How sponge iron is manufactured?

Sponge iron is formed through the reduction of iron ore to metallic iron through reaction with carbon in the form of coal, etc. at approx. 1100 degree Celsius. Sponge iron is also referred to as direct reduced iron, metalized iron, or hot briquetted iron.

Which country produces sponge iron?

Since 2002, India has been the largest producer of sponge iron, also called direct reduced iron (dri), in the world. Today about 20 per cent of the sponge iron produced worldwide is made in India.

How the sponge iron is produced by rotary kiln process?

These plants use iron ore pellets in the rotary kiln. Raw material mix consisting of iron ore, dolomite and non-coking coal is fed at the one end of the rotary kiln and is heated by coal burners to produce DRI. The product DRI along with char (sometimes called dolo char) is taken out from the other end of the kiln.

What is sponge iron division?

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.

What is ABC in sponge iron?

The gases then pass to the after burner chamber (ABC) where the residual carbon or CO is burned by the excess air available. After ABC, the gases are at high temperature and have a lot of heat energy which is normally utilized for steam generation through the waste heat recovery boiler (WHRB).

How is sponge iron made in a DRI plant?

In the DRI plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. The reduction is carried out in a rotary Kiln (which is inclined and rotates at a pre-determined range of speed) at a stipulated temperature ( 850 °C – 1050°C).

What is the market share of sponge iron production?

Market share: About 23% of sponge iron total production. This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction temperature, and reduction is performed on Silicon Carbide (SiC) Crucibles in a tunnel furnace.

What are the raw materials required for sponge iron production?

SPONGE IRON PLANT 1 RAW MATERIAL General The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non- Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur.

Why MSP sponge iron plant?

MSP Sponge Iron plant uses the highest grade of iron ore and premium quality coal. This ensures very high metallization of Sponge Iron. Sponge Iron is fast becoming a significant input in low-cost steel production. With the availability of abundant raw material in India, the production of sponge is set to multiply over the years.