sponge iron industry –past-present-future - SIMA

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From a meager production of 1.31 million tons of sponge iron in 1991-92 to present production level of sponge iron of over 22 million tons in 2009, where world DRI production reached 64.4 million tons, India once again, led all nations for consecutively 8th year in sponge iron production with more than one-third of the world total production of 64.4 million tones. Indian production of sponge iron has continued its steady increase in recent years. Approximately seventy percent of this is via coal-based DR units and 30% via gas-based. Three producers operate gas-based DRI and HBI plants, with a combined capacity of approximately 6MMT/yr, significantly lower than coal-based plants, although with much higher productive capacity and productivity per plant. There have been historical reasons in India for the prosperity of coal-based DRI production over gas-based: India does not have ample reserves of natural gas, and what is currently available is mainly on the west coast. Coal, on the other hand, is abundant and lower grade coals can be used without difficulty. In terms of capital cost, a coal based DR unit is generally small in capacity and can be installed and operated with a much smaller investment. VARIOUS TECHNOLOGIES FOR SPONGE IRON PRODUCTION Globally there are two types of technologies available for producing sponge iron. l Coal based l Gas based GAS BASED SPONGE IRON INDUSTRY – OUTLOOK Ravindra S Borwankar, Asst. Vice President (Mktg.) Welspun Maxsteel Ltd. In the Coal based, coal is the reductant while in Gas based natural gas is used to reduce the iron ore. For coal based rotary Kiln processes several technologies like SL/RN, CODIR, ACCAR, JINDAL,TDR and OSIL are in use while gas based plants have predominantly used MIDREX,HYL I and III technologies. As Natural gas is not available in many parts of the world, the growth of coal based plants have increased in those countries like India (where natural gas is available to a limited extent) where there is abundance of non coking coal and good grade Iron ore. Source : Midrex tech. Figure I: Break up of world Sponge iron production by process JANUARY-2011/14
Figure I clearly depicts the break up of world sponge iron industry in 2009. It is clearly evident that the % share of gas based sponge iron industry is much higher vis-à-vis coal based sponge iron industry. Globally gas based technology is prevailing and coal based sponge iron industry is primarily from India MIDREX – Technology – Gas based sponge iron (mainly due to abundant availability of non coking coal). MAJOR SPONGE IRON TECHNOLOGY GAS BASED - MIDREX - HYL III / Energiron COAL BASED - SL / RN The MIDREX® Process consists of three major stages: 1) reduction, 2) reforming and 3) heat recovery. Reduction Iron oxide, in pellet or lump form, is introduced through a proportioning hopper at the top of the shaft furnace. As the ore descends through the furnace by gravity flow, it is heated and the oxygen is removed from the iron (reduced) by counter flowing gases which have a high H2 and CO content. These gases react with the Fe2O3 in the iron ore and convert it to metallic iron, leaving H2O and CO2. For production of cold DRI, the reduced iron is cooled and carburized by counter flowing cooling gases in the lower portion of the shaft furnace. The DRI can also be discharged hot and fed to a briquetting machine for production of HBI, or fed hot, as HDRI, directly to an EAF, as in the HOTLINK® System. Reforming To maximize the efficiency of reforming, off gas from the shaft furnace is recycled and blended with fresh natural gas. This gas is fed to the reformer, a refractory-lined furnace containing alloy tubes filled with catalyst. The gas is heated and reformed as it passes through the JANUARY-2011/15
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