article refractories sponge iron process

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Sponge Iron - an overview | ScienceDirect Topics

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 ...

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Chrome-Alumina DVC Lining - High Performance Refractories

This is why the phosphorus content is generally quite high in primary pig iron coming out the blast furnace or in sponge iron. Fortunately it is yet possible to eliminate phosphorus by oxidation by using high basicity slags, in which the P 2 O 5 activity remains low, even at very high concentration [3][4].

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Super Refractories - Sponge Iron Production

For Sponge Iron production by Direct Reduction Process CUMI offers the following solutions. COAL BASED SPONGE IRON ROTARY KILN. svenska casino spel. Application. Recommended Products. AFTER BURNING CHAMBER (ABC) CUMICRETE CK 14 SI. ABC BACK UP. CUMICRETE CII 104SI.

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Simulation of Rotary Kiln Used in Sponge Iron Process ...

DOI: 10.7763/IJET.2014.V6.673 Corpus ID: 14769908. Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN @article{Poonia2014SimulationOR, title={Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN}, author={Anil Kumar Poonia and Shabina Khanam}, journal={International journal of engineering and technology}, year={2014}, volume={6}, pages={95-98} }

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Chemical reactions of iron with simple and complex ...

The process takes place in blast furnaces at a temperature of 2,000 °C. The method of reducing iron by hydrogen is also used – special clay is required, which is mixed with crushed ore and processed with hydrogen from a shaft furnace.

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Midrex Process for Direct Reduction of Iron Ore – IspatGuru

Midrex process is simple to operate and involves three major unit operations namely (i) iron ore reduction, (ii) gas preheating, and (iii) natural gas reforming. The heart of the Midrex process is its shaft furnace. It is a cylindrical, refractory-lined vessel and is …

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Study of the Influence of Refractories Structure on the ...

Performance results of reduction process to produce a finish Sponge Iron with increased Fe content of 51.72% to 78.79% with 36.68% metallization degree (Jogja samples) and from 52.93% to 57.90% ...

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Marketing of Refractory Products:A study in the refractory ...

The following figure illustrates the growth of sponge iron in India. 1.3.1 Refractory for Social Cause . While this relative lack of attention might seem warranted in terms of relative size it is not in terms of the strategic importance of refractories as an input in the process of steel production.

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Utilization of Kiln Accretion as a Raw Material in Rural ...

sized and to some extent the waste raw materials not used in other standard process of iron and steel making. The huge dump of Iron ore fines and inferior coal can be well utilized in sponge iron plant. For every 100 ton per day of sponge iron plant, the daily consumptions are: 160-175 ton of iron ore, 120-150 ton of coal, 3.5-5.00 ton of

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The Kroll process and production of titanium sponge ...

The sponge mass then is sliced radially to one to 5 cm sections with a large guillotine or similar blade. The bottom section of the mass is removed first as this likely has the most amount of iron incorporated into the sponge. The sponge mass is removed from the working table, so this material can be segregated from the balance of the mass.

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MIDREX® Process - Midrex Technologies, Inc.

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. To maximize the efficiency of reforming, offgas from the shaft furnace is recycled and blended with fresh ...

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(PDF) Dissolution of refractories for gasification process ...

Dissolution of refractories for gasification process of petroleum coke for the steel industry. ... Introduction new Molten Iron Process (MIP) used in the steel industry are listed in Table 1. ... emission of pollutants compared with other sources is the reduction of iron ore to produce sponge iron also called Di- used for energy.

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Direct Reduced Iron and its Production Processes – IspatGuru

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.

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Coal based Direct Reduction Rotary Kiln Process – IspatGuru

The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. 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).

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Copper LPF Leach Precipitation and Flotation Process

Sponge iron is produced by roasting pyrite and reducing the iron oxide calcine at temperatures in excess of 1500°F. with coal in a Bruckner revolving furnace followed by cooling to 150°F. in an enclosed Baker cooler. The resulting sponge product is ground to —35 mesh for use in the precipitation circuit of the L-P-F process.

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ELECTRIC STEELMAKING The Processing Route

Hot Briquetted Iron (HBI) is a premium form of DRI that has been compacted at a temperature greater than 650° C at time of compaction and has a …

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Reduction Efficiency of Iron Ore–Coal Composite Pellets in ...

In 1954, more kilns came into operation in Sweden and USA. Presently it is more popular in China for sponge iron production from beneficiated cake of iron ore fines. In this process, the material loaded on trolleys passes through different temperature regimes of preheating, reduction and cooling without having any physical movement of bed material.

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Growth of metallic iron particles during coal-based ...

Coal-based reduction followed by magnetic separation is an innovative technology used in processing refractory iron ores. Given that size is essential to the separation of the metallic iron from the gangue, the morphology of metallic iron particles and their evolution during coal-based reduction are investigated in the present work. The size of the metallic iron particle increased from 128.76 ...

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FURNACES AND REFRACTORIES - Modern Eq

Lightweight refractories of low thermal conductivity find wider applications in low temperature heat treatment furnaces, for example in batch type furnaces where the low heat capacity of the refractory structure minimizes the heat stored during the intermittent heating and cooling cycles. Insulating refractories have very low thermal conductivity.

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Powder Production Technologies

The 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 (Fe3O4) ore is mixed with coke and lime and placed in a silicon carbide retort.

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US20030110889A1 - Method for producing sponge iron, and ...

A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m 2 /g or more, and the content of the powdered ...

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THE EFFECT OF REDUCTION TIME AND SIZE DISTRIBUTION OF ...

Sponge Iron Figure 4 shows the effect of reduction time based on a percentage of metallization (removal of oxygen) of sponge iron with variations in the pellet diameter, i.e. Figures 4a and 4b for pellet diameter of (-12+8mm) and (-20+12mm), respectively. Table 3 shows the …

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Influencing factors for the Fenton-like of biological ...

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 ...

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Pig Iron | Scientific.Net

Abstract: The article describes the use of protection ceramic composed of SiO 2 (62-68)-MgO+CaO (29-39) in the frontal region of machines that inject refractory mass to stop pig iron running and liquid slag in blast furnaces. The new protection model (prototype) showed an annual saving of approximately R$ 32,000 compared to the compound previously used CaO-Al 2 O 3-SiO 2.

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(PDF) Production of Sponge Iron through Tunnel Kiln Process

Production of Sponge Iron through Tunnel Kiln Process. April 2010 ... when the furnace is lined with basic/ neutral refractory material. ... The amount of sponge iron in the charge mix varies from ...

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Types of Refractory Materials and Their Applications

The applications of high alumina refractories includes the hearth and shaft of blast furnaces, lime and ceramic kilns, cement kilns, glass tanks and crucibles for melting a …

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The effect of sponge iron chemical composition on energy ...

The chemical composition of sponge iron has a significant impact on the energy and refractory consumption of EAFs. Quality of sponge iron is determined based on its Metallization and residual oxygen. The higher metallization and the lower FeO cause the higher free iron content in the sponge iron. Of course, the presence of carbon, which is in ...

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Control of Slag and Insoluble Buildup in Ladles, Melting ...

effects on refractory linings. Slag Formation: The formation of slag in the melting of ferrous metals in the foundry is inevitable. The composition of slag varies with the type of melting process used and the type of iron or steel being melted. The cleanliness of the metallic charge, often consisting of sand-encrusted gates and risers from

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Gas Based Sponge Iron - Galaxy Refractories

Sponge iron is obtained by direct reduction of iron ore. It contains nearly 94% of metallic iron and thus it is vital constituent in steel making process. It is made either by making use of coal or by making iron ore undergo reaction with reducing gases.

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A Case Study on Accretion Formation in Rotary Kiln of DRI ...

In coal-based 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 …

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