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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.
How Fe separation from coal base sponge iron?
First sponge iron must be Roll crusher Next Magnet separation Next Create block sponge iron
What is the difference between Sponge iron and pig iron and their application?
pig iron is intermediate product of smelting of iron ore sponge iron is product of direct reduction of iron ore in solid state
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.
How do you calculate sponge iron metalization?
It is the ratio of metallic iron to the total iron ,convert in percentage
What is the relation between metallic iron and total iron in sponge iron?
If we talk about metallic iron in sponge, we mean content of reduced (pure) iron. Total iron content reflects Fe in any forms (reduced to pure Fe and Fe in oxides)
Can sponge iron making is a primary metallurgical process - yes or no?
Yes, sponge iron making is a primary or can be a primar metallurgical process base on the Chemistry information that is provided.
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.
How sponge iron produced and the use of sponge iron?
Sometimes known as direct-reduced iron, sponge iron is a product that is produced using iron ore. The iron ore is often in the form of pellets or lumps, and is subjected to a reduction process that is created by the use of a reducing gas that emits from coal or a natural gas source. Sponge iron can be produced in several different types of furnaces, including coke or charcoal ovens, blast furnaces, and basic oxygen furnaces. There are several benefits associated with sponge iron that allow it to compete effectively with other types of smelted irons. One has to do with the actual composition of the final product itself. For example, this type of iron is considered richer than pig iron, another type of iron commonly produced in blast furnaces. Direct-reduced iron has a slightly higher iron content, which often makes it better suited for use in electric furnaces. In addition, the gases emitted during the production of sponge iron can be harvested and used in various other applications. This by-product of the iron making process helps to offset the cost of producing the iron, as well as aid in keeping other processes that require the gas for proper production. Sponge iron can also be used to produce a powdered ore that works very well when mixed with other metals in the production of different types of iron-based products. One of the more common uses for sponge iron is the creation of wrought iron. Iron of this type is helpful in the creation of ornamental objects for use around the house, such as decorative grills for screen doors, burglar bars for windows, and even for various types of wall hangings. Sponge iron is also often used for the manufacture of components used to create durable lawn and patio furniture. When properly treated, wrought iron furniture can easily resist deterioration from the weather, and last for a number of years. In recent years, refinements to the production of sponge iron have made it possible to reduce the iron without necessarily having to melt the ore. Because the iron can be made into pellets and even into powder, it is an economic and useful substitute for the scrap metal sometimes used by steel manufacturers. The amount of time and resources required to produce sponge iron is minimal, so it is possible to manufacture large amounts quickly, a fact that only adds to the advantages of this type of iron product.
Why sponge iron catch fire when it contect with water?
Sponge iron contains carbon oxygen iron sulphur phosphorus when water is mixed it form reaction between oxygen and hydrogen it produce enomous heat that its starting to burn --
