the sponge iron production process

the sponge iron production process. The sponge iron reaction sir is a chemical process based on redox cycling of an ironbased 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 o in application, the sit is used in the reformer sponge iron cycle resc in combination with a steam

PDF The Smart Choice - Tenova

(ambient) temperatures. The process characteristics allow for independent control of the DRI metallization and carbon levels. Metallization can be adjusted at will, typically around 94% and higher. _ DRI carbon levels can be selected in the range of 1.5 - 4.0%, most of which is in the form of iron carbide. _ The high iron carbide content

Direct Reduced Iron and its Production Processes - IspatGuru

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.

Sponge Iron | High & Low Carbon Grade Supplier & Wholesale

Sponge iron is a valuable source of iron for the production of high-quality steel. With the Direct Reduction technology that has been developed considerably in recent years, sponge iron melting in electric arc furnaces has more qualitative advantages than scrap metal smelting for steel making.

SL/RN | Middle East Steel Industry

Iron Carbide Process: Energy input to the process is reported to be 12.6 GJ/t-product (IPPC, 2009. p.500). Total CO 2 emissions from the process are reported to be 2.17 t CO 2 /t-steel. Capital expenses for the process are estimated to be $347.6/t-steel. Production costs are estimated to be lower than other DRI processe. Commercial: Circored

sponge iron process

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.

PDF) i) Direct Reduced Iron: Production

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

DRI production | International Iron Metallics Association

The reducing agents are carbon monoxide and hydrogen, coming from reformed natural gas, syngas or coal. Iron ore is used mostly in pellet and/or lumpy form. The chemical reactions involved in the direct reduction of iron are the following: With H2. 3Fe 2 O 3 + H 2 → 2Fe 3 O 4 + H 2 O Fe 3 O 4 + H 2 → 3 FeO + H 2 O FeO + H 2 → Fe + H 2 O With CO. 3Fe 2 O 3 + CO →2Fe 3 O 4 + CO

reduction of iron ore crusher slrn

slrn procedure for sponge iron production. A simulation study of reduction kinetics for sponge iron, The present process involves treating iron ore-coal composite pellets in a crucible over the hearth in RHF. The various solid phases evolved at the end of theCN1818081A, The invention is about the producing method of the sponge iron. Get Price

Direct Reduced Iron and its Production Processes – IspatGuru

Mar 16, 2013 · DRI has a porous structure. This is because DRI is produced by removing O2 from iron ore. It is also known as sponge iron since its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is around 10,000 times greater than the internal surface area of solid iron.

My favorite part about baking is watching the process play

Yeah, there's a cast iron pan on the rack underneath the pans with the loaves. I pour ~1 cup of boiling water into it to start. It boiled out a little faster than I thought so you can see me add a little bit more boiling water to the pan about halfway through the video.

Sponge Iron - an overview | ScienceDirect Topics

What is sponge iron?

Sponge iron making process - SlideShare

Nov 09, 2014 · Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical Composition

Direct Reduced Iron Industry in India — Problems and Prospects

`the quality requirements for the rotary kiln sponge iron process. The sponge iron fines generation is high and ranges from 15 — 30% depending upon the ore used due to high reduction degradation. This will not only reduce the sales realization of the product but also will lead to accretion formation in the kiln shortening the campaign life.


Steel Exchange India Limited is having a Sponge Iron manufacturing unit in technical collaboration with world renowned M/s Mannesmann Demag of Germany (CODIR Process). With an installed capacity of 2x350TPD and can able to produce Sponge Iron of 0.225 Million Tons per Annum 1.

Sponge Iron – Tulsyan Steel

Sponge Iron can be utilized as a substitute for steel scrap. It plays a pivotal role as feed material in all mini steel plants. Sponge Iron is an apt material as it can be utilized as a coolant in Integrated Steel Plants. Sponge Iron is manufactured by reducing iron ore without the melting process – thereby making it energy efficient. The


Part 3A: Iron Sponge Basics November 2017 One of the oldest technologies for the removal of hydrogen sulfide (H 2 S) from gas is the use of “Iron Sponge”. A chemical-physical process, originally developed to remove H 2 S from natural and coal gas streams, iron sponge has been in use for over 140 years and more recently to remove H 2

Direct reduced iron process - tec-science

In the electric steel process, the sponge iron obtained from the direct reduced iron process is used for crude steel making. In general, scrap is also added to this process as well as pig iron from the blast furnace process. These components are then mixed in a special oven. While the pig iron is already liquid, the sponge iron and the added

Ironmaking 101 – From Ore to Iron with Smelting and Direct

Oct 17, 2017 · However, the reduced "sponge iron" from a DRI process is porous and will oxidize or rust if shipped or stored in the porous form. Sponge iron is pyrophoric and will burn if ignited. HDRI can be compacted and cooled to produce hot-briquetted iron (HBI) pellets, which can be easily handled, shipped or …

Direct reduced iron - Wikipedia

Sponge iron is not useful by itself, but can be processed to create wrought iron or steel. The sponge is removed from the furnace, called a bloomery, and repeatedly beaten with heavy hammers and folded over to remove the slag, oxidise any carbon or carbide and weld the iron together. This treatment usually creates wrought iron with about three percent slag and a fraction of a percent of other impurities.

tunnel kiln process sponge iron crusher in australia

slrn process of sponge iron making. brief process of coal based sponge iron rotary kiln Sponge iron rotary kiln process anticorruption helpline sponge iron composition manufacturing process lloy sponge iron making is a process in which iron ore lumps typically mmmm size are tumbled with a selectgrade of ironcoking coal little dolomite inside an


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 can be classified into:-

HYL III and SL/RN - The two widely accepted Direct

The HYL process was developed in Mexico and was the forerunner of the HYL III direct reduction technology. In HYL I process, a mixture of gases containing about 89% of reducing compounds is used. Each reduction module in HYL plant consists of four units - three “in line” and the fourth in …

Energy Audit Methodology of Sponge Iron Manufacturing

Jul 14, 2014 · Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary

Sponge Iron Production Process - Arij Trading

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.

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.

slrn technology india

slrn process dri Iran Ore Mining Sponge Iron,Steel Sponge Iron,Sponge Cast Iron this fact the heat integration study is done in the sponge iron process by SLRN Process Industrial Efficiency The so-called Stelco-LurgiRepublic Steel-National Lead (SLRN) process is a widely used coal-based DRI-making process which uses a rotary kiln.

Talk:HIsarna ironmaking process - Wikipedia

The SLRN Process : In 1965 the very first DRI developed was the Outokumpu Process by a consortium including STELCO of Canada, Lurgi, Republic Steel (USA) and National Lead, which caused the process to also be commonly known as SLRN. This process adapted the conventional limestone-to-lime converting kiln into an iron ore and coal fines iron reduction kiln which produced sponge iron which was 'refined' …


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

Sponge Iron Production By Direct Reduction Of Iron Oxide

This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is ‘directly reduced’ in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron).