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Sponge iron process diagram india

  • Sponge Iron (DRI) The Hira Group

    With such dimension of notion WE in our Sponge Iron Manufacturing process through 4 Kilns (1 * 350T and 3 * 500T) laid up the best DRI making process in India. It is Coal Fuel based DRI. Coal based Sponge-iron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron

  • (PDF) i) Direct Reduced Iron: Production

    Mar 30, 2016· This product is known as direct reduced iron (DRI) or sponge iron. Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as

  • Sponge Iron Prakash Industries Limited

    Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel


    The process of sponge iron making aims to remove the oxygen from iron ore. 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. Sponge iron manufacture is highly sensitive to raw material characteristics.

  • Chlor Alkali Sector - Bureau of Energy Efficiency

    2.3 Chlorine Derivatives & Their Growth In India 4 2.4 Journey towards Improved Safety, Health & Environment, Green Manufacturing and Sustainable Growth 5 2.5 Environment Management through Green Manufacturing 5 2.6 Process Diagram 6 3. Chlor-Alkali Industry under PAT Scheme. 6 3.1 Status of Designated Consumer (DCs) 7

  • Integrated Steel Plant in India - SEL TMT FE550D Bars

    We have the ability to sell intermediate and final products across the steel value chain. As of March 31, 2020, we were one of the leading players in terms of pellet capacity and the fourth largest player in the sponge iron industry in terms of sponge iron capacity in India (Source: CRISIL Report).

  • sponge iron process

    Jul 29, 2010· 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.


    1 Project & Engineering Consultancy, Keonjhar, Odisha, India 2 . Indian Institute of Technology, Kharagpur 721302, India. Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process

  • Tunnel Kiln Coal Based DRI Plant, in Village

    These pellets are then used for making sponge iron. Rotary kilns have a drawback upon the size and quality of iron ore that can be used. Initially, when the process was first introduced, the ore with an iron content >/= 65% was preferred and the preferred size of ore was 5-18mm.

  • Sponge iron making process - SlideShare

    Nov 09, 2014· Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE Iron = 65-67 % SiO2 + Al2O3 = 2-3 % CaO + MgO = 0,5-1 % Sulphur = 0,02 % max Phosphorus = 0,04 % max Chemical Composition Size = 5-18 mm Shatter Index = +95 % Tumbler index = +88 % Reducibility Index = +94 % Thermal Degradation Index = 5 % Physical Composition

  • Seminar on HYL Process - SlideShare

    Dec 23, 2013· Discharging the sponge and re-charging the reactor with fresh charge to start the process all over again. 14. HYL II is the Development process of HYL where (1) use high temperature alloy tube in the reducing gas reheating furnace, which permits heating the gas to the higher temperature, and (2) reduced the number of heating furnace for the


    India is emerging as the leading producer of sponge iron among developing as well industrially developed nations. 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 process uses coking coal.

  • Sponge Iron Manufacturer India

    Sponge Iron Manufacturers Association. The Sponge Iron Manufacturers Association (SIMA) established in 1992 is an all India apex body of Indian sponge iron industry. It is the voice of the indian iron ore based sponge iron & steel industry, at both domestic and global forums.

  • Process Description and flow diagram of Coal Based DRI Plant

    Aug 07, 2016· 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. Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln as well as some fine coal also fed from discharge end and product sponge iron


    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:

  • Energy Audit Methodology of Sponge Iron Manufacturing

    Jul 14, 2014· Energy Audit, DRI Process, Sponge Iron, Kiln Efficiency, Sankey Diagram of Kiln, Coal Balancing 1. Background of This Study Sponge iron industries in India have mandatory energy performance target in terms of specific energy consump-tion (SEC). They shall have to achieve the target SEC by 31st March, 2015. The non-performing industries are

  • Sponge Iron Plant - Entrepreneur India

    The sponge iron is a substitute for scrap in the electric arc furnace, which can be easily manufactured from indigenously available raw materials at very competitive price. It is the iron ore reduced in solid state by a direct reduction process using natural gas or non cooking coal as reluctant. The sponge iron is also known as Direct Reduced

  • Iron Sponge Process Oil and Gas Separator

    Several grades of treated wood chips are available, based on iron oxide content. The most common grades are 6.5-, 9.0-, 15.0-, and 20-lb iron oxide/bushel. The chips are contained in a vessel, and sour gas flows through the bed and reacts with the ferric oxide. Figure 7-3 shows a typical vessel for the iron sponge process.

  • 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) into 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

  • Basai Steels Pvt Ltd.

    Schematic line diagram / outlay indicating various sections including the positions of Kiln & WHRB boilers is as under - The overall process requires duration of approximately eight to ten hours inside the kiln, during which iron ore is optimally reduced and discharged to a rotary cooler for cooling below 120°C, before coming out into the


    STEEL ROLLING MILL (BY INDUCTION FURNACE) FROM STEEL SCRAP AND SPONGE IRON - Project Report - Manufacturing Process - Cost - Investment Required. Report includes feasibility report, profitability analysis, raw materials, break even points, formulations and formula and much more.

  • Powder metallurgy - Wikipedia

    Sponge iron process. The longest established of these processes is the sponge iron process, the leading example of a family of processes involving solid state reduction of an oxide. In the process, selected magnetite (Fe 3 O 4) ore is mixed with coke and lime and placed in a silicon carbide retort. The filled retort is then heated in a kiln

  • Direct Reduced Iron and its Production Processes IspatGuru

    Mar 16, 2013· Fig 2 Principle of direct reduction process. Gas based process. 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.


    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:

  • MIDREX Processes -

    The process reduces iron ore using a reforming gas made from natural gas. The DRI is used mainly as the raw material for electric arc furnaces (EAFs), as a clean iron source substitute for scrap iron. Pores are left behind in the DRI after oxygen has been removed. These pores, if filled with water, for example, can cause the iron to reoxidize with


    Company of M/S Gagan Group, well known in eastern India for their quality products viz. TMT bars, billets, ingots, sponge iron etc. Gagan Group is one of the fastest growing steel making company in eastern India, started as a manufacturing company for iron & steel products in

  • Coal based Direct Reduction Rotary Kiln Process IspatGuru

    Feb 14, 2017· As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI). The reduced product having high degree of metallization shows a honeycomb structure, due to which it is often called sponge iron.


    sponge iron, originating from Iron Ore, namely, silica and alumina and the sulphur and phosphorous contents adversely affect the economics in subsequent steel making operation. Therefore, the ore should be high in iron content and low in gangue, Physical Specification Size - 5-20 mm Oversize - < 5 % max

  • Case Studies in Thermal Engineering

    The actual process of the coal based sponge iron production is based on SL/RN process (jointly developed by the Steel Company of Canada, Lurgi Chemie, Republic Steel Company and National Lead

  • DRI UPDATE - Sponge Iron Manufacturer India

    office bearers from Karnataka Sponge Iron Manufacturers Association and South India Sponge Iron Manufacturers Association. In his key note address, Mr. Deependra Kashiva, ED, SIMA gave the background of conceiving this Use of MATLAB for better prediction of process parameters.

  • (PDF) Production of Sponge Iron through Tunnel Kiln Process

    India is one of the countries where use of sponge iron contributes a large share in annual crude steel production. The amount of sponge iron in the charge mix varies from 0-90% depending on its

  • Energy Audit Methodology of Sponge Iron Manufacturing

    Energy Audit, DRI Process, Sponge Iron, Kiln Efficiency, Sankey Diagram of Kiln, Coal Balancing. 1. Background of This Study. Sponge iron industries in India have mandatory energy performance target in terms of specific energy consumption (SEC). They shall have to achieve the target SEC by 31 st March, 2015. The non-performing industries are

  • 4th Indian Iron-Ore, Pellet and DRI Summit 2020

    Mr Deshpande was the former Chairman of The Sponge Iron Manufactures Association (SIMA) from 2015-2019, and the former Managing Director of Tata Sponge Iron Ltd. An Executive Director in Tata Metaliks Ltd. Kolkata and before that a Chief (coke, Sinter and Iron) at Tata Steel, during the expansion phase from 6.8 MTPA to 10 MTPA.

  • (PDF) iron-steel making From start to finish

    THEIS PRECISION STEEL INDIA PVT. L TD., NAVSARI, GUJAR General flow diagram of Iron Steel making process : THEIS PRECISION STEEL INDIA PVT. L sponge

  • Formulations and Manufacturing Process of - Entrepreneur

    Personal care industry in India is very huge and is one of the main key drivers for Indian surfactants market. Personal care Process Flow Diagram of Herbal Shampoo 17. Henna Based Hair Dye Iron & Steel, Soak Alkaline Cleaner, Iron & Steel, Spray Aluminun Cleaner/Brightener

  • US5238487A - Process for the production of pig iron and

    A process for producing pig iron is described, which contains a reducing shaft furnace 1 and a melting gasifier 2. 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. The gas produced in the melting gasifier is supplied directly via a line 4 as reducing gas to the reducing shaft furnace.


    blast furnace. Sponge iron is fed into the electric furnace for steel production or into foundries for the manufacture of wrought iron. Commercial production of sponge iron in India commenced in 19801. Sponge Iron India Limited was the first plant to be set up in the country in 1980 in Paloncha district of Andhra Pradesh with a capacity of

  • Pulp and Paper Sector - Bureau of Energy Efficiency

    Processed and Printed in India by Viba Press Pvt. Ltd., C-66/3, Okhla Industrial Area, Phase-II, New Delhi-110020 Overview-Manufacturing Process 2 3.1 Process Flow Diagram 2 4. Perform Achieve and Trade (PAT) 3 5. Indian Paper Industry in context of PAT 4 6. Methodology for Baseline and Energy Ex-GtG Boundary boundary for Sponge Iron

  • Direct reduced iron process - tec-science

    Jun 21, 2018· Direct reduced iron (DRI) process. In addition to the process route via the blast furnace process, there is another option for extracting crude steel from iron ores using the so-called direct reduced iron (DRI) process (secondary route).The starting point for the efforts to find an alternative to the blast furnace process was the relatively high process expenditure.


    In this backdrop TRFI took the first step to set up a coal based sponge iron plant in India. The process technology developed by Allis Chalmers Corporation, USA based on pilot plant studies known as ACCAR process was used initially. This process used 80% coal and 20% oil, which subsequently became uneconomical due to increase in crude prices.


    Part 3A: 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. A chemical-physical 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

  • Steel making process ArcelorMittal

    In the former process, iron ore is the main raw material. In an electric furnace, scrap iron is used and occasionally also sponge iron. Sponge is an intermediate product, which is produced from iron ore by means of direct reduction (= DRI or directly reduced iron) and that is then further reduced and smelted in an electric furnace.

  • SPONGE IRON UNIT - Steel Exchange India Ltd.

    Steel Exchange India Limited is having a Sponge Iron manufacturing unit in technical collaboration with world renowned M/s Mannesmann Demag of Germany (CODIR Process). With an installed capacity of 2x350TPD and can able to produce Sponge Iron of 0.225 Million Tons per Annum 1. The main raw materials used for the production of sponge iron is