sponge iron industry –past-present-future - SIMA

More documents

Recommendations

Info

Process Advantage l Proven performance l Raw material flexibility l Conventional steam reforming l Selective elimination of H2O & CO2 from the reducing gas circuit allows maximum recycling of reducing gases to the reduction reactor l High pressure operation reducing circulating gas volumetric flow at high molar l Flexibility to generate electric power by high pressure steam produced in the reformer. The SL/RN process is a kiln based process that uses lump ore, pellets, beach sand or ilemnite ore and solid carbon to produce hot or cold DRI. The process operates at high temperature and atmospheric pressure. This is the most widely used coal based direct reduction process. Process Description The iron oxides feed to a SL/RN kiln is in the form of lump or pellet iron ore , reductant ( low cost non –coking coal) and limestone or dolomite ( to absorb sulfur present in the reductant) .The rotary kiln is inclined downward from the feed ( elevated end) to the discharge end . The discharge end is provided with a burner to be used for startup or to inject reductant. Typical retention time are around 10 hrs. The kiln is divided into 2 process regions ; preheat and reduction . In the preheat section , the charge is heated to about 1000C , free moisture is first driven off and reduction to FeO occurs . As the reductant is heated , volatile components are released and part of the gases are burnt in freeboard above the bed by the air injected into the kiln. This combustion transfers heat to the charge directly by radiation , and also by conductive heat transfer from the kiln lining , which is first exposed to the flame and heated before contacting the charge. The charge then passes into the metallization or reduction zone ,where the temperature is maintained at about 1100C , depending upon the types of charge used. The final metallization is about 88% and carbon is about 0.1 – 0.2% . Process advantages l Use of any iron bearing material l Wide variety of reductants l Proven DRI technology l Economic production of DRI New Capacity and Plants Under Construction Table below indicates the additional new capacities coming up in gas based technologies in the world .Approx 19.14 million tones would be the capacity addition by 2012 -13 ( considering all the plants are completed on time) . Midrex and HYL / Energiron are the primary technologies mostly accepted in the world. As per Midrex report numerous rotary kiln furnaces would begin operation by 2012 as capacity would rise by 3.2 million tons per year, almost all within India. JANUARY-2011/18
C – Indicates under construction Source : Midrex tech. FUTURE OF GAS BASED SPONGE IRON IN INDIA So far growth of gas based sponge iron industry in India has been stagnant with mainly 3 plants operating. Primary reasons for this stagnancy are low availability and high pricing of natural gas as compared to Middle East countries, High initial capital investment etc. High Priorities of allocating Natural Gas mainly given to power, transport, fertilizer, domestic users etc compared to Sponge iron industry. This situation could, however, change in the near future and natural gas based sponge iron industry in India would have something to cheer for. Looking at demand / supply gap of natural gas, govt. of India is taking some serious initiatives. Huge investments are announced in laying down extensive pipeline network for natural gas across the country to meet the growing demand. As per map of India below in annex I , highlighting the network of natural gas pipeline ( existing , proposed and future proposed ). As more gas lines become available in time to come, definitely availability of natural gas would not be a major area of concern for sponge iron industry. Along with this availability and by setting up some strong policies framework by the Indian government toward strengthening India’s gas based sponge iron industry, natural gas and alternative natural gas based technologies of DRI production could experience a boom in India. Also, considering the environmental issues, which Indian and global steel industry is facing, natural gas based sponge iron will certainly be the metallic of future. This metallic will certainly redefine the steel industry from being a polluting to nonpolluting industry in the time to come. JANUARY-2011/19
Page 2 and 3: CHAIRMAN V S BAPNA VICE CHAIRMAN B
Page 4 and 5: UPGRADING QUALITY OF INPUTS TO AUGM
Page 6 and 7: There is acute shortage of high gra
Page 8 and 9: SUCCESSFUL STARTUP AND OPERATION OF
Page 10 and 11: GSPI Micro-Module Control Room Gulf
Page 12 and 13: SPONGE IRON INDUSTRY -PAST-PRESENT-
Page 14 and 15: JANUARY-2011/12
Page 16 and 17: From a meager production of 1.31 mi
Page 18 and 19: tubes. The newly reformed gas, cont
Page 22 and 23: Annexure I Map of Natural Gas pipel
Page 24 and 25: SIMA DELEGATE TO CHIN JANUARY-2011/
Page 30 and 31: CONTRIBUTION OF SECONDARY STEEL SEC
Page 32 and 33: in total crude steel production wou
Page 34 and 35: New product developments Sabyasachi
Page 36 and 37: advantages over the conventional he
Page 38 and 39: Description “Graspan Tri Flo ® P
Page 42 and 43: Moreover, some analyst suggest that
Page 44 and 45: BRIEF REPORT ON ONE DAY SEMINAR ON
Page 46: JANUARY-2011/44

sponge iron industry –past-present-future - SIMA

Create successful ePaper yourself

Delete template?

Save as template?