CRO PROCESS - DRI (PLANT) - BILASPUR

VINAYAK JOB CONSULTANT

Bilaspur, Chhattisgarh
Permanent
Full-time

1 month ago

A DRI (Direct Reduced Iron) plant using the Coal-based Rotary Kiln (CRO) process converts iron ore into metallic iron in the solid state (without melting) through direct reduction. This process utilizes coal as a reducing agent in a slightly inclined rotary kiln, typically operating at temperatures between 1000°C and 1100°C.Key Aspects of the Coal-Based DRI Rotary Kiln Process:Raw Materials:The primary raw materials are iron ore (typically hematite, magnetite, or other forms), non-coking coal, and dolomite.Reduction Process:Iron ore and coal are fed into the rotary kiln and move through the kiln, where they are heated. The coal reacts with the iron oxide in the ore, removing the oxygen and producing metallic iron. This process occurs at temperatures below the melting point of iron.Temperature Profile:The kiln maintains a temperature profile, with the first section preheating the materials and the subsequent sections facilitating the reduction reactions. Temperatures range from 800°C to 1050°C along the kiln's length.Product Cooling and Separation:The product, a mix of DRI (Sponge Iron) and char, is discharged from the kiln and cooled in a rotary cooler, often using water for cooling. The DRI is then separated from the char using magnetic separation due to its magnetic properties.Product Handling:The separated DRI is screened into different size fractions, and the fines (-3mm) may be briquetted using binders like hydrated lime and molasses.Safety:Ensuring proper purging of the furnace with air and maintaining safe gas compositions (below 5% oxygen) is crucial to prevent explosions from flammable gases.Advantages of the Coal-Based DRI Rotary Kiln Process:

Lower capital expenditure compared to other ironmaking processes.
Does not require coking coal.
Can be implemented in areas with available coal and iron ore resources.
Suitable for smaller-scale operations.

Challenges:Environmental Concerns:Coal-based DRI production can be more carbon intensive than gas-based DRI, and requires managing emissions.Product Quality:The DRI produced may have a higher gangue content and require further processing in steelmaking.Susceptibility to Oxidation:DRI is prone to re-oxidation and rusting if not handled and stored properly.DRI in the Indian Context:

India is a major producer of DRI, with a significant portion of the production being coal-based.

DRI plants in India are often located near coal and iron ore sources.

The National Steel Policy aims to significantly increase DRI production by 2030, with a large portion being coal-based.

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