has been successfully used to remove H 2 S from gas streams for over a century, it is the engineered process of the H2SPlus Systems and operating technique that ensures safety, media life and ease of media removal. Granular Media. A Better Granular Media
Iron ore 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 at o C.
Jul 29, 2010· In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.
Midrex is an innovative ironmaking process, developed for the production of direct-reduced iron (DRI) from iron ores and primarily natural gas. You want to k...
Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & …
The COREX process is a two-stage process, as is shown in Figure 1.1.40.In the first step, iron ore is reduced to sponge iron in a shaft furnace by means of reducing gas. In the second step, the reduced iron is melted in the melter–gasifier vessel.
Jul 29, 2010· In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.
Mar 15, 2004· Sponge iron process for manned space exploration. The Sponge Iron Process (SIR) is a well-known technology for the production and purification of hydrogen. It consists of a cyclic process in which a feed gas, rich in carbon monoxide and hydrogen (e.g. syngas), is passed on an iron oxide (magnetite Fe3O4) at high temperature.
Direct Reduced Iron (DRI) Production Plant NIPPON STEEL ENGINEERING CO., LTD. Basic Concept or Summary S-16 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.
Nov 03, 2016· 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 takes place in the reduction tower.
The sponge iron reaction (SIR) is a chemical process based on redox cycling of an iron-based contact mass, the first cycle is a conversion step between iron metal (Fe) and wuestite (FeO), the second cycle is a conversion step between wuestite (FeO) and magnetite (Fe 3 O 4). In application, the SIT is used in the reformer sponge iron cycle (RESC) in combination with a steam reforming unit.
Jun 25, 2020· Although iron sponge has been successfully used to remove H 2 S from gas streams for over a century, it is the engineered process of the H2SPlus Systems and operating technique that ensures safety, media life and ease of media removal. Granular Media. A Better Granular Media
The purification process consists of down flow gas through a packed bed of IRON SPONGE, with the iron oxide reacting with H2S to produce iron sulfide and water. The water moves down through the bed with the gas and should be drained off to prevent accumulation.