Ahan Pouya - Sale and export of ironware

sponge iron is a metal product Which is produced by direct reduction of iron ore in the solid state. In other words, sponge iron is obtained from direct reduction of iron ore (Direct Reduced Iron). Iron ore is the pellet that is oxygenated following the process of direct reduction (without intermediaries) and without the need to melt iron ore. removal of oxygen in the iron ore is carried out by reducing or carbon dioxide from urban gas and coal . The quality of sponge iron is mainly determined by the percentage of "metallization" (removal of oxygen). the appearance of spongy iron is in the form of globular segments And because it has a spongy appearance, it is called sponge iron. Sponge iron has a positive effect on the production of briquettes and steel ingots in electric arc furnaces and energy consumption , productivity , efficiency and mechanical conditions of steel bars improves .

sponge iron grade :

Foamy iron has a high grade of iron Which is more common today due to the lack of iron waste and its increase in price as well as environmental problems. iron grade and grade of iron in sponge iron are between 84 and 95 % . the high grade of sponge iron has caused a good source of iron and steel production .

Methods of producing sponge iron :

1.using natural gas .

2.using thermal coal .

3.By direct resuscitation of Midrex

in fact iron produced by the process of sponge iron recovery can save energy . Because there is no need for high heat and fuel and the use of traditional furnaces. Sponge iron is converted to steel in electric arc furnaces.

Production by direct reduction method of Midrex :

the use of this technique depends on the location of the manufacturer and available resources . The use of coal resources for direct renewal leads to air pollution and the mines are not easily available. In Iran, due to the existence of good gas resources, the reduction of iron ore is done using Midrex technology. today , india is considered as a producer of sponge iron in the world due to coal waste resources for restoration of iron ore .

use of sponge iron :

sponge iron is a good substitute for iron and scrap iron And with this material, a large amount of raw materials for smelting in steelmaking units is provided instead of using waste. one of the most important uses and applications of sponge iron in induction furnace . In these furnaces some 50 % of the sponge iron can be replaced with scrap . however , using inductance transducers requires knowledge and experience. Because sponge iron is not useful in itself, it can be used to make soft iron. The sponge separated from the furnace is called a "blumer". And by successive blows of the hammer the layers of slag and oxidation and carbon are separated and iron compressed iron. this process causes ductile iron to form About 3% of it is "slag" and a small percentage of it contains impurities. nowadays , sponge iron is produced by reducing iron ore without melting it and it causes An efficient energy source is used for special steelmakers who depended on scrap metal. The use of sponge iron in steel mills, iron tools and weapons is very common because of the special structure of this material during melting , its surface is high And it is used in steel products and makes cast iron possible. 

history :

The first method of producing iron in Europe, the Middle East and Egypt was the production of sponge iron. Evidence suggests that the crystalline method of making sponge iron in China had developed blast furnace technology around 500 BC. 

Advantages of Blummer method :

In this method, iron can also be obtained at a lower temperature (about 1100 ° C). One of the disadvantages of this method compared to casting in blast furnaces is that small amounts of iron are made in the same amount of time. 

Properties of sponge iron :

1.High iron content and high degree of metalworking.

2.Consistent and consistent quality.

3.Less sulfur and phosphorus.

4.Minimum amount of dust from material handling time.

5.Superior technical support for induction furnace operators.

6.Ability to create good flow in tanks, pipes and conveyors for interrupt charging.

Sponge iron problems :

Sponge iron is very sensitive due to oxidation and rust And if not protected, it usually turns into steel quickly. this iron may be ignited in a pasty state . sponge iron may contain impurities that need to be separated for steel preparation .

Advantages of sponge iron over scrap iron :

1.Continuity of product analysis results

2.reduction of nitrogen in molten iron and production of high quality product

3.Reducing the concentration of gross elements ( sulfur and phosphorus )

4.Reduction of unsuitable and annoying elements (copper, lead, tin, zinc, etc.) in cast iron.

5.Low Energy and Energy Consumption

6.Ease of maintenance and storage

7.Reduce the risk of furnace explosion

8.Reduce damage to the floor and wall of the furnace

9.Low energy consumption due to low carbon content in sponge iron

Disadvantages of scrap iron compared to sponge iron :

1.Impurity entering the furnace

2.The probability of a furnace explosion

3.The need for more energy consumption

4.reduction of quality and quality of alloy steel

5.Non-uniform chemical composition and deposition of impure particles

World standard steel mills prefer to use sponge iron to scrap iron But in many countries around the world, such as Turkey and Iran, scrap smelting furnaces are still used In terms of energy consumption and efficiency, sponge iron is superior to scrap iron. 

sponge iron charge :

1.ease and ease of storage.

2.No fluctuation of electricity consumption in electric ovens.

3.Continuous use of sponge iron makes slag operations easy in electric ovens.

4.Creating conditions for continuous charging of hot sponge iron in electric tubs, followed by reducing energy consumption and melting time.

methods of sponge iron protection :

Today, sponge iron (DRI) is an important source of iron in the steel industry And due to the characteristics of this product such as high porosity and absorption of moisture and oxygen, high ignition conditions, mechanical durability and low wear resistance. The process of storage and transportation is associated with problems, and therefore more precise safety measures are needed to protect it.

processes for reducing sponge iron oxidation :

1.Protection in the silo by neutral gas

2.Protection of sodium silicate

3.Natural conservation in the head - covered warehouse

4.Protection by creating a coating layer with lime and briquette