The modern practice of coal mining 1907 chirons, nicholas p. To eliminate fossil fuel use in iron and steel making, renewable hydrogen gas can be used in place of syngas to produce dri. Prized as the best stone in britain by roman invaders who carved jewelry out of it, coal has transformed societies. Direct reduced iron dri is also known as sponge iron. Coal is an important and required energy source for todays world. Production of dri with coke oven gas as reductant ispatguru. In dri production, the reducing agents or sources of reducing gas that drive off the iron ores oxygen content in the form of water vapor and carbon dioxide include synthesisgas mixtures in gasbased directreduction processes and heated coal in coalbased processes. One emerging coalbased technology is the rotary hearth furnace, in which pellets of coal and iron ore are heated above 0 c by natural gas burners for a retention time of less than minutes. In the gas based plant the reactor, the reduction reaction takes place is a shaft furnace. Gas based dri 76 % world dri production coal based coal based dri 24%. The 12 coal channel samples were obtained from 5 coal beds that span about 244 m or 800 ft of stratigraphic section in the pocahontas and new river formations of early pennsylvanian age. Coal age handbook of coal surface mining 1978 isbn 007.
Coal gasification for dri production an indian solution. Nonfuel uses of coal include chemical products such as refined coal tar which is used in the manufacture of chemicals, for example creosote oil, naphthalene, phenol and benzene. Books and some articles relating to coal mining, especially historical. List of books and articles about coal mining online. In 1981 a new edition was published in which the text was unaltered proving that after 20 years the book was still considered a standard work in its field. This 2 mtpy module is the largest plant of this kind ever to be built in the world. Strip mining is the process in which the overburden earth and rock material overlying the coal is removed to expose a coal seam or coal bed. With such dimension of notion we in our sponge iron manufacturing process through 4 kilns 1 350t and 3 500t laid up the best dri making process in india. Angul plant 612mt of jspl at orissa the dribfeaf route technology would be adopted for steel production. Production of dri with coke oven gas as reductant direct reduced iron dri is technically defined as iron ore which has been reduced to metal without melting it. Coal is readily combustible, black or brownishblack, and has a composition that, including inherent moisture, consists of more than 50 percent by weight and more than 70 percent by volume of carbonaceous material. Genesis, uses and environment implications of iron oxides. The structure and energy content of coal varies according to its type.
Processes that produce iron by reduction of iron ore in solid state. Arithmetic mean, observed range, geometric mean, and geometric deviation of 38 elements in 12 coal samples from virginia and west. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. As more alcohol groups are eliminated and more crosslinks are formed, the coal becomes harder and goes. We determine each element through chemical analysis and express it as a percentage of the total mass of the original coal or coke sample.
An american family and the rock that changed the world 2003, owners perspective online. How a few brave americans took on a powerful companyand the federal governmentto save the land they love 2008 schurr, sam h. This product is known as direct reduced iron dri or sponge iron. In this chapter, coalbased products and their uses are.
This book comprehensively deals with the production of sponge iron in the rotary kiln. Mar 18, 20 india is the worlds largest sponge iron producer and mostly uses the coal based process. These power stations generate nearly 40 million tones of fly ash annually. Ammonia gas recovered from coke ovens is used to manufacture ammonia salts, nitric acid and. Current rates of world coal consumption are projected to continue at approximately the same or greater levels well into the twentyfirst century. Kinglor metor is a shaft furnace process, circofer is a fluidized bed process and, further. Direct reduced iron and its production processes ispatguru.
Coal gasification there are three general types of coal gasifiers. Gray mountain by john grisham, fall of giants by ken follett, faith, hope, and ivy june by phyllis reynolds naylor, how gre. Coal provides nearly a quarter of all energy supplies in the united states, with most of this coal used to generate more than half of the nations electricity. Besides covering the recent developments in the field of nonrecovery coke ovens, dry coke cooling, use of coal in dri and blast furnace, and new energy recovery system, the book also covers all the aspects of refractory systems. The effects of reduction temperature, coal dosage and reduction time on the phase transformation of composite pellets were investigated by xray. The hot pellets may be melted in an eaf to produce pig iron, or charged hot to an eaf steelmaking furnace. In the former, the reducing gas is most often obtained by the steam. As per the statistics available, in year 2011, 55 million ton dri was produced through gas based plants and 19 million ton dri through coal based rotary kilns. Sgs uses the results from ultimate analysis tests to determine the elemental composition of the coal including moisture, ash, carbon, hydrogen, nitrogen, sulfur, and oxygen by difference. Comprehensive utilization of ironbearing converter wastes. The last third of coal is dedicated to the environmental impact it canis havehaving on the planet. This process involves pelletizing, direct reduction roasting and magnetic separation.
The dri process can be divided into gasbased and coalbased processes. Optimization of the coal based dri process requires understanding of the thermal properties of the coal ore mixtures and mechanism reactions of reduction, which have still not been well understood. It can also change over the years with alterations in the sources and types of ore being smelted. Just the sheer background of info starting with its formation, discovery and industrialization make it a book not to be put down or taken lightly. The energy in coal comes from the energy stored by plants that lived hundreds of millions of. Dri is successfully manufactured in various parts of the world through either natural gas or coalbased technology. As important source of metal alternate to scrap steel in eaf production could be a good substitute metal input to the blast furnace g therefore reducing coke consumption growth in coal based drihbi should be. Coal is a sedimentary rock made predominantly of carbon that can be burned for fuel. Manufacturing steel delivers the goods and services that our societies need healthcare. The gasbased dri process plays a leading role because of its advantages of high production capacity, low energy consumption, and low pollutant emission 14,15. As such it is also known as direct reduced iron dri. As youve seen, lignite and sublignite coal are derived from peat and are quite similar in structure to lignin. Chapter 7 coal if we as a nation are to benefit in the future from our enormous, lowcost coal reserves, a variety of efforts are necessary to 1 develop and demonstrate new clean coal technologies. Chemical analyses and physical properties of 12 coal.
Direct reduced iron is highly susceptible to oxidation and rusting if left unprotected, and is normally quickly processed further to steel. The coal gasification plant would use local indian coals to generate a synthesis gas or syngas that can be an acceptable reducing gas source for producing dri in a shaft furnace. Metallurgical coal or coking coal is a vital ingredient in the steel making process. These variations affect the relative content of the four major constituents.
Preparation of direct reduced iron and titanium nitride. Directreduced iron dri, also called sponge iron, is produced from direct reduction of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal. Combustion of coalwaste materials is a major source of air pollution. Based on the available information, a comprehensive assessment of the seriousness of en vironmental contamination from trace elements in coalprocessing wastes cannot be made. It is the most abundant fossil fuel produced in the united states. Gasification kinetics of bituminous coal char in the mixture. Chemical analyses and physical properties of 12 coal samples.
Extensive work has been reported on reduction of iron ore and coalore mixtures and its kinetics 34, 35. Nonfuel uses of coal include chemical products such as refined coal tar which. The chemical composition of slag 1,7 can vary over a wide range depending on the nature of the ore, the composition of the limestone flux, the coke consumption and the kind of iron being made. The rotary kiln processes include accarosil, drc, kruppcodir and slrn processes. The framework is based on projected scenarios for future energy demand and markets for coal technologies, taking into account likely future environmental requirements, competing energy sources, institutional issues, international activities, and other factors affecting the. India is the worlds largest sponge iron producer and mostly uses the coal based process. Pdf coalbased products and their uses researchgate. Dri, or directly reduced iron is amethod of producing solid iron from iron oxide 2 3. Energy saving reduction in consumption of coal in blast furnaces the use of dri as blast furnace feed enables reduction in coal consumption in blast furnaces. The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world.
Direct reduction hogan steel archive research guides. Coal is a combustible black or brownishblack sedimentary rock composed mostly of carbon and hydrocarbons. The coal industry in the united statesencompassing coal mining, processing, and transportationis a relatively small but vitally important component of the nations economy. Optimization of the coalbased dri process requires understanding of the thermal properties of the coalore mixtures and mechanism reactions of reduction, which have still not been well understood. The coalbased processes can be grouped into four categories according to their reduction reactors. A novel process for preparing direct reduction iron dri and titanium nitride tin from panzhihua titanomagnetite concentrate is proposed. Chapter 7 coal penn state college of earth and mineral. Coal based spongeiron is a metallic product produced through direct reduction of iron ore in the solid state. The book cliffs coal field is part of the southern rim of the uinta basin, which. It is produced by the reduction of iron ore in the form of lumps or pellets by either noncoking coal or a reducing gas produced by reforming of natural gas. Nonfuel uses of coal united states energy association. When 100 kg of dri is used for the production of 1 ton of molten iron, the consumption of coal in blast furnaces will be reduced by 50 60 kg. The downside of this industry is that it generates significant amounts of solid waste in the form of esp flyash and bag house filter dust. Gas based dri 76 % world dri production coalbased coal based dri 24%.
As more alcohol groups are eliminated and more crosslinks are formed, the coal becomes harder and goes progressively to bituminous, then anthracite, and finally graphite. The gas based dri plants started coming up with the availability of natural gas. Fuels and combustion bureau of energy efficiency 1 syllabus introduction to fuels, properties of fuel oil, coal and gas, storage, handling and preparation of fuels, principles of combustion, combustion of oil, coal, and gas this chapter is a prelude to boilers and furnaces 1. The reducing gas is a mixture majority of hydrogen h2 and carbon monoxide co which acts as reducing agent. This collection of papers provides an introduction to the concept of coal systems analysis and.
Preparation of direct reduced iron and titanium nitride from. Typology chemistry physics constitution appeared in 1961. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. Lordes poetry in coal explored themes related to the several layers of her identity as a black, lesbian, mother, warrior, poet. Since, the coal based dri plants often experience problems with respect to formation of accretion resulting in reduced production rate and shorter campaign life, fluctuation in product quality, high coal consumption, etc. A human history is a well researched and well written novel on coal. Feb 28, 2020 in dri production, the reducing agents or sources of reducing gas that drive off the iron ores oxygen content in the form of water vapor and carbon dioxide include synthesisgas mixtures in gasbased directreduction processes and heated coal in coalbased processes. Coal is a nonrenewable energy source because it takes millions of years to create. Strip mining is the process in which the overburden earth and rock material overlying the coal. Environmental contamination from trace elements in coal. Compared with the traditional direct reduction of fired oxide pellets in coalbased rotary kilns, onestep process for direct reduction can avoid hightemperature oxidation of pellets at 11500c, and possess some advantages such as greater economic profit and good quality of direct reduced iron. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron. It further exposes the reader to the different types of fuels with their testing methods. Publication date 1912 topics coal publisher new york.
Composition of a typical coke oven gas 14 table 2 typical syngas composition 19. The novel talks about the history coal has had on ancient civilizations to modern day societies, and from the uk to the usa to china. During the last four decades, a new route of ironmaking has rapidly developed for direct reduction dr of iron ore to metallic iron by using noncoking coal natural gas. Fly ash contains co 2 emitted from thermal power plants, industries using coal as a fuel emits unwanted ash and smoke from which fly ash is. Feed material in a dri process is either iron ore sized to 10 to 30mm or iron ore pellets produced in an iron ore pellet plant. The desert research institute dri is a world leader in environmental sciences through the application of knowledge and technologies to improve peoples lives. Major dri production processes are either gas based or coal based. At present, the gasbased dri production process comprises 80% of the worlds total dri production. After reduction of iron ore pellet the product resembles sponge because of pores left behind after removal of oxygen. Pollution in coal based dri summer internship project, 2012 supervised by susmita dasgupta, eru, jpc 1 2. The dri plant 2mt has a unique feature of using syn gas. Fly ash bricks and comparison with clay bricks composition, manufacture. The effects of reduction temperature, coal dosage and reduction time on the phase transformation of composite pellets were investigated by xray diffraction.