A Comprehensive Assessment and Analysis of a Direct …

processes, based on the energy assessment of the plant. This is a systematic way of assessment for taking suitable action for optimizing use ... of the flue gas for pre-heating of the coal by using suitable heat exchanger [8], other suitable heat exchanger by tapping ... Coal based Sponge Iron industry", Science Direct, 2015, 1-15 [8] Prasad ...

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to ... promising availability of coal, the coal based sponge iron plants share the major amount of its production. At present, there are 118 large and small sponge iron plants operating in India,

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(PDF) i) Direct Reduced Iron: Production

During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as...

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Process flow diagram of the sponge iron plant.

A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency.

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Addition of 15 MW WHRB + AFBC based Power Generating …

CPP shall be set up in the existing Sponge Iron Plant Area utilizing the surplus land, out of total 30 Acres now available with the Plant. 2.2 Brief description about nature of the project Anindita Steel Limited proposes to Captive Power Plant (CPP) of 15 MW based on WHRB and FBC in the existing 4x100 TPD Sponge Iron Plant. The water requirement of

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(PDF) Operation of Coal-Based Sponge Iron Rotary …

Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...

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INDIAN SPONGE IRON INDUSTRY AT CROSS ROAD

1985-1995, apart from few coal based plants, 3 large gas based plants with an aggregate capacity of 6.10 million tonnes per annum were commissioned. From 2003, coal based sponge iron route dominated because of limited availability of natural gas and fast growing demand of metallics. In fact, no new gas based sponge iron/HBI plant came since last 19

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Energy Efficiency in Sponge Iron Sector | Bicon Consultants

Sponge Iron production gas based; KEY PERFORMANCE INDICATORS. ... Various energy losses occurs in sponge iron plant during the production process. Waste heat in off-gases formed in rotary kiln forms the major share of heat loss. Waste heat recovery (WHR) has been identified as one of the viable options towards maximizing the utilization of heat ...

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Chapter 1 Review of Sponge Iron Making Process Historical …

The OSIL stands for Orissa Sponge Iron Limited. This plant was set up in the year 1983 at Palaspanga, keonjhar, Odisha. It is based on the ACCAR technology with under bed injection …

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ENERGY INTEGRATION IN SPONGE IRON PLANT USING …

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. 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. The advantages of sponge iron are:

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How can India Decarbonise Coal-based DRI Plants in Steel …

In addition, the installed steel production capacity in India is 155 MTPA, and the installed iron capacity is 136 MTPA, of which coal-based DRI plants contribute 37 MTPA (Joint Plant Committee 2023). Coupled with the fact that the type of coal and iron ore utilised for DRI production has an impact on the emission footprint, it is necessary to ...

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Energy survey of the coal based sponge iron industry

The Indian Government has recognized sponge iron as a vital sector for growth of Indian steel industries. At present, India is largest producer of sponge iron with a largest number of coal based sponge iron plant of total capacity around 12.8 million ton. Sponge iron manufacturing units looked profitable since beginning of the nineties.

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SUBSTITUTION OF NATURAL GAS BY COKE OVEN GAS …

The plant is based on usage of natural gas based process to produce Sponge Iron. The availability of Natural Gas is becoming very scarce in India & the prices are also increasing. It is apprehended that it may no longer be viable to operate this plant with Natural Gas leading to closure of the plant and loss of employment of people.

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Vikram Pvt. Ltd.

A bout V IKRAM. V ikram Pvt. Ltd. has an existing Integrated Steel Plant at village- Badtumkela in the district of Sundergarh, Odisha. The project is located at latitude 210 50' 17.66'' N and longitude 840 55' 38.61'' E. Vikram Private Limited was incorporated in the year with the aim of manufacturing value-added steel products.

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Carbon abatement options for large iron and steel plants in India

The difference between the global and the Indian sectors is due to the availability of cheap local coals as opposed to expensive and imported natural gas. Only 19.3% of the sponge iron production in India is from gas-based processes (Ministry of Steel, 2023), using shaft furnaces. The decarbonization of this sector is studied in this paper.

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Rotary Kiln Manufacturers | Electrotherm E&T

Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information. ... Low Capex and gestation period compared to Gas based DRI plant; It can be produced with non-coking coal and poor quality of coal that is available in abundance;

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ENVIRONMENTAL PERFORMANCE EVALUATION OF …

3 Table I: Global Scenario of DRI Production Country Direct Reduced Iron Production (Thousand Tonnes) India 20336 Iran 14551 Mexico 5976

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Coal based Direct Reduction Rotary Kiln Process – IspatGuru

Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . ... Char generated in the plant is stored separately for use as fuel in the power plant. Waste gas system – The kiln waste gases at temperature of around 850 deg ...

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Case Studies in Thermal Engineering

section of coal based sponge iron plant is presented in Fig. 2. In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and

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Direct Reduced Iron

Direct Reduced Iron (DRI), also known as Sponge Iron, offers an alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron ore is reduced in its solid state – unlike BF …

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WORLD DIRECT REDUCTION STATISTICS

According to the Sponge Iron Manufacturers Association (SIMA) of India, rotary kilns saw an 18% increase in ... with 7.66 Mt, all from natural gas-based processes. . The plant is expected to start up in 2026.Saudi Arabia retained its 4th place with 6.48 Mt, and Mexico placed 5th with 5.84 Mt in 2022, compared with 6.13 Mt and ...

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Optimizing Waste Heat Recovery in the Post-combustion

Additionally, the reference values are determined based on the specific type of coal being utilized, which are obtained through data analysis of various coal types used in the sponge iron plant. The selected bandwidth for this analysis is set at 15%, while the reference value is set at 20% of the input feed side FC.

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What is Sponge Iron? Uses and Benefits Explained

The reduced iron (sponge iron) is then discharged from the kiln and cooled. The coal-based rotary kiln process is widely used in countries with abundant coal resources, as it offers a cost-effective way to produce sponge iron. Gas-Based Reduction Process: The gas-based reduction process involves the use of natural gas as a reducing agent.

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(PDF) i) Direct Reduced Iron: Production

In book: Encyclopedia of Iron, Steel, and Their Alloys (pp.pp 1082-1108) Chapter: i) Direct Reduced Iron: Production; Publisher: CRC Press, Taylor and Francis Group, New York.

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SAFETY GUIDELINES FOR IRON & STEEL SECTOR

SAFETY GUIDELINES FOR IRON & STEEL SECTOR MINISTRY OF STEEL, GOVT. OF INDIA Direct Reduction Plant ( Gas Based) Doc. No: SG/33 Rev no. : 00 Effective Date: -- 1. OBJECTIVE : The entire process of making Sponge Iron by coal based DRI process is associated with various Safety hazards like Fire, Explosion, Radiation, Burns hit /

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Direct Reduced Iron (DRI)

Most gas-based direct reduction plants are part of integrated steel mini-mills, located adjacent to the electric arc furnace (EAF) steel plant. DRI can be either hot or cold charged to the EAF. ... known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are captive to steel mills, but there is a ...

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Mass balance around main components of the plant on per hour …

Kumar and Khanam [6] suggested that 21.6 t/h waste gas generated during sponge iron production process. ... During the operation in coal-based sponge iron plant, a tremendous amount of heat is ...

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ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR …

India is the largest producer of direct reduction of iron (DRI), popularly known as sponge iron and accounted for about 39.3% of the global production in 2020. India's growing economy will …

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Bravo Sponge Iron Plans Gas Plant Project in West Bengal

The project is a coal-based gas plant, and its location is Mahuda Village, Post Office Rukni, Postal Station Para, Purulia District, West Bengal. Bravo Sponge Iron Private Limited, the developer of the site The total cost of the project was 475 Crore. Syncgas with a capacity of 4,800 Nm3/hr The sponge iron plant's primary source of fuel.

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Direct Reduced Iron: Most Efficient Technologies for …

Some H 2 can be introduced in a natural gas-based plant as a substitute for part of the natural gas, or the DR plant can be based on H 2. ... In case of pure hydrogen as reducing gas for production of sponge iron, the …

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