The sponge iron is produced via the direct reduction iron process (DRI) (National Iranian Steel Company (NISC), 2021). Direct reduction methods are categorized as coalbased or gasbased, depending on the availability and use of resources. produces sponge iron via the direct gasbased reduction method due to its abundant gas resources.
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Today, the majority of DRI (79%) is produced by gasbased processes: the Midrex process, which is the market leader, and the HYL/Energiron process, while another 21% can be attributed to coalbased processes (Midrex Technologies, 2017a). The Energiron process is the successor of the HYL processes I to IV, which are not marketed any longer.
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DRI: This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H 2 and CO. Although DRI production is more energy efficient than pig iron production from BF ...
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Process optimisation. ... India's predominantly coalbased DRI sector will have to necessarily pass through a phase of energy transition. It is expected that the transition pathway will be from ...
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Because this process does not use natural gas, a lowercarbon content product (around %) is expected. Similar to the gasbased HYL process, in the coalbased process, the furnace top gas is cooled and cleaned, and its CO 2 is removed and then recycled into a reducing gas circuit. Reducing gas is produced in a coal gasifier that can process ...
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7) The utilization of DRI in foundry operations as inocculants improves the properties of the cast iron. 8) The efficiency and throughput of the blast furnace can be improved by the utilization of DRI. 9) The coke and flux consumption of the blast furnace process can also be reduced by the utilization of DRI.
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In comparison to gasbased processes, the coalbased DRI production process is quite energy intensive and poses environmentrelated issues. Being a developing country with steel demand projected to reach between 500 and 760 million tonne (Mt) by 2050, the country needs to adopt energyefficient and environmentfriendly steel production ...
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The above parameters for new steelmaking technologies—scrapbased EAFs, coalbased DRI with and without CCUS, gasbased DRI with and without CCUS, hydrogenbased DRI, and oxygenrich smelting reduction with and without CCUS—were obtained from recent studies and communication with Chinese experts (Battle et al., 2014; IEA, 2020a; IRENA ...
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Coal based Direct Reduced Iron (DRI) / Sponge Iron Plant Process Flowchart. COAL PRIMARY. SCREEN. IRON ORE VS2. GROUND COAL. BC4 GROUND. HOPPER. GH1 HOPPER. +80 mm.
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Such coal based sponge iron is mainly used by induction furnace steel producers leading to technical deficiencies in the steel making process. Further, energy consumption wise, the coal based sponge iron plants are not efficient which can be improved by cogeneration using kiln off gas. CONSIDERATIONS IN SETTING UP COAL BASED SPONGE IRON PLANTS
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DRI production with syngas. The gas based direct reduction (DR) process is designed to convert iron pellet/lump into metallic iron by the use of reducing gases in a solidgas moving bed shaft furnace. O2 is removed from the iron ore by chemical reactions based on H2 and CO for the production of highly metallized DRI.
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Scrapbased EAF operations present the most CO 2 friendly route (Figure 3) even when including electricity contributions (assuming 65 kg CO 2 /Te DRI and about a 15% scrap charge in the BOF). However, the beneficial continuous recycling in the EAF will render prime scrap sources fewandfarbetween long term (Figure 4), necessitating greater use of Ore Based Metallics (OBMs DRI/HBI and Pig ...
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India has vast coal resources, consequently DRI production in India is primarily coal based (Indian Bureau of Mines, 2011). Today, gasbased DR Comfort Ramakgala et al. / Procedia Manufacturing 35 (2019) 242â€"245 243 Available online at ScienceDirect Procedia Manufacturing 00 (2019) 000â€"000 ...
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In coalbased DRI process, accretion formation inside the rotary kiln is a genuine complex problem. Accretion formation in a rotary kiln of 100 tpd DRI plant has been investigated. The nature of accretion formation with respect to the charge burden and operational parameter have been discussed. High ash content in the coal and excess use of dolomite lead to accretion formation. Two different ...
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Direct reduced iron is iron ore in the form of lumps, fines or pellets that have had the oxygen removed by using hydrogen and carbon monoxide. Typical sources of carbon monoxide are natural gas, coal gas, and coal. Other energy inputs into the production process often include oil and electricity. Since much of the energy used is in the form of ...
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Directreduced iron and its more transportable sister hotbriquetted iron have dallied in the wings of mainstream steelmaking as highquality and lowresidue furnace inputs for nearly 60 years. ... Hydrogenbased DRI was produced at a commercial scale in Trinidad and Tobago using a fluidized bed reactor process as long ago as the early 2000s ...
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Circofer and MXCOL are two coal gasificationbased DRI manufacturing technologies. The Circofer technology was developed by Lurgi Metallurgie , Germany, and operated based on Lurgi's twostage fluidised bed gasifier (Chatterjee, 2010). The Circofer process is similar to the Circored process based on natural gas (Section ). There is no ...
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For scenario 4, 30% DRI (coal gasification gasbased DRI) and 70% scrap steel collocation of EAF steelmaking short process, because of China's rich coal resource, compared to scenario 3, has certain economic costsaving ability, but since coal gasification process for hydrogen production will stretch out more carbon footprint, which is contrary ...
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The Coal based DRI processes can be sustained over time if proper holistic strategies are deployed to monitor and control the network of activities. This would minimize the overall cost of the production process and negative impact on the environment.
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The DRI also has high impurity content in form of gangue which is mostly locked within the clusters of the DRI crystal structure. Coal based DR process was done on iron ore/coal pellets under ... Kekkonen M, Saxén H. Optimization of Midrex direct reduced iron use in orebased steelmaking. Steel Research International. 2014; 86 (5):456465. DOI ...
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Coal based DRI plants are flexible with respect to plant location since noncoking coal is widely distributed in large deposits and is easy to transport. Most plants employ reduction process which is carried out in rotary kilns. These plants use wide variety of raw materials and noncoking coal. ... Fig 3 Schematic flow sheet of coal based ...
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Abstract In coalbased DRI process, accretion formation inside the rotary kiln is a genuine complex problem. Accretion formation in a rotary kiln of 100 tpd DRI plant has been investigated. The nature of accretion formation with respect to the charge burden and operational parameter have been discussed. High ash content in the coal and
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Natural gasbased DRIEAF (± tCO 2 /tSteel) reduces emissions by ±42% compared to BFBOF (± tCO 2 /tSteel) [11]. While that is a reduction in emissions compared to the worst performing process (coalbased steal making), driving the emissions down to zero will depend on the use of hydrogen produced only with renewable electricity.
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Direct Reduced Iron (DRI): This iron production process directly reduces iron ore in solidstate with the reaction temperature below the melting point of iron. Reducing gases are produced from natural gas (gasbased DRI) or coal (coalbased DRI) called syngas, a mixture of H2 and CO.
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Fig 4 Flowsheet of Midrex process. Coal based process. In a coal based process, the reactor for the reduction reaction is a rotary kiln which is slightly inclined to the horizontal position. The process of direct reduction is carried out with the operating temperatures maintained in a range from 1,000 deg C to 1,100 deg C.
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Of total DRI the production in 2008, 74 percent was produced from coal and 26 percent from natural gas. India is now the world's largest producer of DRI. Currently, there are two primary means of DRI production in India: smallscale rotary kilns using coal and iron ore lump, and largelocal scale shaft furnace plants using
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THE HEART OF THE MIDREX® PROCESS IS THE MIDREX® SHAFT FURNACE. AS A KEY COMPONENT OF THE MIDREX® DIRECT REDUCTION PROCESS, THE MIDREX SHAFT FURNACE IS THE MOST FLEXIBLE AND VERSATILE REDUCTION VESSEL FOR DRI PRODUCERS. The MIDREX® Shaft Furnace can use natural gas or a syngas from coal or coke oven gas as its reductant.
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This is a coalbased reduction technology, applicable to both steel mill waste and iron ore fines, with coal as a Creductant agent. The reduced iron can be fed to a BF or directly into a melting process. If exposed to air for a long time, the metallic iron reoxidizes into iron oxide, deteriorating its quality.
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Nearly million tons of DRI were produced in 2006 over the world, some 80% of which were produced by gasbased processes, the left by DOI: / 98 | Page "A study on the accretion formation in DRI kilns and possible ways for its reduction" coalbased processes. However, total DRI output continued ...
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The operational experiences of Bhushan Steel, operating seven coal based Direct Reduced Iron (DRI) plants at its Dhenkanal Works, Orissa, India, focusing on production and use parameters, are ...
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A material supplier from Belgium would like to produce limestone powder for his custome...
India is rich in various mineral resources and it is an important mineral processing market
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