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Sponge iron has higher iron content and is obtained from the direct reduced process of iron ore in major companies around the world. In the investigation of the sponge iron analysis, we found that the oxygen in the iron ore is removed and that the iron ore does not melt in any way.
direct reduced iron
Overall, it can be said that the mushroom iron analysis shows us whether the product contains high iron. For example, in this analysis, you will notice differences between grades and their numbers.
This means that these grades are completely different in first and second grade. In this way, the first (88-92%) and second (70-80%) are mostly sponge iron.
In the analysis of sponge iron, high quality is also taken into account, also other components such as carbon content and phosphorus content.
As is known, the first case (carbon) is an important alloying element in the steel industry, and the second case (phosphorus) is known as a harmful element in the steel industry.
Analysis of sponge iron is important because buyers are aware of the quantity and quality of iron when purchasing.
This means that this has been proven worldwide and for this reason, the point of view of factory owners and producers has also turned towards the production of sponge iron.
Benefits of sponge iron
Sponge iron and iron scrap are the two most important raw materials for ironmaking and the production of steel products. But sponge iron has advantages over scrap, so most steel mills use it as the main raw material.
One of the advantages of sponge iron is its iron purity, which is 95% pure. Therefore, it is easier to use than scrap due to the lack of many impurities.
Although such porous particles are much cheaper than other raw materials, due to the low energy and water consumption in the melting process.
Another advantage of this raw material is that it contains a small amount of nitrogen when melted, so the quality of the product produced with it will be better.
In addition to the above, sponge iron is also portable, easy to move and carry. In addition, its use in furnaces eliminates the risk of explosion due to the presence of impurities.
Another advantage of this iron is the low oxygen consumption during melting. While the presence of oxygen reduces its electrical resistance, one of the main advantages of using such porous pellets is that it does not damage the furnace walls.
Furthermore, cast iron products made with this iron are of very high quality due to their consistency and lack of toxic elements. Due to the need for filtration, metallurgical and smelting operations are easy to perform and as a result, the furnace works well.
direct reduced iron plant
Disadvantages of sponge iron
In addition to many advantages, sponge iron or porous particles also have disadvantages. First, the production of sponge iron goes through several stages, where the scrap is collected and sent to the foundry.
Another form of this iron is the many different production steps that end up in products with different chemical compositions.
In other words, each mushroom manufacturing process produces a product with a different chemical composition. Therefore, not all porous particles melt at the same temperature.
What are briquettes?
A briquette is a dense and compact iron sponge designed and manufactured for easy storage and transport. Briquetting is the most effective way to reduce the oxidation or oxidation of tobacco during storage and transport.
Briquetting reduces surface porosity (segregation) and increases density and wear resistance.
Types of briquettes according to the type of production process and temperature:
- sponge Hot Iron Ball
- Soft sponge iron ball
- sponge iron cold briquettes
Summary of the main points of sponge iron
Sponge iron is a very important raw material for the production of high-quality steel products so that it can replace scrap. In this article, we try to introduce sponge iron and its production method.
By introducing its advantages, disadvantages, and uses, we are able to better understand this raw material. Of course, this type of raw material must be used sparingly, as its main source is iron ore, and improper mining can damage the environment.
Soft sponge iron is a by-product from sponge iron factories, or scrap iron. The option for factories to use soft iron sponge alone (to make briquettes) or to sell it together with the main sponge iron product can reduce production costs for the direct recovery unit.
direct reduced iron price
In this way, the product can be offered at a better cost price.
soft iron sponge
It has uses, we announce two of them below:
- Soft for making iron balls
- Soft for the production of brake pads for cars
As we mentioned, one of the soft uses of sponge iron is to use it to produce cold sponge iron balls. Soft briquetting is done by mixing a soft iron sponge with silicate glue, and lime heat.
Of course, according to the buyer's request, the necessary alloying elements can be added to the product during the production stage of the sponge iron ball.
Analysis of fungus and soft iron
The analysis of sponge iron and soft iron from the same plant tends to be the same. Soft sponge iron is actually the sponge iron that is separated from the product in the final stage of sponge iron transfer.
direct reduced iron in major companies
Sponge iron is an excellent source for steel production, it is obtained by recovering natural or processed iron ore in direct reduced iron without reaching melting temperature in major companies.
In this method, iron ore pellets are regenerated with a quality of 67% and the result is sponge iron (porous pellets) with Fe metallization (approx. 92 degrees).
The product of the regeneration device does not pass through the cooling part of the furnace, and the temperature is about 600 degrees Celsius, and is transported to the steel-making department through a special material transport system for direct furnace loading.
After being melted and regenerated in steelmaking, sponge iron is used in the casting process in the form of the desired product and is used in three forms: plate, billet, and rebar. Today, about 5% of the world's steel is produced from sponge iron (DRI), and this trend is increasing.
Sponge iron is obtained by direct reduction of iron ore, also known as direct reduced iron.
direct reduced iron uses
Application of iron sponge
The use of sponge iron in induction furnaces is one of its most important uses. It can be said that the use of sponge iron in an induction furnace can replace almost 50% of scrap steel.
But its use in induction furnaces requires technical knowledge and experience. In addition, the use of sponge iron is a major change in strand casting in the steel industry.
It can be used in almost all steel production methods. These methods are used by many large and small steel production units in the country.
Iran has several available natural resources that can be recycled directly, sponge iron is a good substitute for iron scrap, so we can supply a high proportion of raw material through sponge iron to meet the smelting needs of steelmaking units instead of using scrap.
Iron ore is recovered directly from natural gas or coal sources. The choice of direct iron ore recovery method depends on the location of the production facility and available resources.
For example, in Iran, which is rich in natural gas resources, it is a reasonable choice to choose natural gas resources, and natural gas is used as a renewable material.
As you know, the use of coal resources for regeneration can also cause air pollution problems, and access to their mines is not an easy task. But currently, the world's largest producer of sponge iron is India, which uses coal resources.
Production of Sponge Iron by the Midrex Process
The method is the most widespread production method in Iran and the world, where natural gas enters a gas fracturing unit and is then converted into hydrogen and carbon under the influence of heat and special catalysts.
This hydrogen and carbon then goes into a furnace called a regeneration furnace where we put the iron ore pellets and it combines with the oxygen in the iron ore pellets to regenerate the iron ore, this method is considered to be the most effective method.
hot direct reduced iron
The most popular method in Iran and the world.
About 80% of the mushroom iron in Iran is produced in this way. Then there is the HYL method, but there are problems with high power consumption and large capacity.
What is the difference between sponge iron and briquettes?
The briquettes are actually compressed sponge iron in larger sizes. Cast iron has many more uses and benefits than sponge iron. In general, the briquetting process has been extended due to the limitations of sponge iron storage.
There are two methods of briquetting: cold pressing and hot pressing. Cold briquetting is to put the materials with the same temperature as the ambient temperature into the briquetting machine to produce the following two briquettes.
- Soft sponge iron ball
- Cold sponge iron ball
Generally speaking, the above types of briquettes, in contrast to sponge iron, have no problems with transport and storage.
They are easy to store. Another type of sponge iron briquette is the thermal briquette, which is produced in an oven at a temperature of 650 degrees and is considered the most widespread type of briquette.
The application areas for the briquette are very broad but are generally used in steel production, fertilizer, sanitary materials, and cleaning agents.
direct reduced iron arcelormittal
Benefits of sponge iron
In Iran, the use of directly recovered iron ore and electric furnaces for steel production is more common than the use of blast furnace methods. Among the advantages of using iron sponges and producing steel in this way, the following points can be mentioned.
- Sponge iron can be made from scrap metal.
- Sponge iron is widely used in the steel and cast iron industry.
- Sponge iron contains very small amounts of sulfur and phosphorus.
- The quality of sponge iron is higher than pig iron.
- Compared to other methods, the direct reduction method is less restrictive for steel production.
- With the direct recycling method, steel can be produced in small steel mills, and in this sense it is economical for the producers.
- Impure natural gas can be used in direct regeneration methods.
- The direct regeneration method has many advantages over other methods due to the easy transport of sponge iron in the round and lump form.
- Sponge iron is always a suitable substitute for iron scrap in oxygen furnaces.
Application of iron sponge
The existence of sponge iron is considered a major advance in casting in the steel industry. One of the most important uses of sponge iron is in induction furnaces (almost 50%, it replaces scrap).
The problem they face when using an induction furnace is that using sponge iron in an induction furnace requires special knowledge and expertise.
Since sponge iron can be used in all steel production methods, this material can be a good substitute for iron scrap, and it can replace iron scrap, providing a high proportion of raw materials required for smelting steelmaking units.
Considering that Iran has abundant natural gas resources, and the method of directly recovering iron ore from natural gas or coal resources, this method can be used in the country.
The use of air sources can also lead to air pollution. Today, the world's largest producer of sponge iron is India, which uses coal resources.
Benefits of sponge iron
Using briquettes or sponge iron in an arc furnace results in the properties we will mention below during the melting process.
- Due to the uniform chemical composition, the concentration of impurity elements and deposits in the melt is reduced by increasing the iron quality of the charge, and sponge iron is a better substitute for scrap in steelmaking. The reduction of deposits in the melting results in a reduction of nitrogen, which in turn results in the production of high-quality ingots and ingots for the production of hot plates, wire rods, and other types of products.
- High iron content for high quality
- Reduce the amount of sulfur and phosphorus
- Iron scrap does not contain waste substances
- Sponge iron can replace iron scrap as a coolant in oxygen furnaces and installations.
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