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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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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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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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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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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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(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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(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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Sponge Iron

1. Less capital cost: The capital cost per tonne of installed capacity, in case of coal-based plants, is 1.8–2 times as high as in the gas-based plants.. 2. High productivity: The throughput rates for gas-based sponge iron plants are much higher than in coal-based plants.The productivity for gas-based plants can be as high as 11 t/m 3 /day as against merely 0.5 to 0.9 …

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Analyses of Different Modifications Proposed for the Sponge Iron

Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...

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(PDF) Environmental performance evaluation of …

Table II shows the growth of coal based as well as gas based Sponge Iron industries in India. ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with Sources of .

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Comparative life cycle assessment of natural gas and coal-based

On sponge iron-making in coal-based rotary kilns, there are studies on process modeling (Gaurav and Khanam, 2016), ... Similarly, direct plant GHG emissions for the lean gas case are 1.8% (9 kgCO 2 e/t-DRI) lower than that of …

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ENERGY INTEGRATION IN SPONGE IRON PLANT USING …

In the present work a system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is …

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Industrial Training Report on Direct Reduced Iron Plant(DRI)

4. 4 | P a g e Introduction of Jindal Steel and Power Ltd JSPL is an industrial powerhouse with a dominant presence in steel, power, mining and infrastructure sectors. Turnover of approx. US$ 3.3 billion, JSPL is a part of about US$18 billion diversified Jindal Group conglomerate. In terms of tonnage, it is the third largest steel producer in India. The company …

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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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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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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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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

Sponge iron is produced by direct reduction of iron ore (DRI. process) and is popular because of use of non-coking coal. The conventional blast furnace. coking coal. advantageous. in the …

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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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Pathways for decarbonizing the sponge iron industries: Effect of …

In this regard, the Indian government has set a target to reduce the greenhouse gas (GHG) emissions of the iron and steel sector to 2.4 t CO 2eq. /tcs by 2030 (Ministry of steel, 2017). The government also plans to increase its production capacity from 113.6 Mt in 2021–22 to 300 Mt by 2030, thereby underscoring the need for decarbonizing the iron and steel industry …

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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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Sponge Iron Plant Complete Project & Equipment Technical …

Sponge iron plant rotary kiln and cooler list of machinery spare parts and casting and forging technical procurement specifications budgetary cost for coal based, gas based, electric based sponge iron plant for 50 TPD, 75 TPD, 100 TPD, 150 TPD, 175 TPD, 200 TPD, 300 TPD, 350 TPD, 500 TPD, 600 TPD (Tons per day).

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Sponge Iron Manufacturer India

It is the voice of the indian iron ore based sponge iron & steel industry, at both domestic and global forums. As a not-for-profit society, SIMA has been mandated to communicate the viewpoints of its constituents & al stakeholders and represent their interest. ... Gas Based DRI / HBI. In this process route, iron oxides are converted to the DRI ...

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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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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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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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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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Evaluation of new equipments for utilization of waste heat in sponge

The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coal-based sponge iron plant, a tremendous amount of …

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Sponge Iron Industry | PPT

Sponge Iron Industry - Download as a PDF or view online for free ... DRI produced in coal 1. Blast Furnace, needs based kilns coking coal. 2. HBI produced in gas 2. Corex, can use based kiln. ... Cooler discharge 4. Gas cleaning plant 6. Product separator 5. Dust settling chamber 7. Stock house 6. Waste Heat Recovery 8. Loading points Boiler 9 ...

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Decarbonizing rotary kiln–induction furnace based sponge iron

The direct carbon dioxide (CO 2) emissions from the iron and steel sector are nearly 7 % of the global CO 2 emissions from energy use. India is the world's second-largest producer of steel and the largest sponge iron producer. India produces one-third of the global sponge iron, mostly from rotary kilns using coal as an energy source, resulting in higher …

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