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The main difference between sponge iron and pig iron is that we can produce sponge iron by directly reducing iron ore with reducing agents whereas pig iron is produced by Under intense pressure, limestone and coal are used to melt iron ore.
direct reduced iron
Sponge iron and pig iron are the different forms of iron that we can produce from naturally occurring iron ore in the ground.
Pig iron and sponge iron have different uses due to their different properties. While there are similarities, there are also differences between pig iron and sponge iron, which we will discuss in this article.
What is sponge iron? Sponge iron is a type of iron that we can produce directly from iron ore through a reduction process.
It can also be referred to as "direct reduced iron" because of this. There, the ore is exposed to different reducing agents like natural gas or coal-burning gas. Additionally, in a variety of furnaces such blast furnaces, charcoal furnaces, and oxygen furnaces, sponge iron can be made.
Sponge iron has many advantages over other similar forms of molten iron. Sponge iron is superior to pig iron because it is more abundant in iron.
Due to this characteristic, it has many applications in electric ovens. We can mix sponge iron in powder form with many other metals to produce a variety of iron-containing products. For example, we can produce wrought iron from sponge iron.
This is one of the types of iron we use to make decorative items like grills and patio furniture. Wrought iron furniture is in high demand and can last for years if properly maintained. The latest method of making sponge iron using reducing gas has been abandoned.
Therefore, there is no need to even smelt the ore. What is pig iron? Cast iron is a type of iron that we can produce via intense pressure-based melting of iron ore, coal, and limestone. After cooling, the resulting product, which we call cast iron, is an iron with very high carbon content.
Therefore, we cannot use it directly in this form to become fragile and unstable. However, we can refine this form of iron by further smelting and mixing to produce wrought iron, cast iron and steel which are very useful building materials.
Pig iron is thought to have been discovered by Chinese blacksmiths in the 11th century.
Pig iron in its true form is useless, but further processing and refining yields wrought iron and steel, the most widely used materials on the planet.
Sponge iron is a type of iron that we can produce directly from iron ore through a reduction process, while pig iron is a type of iron that we can produce by smelting iron ore with coal and limestone under very high pressure.
So, the main difference between sponge iron and pig iron is that we can produce sponge iron by directly reducing iron ore with a reducing agent, whereas pig iron is made by smelting iron ore with coal and limestone with very high pressure.
Also, another difference between sponge iron and cast iron is that sponge iron is porous whereas cast iron is not porous and therefore relatively denser. In addition, sponge iron and cast iron are also different in the production process.
direct reduced iron process
In a sense, the production process of sponge iron is a liquid process while pig iron is a solid-state process. Summary – Sponge Iron vs Pig Iron Both sponge iron and pig iron are the two basic forms of iron that we can obtain by processing natural iron ore.
The main difference between sponge iron and pig iron is that we can produce sponge iron by directly reducing iron ore with reducing agents whereas pig iron is produced via intense pressure-based melting of iron ore, coal, and limestone.
Recycled iron is almost the same as pig iron, generally 90-94% total iron (depending on the quality of the ore), so it is an excellent raw material for electric furnaces used in small factories and can be used. Low-grade scrap for residual charge or production of higher-grade steel.
Currently, it mainly produces pig iron Through the path of the blast furnace. Blast furnace operation and it auxiliary process help Maximum CO2 emissions per ton of steel production.
due to the use of coal and DRI process kola, based on natural gas, production is less than half the Emission of carbon dioxide from a blast furnace.
So, there is context an opportunity to fix the shortcomings of DRI and make it closer to cast iron, while maintaining the total emission Low.
In this article, two methods are mentioned Overview to improve usage value Direct reduced iron in electric steelmaking The first method is based on preheating DRI before entering the electrical system Using an oxy-fuel torch.
The latter is quite a Conversion of DRI to hot metal or Pig iron smelting using oxygen-rich fuel Combustion is both methods Based on natural gas combustion and/or hydrogen as fuel to minimize Carbon dioxide emissions.
The next part Describes these two methods Advantages of the plan, feasibility, and possible next steps.
Products Market in Other Countries
The market for products in Russia: Russia is currently in an excellent position to scrap steel significantly cheaper than DRI compared to manufacturing costs as it is only increasing its steel output by no more than 5% per year.
Furthermore, because DRI contains a lot of non-metallic components, Russian experience with DRI in electric furnaces demonstrates that scrap is more effective than DRI.
If the amount of highly polluted scrap surpasses a crucial threshold and needs to be diluted with primary iron, Russia will only want DRI. If DRI is less expensive than scrap, there may be additional factors influencing its strong demand in Russia.
According to recent data, scrap output has peaked, and Russia will soon experience a scrap deficit. China: Using mainly converters that use pig iron and scrap, China is expanding its steelmaking capacity.
Although DRI can be utilized in the Chinese steel industry, its cost should be comparable to that of scrap metal. It should be considered that China will eventually consume its own (more or less clean) rubbish and that there will be a sufficient supply.
China currently produces 50 million tons or so of electric furnace steel annually. In any case, DRI's products will always have a place here in terms of the market price. Other Markets: You should be informed that DRI oxidizes while transporting, which is one of its main drawbacks.
Because of this, only 20–25% of DRI generated worldwide is marketed. The DRI uses the remaining resources for its own manufacturing.
Any nation that produces steel has the capacity to use DRI. When we use the word "metal," we mean a material that is typically used to make iron or steel and typically contains at least 60% iron (Fe). This comprises the following things, which are displayed in the right column.
Because they are made from natural iron ore, the various types of DRI, including cold DRI (CDRI), hot DRI (HDRI), and HBI, as well as pig iron, are together referred to as ore-based metals (OBM).
OBM is especially useful for producing steel in electric arc furnaces (EAF) since it has extremely little copper and other residual metals and significantly less nitrogen and hydrogen than conventional steel.
These characteristics enable EAF steelmakers to create malleable, malleable, and formable steel—steel that can be shaped without being torn or damaged.
EAF can be calculated using any DRI/HBI number between 0% and 100%. Yes, given how difficult and expensive it is to procure scrap, some smelters only use DRI. Keep in mind that the main objective is to satisfy the steel's chemical requirements.
To achieve the aim at the lowest cost, it would be helpful to be able to blend DRI/HBI, scrap, or even pig iron. The steel market remained sharply fragmented until recently.
Molten iron is produced by integrated steelmakers and their blast furnaces, and low-residue steel grades are produced in simple oxygen furnaces (BOF).
Scrap is used in small electric arc furnace-based steel mills to create higher residue and commodity grades. Everything changed in the 1990s when the thin-plate machine was invented.
Numerous similar rolling mills with a combined yearly production capacity of 20–25 million tons of premium flat goods have been erected in the United States.
They combine thin slab continuous casting with electric arc furnace small rolling mills. The defense of steel against residual metals, particularly copper, has been and will continue to be one of the major considerations.
Hot Metals are almost entirely devoid of copper and other residual metals, like other OBMs (often less than 0.005% copper, or the "zero point" on a 0.01% copper point scale).
Consider heating steel that has an 18-point copper standard (0.18% copper content) in an electric arc furnace. For the sake of straightforward math, let's simplify the numbers.
We have DRI/HBI or pig iron with zero copper points (0.005%), as well as scrap with an average copper content of 0.20%, ranging from roughly 0.18% to nearly 0.25%.
We cannot lose steel profiles because the trash is in a different range, so we must be vigilant.
Therefore, we target 15-point copper (0.15%), employing 25% OBM and 75% scrap, making the profile better 99.99% of the time. By using 75% scrap for iron loading, costs are reduced to a minimum.
Due to the inability of BF-BOF facilities to limit scrap utilization above 20%, EAF steals market share from BF-BOF.
A base of primary scrap is required as the number of electric arc furnace flat product facilities rises, and no one wants to construct extra machines, refrigerators, or washing machines to manufacture more primary scrap.
Therefore, it can be claimed that OBM is a must for the construction of the majority of EAF-based flat product facilities.
DRI/HBI and commercial pig iron are therefore necessary for at least half of the market to exist, even if scrap providers had to compete with OBM (MPI).
Conclusion
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