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Direct reduced iron (DRI), also called sponge iron, [1] is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) into iron by a reducing gas which contains elemental carbon (produced from natural gas or coal) and/or hydrogen. When hydrogen is used as the reducing gas no carbon dioxide is produced.
This formed the basis of the first commercial sponge iron plant of India. [6] in 1976, installations in service totalled less than 5 Mt; [3] in 1985, annual production was 11 Mt for an installed capacity of around 20 Mt, [nb 5] the difference being explained by fluctuations in energy costs; [7] in 1991, production reached 20 Mt. [3]
The HIsarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron ().The process combines two process units, the Cyclone Converter Furnace (CCF) for ore melting and pre-reduction and a Smelting Reduction Vessel (SRV) where the final reduction stage to liquid iron takes place.
Chemical plant cost indexes are dimensionless numbers employed to updating capital cost required to erect a chemical plant from a past date to a later time, following changes in the value of money due to inflation and deflation. Since, at any given time, the number of chemical plants is insufficient to use in a preliminary or predesign estimate ...
It reduced plant capital costs and smelting time, and increased labor productivity. Between 1920 and 2000, labour requirements decreased by a factor of 1000, to 3 man-hours per thousand tonnes. [ citation needed ] In 2013, 70% of global steel output came from the basic oxygen furnace. [ 14 ]
It is widely used in industrial engineering to calculate the capital and operating costs of a plant. [ 1 ] [ 2 ] [ 3 ] The factors were introduced by H. J. Lang and Dr Micheal Bird in Chemical Engineering magazine in 1947 as a method for estimating the total installation cost for plants and equipment.
A bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a bloom. The mix of slag and iron in the bloom, termed sponge iron, is usually consolidated and further forged into ...
Gohar Zamin Iron Ore Mine is expected to produce 140 million tons of ore by 2013. [45] In 2012, Iran opened a sponge iron plant in Hormozgan Province with a projected annual output of 1.8 million tons. [46] Tariffs for the export of iron ore concentrate and pellet have been set at 50% and 35% respectively (2010). [47]