The sponge iron formed in the direct reduction process is then melted in an electric arc furnace. In these processes, the iron oxides in the ore are reduced to metallic iron. In the next step, the raw iron is usually dropped into a torpedo ladle car where reagent is added to purify the iron from sulfur.

The theoretical yield can be calculated from the balanced equation by doing a reacting mass ratio calculation. Yield and industrial production. The higher the yield of a reaction, the more economic is the process. There will be less waste to deal with and dispose of, which involves extra cost.

A yield loss arises in any parts of the iron and steel making process, when for a particular step, the weight of the steel product made is less than the input of steel that is used. In a cold rolling mill for example, if the input - often called a charge weight - is 100 tonnes of hot rolled coil, and the output is 95 tonnes of cold-rolled steel ...

To calculate percent yield in a chemical reaction, divide your actual yield by your theoretical yield and multiply by 100.

In a 100 TPD Sponge Iron plant, the sponge iron is fed to the Induction melting furnace, producing molten steel at 88% yield. The Energy consumption details are as follows: Coal Consumption : 130 TPD GCV of coal : 4500 kcal/kg Power Purchased from Grid : 82400 kWh / day Specific Energy consumption for Kiln producing Sponge Iron: 120 kWh / ton sponge iron Calculate the following 1.

The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant. The sponge iron is also known as Direct Reduced ...

12.5.1 Process Description1-3 The production of steel at an integrated iron and steel plant is accomplished using several interrelated processes. The major operations are: (1) coke production, (2) sinter production, (3) iron production, (4) iron preparation, (5) steel production, (6) semifinished product preparation, (7) finished

iron ore creates lots of microscopic pores. These microscopic pores give the iron a sponge texture, therefore it is in another sense known as sponge iron [3] . HBI is currently produced via two major process routes. By one process route, reduced DRI pellets can be fed from the reducing furnace into a briquetting machine. Physically

ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3 …

cracking unit (FCCU) for the production of gasoline and diesel. Improving vacuum distillation is one of the best methods for increasing gas oil yield in a refinery while at the same time reducing the amount of vacuum reduced crude (coker feed). This enables higher refinery throughput rates to be achieved.

The contribution of coal based sponge iron to the total production in India has remained above 60 per cent since 2004-05. The contribution of coal based sponge iron has been on the rise. From about 8 MT in 2004-05, contributing 63 per cent to the total production, it has grown to

In the primary route of steel making iron ore is used as raw material. In the first stage iron ore is melted in a blast furnace to produce hot metal, and in second stage this hot metal is moved to a steel making shop to produce steel in a basic oxygen furnace. In the secondary route of steel making steel is produced using sponge iron, scrap etc.

Jul 07, 2020· As mentioned previously, titanium is currently produced by the Kroll process In the reduction and separation stages, iron in the steel reactor diffuses into the titanium sponge and accumulates in the titanium product as an impurity.[67,68,69,70] In the current Kroll-based technology, the iron concentration at the bottom and side ...

Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of Vibro Feeder, where Oversize i.e. + 20 mm and Undersize i.e. – 5

Procedure. (rev 6/10) During Weeks 2 and 3 of lab, you will do two experiments - Cyclohexene and Melting Points (MPs). Because of a limited number of melting point devices and gas chromatographs, one half of the class will do Cyclohexene during the 2nd week …

sponge iron or copper. The lower compacting pressures required for aluminum permit wider use of existing presses. Depending on the press, a larger part often can be made by taking advantage of maximum press force. For example, a part with a 130 cm 2 (20 in. 2) surface area and 50 mm (2 in.) depth is formed readily on a 4450 kN (500 ton) press.

12/16/2010 3:58 AM. we would like to know the correct method for calculating the yield for working the production of Sponge Iron in a rotary kiln. we have been evaluating the yield for production using the following formula : P = (Q-%TM)X (% Fe (T) in ore - % LOI - 1 / 2 % L&P) where. P = Production,

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron …

A laboratory study was carried out to explore the prospect of obtaining a high quality pelletizing concentrate suitable for sponge iron (SI) production by concentration of an iron ore rich in ...

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H ...

In the primary route of steel making iron ore is used as raw material. In the first stage iron ore is melted in a blast furnace to produce hot metal, and in second stage this hot metal is moved to a steel making shop to produce steel in a basic oxygen furnace. In the secondary route of steel making steel is produced using sponge iron, scrap etc.

BENEFITS UOM IRON ORE PELLET VARIANCE YIELD IMPROVEMENT % 56.80% 67.57% 10.77% PRODUCTION FACTOR MT 1.76 1.5 0.26 REDUCTION IN SOLID FUEL CONSUMPTION MT 1.54MT/MT 1.4MT/MT 0.14MT/MT 3. Use of Pellet Pellets are balls of iron ore used in the DRI Plant. They are made with technology that uses the powder that is generated during

Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) into iron by a reducing gas or elemental carbon produced from natural gas or coal.Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting ...

Iron ore is the key raw material for steel production enterprises. Generally, iron ore with a grade of less than 50% needs to be processed before smelting and utilization. After crushing, grinding, magnetic separation, flotation, and gravity separation, etc., iron is gradually selected from the natural iron ore.

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.

Thursday, July 29, 2010. TECHNICAL ASPECTS OF MANUFACTURE OF SPONGE IRON. We have produced 55 million tons plus of steel in our country in the year 2008.This production of steel has come thro both conventional blast furnace route, electric arc/induction furnace route and thro new iron making technology COREX. Process.

The process of sponge iron making aims to remove the oxygen from iron ore. The quality of sponge iron is primarily ascertained by the percentage of metallization (removal of oxygen), which is the ratio of metallic iron to the total iron present in the product. Sponge iron manufacture is highly sensitive to raw material characteristics.

Market share: About 23% of sponge iron total production. 4) Tunnel furnace process . This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction temperature, and reduction is performed on Silicon Carbide (SiC) Crucibles in a tunnel furnace.

about 30 to 40% of sponge iron. These agglomerates can only be removed by time-consuming measures such as oxygen lancing or overheating of the bath. The so-called Iceberg process (process technique No. 2) developed by IRSID is characterized by the continuous charging of sponge iron onto an unmolten sponge iron heap. The feed rate is regulated ...

stresses meet a rising yield point and all further particle deformation ceases, i.e. the densification process stops. The deformation strengthening of the powder particles can be made evident by means of X-ray structural analysis. In, three photo-records of X-ray Fig. 4.4 back-reflections are shown, obtained (A) from a commercial sponge-iron

Fig. 2 show the world DRI production by process in 1999. Other gas. 2.3 %. ... yield the material obtained from the cooler will first ... metallized sponge iron pellets into liquid ho t metal in ...

Properties of three sponge-iron grades – NC100.24, SC100.26, MH80.23, and of two water-atomized iron powder grades – ASC100.29, ABC100.30, are presented in the diagrams at Figs. 3.2 and 3.3 and in Table 3.1. Table 3.1 Properties of some Höganäs Iron Powders Powder grade Approx. particle size range µ m Apparent density g/cm 3 Flow s/50g H ...

Reaction: C+O2=CO2 CO2+O2=2CO Fe2O3+CO=Fe3O4+CO2 Fe3O4+CO=FeO+CO2 FeO+CO=Fe+CO2 Typical Analysis of Sponge Iron Produced from Coal Based Process Total iron 91 - 93 % Metallic iron 80 - 84 % Metallisation 90 - 92 % Gangue 3 - 4 % Carbon 0.25 % Sulphur 0.02 - 0.03 % Phosphorous 0.035 - 0.05 % KINETICS OF IRON ORE REDUCTION It is reduction ...

CHEM 1105 Experiment 7 1 EXPERIMENT 7 – Reaction Stoichiometry and Percent Yield INTRODUCTION Stoichiometry calculations are about calculating the amounts of substances that react and form in a chemical reaction. The word "stoichiometry" comes from the Greek stoikheion "element" and metriā "measure." Based on the balanced chemical equation, we can calculate the amount of a …

• The best scrap substitute with respect to energy usage is liquid pig iron or hot metal. • Gangue and ash in ore and coal increase minimum ironmaking energy by about 6%. • In BOF steelmaking, the energy to produce steel is less than the energy to produce iron because scrap is melted in the process.

applicable for change in major process due to external factor. B:Sponge Iron Sub-Sector 14. The entire sub-sector is divided into 7 group on similarity of product 15. The major product in 7 group is as per table below 16. The Energy consumption of Pellet Plant shall not be included in the assessment year as well as in the baseline year.

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 ...

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.

The Al Reyadah [(CSLForum, 2020)][ (Sakaria, 2017)] plant uses SMR for syngas production and then feed it as reducing gas to a HYL DRI plant for sponge iron production. The off-gas from the process consists of CO2 and H2O, which is the source of capture for CCS facility.