Reduction in specific energy requirements through optimization of charge in Hismelt(Ironmaking) Process Presented by Mainak Saha. ABSTRACT. Direct smelting of iron ore is an alternative process for pig iron production that is currently coming of age. The. HIsmelt Direct. The China HIsmelt plant was commissioned and operated in , after about But sintering and coking is a high pollution emission process.

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Schematic of the HIsarna process Tata Steel [4]. Between the cyclone and the slag layer, oxygen is injected through water cooled lances to generate heat by partly combusting the gasses being released from the final reduction reaction step that takes place in the slag. Since the slag is batch tapped through a slag notch, the hot metal is slag free.

The reduction reaction now continues “as normal” in the bottom of the furnace, with the partially reduced iron ore further reducing to regular pig iron and the whole separating into two molten layers a top layer of slag and a bottom layer of molten pig iron. At that time the desire was mostly a cost-cutting measure in provess to make the process cheaper in trying economic times. Any other technology to reach the level of BF will take a lot of time.

HIsmelt process is highly flexible. Heavy environmental restrictions made it unattractive to build new facilities, so steel producers sought ways to reduce the need for cokes; Hoogovens started putting more effort into the cyclone technology as a solution to this problem and a test facility for the cyclone part proved capable of producing twenty tons of pig iron per hour.

But some iron making technologies like finex, HIsmelt and HIsarna are technologically sound and have potential to have better techno-economics. Retrieved 17 March HIsarna – Highly energy efficient ironmaking.


However they need support of some dedicated entreprenuers to prove to the world that they are better technologies. Bessemer process Open hearth furnace Electric arc furnace Basic oxygen process. The HIsarna plant is shaped like a wine bottle: Injected iron ore fines are injected deep into the bath where they are reduced instantly on contact with carbon dissolved in the bath for smelting to take place. The process allows the use of non coking coal and iron ore fines with significant impurities.

The HIsarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron or hot metal.

The process is carried out in this vessel. This reduction reaction produces iron Fe and carbon monoxide CO. To overcome this deficiency a design was developed for water cooled vertical vessel.

Retrieved from ” https: HIsarna is considered one of the most promising developments in reducing CO 2 emissions from the steel industry.

The molten iron droplets then drip down the furnace wall to the place where the “neck” widens into the “bottle”. The environmental benefits of the HIsmelt process are considerable.

HIsmelt process of Ironmaking

This is done through large amounts of liquid splash moving between the two regions. HRDF vertical smelt reduction vessel was commissioned in the first half of and operated through to May Leave a Reply Cancel reply Your email address will not be published.

A theoretical answer was found to the earlier problems of the post-cyclone part of the cyclone furnace in the form of a Smelting Reduction Vessel and the Rio Tinto Group had industrial-scale experience with the hismlt process, called HIsmelt. Without these steps, the HIsarna process is more energy-efficient and has a lower carbon footprint than proecss ironmaking processes.

The heat of the cyclone causes the initial partial reduction reaction to take place that reduces iron ore to iron.

HIsmelt process of Ironmaking |

The projected improvements from the process are as follows. Blast furnace process is no doubt proven route globally. Both layers can be tapped individually and the pig iron can be used immediately in rpocess remainder of the basic oxygen steelmaking process.


History of ferrous metallurgy List of steel producers. By using this site, you agree to the Terms of Use and Privacy Policy.

In November it was announced that a large scale HIsarna pilot facility would be built at the Tata Steel site in JamshedpurIndia[25] [26] but that the site in IJmuiden would still be a potential location for further industrial implementation of the technology.

The main advantages of the process are derived from those mentioned above, however: Annealing Low hydrogen Short circuit. Once there are successful operating references available for these technologies then all the future installations will be of these technology based iron making units.

Electro-slag remelting Vacuum arc remelting Argon oxygen decarburization. Construction of the HRDF with a design capacity oftons per annum, commenced in The pilot plant has a capacity of producing 65, tons of pig iron per year.

Views Read Edit View history. The main improvements incorporated into the design included a stationary vertical vessel, top injection of solids, a simplified hot air blast lance, a fore hearth for continuous tapping of metal and water cooled panels to overcome refractory wear problems. By comparison, in HIsarna, the powder form of the coal and ore are an advantage because the increased surface area improves the speed and quality of the reduction reaction in the cyclone.

Hence this process has flexibility to use high phosphorus containing ores. Whilst scale-up of the process was successfully demonstrated, the complexity of engineering a horizontal vessel limited its commercial viability. The new plant is expected to be commissioned in