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
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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:
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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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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 ...
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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 ...
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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.
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Of total DRI the production in 2008, 74 percent was produced from coal and 26 percent from natural gas. India is now the world's largest producer of DRI. Currently, there are two primary means of DRI production in India: smallscale rotary kilns using coal and iron ore lump, and largelocal scale shaft furnace plants using
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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.
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ArcelorMittal's plans for more coalbased steelmaking in India contrasts markedly with its developments in Europe and Canada, where the company is planning a transition away from blast furnaces to direct reduced iron (DRI)based steelmaking using green hydrogen under its 'Innovative DRI' decarbonisation pathway. In October 2022 ...
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Direct reduction processes ScienceDirect Available online at Procedia Manufacturing 35 (2019) 242â€"245 © 2019 The Authors. Published by Elsevier Peerreview under responsibility of the organizing committee of SMPM 2019. / / © 2019 The Authors.
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Emissions from DRI vary with the source of fuel, with coalbased DRI in India, producing around t CO 2 /t steel and natural gasbased DRI producing around t CO 2 /t steel. Of all the current commercially available technologies, scrap based EAF steel making is the greenest with emissions of around t CO 2 /t steel on average ...
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The decarbonization pathways projected by this study revealed that coalbased DRI production had a lower carbon abatement cost than gasbased DRI production and can account for 45% of the iron and steel's total carbon reduction under the HCN scenario. Therefore, China could adapt its resource endowment, taking coal as the foundation of ...
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Over the past two years, nearly all European flatsteel players have announced the gradual replacement of their cokingcoalbased blast furnaces (BFs) with directreducediron (DRI) plants to decarbonize their steel more than 16 DRI plants currently announced represent more than 25 million metric tons 1 Metric tons: one metric ton = 2,205 pounds. of capacity (Exhibit 1).
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and since the inception of first DRI plant in 1957 in Mexico, there has been a continuous growth of this industry in last three decades. This is evident from the steep rise in world DRI production during the past three decades. India, entered the sponge iron industry only in 1980, when the coal based DRI plant of Sponge Iron India Limited (SIIL)
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The above parameters for new steelmaking technologies—scrapbased EAFs, coalbased DRI with and without CCUS, gasbased DRI with and without CCUS, hydrogenbased DRI, and oxygenrich smelting reduction with and without CCUS—were obtained from recent studies and communication with Chinese experts (Battle et al., 2014; IEA, 2020a; IRENA ...
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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.
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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.
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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 ].
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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.
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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 ...
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