DRI is produced predominantly by gas based processes around the world in vertical shaft furnaces utilizing natural gas. DRI is also used in some countries by rotary kiln process or by rotary hearth process with the use of thermal coal.
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Another case study of a CGP based DRI plant in Angul of Odisha, India which is the first CGP based DRI plant in India with a maximum steel producing annual capacity of about using syngas ...
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efficiency. Both coal and gasbased DRI plants are operational in India. However, the share of coalbased DRI production is quite substantial and in comparison to gasbased production, this route is energy and carbonintensive. To meet the DRI production target of 80 million tonne by 203031 as envisaged under the
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To avoid locking in further coalbased steelmaking capacity for decades, some technology switching to DRIelectric arc furnace (EAF) processes will be required before 2030 to achieve net zero by 2050. Agora Industry has already tracked 59Mt of new DRI capacity announcements since 2019, requiring about 80Mtpa of iron ore if all proceed.
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Direct Reduced Iron Industry in India — Problems and Prospects Ramachandra Rao Consultant (Mineral Processing, Iron Steel Technology and Engineering) Abstract India is the largest producer of Direct Reduced Iron in the world with annual capacity of nearly 10 Mt comprising coal and gas based DRI plants. India has the largest coal based DRI
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Abstract. Production of direct reduced iron from indigenous raw materials is an attractive alternative to the use of scrap for electric steelmaking or for a DRbased integrated steel plant. The SL/RN process is a proven coalbased direct reduction technology, its versatility being characterised by flexibility in the use of raw materials (lump ...
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Going by the energy efficiency and GHG emission, gas based DRIEAF route is considered the best with minimum energy consumption and GH emission, while the coal based DRIEAF/IF route is considered most energy intensive with highest GHG emission. However, production of gas based DRI has been diminishing over the years for
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To avoid locking in further coalbased steelmaking capacity for decades, some technology switching to DRIelectric arc furnace (EAF) processes will be required before then. Potential new DRgrade iron ore capacity by 2030 ranges from 40 million tonnes per annum (Mtpa) to an optimistic high of 100Mtpa. Unless technology innovations allow use of ...
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Direct reduction processes can be divided roughly into two categories: gasbased, and coalbased.
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TERI proposes to undertake the following activities in collaboration with SIMA (Sponge Iron Manufacturers Association ) in the coalbased DRI production process: Detailed mapping of DRI production units and shortlisting 23 prominent coalbased DRI manufacturing clusters representing domestic production ranges, existing and proposed capacity, operating practices etc. Explore possibilities ...
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Another way to make primary steel is through what is termed Direct Reduced Iron (DRI), when iron ore is mixed with a fuel and a reductant to reduce the oxygen content. ... Worldwide, natural gas is the fuel typically used while in India 82% of DRI is produced in coalbased rotary kilns with the remainder being produced via gasbased routes ...
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Direct Reduced Iron (DRI) manufacturing, a growing technology in ironmaking, offers the potential to reduce emissions. India, as the largest manufacturer of DRI, is characterized by technological diversity, while simultaneously dominated by coalbased DRI processes.
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Direct reduced iron to electric arc furnace (DRIEAF) production is 5% and growing, it appears to have better decarbonization potential to move towards netzero.
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DRI processes can reduce CO 2 emissions by using natural gas instead of coal due to the replacement of carbon reductant by hydrogen from the methane. Many complementary gasification processes have been developed in order to synthesize the reducing atmospheres.
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Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coalbased DR process and (2) gasbased DR process. Details of DR processes, reoxidation,...
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Although 84Mt is only around 5% of global steelmaking capacity, more than 70% of global capacity will reach a reinvestment decision prior to 2030. As such, it can be expected that the pipeline of noncoalbased DRI steelmaking projects will increase much further while CCUS is left behind again, just as it was in the power sector by wind and solar.
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Coal based DRI plants are flexible with respect to plant location since noncoking coal is widely distributed in large deposits and is easy to transport. Most plants employ reduction process which is carried out in rotary kilns. These plants use wide variety of raw materials and noncoking coal.
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An established alternative to coal and cokebased reduction of iron ores in blast furnaces is the ore reduction by coal or reformed natural gas (CO, H2) to direct reduced iron (DRI) or hot ...
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Currently, DRI is mainly produced using natural gas (approximately 76%), while the rest is made from coalbased rotary kilns (MIDREX, 2020; DRI production, 2022). Access to lowcost renewable hydrogen will allow many countries to produce steel using the hydrogenbased DRI (H 2 DRI), which is anticipated to be about 15% by 2050 ( Iron and Steel ...
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The above parameters for new steelmaking technologies—scrapbased EAFs, coalbased DRI with and without CCUS, gasbased DRI with and without CCUS, hydrogenbased DRI, and oxygenrich smelting reduction with and without CCUS—were obtained from recent studies and communication with Chinese experts (Battle et al., 2014; IEA, 2020a; IRENA ...
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10 0 1975 1980 1985 1990 1995 2000 2005 2008 Fig. 1 World DRI production by year reduction processes including SL/RN employ rotary kilns. Pellets, or lumpore, mixed with coal 2) are/is charged into the rotary kilns and heated by coal burners to produce DRI.
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2
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While coalbased DRIEAF is common in India, a majority of DRIEAF steelmaking entails the reforming of natural gas to generate a mixture of carbon monoxide and hydrogen—the first step toward producing gray or blue hydrogen. Both carbon monoxide and hydrogen are used to reduce iron ore in a furnace, which then yields solid iron, steam, and CO₂.
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In coalbased DRI plants rotary kiln is used for the reduction of iron ore. Accretion rings formations inside the kiln adversely affect the performance of plant in terms of low production and inferior quality, which frequently lead to shut down. About 70% of the coalbased DRI rotatory kiln shut down is due to the accretion formation [ 1 ].
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