Direct Reduced Iron (DRI) manufacturing, a growing technology in ironmaking, offers the potential to reduce emissions. India, as the largest manufacturer of DRI, is characterized by technological diversity, while simultaneously dominated by coalbased DRI processes.
Direct reduction processes can be divided roughly into two categories: gasbased, and coalbased.
DRI processes can reduce CO 2 emissions by using natural gas instead of coal due to the replacement of carbon reductant by hydrogen from the methane. Many complementary gasification processes have been developed in order to synthesize the reducing atmospheres.
Direct Reduced Iron (DRI) is the product of the direct reduction of iron ore in the solid state by carbon monoxide and hydrogen derived from natural gas or coal. See more information about the production of DRI . Most gasbased direct reduction plants are part of integrated steel minimills, located adjacent to the electric arc furnace (EAF ...
gasbased fluidized bed processes (the Finmet / Finored process being the only commercial scale one in operation) accounting for % of 2019 DRI production; coal based rotary kiln furnaces (mainly in India) accounting for 24% of 2019 production. Generic illustrations of the types of process are shown in the graphics below.
The coalbased DR process is more popular in India and China. Different types of reactors, such as shaft furnaces, fluidized beds, rotary kilns, and rotary hearth furnaces, have been used in different variations of the processe to achieve the metallization required.
From 2016, worldwide DRI output has grown by almost Mt, or nearly 64%, primarily driven by the increase in coalbased DRI in India, new gasbased plants in , and rampup of new gasbased capacity in Algeria, Egypt, USA, and Russia. The reduced effects of the global COVID19 pandemic, an % jump in coalbased production in India,
10 0 1975 1980 1985 1990 1995 2000 2005 2008 Fig. 1 World DRI production by year reduction processes including SL/RN employ rotary kilns. Pellets, or lumpore, mixed with coal 2) are/is charged into the rotary kilns and heated by coal burners to produce DRI.
The scope for the adoption of these technologies depends on how steel is produced. There are two basic production routes: the Blast Furnace (BF) route, where coke is the primary fuel, and the Direct Reduced Iron (DRI) route, where the fuel can be coal or natural presently produces around 90% of crude steel through the BF and coal based DRI routes (with an approximately equal share ...
To avoid locking in further coalbased steelmaking capacity for decades, some technology switching to DRIelectric arc furnace (EAF) processes will be required before 2030 to achieve net zero by 2050. Agora Industry has already tracked 59Mt of new DRI capacity announcements since 2019, requiring about 80Mtpa of iron ore if all proceed.
Major DRI production processes are either natural gas based or coal based. Feed material for the DR process is either sized iron ore of size ranging from 10 mm to 30 mm or iron ore pellets of size ranging from 8 mm to 20 mm produced in an iron ore pellet plant.
The broad interest shown by the steel industry in coalbased direct reduction is a result of: (1) the need for a scrap supplement, (a) due to the steadily increasing electric arc furnace capacity in the USA, direct reduced iron (DRI) is required as a substitute in times of scrap shortages, and (b) due to the decreasing quantities of quality ...
World DRI Production by Process. Midrex Technologies,Inc. Midrex ® Process HOTLINK ® Process. Achievements. Iron Unit Division. Engineering Business. Kobe Steel, Ltd. Direct Reduction is an iron making process for the new era, which utilizes natural gas to reduce iron ore to produce Direct Reduced Iron (DRI).
It is widely understood that manmade climate change is chiefly caused by greenhouse gas emissions, especially carbon dioxide (CO 2 ), and that the consequences of global warming will be profound, widespread, and destructive. 1 Nonetheless, global emissions have risen more or less continuously for the past 25 years and have increased each of the...
4 for gas based DRI, for coal based DRI: Material handling: Easy: Challenging (pyrophoric and fines) Melting temperature: deg C: Around 1,250: Around 1,300: Power to melt in EAF (with energy from carbon) kWh: Around 150: Around 400:
At present, fossil fuels are the steel sector's bloodstream: 27 EJ (10 18 J) of coal, 3 EJ of gas and 5 EJ (1400 TWh) of electricity are consumed annually for the production of the mostly widely ...
Another way to make primary steel is through what is termed Direct Reduced Iron (DRI), when iron ore is mixed with a fuel and a reductant to reduce the oxygen content. ... Worldwide, natural gas is the fuel typically used while in India 82% of DRI is produced in coalbased rotary kilns with the remainder being produced via gasbased routes ...
The remaining 18 % of direct reduced iron is produced through coalbased reducing agents in rotary kilns (ACCAR, DRC and Krupp Rein processes) or rotary hearth furnaces (Fastmet process) [29]. ... Given the long period obtained for the hydrogenbased DRI technologies to be profitable, the possibility of using HDRI in blast furnaces (Fig. 5) ...
The coalbased direct reduction iron (DRI) plants are mainly concentrated in India, where they produce % of the global crude steel output from coalbased DRI plants.
well over half of the global DRI. From, worldwide DRI output increased by Mt, or nearly 49%, primarily driven by the increase in coalbased DRI in India, the high capacity utilization of existing and new gasbased plants in , and the ramp up of new capacity, such as Tosyali Holding's MIDREX® Plant in Algeria.
A coalbased dual fuel DRI process (FASTMET) shows lower gross CO 2 emission ( t CO 2 /t DRI) compared to rotary kiln (RK) process ( t CO 2 /t DRI)) without electricity rebate. In RHF, coal is used as a reductant, and hydrogenrich or carbon lean natural gas is used as the heat producer. The coal used is substantially lower (400 kg/t ...
An established alternative to coal and cokebased reduction of iron ores in blast furnaces is the ore reduction by coal or reformed natural gas (CO, H2) to direct reduced iron (DRI) or hot ...
Direct Reduced Iron Industry in India — Problems and Prospects Ramachandra Rao Consultant (Mineral Processing, Iron Steel Technology and Engineering) Abstract India is the largest producer of Direct Reduced Iron in the world with annual capacity of nearly 10 Mt comprising coal and gas based DRI plants. India has the largest coal based DRI
Coal plays a dual role in the Kiln. Part of coal is used as fuel to supply the desired heat so as to take the raw materials to the desired temp. But main role of coal is to supply carbon in the reduction process. Dolomite is used as sulphur scavenger which finally comes out with the char. Char contains ash of coal and other impurities of iron ore.
Although 84Mt is only around 5% of global steelmaking capacity, more than 70% of global capacity will reach a reinvestment decision prior to 2030. As such, it can be expected that the pipeline of noncoalbased DRI steelmaking projects will increase much further while CCUS is left behind again, just as it was in the power sector by wind and solar.
Another case study of a CGP based DRI plant in Angul of Odisha, India which is the first CGP based DRI plant in India with a maximum steel producing annual capacity of about using syngas ...
In coalbased DRI plants rotary kiln is used for the reduction of iron ore. Accretion rings formations inside the kiln adversely affect the performance of plant in terms of low production and inferior quality, which frequently lead to shut down. About 70% of the coalbased DRI rotatory kiln shut down is due to the accretion formation [ 1 ].
For instance, energy efficiency of rotary kilns in coalbased DRI units is hardly 3755% due to nonutilization of waste heat, therefore waste heat recovery systems should be made mandatory for coalbased DRI units. Similarly, induction furnaces in India should be restricted to prevent excess of poor quality steel or at the very least be ...
The DRI technology includes the coalbased DRI reduction and gasbased DRI reduction process. The application of hydrogen metallurgy in DRI process mainly focuses on the gasbased DRI process, which accounts for more than 90% of the total annual output of DRI at present.
Product Characteristics DRI can be produced in powder, pellet, lump, or briquette form. The powder, pellets, and lumps retain the shape of the iron oxide material fed into the DR process. The removal of oxygen leaves voids, giving the DRI a spongy appearance when viewed through a microscope.
To avoid locking in further coalbased steelmaking capacity for decades, some technology switching to DRIelectric arc furnace (EAF) processes will be required before then. Potential new DRgrade iron ore capacity by 2030 ranges from 40 million tonnes per annum (Mtpa) to an optimistic high of 100Mtpa. Unless technology innovations allow use of ...
Understanding of Syngas based DRI's operational aspects and Development of GasUtilization Model for SynGas Based DRI Plant at JSPL, Angul August 2017 DOI: /
In the last six years, worldwide DRI output has grown by almost 55 Mt, or approximately 75%, driven by a 136% increase in DRI production in India (mainly coalbased DRI), a doubling of natural gasbased DRI production in , and new natural gasbased plants in Algeria, Egypt, USA, and Russia.
TERI proposes to undertake the following activities in collaboration with SIMA (Sponge Iron Manufacturers Association ) in the coalbased DRI production process: Detailed mapping of DRI production units and shortlisting 23 prominent coalbased DRI manufacturing clusters representing domestic production ranges, existing and proposed capacity, operating practices etc. Explore possibilities ...
Abstract. Production of direct reduced iron from indigenous raw materials is an attractive alternative to the use of scrap for electric steelmaking or for a DRbased integrated steel plant. The SL/RN process is a proven coalbased direct reduction technology, its versatility being characterised by flexibility in the use of raw materials (lump ...
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