The iron and steel corporations iscor need for coking coal led to major developments in the natal coalfields now all closed and more recently the waterberg basin. The key objective is to keep our customers investments productive, by continuously optimising their operations with an aim to enhance availability, output, efficiency of power plant along with power plant life. Jindal steel and power strengths below are the strengths in the swot analysis of jindal steel and power. Operates the largest coal based sponge iron plant in the world. Operation of coalbased sponge iron rotary kiln to reduce. Sponge iron plant itc the major raw materials required for production of sponge iron by the rotary kiln process are sized graded iron ore and non coking coal government have the process flow diagram of conventional coal based sponge iron pla. In coal based sponge iron manufacturing reduction unit is heart of the plant where the actual reduction of iron ore is takes place. Pdf energy survey of the coal based sponge iron industry. It is based on the normal operating conditions, and partly, accounting waste heat for dryingup of moisture in the raw material and coal av.
The efficiency of the coal based sponge iron process is defined as the energy needed for the reduction reactions compared to the energy added to the system. Pro minerals is a sister company of hari machines ltd. What are the examples of mineral based industries in india. The company has been operating a beneficiation plant since january 2014, and the pellet plant will follow in late 2015. Noncoking coal is required in sponge iron production, since the. Pdf operation of coalbased sponge iron rotary kiln to. The hoganas process is a direct reduction method for production of sponge iron powder using magnetite ore fe3o4 and carbon as raw materials. Such a wide variation in consumption range gives opportunity for enhancing energy efficiency to achieveover achieve the target set under pat mechanism. The level of removal for trona can vary from 0 to 90% depending on the normalized stoichiometric ratio nsr and particulate capture device.
Power plant operations operation and maintenance of power. To avoid entry of proper size coal in crusher the screens are used. The industrial development program of any country, by and large, is based on its natural resources. Coal based rotary kiln for direct reduced iron sponge iron 100 tpd, 350 tpd, 500 tpd solid state reduction of iron ore using either coal gas as a medium of reduction to produce a substitute raw material for steel making is termed as direct reduced iron dri. Sponge iron subsector major product details 159 table 17. The largest part of the coal resources of the country is noncoking.
Process design of the phola coal j preparation plant o. After unloading of the coal, required quantity of coal is to be bunkered. Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. Waste heat recovery based captive power plant client name project location capacity mw 1.
Sports a product portfolio that caters to varied needs in the steel market. We manufacture complete rotary kiln for making sponge iron of 50 tpd, 100 tpd, 300 tpd and 500 tpd for dri sponge iron which is used with other melting materials. Brief process of coal based sponge iron rotary kiln. Factories are located close to raw material sources 9. Coking coal is mainly used in metallurgy, steel, cement and sponge iron industries. Thermal power plant sector bureau of energy efficiency. Sponge iron is produced primarily both by using noncoking coal and natural gas as reductant and therefore classified as coal based and gas based process respectively. Jindal steel and power swot analysis top jindal steel. Sponge iron coal based in tunnel kiln grinding mill china. Modeling of rotary kiln for sponge iron processing using. The target removal efficiency is a requirement from the utility and is independent of unit size. Presently, there are 118 large and small sponge iron plants in india 115 of them are coal based while only 3 are natural gas based. Direct reduced iron dri production plant nippon steel engineering co.
Section wise specific power consumption details 163. No wonder then most dri plants are located in odisha, jharkhand. India s sponge iron production data was reported at 2 978 000 metric ton th in oct 2019 this records an increase from the previous number of 2 932 000 metric ton th for sep 2019. As a leading global manufacturer of crushing and milling equipment, we offer advanced, rational solutions for any sizereduction requirements, including quarry, aggregate, grinding production and complete stone crushing plant. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a selectgrade of ironcoking coal little dolomite inside an inclined rotary kiln and control busted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and. Brief process of coal based sponge iron rotary kiln minig. Apr 09, 2018 objective a typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal based sponge iron plant machinery equipment sponge iron plant, 727 online. A thesis submitted for partial fulfillment of the degree award of. Pdf operation of coalbased sponge iron rotary kiln to reduce.
Apr 09, 2018 objective a typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal based sponge iron plant machinery equipment sponge iron plant, 727 online direct reduction iron production line dri sponge iron. Installation of the waste heat recovery plant has to be tackled as a system approach, rather than considering cement plant and whrpp operations, independently. India is producing 79 different minerals excluding fuel and atomic resources. Produces economical and efficient steel and power through backward and forward integration. Selection of coals for rotary kiln sponge iron plant. The major quality requirements of coal for sponge iron production are 1 noncoking characteristics 2 low ash content 3 low sulphur content 4 good reactivity 5 high ash fusion temperature 6 medium volatile matter 1. Building materials equipment rotary kiln reduced iron in.
Rotary kiln process of making sponge iron grinding mill coal used in rotary kiln sponge iron the process of sponge iron making aims to remove the oxygen from iron ore gangue content in sponge iron process two types of coal are being used such as feed for the direct reduction of iron ore the main furnace used is rotary kiln. Depleting resources of coking coal, the world over, is posing a threat to the conventional. A typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal and air as well as increase the productivity of sponge iron by applying heat integration using simulation process. Energy survey of the coal based sponge iron industry sciencedirect. Oriental journal of chemistry sponge iron powder the hgans process is a direct reduction method for production of sponge iron powder using magnetite ore. Sand making machine sponge iron making process rotary kiln. More details rotary kiln for sponge iron philippines.
Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production. Sponge iron industry, 78 char based power plant 111 79 new sponge iron plants 111, later natural gas is used to reduce the iron ore for coal based rotary kiln. The reduction in co 2 emission, makes it environmental friendly. A demonstration sponge iron plant of 30000 tpatons per annum capacity. A typical coal based sponge iron plant is investigated to utilized waste heat to preheat the feed coal and air as well as increase the productivity of. Rotary kiln process of making sponge iron c assimilating coal based sponge iron fig 2 4 essential features of a reduction kiln in a rotary kiln sponge iron plant air fine coal sponge iron char a i r rotary. Thermal power plant sector is one of the 8 notifiedenergy intensive sectors under which a. A thesis submitted for partial fulfillment of the degree. Final thermal power plant cover bureau of energy efficiency. Optimization of operating parameters for sponge iron production. The design of the phola coal preparation has its roots in the late 1980s when there was a requirement for a plant to treat 8 mtpa coal from ingwes now becsas adjacent klipspruit opencast mine at ogies, mpumalanga. Productivity increment of coal based sponge iron plant using. The largest beneficiation plant in the world is at grootegeluk.
Shubhajit mondal 1, puneet choudhary 1, sam purna borah 1. Power plant operations operation and maintenance of. Productivity increment of coal based sponge iron plant. Possible power generation from waste heat of a cement plant based on the above, amount of power which may be generated for the standard sizes of plants, is. Operation of coal based sponge iron rotary kiln to reduce accre tion formation and optimize. The initial project to manufacture sponge iron c apacity 1,05,000 tonnes, billets.
Coal based sponge iron plant using magnetite ore mine. Noncoking coal is required in sponge iron production, since the coking reaction leads to formation of rings inside the kiln. The commercial operations begin in 2001 at the companys sponge iron plant with an annual capacity of 1,05,000 tonnes. The largest part of the coal resources of the country is noncoking coal. Coal based sponge iron plant confederation of indian. At present, there are 118 large and small sponge iron plants operating in india, among them only 3 are natural gas based and the remaining 115 plants are coal based. Energy balance in a rotary kiln sponge based iron making. Sponge iron, tunnel kiln, energy e ciency, exhaust, pushing time, sponge iron.
Coal is used as a reducent for sponge iron making in. Brief process of coal based sponge iron rotary kiln 20718brief process of coal based sponge iron rotary kiln manufacturer in shanghai china brief process of coal based sponge iron rotary kiln is manufactured from shanghai xuanshiit is the main. Technology and, iron ore fines withough any need of either pelletisation nor sintering is offered adopted tunnel kiln and hematite iron ore fines. Jul 29 2010 flow chart of slrn process has been shown in fig iron ore and non coking coal along with dolomite are fed continuously to the charge end of rotary kiln inclined at 25 coal is also injected through an injection pipe at the discharge end of kiln. Energy survey of the coal based sponge iron industry. Sponge iron is produced primarily both by using non coking coal and natural gas as reductant and therefore classified as coal based and natural gas process respectively.
The plant was commissioned in 1980 to supply 2 mta of coking coal at 12. The remaining quantity of coal is to be required to store. Main of them are iron ore, manganese, mica, bauxite, chromite, limestone, asbestos. Pollution in the coal based sponge iron industry in india. Practically permissible caking index is 3 maximum for rotary. Pdf a survey is made on a typical coal based indian sponge iron plant of capacity 500 td in order to identify the largest energy losses and. A scientific program of preventive maintenance and periodic repair ensures that the plant remains in peak condition.
Development of condition based maintenance for coal handling. Coal based sponge iron industry is highly energy intensive industry. Rotary kiln for sponge iron 500tpd spong iron rotary kiln sponge iron dri rotary kiln the introduction of rotary kiln a rotary kiln is the main equipment for sintering cement clinker b the rotary kilns produced by our pany can be divided into dry process and wet process pared to bee. Installation of preheating furnace in the sponge iron plant can save 30647 mt of coal per year. Due to promising availability of coal in india the coal based sponge iron plants share the major. Exgtg boundary boundary for sponge iron subsector 160 figure. Plant details sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore.
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