Conversion of Sponge Iron From Low Grade Iron ore And Mill Scale Through Simulating Tunnel Kiln Condition

Abstract

The present investigation deals with the feasibility study of the process development for production of Directly Reduced Iron (DRI) using waste/low grade iron ore (slime), mill scale and waste/less reactive coal (partly oxidized coal i.e. Jhama coal). In order to get most green and dry strength for safe handling and transportation, the pellets of iron ore slime and the pellets of mill scale were made in disc pelletizer with optimum moisture. Dried iron ore slime pellets reduced the bed of Jhama coal fines at different temperature and sintering time. Detailed investigation for the reduction kinetics of slime pellets with Jhama coal has been carried out to explore the feasibility of slime pellets reduction. Based on reduction kinetics, process criterion for reduction of pellets with Jhama coal is optimized to produce highly metallic DRI. The Reduction of dried pellets was carried out without in duration/firing higher temperature as compared to the conventional DRI process yielding high energy efficient and cost-effective process. An optimized work flow sheet and innovative process has been developed for production of high quality DRI utilizing waste iron ore slime and less reactive coal (Jhama coal). The DRI produced from this process have high metallization (<92%) suitable for blast furnace and electrical for iron and steel making.