Coal based Direct Reduced Iron (DRI) / Sponge Iron Plant Process Flowchart. CHAIN CONV. CHAMBER SAF1 SAF3 SAF5 SAF7. CONV. COMPRESSOR WATER PUMP. BC12 Fe >50mm.
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Emissions from DRI vary with the source of fuel, with coalbased DRI in India, producing around t CO 2 /t steel and natural gasbased DRI producing around t CO 2 /t steel. Of all the current commercially available technologies, scrap based EAF steel making is the greenest with emissions of around t CO 2 /t steel on average ...
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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 socalled 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 ...
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In coalbased DRI process, accretion formation inside the rotary kiln is a genuine complex problem. Accretion formation in a rotary kiln of 100 tpd DRI plant has been investigated. The nature of accretion formation with respect to the charge burden and operational parameter have been discussed. High ash content in the coal and excess use of dolomite lead to accretion formation. Two different ...
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2. Overview of DR processes. Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing. gas to produce Direct Reduced Iron (also known ...
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Hot DRI charged into an EAF typically generates the most efficiency, compared with briquetting and heating cold charge. FerroSilva expects its process to require less than a tenth of the electricity per ton of iron compared with electrolysisbased green hydrogen plants, and can generate byproducts such as liquid biogenic CO2.
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The main raw materials for the production of DRI by the rotary kiln process are (i) sized graded iron ore or iron ore pellets, (ii) noncoking coal, and (iii) dolomite in small quantities to scavenge the sulphur. Iron ore of the right quality is the basic input for the coal based direct reduction process.
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The DR process may be adapted for coalbased processing, which will contribute to the stable supply of direct reduced iron (DRI). This paper outlines the DR technologies developed by Kobe Steel and includes a survey on the contribution of DRI as a substitute for scrap used in electric arc furnaces (EAFs) and as a burden material in BFs.
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Direct reduced iron (DRI) is the alternative iron source for steelmaking. Its advantages as a iron product and diluent for impurities, introduced with scrap, are well documented. DRI is also known as sponge iron. It refers to porous iron produced by the direct reduction (DR) process.
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Both processes are very energy intensive through the direct burning of fossil fuels such as coal and natural gas, or indirectly through the use of electricity. Global steel production is heavily dependent upon the use of coal via the BFBOF process. In 2013, over 70% of total global steel production relied directly upon coal.
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Although there is no commercial DRI process that uses biomass as the reducing agent, ... Developments in the use of RHFs for coalbased DR of iron go back at least to the development of the HeatFast process at Surface Combustion in the 1960s [52]. However, Surface Combustion and their parent company MidlandRoss decided to focus on their gas ...
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The DRI processes are categorized in two groups based on the use of reducing agent, natural gasbased direct reduction (DR) processes like MIDREX, HYL and Finmet, and coalbased DR processes like ...
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Coalbased reduction of ore needs to be replaced by carbon reduced techniques. ... DR technology and direct reduced iron (DRI) material can be included into the existing material streams of existing plants in different ways. ... Sen PK (2017) Modeling MIDREX based process configurations for energy and emission analysis. Steel Res Int. https ...
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DR process configuration, from the total Carbon input to the DR plant, only 1025% (depending on the Carbon content in the DRI) exits the process as combined Carbon in the DRI. By the principle of mass conservation, the balance must leave the process, which for the DR process, is in the gaseous form as CO 2.
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Coalbased reduction (DR) technologies using syngas are of recent origin. MIDREX, in association with Praxair, has developed a process called MXCOL, where coalbased synthetic gas can be used in the reduction shaft. ... A coalbased dual fuel DRI process (FASTMET) shows lower gross CO 2 emission ( t CO 2 /t DRI) compared to rotary kiln (RK ...
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In comparison to gasbased processes, the coalbased DRI production process is quite energy intensive and poses environmentrelated issues. Being a developing country with steel demand projected to reach between 500 and 760 million tonne (Mt) by 2050, the country needs to adopt energyefficient and environmentfriendly steel production ...
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DRI or sponge iron refers to porous iron produced by the DR process.a solidstate reaction process (, solidsolid or solidgas reaction) in which removable oxygen is removed from the iron oxide, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or agglomerates of fine ore.
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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 processes. Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coalbased DR process and (2) gasbased DR ...
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Depending on the source of reducing gas, DR processes can be described either as gasbased or coalbased (Lu, Pan and Zhu, 2015). In the gas based process, the reducing agent is a chemically reformed mixture of natural gas and offgas from the reducing reactor in the presence of a nickel based catalyst to produce a gas that is rich in hydrogen ...
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coal based DR! industry. INTRODUCTION India is the largest producer of coal based sponge iron. Today many of the plants are operating with raw materials of inferior grade and the sponge iron produced by many plants are of inferior quality mainly with regard to gangue content and to some extent metallisation. Such coal based sponge iron is
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The development of the HDR process, in addition to the limitations caused by the reduction or the elimination of carbon in the process, creates changes in the operating conditions of the equipment (such as operating pressure). ... (4 million tons of Hydrogen) for coalbased DRI technology and Ammonia and Methanol production [64]. The Asia ...
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Natural gasbased DRIEAF (± tCO 2 /tSteel) reduces emissions by ±42% compared to BFBOF (± tCO 2 /tSteel) [11]. While that is a reduction in emissions compared to the worst performing process (coalbased steal making), driving the emissions down to zero will depend on the use of hydrogen produced only with renewable electricity.
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