Sponge Iron Production By Direct Reduction Of Iron Oxide

Front Cover
PHI Learning Pvt. Ltd., 2010 - Electric furnaces - 353 pages

This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is ‘directly reduced’ in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces (sometimes even in basic oxygen furnaces) to produce liquid steel. Such a process combination enables steel to be produced without using coking coal, which is an expensive input in the normal blast furnace—basic oxygen furnace route of steelmaking adopted in integrated steel plants.

The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production. The concluding part of this seminal book summarises the present and future scenario of direct reduction, including the use of gas generated from coal in direct reduction processes.

The book is primarily intended for the undergraduate and postgraduate students of metallurgical engineering. It is also a must-read for researchers, technologists and process metallurgists engaged in the rapidly developing field of direct reduction of iron oxides, which is of critical importance for India and other developing nations that are beginning to play a major role in global steelmaking.

 

Selected pages

Contents

The Need for Alternative Iron Units 117
1
Type Availability and Demand 1836
18
Fundamentals of Direct Reduction 3781
37
Coalbased DR Processes Using Rotary Kilns 82134
82
Coalbased Processes Using Reactors Other Than Rotary Kiln 135176
135
Gasbased Direct Reduction
177
Gasbased Direct Reduction Using Alternatives to Natural Gas 243277
243
Present and Future of Direct Reduction 325347
325
Index 349353
349
Copyright

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SPONGE IRON PRODUCTION BY DIRECT REDUCTION OF IRON OXIDE
AMIT CHATTERJEE
Limited preview - 2012

Common terms and phrases

amount blast furnace capacity carbon carbon monoxide characteristics charge coal coke composition concentration consumption containing continuous cooling cost decrease depending developed direct reduction discharge DR processes dust effect electric energy feed Figure fines flow fuel gangue gas-based gases gasifier given hearth heat higher hot metal hydrogen important increase India industry injection iron oxide layer levels lower lump material melting metallisation Midrex Mtpa natural gas normally operation oxygen particles pellets plant possible pre-heating present pressure production reaction reactor recycled reducing gas reforming relatively removal result rotary kiln scrap shaft furnace shown slag solid sponge iron stage steam steel steelmaking sulphur surface Table takes temperature tonne transfer typical unit volume waste zone

About the author (2010)

A metallurgical engineer from Banaras Hindu University, AMIT CHATTERJEE was awarded the Doctorate of Science (Engineering) Degree by the University of London in 1988 for his outstanding work on coal-based direct reduction and oxygen steelmaking. He had earlier obtained his Ph.D. in process metallurgy from the prestigious Imperial College of Science and Technology, London, of which he is also a Fellow. He started his professional career in the steel industry in Germany, followed by over 39 years of distinguished service in Tata Steel, from where he superannuated on 30th September 2011. br>

Dr. Chatterjee is a Fellow of the Institute of Materials, England, The Indian Institute of Metals, India as well as The Indian National Academy of Engineers, India. He has over 550 publications to his credit and is the recipient of several awards from India and overseas, including the National Metallurgist Award (1977), Visvesvaraya Gold Medal (1981 and 1996), SAIL Gold Medal (1982), Bhoruka Gold Medal (1992), Thomas Sidney Gilchrist Thomas Medal & Prize (1994) by The Institute of Materials, London, Application to Practice Award (1997) of TMS (The Minerals, Metals & Materials Society), USA, Tata Gold Medal (1997), Platinum Medal (2002) and many others.

Dr. Chatterjee has authored several books: Ironmaking and Steelmaking—Theory and Practice and Sponge Iron Production by Direct Reduction of Iron Oxide (both published by PHI Learning, Delhi) as well as two other books entitled Beyond the Blast Furnace and Metallics for Steelmaking—Production and Use, besides a number of Monographs on Cokemaking, Sintermaking, Ironmaking, Continuous Casting, etc.

Dr. Chatterjee is recognised all over the world as an authority in the field of process metallurgy, particularly in the area of alternative method of iron production comprising direct reduction and smelting reduction, in both of which hot metal is produced without using coke.

Bibliographic information

TitleSponge Iron Production By Direct Reduction Of Iron Oxide
AuthorCHATTERJEE, AMIT
PublisherPHI Learning Pvt. Ltd., 2010
ISBN8120336445, 9788120336445
Length353 pages
  
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