Iron ore: Since the manufacture of DRI is a solid-state reduction process, gangue from the ore remains in the product.ĭue to the removal of oxygen, the weight decreased by about 30% and the percentage of gangue matter increased by a factor of about 1.4. The company’s entire coal needs are linked to the best coal resources of its subsidiary Coal India Limited and imports from South Africa. Additionally, ash melting characteristics should be considered when selecting coal for DRI production. Since coal sulfur is collected through DRI, it should be as low as possible. High humidity can also reduce the efficiency of the furnace and increase the amount of energy required. The ash content should be as low as possible as it can negatively impact furnace performance and heat requirements. In general, coals with higher fixed carbon are preferred because they produce more carbon for reduction and have a higher heating value. Coals with higher reactivity are preferred because they allow the furnace to be operated at lower temperatures with higher furnace output. Oal: An important factor in determining the quality of coal, in addition to chemical properties such as fixed carbon, Ash content, volatile substances, etc. Several tests were carried out in the company’s laboratory to ensure their suitability in rotary kilns. The main raw materials for producing sponge iron are iron ore and non-coking coal. Therefore, it is necessary to check the chemical and physical properties of the raw materials separately and in combination. Next to it are the characteristics of the sponge iron produced by TSLP raw material The production of sponge iron is very sensitive to the properties of the raw material. The quality of sponge iron mainly depends on the percentage of metal content (iron) in the product. Since the metallurgical process involves solid-state reduction, sponge iron is also known as direct reduced iron (DRI). When the final product is observed under a microscope, it resembles a honeycomb structure and has a “sponge-like” texture, hence the name sponge iron. The process of making sponge iron is to remove oxygen from the iron ore, and when this happens, the outflowing oxygen creates micropores in the stone body and makes it porous. The entire production process in the furnace takes 10-12 hours, during which the iron ore is reduced and discharged into a rotary cooler to cool below 1000☌ to prevent re-oxidation and better separate non-ferrous iron. The reduction process takes place in the solid state.Īn important factor in this reduction process is the controlled combustion of coal and its conversion to carbon monoxide to remove oxygen from iron ore. Coal plays a dual role in this process, both as a reducing agent and as fuel to provide heat to maintain the desired temperature in the furnace at 10,500-850☌. They are charged into the rotary kiln in the required proportion together with some dolomite used as a desulfurizing agent. Raw Material for Steel Products Industry.
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