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Now a days,sponge iron is a household name in steel making process.There are different methods to manufacture sponge iron but in India largely coal based process are carried out.In this process iron ore lumps (5-20mm)are feed into a horizontaly inclined vessel named as Rotary kiln (length 40mt. and dia 3mt.) from one end with required quantity of coal(5-20mm).The kiln revolves in a certain rotation and during the travel time iron ore is reduced by coal and converted to sponge iron .To reduce the iron certain temperatures are maintained with the help of coal and air supplied through fans mounted in the kiln.The temp. are regulated by dampers provided with the fans. Some imp. reactions that take place inside the kiln are given below,
The following reaction takes place inside the kiln.
Fe2O3 + 3 CO = 2 Fe + CO2
However the reduction from oxide to metal does not occurs in one step but by a gradual removal of oxygen giving rise to various intermediate oxides the reduction chain may be expressed as follows:
2 Fe2O3 ------------------------- 2 Fe3O4 ------------------- 6 FeO -------------6 Fe
Hematite Magnetite Wustite Iron
The degree of reduction between each stage is as follows:
11% 22% 67%
3Fe2O3--------------------- 2Fe3O4-------------------------- 6FeO--------------6 Fe
The byproduct of above reaction is carbon die oxide (CO2).
This Co2 reacts with carbon from coal to produce CO.
CO2 + C = 2 CO.
The above reaction is known as bound ward reaction which is reversible.
The above kiln dia and length can produce 100MT of sponge/day.Though all reaction takes place in solid state the product from the kiln transfered to a rotary drum called COOLER ,where sponge iron from the klin are cooled indirectly by water and temp. decreased from 1100˚C to 150˚C.Further the discharge material transfered to separation chamber by conveyor belts where magnetic sponge is separated from char by magnetic separators and stored in bunkers.
With development and research production quantity also increased from 100MT TO 500MT by increasing the size of kilns.
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How do you found Fe total of sponge iron?
Measuring the mass of sponge iron.
What is the relation between metallic iron and total iron in sponge iron?
Metallic iron refers specifically to the iron that is in its metallic form in sponge iron. Total iron in sponge iron includes metallic iron as well as any iron present in other forms such as iron oxides. Therefore, metallic iron is a subset of total iron in sponge iron.
How Fe separation from coal base sponge iron?
First sponge iron must be Roll crusher Next Magnet separation Next Create block sponge iron
Is propane used as feedstock for sponge iron?
No, propane is not typically used as a feedstock for producing sponge iron. The most commonly used feedstock for sponge iron production is natural gas or coal. These feedstocks provide the necessary carbon and heat required for the direct reduction process to convert iron ore into sponge iron.
Can sponge iron making is a primary metallurgical process - yes or no?
Yes. Sponge iron making is a primary metallurgical process where iron ore is directly reduced in the solid state to produce sponge iron, which is a highly porous form of iron used in steelmaking.
Difference between pig iron and sponge iron?
http://encarta.msn.com/encyclopedia_761559225/iron_and_steel_manufacture.html Provides the answer. basic summary: 1. Pig Iron and Sponge Iron are the result of different production processes 2. Which results in different purities. Pig Iron has a lower purity than Sponge Iron.
What is the difference between Sponge iron and pig iron and their application?
Sponge iron is produced by reducing iron ore pellets in a direct-reduction process, whereas pig iron is produced by melting iron ore with a high-carbon fuel in a blast furnace. Sponge iron is mainly used as a raw material for steelmaking in electric arc furnaces, whereas pig iron is typically used in the production of cast iron and wrought iron products.
How do you calculate sponge iron metalization?
It is the ratio of metallic iron to the total iron ,convert in percentage
How do you calculate the yield of production of sponge iron?
The yield of production of sponge iron is calculated by dividing the weight of sponge iron produced by the total weight of iron ore initially taken for the process, and then multiplying by 100 to get the percentage yield. It is important to consider losses during the process to get an accurate yield calculation.
Why do made sponge iron?
spong iron is the porous product of direct reduction of iron ore .it is better than scrap of iron because of less polution of the environment and more homogenous and have less harmfull element such as phosphor sulphur( S and P).
What is a sponge garden?
a garden made of sponge
What are SpongeBob and Patrick made of?
They're made of natural sea sponge, while Spongebob was made to look like a synthetic dish sponge.
