Iron ore is used mostly in pellet and/or lumpy form. Oxygen (O2) is removed from the iron ore by chemical reactions based on H2 and CO for the production of highly metalized DRI. In the direct reduction process, the solid metallic iron (Fe) is obtained directly from solid iron ore without subjecting the ore or the metal to fusion.

The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world. This book comprehensively deals with the production of sponge iron in the rotary kiln. The book is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and …

sponge iron is that the powder is slightly coarser and has better flowability, thus allowing it to be used with MBJ. Inherently, the sinter-ability of pure iron is extremely low, so in …

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.

High silica (SiO2) content in the dolomite used for sintering purpose is preferred since SiO2 counter the effect of alumina (Al2O3) in the blast furnace. In the production of direct reduced iron (DRI) by the rotary kiln process, dolomite is used as a desulphurizing agent. Raw dolomite is used in the size range of 4 mm to 8 mm.

The sintering was effective when carried out for 1 hour, but it was not of much significance for 2 and 3 hours sintering. Bardhan et al. [74] analyzed the sintered iron powder component's density ...

Input iron ore: Input iron ore is in form of cooked pellet in this process and high grade hematite iron ore can be used to a certain extent depending on its condition. Reducing agent: Natural gas is broken after the reforming process. In the Midrex process, carbon monoxide gas has a larger share than hydrogen gas in the reducing gas mixture.

The possibility of using iron powders of different morphological, chemical and physical properties as the bases of the metal matrix of the friction layer in sintered friction materials for dry friction under severe braking conditions was investigated. Sintered friction materials, based on sponge iron powder and on iron powder with a fiber-like structure …

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For this gap, a novel approach was proposed to effectively treat the zinc extraction residue via the iron ore sintering process. It was feasible to add 1 wt.% of zinc extraction residues to the sintering raw materials. ... In recent years, China's crude steel production has exceeded 1 billion tons, accounting for over 50% of the global share ...

Sponge iron, also called direct reduced iron (DRI), is made from directly changing iron ore (in any form whatsoever) to iron by a cutback gas or carbon, produced from natural gas or coal. It is one of the many raw …

Two types of Hoganas iron powders—sponge (NC), and highly compressible (SC) were investigated. These specimens were compacted with a pressure of 300, 400, 500, 600, and 700 MPa, before sintering in a production belt-type furnace. Steam treatment of the specimens was at 570 °C for 30 min. The sintered density and …

We offer an exceptionally wide range of iron powders that are used for many different technologies, such as pressing and sintering, additive manufacturing and surface coating. ... Höganäs is famous for its consistent production of high-quality iron powder. We produce sponge iron powder and atomised iron powder from scrap metal. As the world ...

It can produce high-quality liquid pig iron with little environmental pollution. Smelting reduction can use lump ore, pellets, sintered ore, or their mixtures. The choice of coal types is also relatively wide. ... The lower melting gasifier includes two functions, hot metal production and gas production. Coal and sponge iron are fed into the ...

25 July 2017. Contact sales. This application note describes the benefits of X-ray diffraction (XRD) to the quantitative determination of the phase content and the calculation of process critical parameters for the production of direct reduced iron (DRI). Direct reduced iron (DRI), also called sponge iron, is produced by the reduction of iron ...

The production of high-quality sinter is crucial for assuring consistent, stable furnace productivity with a low consumption of reductants. Sinter quality begins with the mined iron ore and the proper selection …

Abstract. This master thesis was a project in cooperation with Höganäs AB. The aim was to increase the apparent density (AD) of two biomass chars, by three different …

The various advantages of iron ore pellets are given below. Iron ore pellet is a kind of agglomerated fines which has better tumbling index when compared with the iron ore and it can be used as a substitute for the iron ore lumps both in the BF and for DRI production. Pellets have good reducibility since they have high porosity (25 % to 30 %).

Sponge Iron plant manufacturers in India use sponge iron as a substitute for scrap in induction and electrical furnaces. The reason for this is that melting scrap is expensive and also in short supply, so sponge iron is the perfect alternative when it comes to using it in the production of high-quality steel.

The DRI-EAF combination allows for higher electrification and lower emission if low-carbon feedstocks and electricity are used. The production of steel from the DRI-EAF route exceeded 90 million tons in 2018 (5% global production) [Worldsteel Association, 2019], with DRI sponge iron production over 100 million tons [(Midrex, …

Production of sintered iron ores is also included]. S S P Sponge Iron Private Limited's Annual General Meeting (AGM) was last held on 30 September 2016 and as per records from Ministry of Corporate Affairs (MCA), its balance sheet was last filed on 31 March 2016. Directors of S S P Sponge Iron Private Limited are Lokeswara Reddy Putha, Yedida ...

Sponge iron is considered more environmentally friendly due to its lower energy requirements and lower carbon emissions compared to pig iron production, which is energy-intensive and has higher carbon emissions. 13. The quality of sponge iron, with fewer impurities, makes it suitable for producing high-quality steel.

the largest shrinkage at low temperatures. The reduced sponge-iron powder is less prone to early sintering owing to its small specific surface and to the lower activity caused by …

The capacity increased from 20.70 in 2010 to 37.4 Mt/year. This has been necessitated by a drop in iron ore production through bans on production as a result of illegal mining detected in iron ore-producing states like Karnataka and Goa and imposed caps on production on well-known iron ore-producing belts of Orissa.

Alternative routes of iron making: Introduction, Processes of Sponge Iron production; SL/RN, MIDREX, HyL processes. Smelting Reduction Processes; COREX, ROMELT, Hismelt. Suggested Text books 1. Ahindra Ghosh and Amit Chatterjee: Ironmaking and Steelmaking Theory and Practice, Prentice-Hall of India Private Limited, 2008. 2.

The use of non-coking coal as an alternative energy source for sponge iron production instead of the conventional metallurgical coke cannot be overemphasized …

Chu Mansheng & Xu Kuangdi. 1 Accesses. Download reference work entry PDF. Sponge iron adopts direct reduction ironmaking method to obtain iron with sponge …

In this study, production of sponge iron by direct reduction of oxides and the effect of reductant on metallization were investigated. In the first stage of the study, scale formed during hot rolling of slabs was reduced in a rotating furnace using solid and gas reductants. Coal was used as solid reductant and hydrogen released from the …

Observing the distribution curve of μ for the sintered friction material based on fiber-like iron powder (Fig. 5, graph 1), it was noticed that the mean value of μ is greater and that there is considerable disparity of the value of μ compared to the same values for the sintered friction material based on sponge iron (Fig. 5, graph 2).

The sintering process is a well-established process in use at integrated steel making plants. It consists of an agglomeration through an oxidizing/reducing fusion of iron ore fines (sinter feed) and fluxing agents (lime, limestone, etc.) as well as re-circulated materials (dust, sludge, etc.) at temperatures between 1200 °C to 1400 ° C. A carbon …