We are offering a range of sponge iron plant and other equipment to our clients at optimum prices. Four different applications of the sponge iron reaction have been considered within this initial study. Presently, there are 118 large and small sponge iron plants in india 115 of them are coal based while only 3 are natural gas based. This hot metal is then tested for its chemical composition. In general, sponge ore reactor is divided by3zones,whicharereferredtoasreduction,isobaric, and cooling zones. In realizing this, it is necessary to plan and design a sponge iron plant by applying the requirements specified in industry 4. Jul 14, 2014 most of the plants in india use dri processa solid state direct reduction process by which iron ore is reduced to sponge without phase change figure 1. Material balance 05 raw materials requirement and its source 01 06.
Pdf fsn analysis for inventory management case study. Energy audit methodology of sponge iron manufacturing. 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. Tata sponge iron limited tata sponge iron limited was incorporated on july 31, 1982, as a public limited company, under the provisions of the companies act, 1956, registered with the registrar of companies, odisha at cuttack. Mar, 2011 iron ore reactor is a moving bed reactor to produce sponge iron product from iron ore. Out of the total 107 number of sponge iron plants located in orissa, sundergarh district has maximum number 47 followed by keonjhar 20, jharsuguda, sambalpur 10, jajpur 5, dhenkanal 4, cuttack 4, angul 3. The repercussions are already visible near sponge iron factories which have mushroomed in iron ore and coalrich areas. Effluent and emission standards for sponge iron plant.
A chemicalphysical 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. Pdf waste heat recovery steam generator in sponge iron. Iron ore is reduced in solid state at 8001050 c either by. Pdf during the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and. The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace. If an item is not applicable also known as iron sponge, not spent or information unavailable, the space must be so marked.
For this purpose a case study of typical sponge iron production process is considered. Janki corp plans sponge iron unit in sidiginamola in bellary. The direct reduction process uses palletized iron or natural lump ore. Either coal or natural gas is used in sponge iron production. The external shape of the ore is retained with 30% reduction in weight due to oxide reduction resulting in change in true density from 4. District like dhenkanal, jajpur, anugul and cuttack followed the top four district with fig. Hoganas sponge iron process and the wateratomizing process.
Project feasibility report for expansion project chapter 01 2 of p a g e 2 salient features of the project the company has acquired 78. The material gets melted at a temperature of 1500c 1700c. It has a slightly higher iron content that makes it better suited for use in an electric arc furnace route of steel making. In the sms plant, sponge iron along with pig iron and scrap in a predetermined ratio is charged in the furnace.
Such tumbling of prices hits at the economic viability of the sponge iron sector. The process of sponge iron making aims to remove the oxygen from iron ore. Sponge iron is the product created when iron ore is reduced to metallic iron, usually with some kind of carbon charcoal, etc, at temperatures below the melting point of iron. Pdf abc analysis for inventory managementcase study of. The waste gas from a sponge iron plant exits at a temperature of around 200300 c. The direct reduction process uses pelletized iron ore or natural lump ore. Gas and solid phases are passed in counter current. Also, we have an inhouse design unit which facilitates our experts to fabricate the latest design of ongoing trend of the market. Sponge iron is also known as direct reduced iron dri.
Tata sponge iron limited has the distinction of being one of the early players in sponge iron industry. 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. Board of directors our board of directors ensure the companys prosperity by collectively directing its affairs, whilst meeting the appropriate interests of its shareholders. Sonahatu block, district ranchi, jharkhand private railway siding for loading of iron ore at manoharpur station in chakradharpur division of ser.
Abc analysis for inventory managementcase study of sponge iron plant. Similarly, coal fines, left over by the dri plant are fed to fbc boiler to generate power. Sponge iron at its plant at village dagori, chhattisgarh with an installed capacity of 1, 50, 000 mt per annum. In this pilot plant, a totally indigenous technology for production of sponge iron has been developed in which noncoking coal is essentially used as the reductant. Ca2052659c process for the production of pig iron and. Direct reduction, is an alternative route of iron making has been developed to overcome some of these difficulties of conventional blast furnaces. Introduction the tunnel kilns are mostly used by the ceramic industries for heating refractory and ceramic products 12. Tunnel kiln, iron orecoal composite pellets, sponge iron, thermal efficiency, carbon utilization efficiency, percentage metallic iron.
Sponge iron production in india million tonnes data source. The project will have facilities like 6x100 tpd sponge iron plant 1,80,000 tpa, pellet plant 6,00,000 tpa, captive power plant 24 mw, 2x350 tpd. In the year 1908 use of tunnel kiln started for iron oxide reduction. The simulation model of iron sponge plant layout for the defense industry based on industry 4. In odisha, women from the bonai vana suraksha committee marched up to the district collector with samples of soil, water and grain to protest against sponge iron plants. Dri is successfully manufactured through either gas or coalbased technology. But its manufacturing process, based on coal, is highly polluting.
Mining 450 saraikelakharsawan 5 mis jharkhand is pat pvt. At present, there are 18 sponge iron plants coalbased in orissa producing about 0. Sponge iron manufacture is highly sensitive to raw material characteristics. Janki corp is planning to expand its sponge iron plant 1,80,000 tpa to 4,00,000 tpa and installation of iron ore beneficiation plant 0.
The paper attempts to establish a case for sponge iron plants in india to meet the future raw material requirements of the mini. Development of energy conservations scenarios for sponge. For details regarding change in the name of our company, please refer to the section titled general. Jharsuguda district contain 10% sponge iron plant of state followed by sambalpur 9% 10.
The simulation model of iron sponge plant layout for the. A sponge iron sponge iron or direct reduced iron is a high quality porous solidstate metallic product that is produced from iron ore in the form of lumps, pellets or fines using a reducing gas such as natural gas or coal. Kumar, journalinternational journal for research in applied science and engineering technology, year2017, volume5, pages5357. Documented data meteorology the meteorology of the area is summarized below. Construction of a public railway siding at jagdalpur is to be taken up by railways. Flow of materials in rotary kilns used for sponge iron manufacture. A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. 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 8001200 c. Project report on sponge iron reduction plant steel.
The company operates a 150,000 mt per annum plant for manufacturing sponge iron at village dagori in the state of chhattisgarh. Sponge irons with a diameter less than 5 mm go to the briquet unit to produce briquets diameter above 25 mm. The sponge iron manufacturers association sima established in 1992 is an all india apex body of. This has brought riot of colors in the mining industries around potential iron zones of keonjhar, sundergarh and mayurbhanj. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. Measures in sponge iron indust with particular reference to tata sponge iron limited fig. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting. Sponge iron is the product created when iron ore is reduced to metallic iron, in the presence of coal, at temperatures below the melting point of iron. Orissa sponge iron manufacturers association a8palashpalli,bhubaneswar20 sl. Direct reduced iron industry in india problems and prospects. Integrated steel plants isp data is updated monthly, averaging 2,924. Durluga,near helipad, jharsuguda, orissa768204 sri m.
H 2s removal from gas manufacturers name emergency telephone number connellygpm, inc. Iron ore the quality requirement of sized ore for sponge iron production can be classified into. Thus, the sector depends mostly on coalbased sponge iron and nearly 80% of the total coalbased sponge iron plants are located in india. The former process is based on reduction of iron ore, yielding a highly porous sponge iron which subsequently is comminuted to powder. Sponge iron quality the rotary kiln sponge iron has lower metallisation about 85 88% on the average and low carbon content 0. Energy audit methodology of sponge iron manufacturing units.
Durluga,near helipad, jharsuguda, orissa768204 vill. Then, they are transferred to the steel plant with the sponge iron. The latter process is based on atomization of a stream of liquid iron or steel by means of a jet of pressurized water. Dec 30, 2015 nova iron and steel limited is a manufacturer of sponge iron, a metallic product produced from iron ore and used for making primary steel products. Sponge iron plants can be established in designated industrial areasestates as notified by state government. Further, the waste gas at reduced temperature is used to cool hot sponge iron which is previously carried out by water. Most of the plants in india use dri processa solid state direct reduction process by which iron ore is reduced to sponge without phase change figure 1. Iron ore pellets are used in blast electric furnaces for producing sponge iron and steels. 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. Prevalence and predictors of respiratory diseases among.
The sponge iron plants are mostly distributed in 9 districts of state. This results in a spongy mass, sometimes called a bloom, consisting of a mix of incandescent wrought iron and slag. 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. Sponge iron plant sip sponge iron reformer properties of sponge iron microstructure of sponge iron reactions apparent density of the final product varies between 1. Sponge iron dri is the product obtained in the direct reduction process, which is used as feedstock. Pdf design modifications for energy conservation of sponge iron. This heat is utilized to preheat the air entering to kiln. Data1 and data2, are collected from a typical sponge iron plant, which correlate the input and output. The location of sponge iron plant should be at least 500 m away from national highway and state highway. The material downloaded from the site before the hopper. In the direct reduced iron dri plant, production of sponge iron using a solid reductant involves reducing iron ore lumpspellets with a carbonaceous material such as coal. 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. The radial distance between two sponge iron plants should be 5 km for plants having capacity tpd or more.
The simple scheme of iron ore reactor is shown in figure 1. Pdf fsn analysis for inventory management case study of. Pollution from the sponge iron industries is the core reason whycommunities rise in arms against this industry. In the years to come, indias expanding steel production will be largely driven by sponge iron. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. Optimization of the iron ore direct reduction process. The sponge iron produced from iron ores in the reducing shaft furnace is supplied to the melting gasifier and converted there into a pig iron melt. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively. Sponge iron or directreduced iron is a transitional material used in the production of steel.
Sponge iron industry has made several representations to the competent authorities for changes in policy which will help the sponge iron industry to procure iron ore at a regulated reasonable price. Sponge iron industry low cement castables sharadaa refcast lc45 lc dri lc 80 velcrete 0a for standard requirement, veclrete 003 for premium requirement standard products for kiln velcrete 0a velcrete 003 duct lining repair castables velcrete for 3 years campaign life sharadaa refcast 45, re. As such it was the first commercial plant based on indigenous. The reduction is carried out in a rotary kiln which is inclined and rotates at a predetermined range of speeds at a stipulated temperature 850c 1,500c. Summary report of investigation for cdm project of waste figure 3 energy conservation in iron plant heat recovery based captive power plant in sponge iron 90% of total produced heat can use plants of orissa, india a lot of sponge iron manufacturers with rotary kiln are 3. Therefore, the ore should be high in iron content and low in gangue, physical specification size 520 mm oversize sponge iron process.
A thesis submitted for partial fulfillment of the degree. In this process route, iron oxides are converted to the dri hbi by using natural gas in a vertical shaft fur. Nov 17, 2012 pollution from the sponge iron industries is the core reason whycommunities rise in arms against this industry. Strength and granulometry are the two important physical requirements. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. Environmental control measures in sponge iron industry.
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