Briquetting of Iron Bearing Materials

In direct reduction process, oxygen is removed from iron ore to make sponge iron with high porosity. So due to its large specific surface area, DRI reacts with water or air very easily. This reaction produce large amount of heat as it is an exothermic reaction. The spongy structure of DRI does not allow the heat to …

How much iron ore is needed for 1 tonne of steel rebar ...

Answer (1 of 2): Naturally-occuring iron ore varies in it's content. Also, you haven't said whether it is "benefacted ore" (crushed, with gangue material removed), or straight out of the ground. Obviously, if the latter is the case, even very rich ores seldom contain better than a few percent of ...

Sponge Iron Production Process - Arij Trading

Market share: About 23% of sponge iron total production. 4) Tunnel furnace process . This process is the oldest direct reduction method. In this method, Thermal coal is mixed with iron ore as a reducing agent. Natural gas generates the required reduction temperature, and reduction is performed on Silicon Carbide (SiC) Crucibles in a tunnel furnace.


The heat requirements of 4.6-5.25 million kilo-calories/ton of sponge iron could be lowered to 3.5-3.7 kilo-caloriesIton of sponge iron with partial recirculation of char. The trials yielded adequate data for designing a commercial prototype, or for industrial production

International Journal of Scientific & Engineering Research ...

volume, the weight of Sponge-iron in one hour was derived by multiplying it with the density of Sponge-iron (2 tons/cubic meter). Thus the ammeter reading was linked with the Sponge-iron feeding rate in tons/hour per ampere. EXPERIMENT 3 The next task was to establish the energy required to melt one ton Sponge-iron.


Iron ore crushing is not required since sized material has to be purchased. Iron ore of size 5 mm to 20 mm is being used for the production of Sponge iron. Iron ore is being fed to the Ground hopper, from where it conveyed to the Screen with the help of Vibro Feeder, where Oversize i.e. + 20 mm and Undersize i.e. – 5

Water Requirements of the Iron and Steel Industry

ton of pig iron. At the 1956-60 average rate of pig iron consumption, this amounts to about 13,000 gallons per ton of steel ingots or about 40 percent of that required by a typical integrated steel plant 33,200 gallons per ton. Dif­ ferent processes of iron ore concentration are devised specifically for the various kinds of ore.


Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. ... method the final amount of coal required is …

iron ore required for tonne of sponge iron

production of steel iron ore requirements Sponge Iron Units 1850 2960 Total: 5331 Note: Assuming no scrap is being used For producing one tonne of crude steel, 16 tonnes of iron ore consumption has been assumed If we add iron ore requirements of RINL of about 500MT (313 MT x 16 tonnes), the total iron ore requirements from noncaptive mines work out to 5831MT or about 60MT Out of the total

Theoretical Minimum Energies To Produce Steel

required to produce steel from ore and mixtures of scrap and scrap alternatives, clearly defining the necessary assumptions involved. The energy calculations are then repeated for a series of cases in which the assumptions are changed one by one to more closely approximate the actual conditions.

Iron Sponge Process - an overview | ScienceDirect Topics

James G. Speight Ph.D., D.Sc., in Natural Gas (Second Edition), 2019 8.5.1 Iron sponge process. An example of a hydrogen sulfide scavenger process is the iron sponge process (also called the dry box process), which is the oldest and still the most widely used batch process for sweetening of natural gas and natural gas liquids (Anerousis and Whitman, 1984).

sponge iron process

In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.

How many tons of iron ore is required to produce 1 ton of ...

Now sponge iron mass is 90 to 95% of the pig iron used. If you want 1 ton of sponge iron,you need around 1.05 tons of good quality pig iron and 2.10 tons of good quality iron ore.Remember you should use good quality of coke and lime stone during the smelting process of pig iron too.

Sponge Iron - an overview | ScienceDirect Topics

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H ...


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