Sponge Iron Plant Gunning

Manufacturing sponge iron is extremely sensitive to the properties of raw materials. Therefore, it is crucial to look at raw materials' physical and chemical properties, both alone and together. Iron ore and non-coking coal are the two main basic materials used to make sponge iron. Several tests are carried out at the company's laboratory to determine if they are suitable for use in a rotary kiln. Sponge iron is a more desirable intermediate for better-grade steel due to its reduced sulfur content. The operators of electric furnaces can accurately adjust their process settings since the gangue constituents are few and well-known. It is not pyrophoric and contains no tramp materials, such as. Scrap typically contains metals, including copper, zinc, tin, chrome, tungsten, and molybdenum. The sponge iron process in Refractory Installations can employ non-coking coal of average grade, which cannot be utilized to make iron.

Continuous feeding of sponge iron produces a greater power level than 100% scrap charge at comparable EAF settings. Increased breakages are a result of scrap collapse, whereas sponge iron charge experiences far fewer breakages. Our thermocouples are ideal for making sponge iron because they are very accurate, portable, and dependable. Before delivery, they are checked for factors including performance, quality, and lifespan. We ensure that our valued customers provide the highest-quality thermocouples at the best prices. Our primary goal is to satisfy the needs for Refractory Application and provide standard items in accordance with their specifications.

Sponge Iron Plant Gunning

The characteristics of the raw materials are particularly important for producing sponge iron. Therefore, it is essential to consider raw materials' physical and chemical qualities. As the top Sponge Iron Plant Manufacturers In India, Refractory Engineering Construction has been recognised in all states. Due to its lower sulphur concentration, sponge iron is a more attractive intermediary for better-grade steel. Electric furnace operators can precisely alter their process parameters because of the small number of well-known gangue elements. It does not include tramp materials and is not pyrophoric. Metals are frequently found in scrap, including copper, zinc, tin, chromium, tungsten, and molybdenum. In the sponge iron process, Sponge Iron Plant Gunning can use non-coking coal of ordinary grade, which cannot be used to manufacture iron.

Contrary to its name, sponge iron is a metallic mass with a honeycomb structure all over its surface and volume rather than being soft and spongy. Sponge iron has been a popular raw material for steel production for the past ten years. After realising its enormous potential, the government has acknowledged sponge iron as a crucial sector for expanding the Indian steel industry. Again, India is lucky to have vast quantities of non-coking coal needed to make sponge iron and substantial high-grade iron ore deposits. Iron ore and coal both have typical moisture levels of roughly 2% and 13%, respectively. Today, avail the best Sponge Iron Plant Gunning service only from Refractory Engineering Construction Pvt. Ltd.!

Iron and steel are frequently referred to be the foundation of international infrastructure. Steel and related items are used in everything from skyscrapers to highways, trains, bridges, autos, etc. India's steel sector is essential to expanding and modernising the country's economy. The expansion of India's steel sector is intimately related to the country's economic development. Let's now discuss the factors contributing to the sponge iron industry's performance and those of the TMT bar firms in India. Please find the best Sponge Iron Plant Near Me at Refractory Engineering Construction. Direct reduction of iron ore to a solid form yields a type of metallic product known as sponge iron, sometimes called direct reduced iron (DRI) (iron). India overtook China as the world's largest producer of sponge iron in 2016, accounting for almost 24% of worldwide production. In addition, India's crude steel sector expanded rapidly between 2006 and 2016, growing at a CAGR of 6.75%.

Sponge iron cannot be used on its own; it has to be treated to produce wrought iron or steel. To remove the slag, oxidise any carbon or carbide, and join the iron, the sponge is taken out of the furnace and repeatedly hammered with hammers and folded over. Today, sponge iron is produced by reducing iron ore without melting it, which makes it an energy-efficient feedstock for speciality steel producers that formerly relied on waste metal.

A metallic material called sponge iron is created by directly reducing solid iron ore. It serves as a replacement for scrap and is mostly utilised in the secondary process of manufacturing steel. Iron ore is intended to be oxygen-free through the sponge iron manufacturing process. The amount of metallisation (removal of oxygen), or the proportion of metallic iron to total iron in the product, is a key determinant of sponge iron quality.

Manufacturing sponge iron is extremely sensitive to the properties of raw materials. Therefore, looking at raw materials' physical and chemical properties, both alone and together, is crucial. Iron ore, non-coking coal, and dolomite are the primary raw materials used to manufacture sponge iron. The raw materials' sizes are extremely important in sponge iron production. The needed size of iron ore, MPS (Mean Particle Size), and its physical and chemical parameters, such as T.I., A.I., Fe (T), LOI, and gangue content. Two types of coal, feed coal and injection coal, are utilised in the sponge iron manufacturing process.

Benefits of sponge iron –

In sponge iron, there is less sulphur. Poor-grade coal is unsuitable for making regular iron and can be used in the direct reduced iron process
Steel scrap can be replaced with sponge iron while making steel using the EAF/IF processes
The electric furnaces utilised by many manufacturers employ sponge iron as a superior feedstock, enabling the firms to use lesser grades of waste or produce the best steel.

Applications of sponge iron:

An essential component in the creation of many steel products is sponge iron
The steel melting scarp serves as feed material for small steel mills and is, therefore, highly helpful
In L.D. converters of integrated steel plants, sponge iron is a particularly suitable material to be utilised as a coolant.

The kiln feed pipe supplies the sized iron ore, feed coal, and dolomite to the rotary kiln. Different size fractions of coal are gathered on a separate conveyor and introduced into the kiln from the discharge end side. In the typical 500 t/day sponge iron facility, the air is pumped by eight air fans, each individually controlled along the kiln's length. A central burner pipe, which acts as the process air input during normal operation, is also used to inject air at the kiln exit.

Sponge Iron Plant Gunning is used to line the kiln's interior, supported by three piers known as support rollers that are 2.5 degrees incline. The girth gear provides rotation. The material in the kiln travels along the axis as a result of its tilt and rotation. Mechanical air sealing is present at both ends of the rotating kiln to prevent air infiltration. Gases that flow in the opposite direction heat the charge as it passes through the kiln. Regulated airflow raises the material temperature by directly igniting the volatile components of the material charge at the kiln's inlet side. A heat recovery boiler system is placed in the traditional plant to utilise waste gas heat, leaving the Dust setting chamber, Rotary Klin, and after-burning chamber to produce electricity. According to statistics from the facility, this option produces 2.6 MW of power. With 3.5 kW/h, the electricity may be exported. Spot us online as the best Sponge Iron Plant Near Me.

At equivalent EAF settings, continuous feeding of sponge iron results in a higher power level than 100% scrap charge. Scrap collapse causes more breakages, but sponge iron charge breaks much less frequently. The rotary kiln is the primary furnace used to reduce iron ore directly. The rotary kiln is a cylindrical, Sponge Iron Plant Gunning-lined vessel with blowers and air pipes installed to supply combustion air inside the kiln. The rotating kiln is heated up during light-up by an oil-fired start-up burner at the kiln discharge end. To ignite the coal injected from the kiln's outflow. Iron ore, coal, limestone, or dolomite are supplied from the kiln feed end when the necessary temperature is attained, and coal is also injected from the kiln discharge end.

After determining the coal injection's ignition temperature, the oil-based start-up burner is turned off. Now that the coal has reached the proper temperature for the reduction process, iron ore and dolomite are fed into the kiln. The iron ore and coal mix as they go through the system because of the kiln's rotation and 2.5% downhill slope from the feed end to the discharge end. The kiln's rotating speed may be changed depending on the feed rate and the degree of metallisation. The material's age, rotating speed, length of the kiln, amount of time it is exposed to C.O., and temperature must all be considered.

Our thermocouples' high accuracy, portability, and dependability make them perfect for producing sponge iron. They are examined before delivery for qualities including performance and longevity. We offer the highest-quality thermocouples at the most competitive pricing for our cherished clients. Our mission is to meet the requirements for Sponge Iron Plant Gunning and offer standard goods that adhere to their standards. Find us online as one of the best Sponge Iron Plant Manufacturers In India.