Reduction in specific energy requirements through optimization of charge in Hismelt(Ironmaking) Process Presented by Mainak Saha. ABSTRACT. Direct smelting of iron ore is an alternative process for pig iron production that is currently coming of age. The. HIsmelt Direct. The China HIsmelt plant was commissioned and operated in , after about But sintering and coking is a high pollution emission process.

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The hot metal produced in HIsarna also has advanatges for the steelmaking process, allowing for lower slag and metal phosphorus levels in the BOF converter or larger hot metal charges in an Electric arc furnace [23]. Designed by Elegant Themes Powered by WordPress. The main improvements incorporated into the design included a stationary vertical vessel, top injection of solids, a simplified hot air blast lance, a fore hearth for continuous tapping of metal and water cooled panels to overcome refractory wear problems.

Archived from the original on 3 April Bloomery produces sponge iron Blast furnace produces pig iron Cold blast Hot blast Anthracite iron Direct reduced iron.

However, at the time they couldn’t get it to work properly and the experiment was quickly abandoned. Typical flow sheet of the process is shown in Fig 2 and the typical layout of the process is in Fig 3. Construction of the HRDF with a design capacity oftons per annum, commenced in The horizontal vessel was operated from October to August Any other technology to reach the level of BF will take a lot of time.

In the traditional process one cannot use powdered coal alone since the strength of the coke is required to support the his,elt.

HIsmelt process of Ironmaking

By using this site, you agree to the Terms of Use and Privacy Policy. This vessel addressed all the key requirements for a successful direct smelting iron making technology — combining a high level of technical achievements with simple engineering concepts and plant technology.

Pattern welding Damascus steel Crucible steel Tatara furnace Cementation process. It is cleaned, procews and used as a fuel ptocess for power generation. The HIsarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron or hot metal.

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Whilst scale-up of the process was successfully demonstrated, the complexity of engineering a horizontal vessel limited its commercial viability.

The plant had provess a production rate of 80 tons of hot metal per hour in early with a coal rate of kg per ton of hot metal. Without these steps, the HIsarna process is more energy-efficient and has a lower carbon footprint than traditional ironmaking processes. The process uses high velocity injection of coal and ore into the melt through downwardly angled water cooled injection lances.

HIsmelt | Industrial Efficiency Technology & Measures

Stahl – Stahl in Bewegung. Injected iron ore fines are injected deep into the bath where they are reduced instantly on contact with carbon dissolved in the bath for smelting to take place.

Iron and steel production. The vertical vessel demonstrated major improvements in terms of refractory hiismelt, reliability, availability, productivity and simplicity in design.

Posted by Satyendra on Jul 2, in Technical 2 comments. Tapping slag at the HIsarna pilot plant. The process has been developed to treat iron ore fines with minimum pretreatment, making the process more flexible in terms of the quality of iron ore it can treat. The refractory hearth contains the molten iron bath and liquid slag. The trying times did not last however and the project was put on the back burner until the early s. Slag is formed by fluxing the gangue in the iron ore and ash in the coal with lime and dolomite.

Heavy environmental restrictions made it unattractive to build new facilities, so steel producers sought ways to reduce the need for cokes; Hoogovens started putting more effort into the cyclone technology as a solution to this problem and a test facility for the cyclone part proved capable of producing twenty tons of pig iron per hour.

Cast house and metal tapping at the HIsarna pilot plant. This reduction reaction produces iron Fe and carbon monoxide CO. Electro-slag remelting Vacuum arc remelting Argon oxygen decarburization. The geometry of this furnace causes a cyclone to form in the neck when the crushed iron ore is injected into this cyclone together with oxygen so oxygen is injected at the top rather than at the bottom.

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The heat transfer between the upper oxidizing regions to the lower reducing region is achieved in such a way that the oxygen potential gradient is maintained. The fifth campaign started in the autumn of Located in Kwinana, Western Australia, the merchant pig iron facility was designed and engineered with a 6 meter hearth diameter SRV.

Retrieved 25 September Between the cyclone and the slag layer, oxygen is injected through water cooled lances to generate heat by partly combusting the gasses being released from the final reduction reaction step that takes place in the slag.

The first serious revival came inwhen Hoogovens sought a method of producing steel without having to produce iron ore agglomerates such as pellets and sinter. Annealing Low hydrogen Short circuit. Further there is big reduction in dust emissions and specific wate consuption.

HIsarna ironmaking process – Wikipedia

Schematic of the HIsarna process Tata Steel [4]. The very first attempts at applying cyclone oven technology in the reduction of iron ore took place at Koninklijke Hoogovens in the s. Donate Grateful for your donation! In November it was announced that a large scale HIsarna pilot facility would be processs at the Tata Steel site in JamshedpurIndia[25] [26] but that the site in IJmuiden would still be a potential location for further industrial implementation of the technology.

HIsarna is considered one of the most promising developments in reducing CO 2 emissions from the steel industry. Blast furnace process is no doubt proven route globally. HIsmelt is short for high intensity smelting. If BF is present then these technologies are the future. Reaction gas CO and coal devolatilization products which are generated from deep within the bath form a fountain of mostly slag and some metal.