Integrated Steel Plant | TMT Bar Manufacturing Plants ...

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.

SL - RN (Iron Making Rotary Kiln Process for DRI Production)

Aug 07, 2016· Process Description and flow diagram of Coal Based DRI Plant Description of Sponge Iron Manufacturing Process 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.

Coal Gas for DRI plant - Jindal Steel and Power

PROCESS FLOW CHART FOR MANUFACTURE OF SPONGE IRON Raw Material Feeding at ground hopper (Coal, Ore) Coal Over Size Crushing Screening Coal Bin Iron Ore Bin Screening Crushing Sized Iron Ore Over Size Limestone Bin Screening of mixed end product (Sponge Iron and unburnt coal) Indirect cooling in rotary cooler with water spray

Process Description and flow diagram of Coal Based DRI Plant

The proposed project is a Greenfield Steel Mill consisting of Primary Sponge Iron Plant, and Secondary Plant to produce Ingots/Rolled Products. The proposed project will consist of Rotary Kilns to process Iron-ore to produce Sponge Iron. The Sponge Iron, and M.S. Scrap will be melted in Electric Induction Furnace.

Sponge Iron Composition & Manufacturing Process - Lloyd's ...

DRI is also known as sponge iron, it is a solid-state direct reduction process (Fig. 2.6). Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from the other end. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes (Choudhury, 2014 ...

Process flow diagram - Wikipedia

The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and basic oxygen furnace (denoted BF and BOF hereinafter, respectively), which is presently the most commonly used method (51% of world steel production).

(PDF) i) Direct Reduced Iron: Production - ResearchGate

The process flow diagram (PFD) of a conventional coal based sponge iron plant is shown in Fig. 1.Different streams in the PFD are assigned individual number and henceforth each stream will be referred through its respective number.

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

Bars are produced in fully automated Re-Rolling Mills. The Captive Power Plant of 12MW (synchronized with PDB grid) and the National Grid are the sources of electricity of the factory. Fig: Production Flow Chart . Once the bars are cooled, they are cut into desired length by means of cold shearing.

MIDREX Processes

Iron Ore Pellets Electric Arc Furnace Steelmaking ... Salzgitter The process shown above is illustrative only and is not designed to show the steelmaking process in detail. Not all steel plants produce all of the products shown in this diagram. OVERVIEW OF THE STEELMAKING PROCESS Pellets Sinter Limestone Coke Iron Ore Coal Scrap ...


Nov 09, 2014· Making process iron ore to sponge iron. ... Sponge iron making process 1. ... SECONDARY AIR Secondary air is introduced axially in the direction of the gas flow The air supplied to the length of the kiln is metered for close control of temperature and gas atmosphere in the kiln Heating zone extends from 25% to 40% along length of the kiln and ...

12.5 Iron And Steel Production - US EPA

2. Description of Sponge Iron Manufacturing Process 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 ...


plants. 2. MIDREX process Fig. 3 is a flow chart for the MIDREX process. Either lump ore, or pellets prepared for direct reduction ironmaking, are charged as raw material from the top of a shaft furnace. The ore is reduced inside the furnace and the reduced iron is discharged from the bottom of the furnace. Reductant gas blown


SPONGE IRON PRODUCTION. The quality of sponge iron employed in the LPF process is important since it relates to the precipitation efficiency and sponge iron consumption. Normally a 40 to 60% metallic iron content in the sponge iron …


process flow iron ore wet washing plant Iron Ore Beneficiation and Washing Plant - Star, We offer Iron Ore Beneficiation and Washing Plant for Iron ore beneficiation from low grade to high grade from Hematite/Magnetite ore by wet or dry process by using state of the art technology iron ore beneficiation plant process flow chart ppt iron ore ...


Coal Gasification Plant and use of by-products, Angul. Direct-reduced iron (DRI), also called sponge iron is produced from direct reduction of iron (in the form of lump, pellets or fines) by a reducing gases produced from natural gas or coal.

What is a Process Flow Diagram | Lucidchart

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) to iron by a reducing gas or elemental carbon produced from natural gas or coal. Many ores are suitable for direct reduction.

sponge iron process: 2010

The overall process requires duration of approximately eight to ten hours inside the kiln, during which iron ore is optimally reduced and discharged to a rotary cooler for cooling below 120°C, before coming out into the finished product circuit, flowchart of the process is given below:

A Thesis Submitted for Partial Fulfillment of the Degree ...

Jul 29, 2010· 2.0 DESCRIPTION OF PROCESS: Flow chart of SL/RN process has been shown in fig. 1.Sized Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge end of Rotary Kiln inclined at 2.5%. Coal is also injected through an Injection Pipe at the discharge end of Kiln.

Process Flow Diagram Sponge Iron Plant

i) Direct Reduced Iron: Production. March 2016; ... This product is known as direct reduced iron (DRI) or sponge iron. Processes that produce iron by reduction of iron …

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