Refractories for Iron and Steel Plant
Despite such class of refractories, insulating alumino silicate ceramic drawn fibres produce several refractory articles including blankets, felt, rope, 2–10-mm-thick papers, etc. ... addition of NaCl to the charge eliminates the impurities in the form of volatile chlorides of iron and aluminium. The process of SiC formation takes 25–36 h ...
Influencing factors for the Fenton-like of biological sponge iron …
Sponge iron as a special type of zero-valent iron combined with microorganisms to form the biological sponge iron (SFe-M) system. It has obvious benefits in removing refractory pollutants. The optimum parameters based on the production of hydroxyl radicals in the SFe-M system were determined as initial pH 4, SFe dosage of 90 g/L, and sludge ...
Direct Reduced Iron: Most Efficient Technologies for …
Direct reduced iron (DRI) is also known as sponge iron (Hasambeigi et al. 2014). This high porous material has a metallization degree in the range 85–95% with a carbon content in the range 0.5–4% depending on the processing route. During the process, the iron oxides are reduced at the solid state.
Detailed explanation of refractory materials for three types …
The main products produced by the direct reduction method include solid sponge iron, iron granules and liquid pig iron. Among them, the sponge iron production method is the most mature and has the ...
Substantially enhanced degradation of nitrobenzene by biosponge iron
Sponge iron (SFe), a typical ZVI material, has high Fe(0) content and large specific surface area, and is a promising alternative electron donor for the degradation of nitroaromatic compounds (NACs) [12].It was previously supplemented into activated sludge to form a biological sponge iron (bio-SFe) system to enhance treatment effects in previous reports [13, 14].
Influencing factors for the Fenton-like of biological sponge iron
Sponge iron as a special type of zero-valent iron combined with microorganisms to form the biological sponge iron (SFe-M) system. It has obvious benefits in removing refractory pollutants. The optimum parameters based on the production of hydroxyl radicals in the SFe-M system were determined as initial pH 4, SFe dosage of 90 g/L, and sludge ...
Computational fluid dynamics analysis of sponge iron rotary …
The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 ... A 2D CFD model of rotary kiln for sponge iron process is developed in this work and simulated using ANSYS 14.5. The present study discusses the behavior of temperature profile of bed and gas along the length of the kiln and ...
Basic Concepts of Iron and Steel Making
Metallic iron, as one of the main components of steel, can generally be produced by three process routes [2]: blast furnace, direct reduction and smelting reduction. At present, due to the ...
MIDREX® Process
The shaft furnace is where iron ore is converted to metallic. ... as HDRI to an EAF. The MIDREX® Direct Reduction Process fueled by natural gas paired with an electric arc furnace (EAF) has the lowest CO² emissions of any commercially proven steelmaking route using iron ore at 1.1 – 1.2 kg CO² / kg steel. ... This gas is fed to the ...
Midrex Process for Direct Reduction of Iron Ore – IspatGuru
Process description. Iron burden for the shaft furnace can be iron ore pellet or sized lump ore or a combination of the two. ... The heart of the Midrex process is its shaft furnace. It is a cylindrical, refractory-lined vessel and is a key component of the direct reduction process. It is flexible as well as a versatile reactor. It can use ...
(PDF) Operation of Coal-Based Sponge Iron …
The temperature profiles of the gas and charge in a coal-fired rotary sponge iron kiln affect both the iron ore reduction process and accretion formation.
Mathematical Modelling of Sponge Iron Production in …
VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coal-based sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore
A study on the accretion formation in DRI kilns and …
sponge iron. 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). Sponge iron is produced primarily both …
A REVIEW OF IRONMAKING BY DIRECT …
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 DR ...
(PDF) Refractories and ceramic
Iron staining and iron oxide minerals are considered as objectionable. ... process is carried out in acid circuits (with pH between 2 and 3). ... super-refractories are manufactured by blending ...
Sponge Iron Production by Calcium Carbonate, Sodium …
very low volume of water for the process in which sponge iron is produced. A tunnel kiln (Figure1) is a long stationary insu-lated furnace made of refractory bricks which has a rail track provision for trolley movement. Materials are filled inside the containers called …
Direct-Reduced Iron
2.1 Midrex Process. Midrex is the most successful gas-based DR process; it is a continuous process. It is basically a countercurrent process where a hot and highly reducing gas (95vol.% of this gas mixture being hydrogen and carbon monoxide with a ratio of H 2:CO varying from 1.5 to 1.6) reduces lump iron ore or pellets to metallic iron as the metallic charge descends through …
REFRACTORY Refractories for Direct Iron Reduction …
REFRACTORY VOL. 65 NO. 4 IRON & STEEL REVIEW | 90 | SEPTEMBER 2021 Introduction ... In this article, the refractory selection process for DRI production using coal, CO-H 2 mix and H 2
Iron- and Steel-Making Process
Hence, starting with the master plan, it was decided to provide a brief introduction on modern iron- and steel-making practice along with background of refractory choice in Chap. 2, to amalgam the relation of refractory performance with changed escalating demand on safe performance. As small blast furnaces have been closed and replaced by large ...
Development of energy conservations scenarios for sponge iron …
This paper presents an approach to find the best modification in the coal-based sponge iron process with an aim to integrate energy in it. For this purpose, a few energy conservation cases are formulated by integrating unutilized energy present in possible areas of process flow sheet. When unutilized energy of the process is properly integrated, energy …
Accretion Build Up Resistant Refractories for Sponge Iron Kilns IREFCON 06
Formation of new phases owing to the interaction of the aforementioned constituents, in addition to the desired reduction iron ore to metallic iron, is expected. This aspect is the major...
A Case Study on Accretion Formation in Rotary Kiln of …
accretion formation is shown in Table 2. Metallic iron Fe (m) in sponge iron varied between 84 and 62%. Approxi-mately 300 ton of accretion was generated for a running of 25 days. 3.1 Accretion Formation The accretion formation inside the kiln is inspected time to time from the alignment hole by stopping air supply. A
Powder production technologies
The sponge iron process. ... Sponge iron provides the base feedstock for all iron-based, self-lubricating bearings and still accounts for around 30% of iron powder usage in PM structural parts. Solid state reduction is also used for the production of refractory metal powders, using hydrogen as the reducing agent, and for the production of ...
Isothermal reduction and comparative analysis of reaction …
A non-contact direct reduction (NDR) technique is an extractive metallurgical method for decarburizing undesirable carbonaceous components from sponge iron created by …
A study on the accretion formation in DRI kilns and …
Thus, due to this porous structure, DRI is often called sponge iron. Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced product having high degree of metallization exhibits a „honeycomb ...
Sponge Iron
DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H ...
Mathematical Modelling of Sponge Iron Production in a …
VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coal-based sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore
Sponge iron making process | PPT | Free Download
The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln. It describes the chemical and physical composition of iron ore, coal, and dolomite that are fed into the kiln. It then outlines the rotary kiln process which involves preheating and combustion zones, use of primary and secondary air, coal injection ...
Monitoring of Process Flow Diagrams in the Production of …
An equivalent correlation (R = 0.847942, t R = 6.035314 > 2 for a systems determination, R = 0.991408, t R = 115.8812 > 2 for a level determination) is established by comparing reference data on the recovery and content of a valuable component on the basis of the technology of steel production in blast furnaces (Table 2) with the characteristics of the …
Enhanced refractory organics removal by sponge iron …
Sponge iron (SFe) is a zero-valent iron (Fe0) composite with a high-purity and porous structure. In this study, SFe was coupled with microorganisms that were gradually domesticated to form a …