In the smelting reduction process, pelletized iron oxide ore or fine ore powders are pre-reduced in a fluidized bed or reduction …

Iron ore is one of the basic among other raw materials used in the production of iron. It is described as any mineral substance that contains enough iron which makes its smelting a viable proposition, i.e. an iron content of less than 20%. Ores vary considerably in form and composition from one source to another.

sponge iron production plant at Chandrapur, Maharastra. The OSIL process uses a rotary kiln of 3.5mtr diameter and 84mtr long. The output of this plant is 300 tons per day. The rotary kiln product is discharged into a rotary cooler at a temperature of 1050oC and subsequently cooled by spraying water on the cooler.

Dolomite is an anhydrous carbonate mineral. It is a double carbonate of calcium and magnesium (CaCO3.MgCO3). It is one of the important raw materials used in production of iron and steel. Dolomite contains theoretically 54.35 % of CaCO3 and 45.65 % of MgCO3 or 30.41 % of CaO, 21.86 % of MgO, and 47.73 % of CO2.

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 …

Limestone was used as a flux. ... Based on EDX and XRD results of pig iron and slag, the optimum process of sponge iron smelting is use the CaCl 2 as additive. ... were used for production of iron ...

sponge iron production plant at Chandrapur, Maharastra. The OSIL process uses a rotary kiln of 3.5mtr diameter and 84mtr long. The output of this plant is 300 tons per day. The …

The charge materials, used in production of sponge iron in a rotating furnace, are mill scale, coal and slag formers. Mill scale is a steelmaking by-product from the rolling mill in the steel hot rolling process. ... The slag formers having a particle size of ~200 μm include bentonite, dolomite, limestone and are added to charge as 20 kg ...

Alternative routes of iron making: Introduction, Processes of Sponge Iron production; SL/RN, MIDREX, HyL processes. Smelting Reduction Processes; COREX, ROMELT, Hismelt. Suggested Text books 1. Ahindra Ghosh and Amit Chatterjee: Ironmaking and Steelmaking Theory and Practice, Prentice-Hall of India Private Limited, 2008. 2.

Sponge Iron SpringerLink. The major part of sponge iron production is used as a substitute for scrap in steelmaking Sponge iron is consumed in three primary product forms, namely lump, Atomization requires a gas, and the sponge iron process involves heating up in a kiln to produce the intermediate sponge iron, followed by crushing the …

The cast iron processing in hearth furnaces was developed in the 16th century, where excess carbon oxidized in the melt. Since then, cast iron was mainly used as intermediate material for steel production. The design and use of blast furnaces opened the next page in the development of ferrous metallurgy.

In the blast furnace, iron ore, carbon in the form of coke, and a flux such as limestone are fed into the top of the furnace, while blast of heated air is forced into the furnace at the bottom. Reduction of iron …

Crushed limestone is also used in landscaping and as a base material for construction projects. Industry: Limestone is utilized in various industrial processes. It is used to remove impurities in the production of metals, such as iron and steel. It is also employed in the production of glass, paper, and plastics.

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 ...

Raw Material: Limestone is used as a raw material in the production of iron and steel. It is combined with other materials such as iron ore and coke in a blast …

DOLOMITE/LIMESTONE Limestone is used as a de-sulphuriser in the production of sponge iron. Typical specification of limestone is given below – CHEMICAL COMPOSITION PERCENTAGE MIX MgO 22% (Minimum) CaO 28% (Maximum) L.O.I. Remainder MANUFACTURING PROCESS Coal based Direct …

The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world. This book comprehensively deals with the production of sponge iron in the rotary kiln. The book is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and …

In general, the main types of pellets for the purposes of making iron are acid, basic and fluxed. In order to produce high-quality pellets, certain additives are important. The most common fluxing materials for iron ore pellet production are limestone (CaCO 3), dolomite (Ca,Mg(CO 3) 2) and olivine (Mg 2 SiO 4), but sometimes magnesite …

Natural Pellet: It is a term coined by producers like NMDC to designate sized iron ore used directly in Sponge Iron production. ... It provides the required permeability for movement of gases through the bed of iron ore, coke and limestone inside the blast furnace. BF Coke is characterised by the following parameters: Specified Size Range (25/ ...

Sponge iron is a better alternative to scrap in EAF / IF steelmaking units because of its homogeneity, good productivity and lower coke consumption. Sponge iron can be used as a substitute for steel scrap in the LD converter as a coolant. Not a firefighter. It does not contain harmful or waste elements such as copper, zinc, tin,

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Recent Trends in the Technologies of the Direct Reduction …

Although iron powder could be produced in sponge iron tunnel kiln production line and it is the main raw material for powder metallurgy production lines. Process. In sponge iron production plant by tunnel …

Webis limestone used in the production of sponge iron. is limestone used in the production of sponge iron Calcium carbonate - Wikipedia, the free . Calcium carbonate is widely used medicinally as an inexpensive dietary calcium supplement or gastric antacid It may be used as a phosphate binder for the treatment . Get More. ...

The iron-bearing material is reduced to sponge iron over 70–90% metallization in the shaft . The hot sponge iron at about 700–800 °C along with partially calcined limestone and dolomite is continuously fed into the melter-gasifier through downpipes for smelting.

1. Fluxing Agent: Limestone is commonly used as a fluxing agent in the iron and steel industry. It is added to the blast furnace during the production process to remove impurities and facilitate the formation of slag. The slag helps in the removal of impurities like sulfur and phosphorus from the molten iron [ 3 ]. 2.

All iron oxide bearing wastes and coke breeze is used for sintering purpose. The use of limestone in blast furnace is also avoided by using fluxed sinters of suitable basicity. This results in increasing the productivity of the furnace for iron making. Almost all the iron bearing wastes generated at plant site can be recycled as sinter charge mix.

Limestone is a source of lime (calcium oxide), which is used in steel manufacturing, mining, paper production, water treatment and purification, and plastic production. Lime also has major …

Abstract. Main raw material for pneumatic or autogenous steelmaking processes is hot metal and pig iron and/or scrap/sponge iron is for non-autogenous steelmaking processes. The oxidizing agents used for steelmaking are air, oxygen and iron oxide. Lime is generally added during steelmaking to make the slag basic enough to …

This operation is aimed to actualize a slagging process through the introduction of limestone (CaCO 3) or quicklime (CaO). The pure metallic iron condenses, while the gangues are fluxed out as aluminate and silicate compounds known as slags. ... The use of non-coking coal as an alternative energy source for sponge iron production …

Therefore, many iron and steel companies focus on the production of iron ore fluxed pellets to replace the sinter and increase the pellet proportion in the blast furnace's burden [4–7]. The main technologies used for iron ore pellet production include the grate-kiln, straight grate, and shaft furnace processes [1,8,9].

Figure 3: Direct iron reduction shaft furnace Source: MIDREX® Direct iron reduction processes reduce iron ore to sponge iron without a molten metal step. Direct iron reduction or sponge iron …

is limestone used in the production of sponge iron. ... limestone is used in the production of iron and steel,in ... Lime and Calcined Dolomite for Use in Steel Plant – IspatGuru. limestone production in zim using burr mills. production of iron and steel. What is Sponge Iron? (with pictures) - Info Bloom

A survey is made on a typical coal based Indian sponge iron plant of capacity 500 t/d in order to identify the largest energy losses and find ways to increase the efficiency. The required data are obtained by measurements or taken from production industries. The process efficiency is about 51.31%.

It has been estimated that approximately 65-75% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011). As a measure to improve process flexibility and reduce operational costs, DR processes resort to the use of fine ore instead of lumps, as well as cheap waste gases (Friedl et al., 2018 ...

This plant, if it's making about a million tons a year of cement, will emit roughly 800,000 tons a year of CO2 carbon greenhouse gases. One reason is the extremely high heat, about 2,800 degrees ...