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  • Sponge Iron Production Process Iron&Steel

    This process is one of the oldest direct reduction methods and the idea of its structure is based on a horizontal cement kiln. In this method, heat coal (as a reducing agent) is mixed with iron ore and sponge iron is produced in a horizontal furnace.

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  • difference between sponge iron kiln and cement kiln «

    01.05.2013· A Process-Step Benchmarking Approach to Energy Use at Industrial . We then illustrate the approach using the cement and the iron and steel industries, . During this stage the mixture is passed through a kiln (and possibly a preheater . This electric arc furnace can also use a form of iron known as sponge iron or There is no difference between the Eco-Tech and All-Tech performance

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  • Sponge Iron an overview ScienceDirect Topics

    The process involves heating the naturally occurring iron oxide in the presence of carbon, which produces “ sponge iron.” In this process, the oxygen is removed without melting the ore. Iron oxide ores extracted from the Earth are allowed to absorb carbon by a reduction process. In this natural reduction reaction, as the iron ore is heated with carbon, it results in a pop-marked surface

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  • Direct reduced iron Wikipedia

    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. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting

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  • OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A

    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 iron. Depending on its content of volatile matter, the coal is part-ly blown into the

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  • PRODUCTION OF IRON AND STEEL POWDERS

    The Höganäs sponge iron process, is essentially a chemical process in which finely divided iron ore is being reduced with coke breeze yielding a spongy mass of solid metallic iron, which can readily be comminuted to iron powder. The iron ore used at Höganäs is a magnetite slick (powdery Fe 3 O 4) obtained by selective mining from mines in the north of Sweden and Norway. This magnetite

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  • sponge iron process

    In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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. The mean particle size ratio of iron ore to feed coal shall be in the range of 1.2 to 1.5 depending

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  • What is Sponge Iron? (with pictures) wiseGEEK

    27.12.2020· Malcolm Tatum Date: December 27, 2020 Sponge iron is created from iron ore.. Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source.

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  • Steel making today and tomorrow Hybrit

    The sponge iron can be used as hot DRI and melted immediately in an electric arc furnace (EAF) together with recycled scrap. The DRI can also be processed into hot briquetted iron (HBI), which can be stored and shipped to another site. The crude steel from the EAF goes through a similar process as in the blast furnace based route, i.e. alloying and refining before being cast into slabs, ready

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  • Cement Manufacturing Process Phases Flow Chart

    30.08.2012· Cement Manufacturing Process Phase 1: Raw Material Extraction. Cement uses raw materials that cover calcium, silicon, iron and aluminum. Such raw materials are limestone, clay and sand. Limestone is for calcium. It is combined with much smaller proportions of sand and clay. Sand & clay fulfill the need of silicon, iron and aluminum.

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  • What is Sponge Iron? (with pictures) wiseGEEK

    27.12.2020· Malcolm Tatum Date: December 27, 2020 Sponge iron is created from iron ore.. Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore.The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source.

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  • Difference Between Sponge Iron and Pig Iron Compare

    30.04.2011· That is; the production process of sponge iron is a liquid state process whereas it is a solid state process for pig iron. Summary Sponge Iron vs Pig Iron. Both sponge iron and pig iron are two basic forms of iron that we can obtain via processing natural iron ore. The key difference between sponge iron and pig iron is that we can produce sponge iron by direct reduction of iron

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  • Iron Sponge Process Oil and Gas Separator

    The iron sponge process uses the chemical reaction of ferric oxide with H2S to sweeten gas streams. This process is applied to gases with low H2S concentrations (300 ppm) operating at low to moderate pressures (50-500 psig). Carbon dioxide is not removed by this process. The reaction of H2S and ferric oxide produces water and ferric sulfide as follows: The reaction requires the presence of

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  • Agni Steels Sponge Iron Manufacturing Process

    02.11.2017· Right from the selection of high grade iron ore and coal, we use only the finest raw material for production. Sponge Iron (DRI) is the main constituent in pr...

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  • Direct Reduced Iron and its Production Processes

    In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as to prevent its re-oxidation. The reducing gas is passed through the ore bed, and spent gas is recirculated after heating and reforming to a mixture of H2 and CO in a reformer, where it is also heated

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  • Coal Base DRI Operation: Process Description and flow

    • Sponge iron produced by the process will be the high grade which contains 80% Fe, 12% FeO and 8% gangue material. After separation of sponge iron in the magnetic screen/pulley, the remains are collected as char. Char has good amount of fixed carbon (25% 30%) and moderate GCV (2500 2600 Kcal/Kg). Char is sold outside as low grade fuel which is subsequently used in brick kiln or large

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  • Decarbonizing Steel and Cement The Energy Transition

    And while there are inherent emissions in the steel- and cement-making processes, a large portion of the emissions associated with the production of these two materials comes from this need for high-temperature process heat and our current practices of getting this heat—which is consistently burning fossil fuels. But not all technology can produce the temperatures that are needed. In an

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  • cement Definition, Composition, Manufacture, History

    cement-making process. The cement-making process, from crushing and grinding of raw materials, through roasting of the ground and mixed ingredients, to final cooling and storing of the finished product. Encyclopædia Britannica, Inc. This article surveys the historical development of cement, its manufacture from raw materials, its composition and properties, and the testing of those properties

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  • Steel Production American Iron and Steel Institute

    The blast furnace is the first step in producing steel from iron oxides. The first blast furnaces appeared in the 14th century and produced one ton per day. Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace remain the same. The blast furnace uses coke, iron ore and limestone to produce pig iron. Coal is a key part of the coke

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  • Process Flow Diagrams (PFDs) and Process and

    Process flow diagrams (PFDs) are used in chemical and process engineering. These diagrams show the flow of chemicals and the equipment involved in the process. Generally, a Process Flow Diagram shows only the major equipment and doesn't show details. PFDs are used for visitor information and new employee training. A Process and Instrument Drawing (P&ID) includes more details than a PFD. It

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