k b sponge iron ltd company in India

K B Sponge Iron ltd is a public company incorporated on April 4, 2002, in India. It is classified as a non-government company and is registered in the Kolkata Companies Registry. Its authorized share capital is Rs. 30,000,000, the actual paid-up capital is Rs. 20,710,000.

it involves the manufacture of the base steel

KB Sponge Iron Limited’s annual general meeting (AGM) was last held on 30 November 2021 and its balance sheet was last submitted on 31 March 2021, according to the Ministry of Corporate Affairs (MCA). The directors of KB Sponge Iron Limited are Vishal Kejriwal, Aditya Kejriwal, Ramesh Kumar Kejriwal.

The ability to select appropriate production processes and production cells from the core around which the factory’s basic concept is developed. While the choice of process takes into account factors such as product type, availability and compliance of local raw materials, state of the process, specific energy consumption, required energy levels, environmental pollution, etc.

The choice of capacity for larger units will depend on throughput, available unit sizes, economies of scale, etc. The basic manufacturing process of sponge iron is very simple. The percentage of iron-related oxygen removed from the ore particles, a process commonly referred to as “percent reduction”, and the percentage of iron in the total iron, present in metallic form, reflecting the degree of metallization in sponge ironmaking technology.

Direct reduction processes can be broadly divided into groups based on the type of undesired used (ie, solid or gas). There are two mature processes for making sponge iron viz

The process of reforming natural gas, i.e. by gaseous reduction of iron ore.

Coal-based rotary kiln process – solids reduction.

There are no plants in India using liquid fuel to reduce iron ore due to its availability issues and the injection of iron ore is in pellet form which becomes very expensive. All gas plants in operation use natural gas as a reluctance and are along the entire HBJ line. Gas is controlled by the state organization GAIL and the steel industry is not a priority sector for gas sanctions.

Most solid recalcitrant coal-based processes use uncoked coal as the recalcitrant coal. Due to the abundant raw coal resources in our country, the process of using raw coal is of great importance to us. The various important types of coal-based processes are as follows:

  • HYCL process, which is very flexible.
  • MIDREX process, continuous; looks like blast furnace,
  • fluid bed process
  • SL/RN process for coal with low ash and sulfur content
  • The rotary kiln process, the most accepted process.

ITC Technology has experience in operating small scale plants using different raw materials from different sources such as iron ore from Ballery-Hospet region, Bailadilla, Barbil etc. Different size ranges of iron ore such as 3-6 MM, 3-12 MM, 5- 15 MM, 5-20 MM etc. and 3-6 MM, 5-12 MM, 5-18 MM etc. feed coal are combined.

Different particle size combinations of different types of coal and different iron ores were also tested and parameters were optimized.

Using coal to produce sponge iron involves the reduction of iron ore with solid carbonaceous materials such as coal, coke or lignite.

Reduction takes place in a rotary kiln at a predetermined temperature and controlled atmosphere, followed by cooling to ambient temperature in a rotary cooler with an indirect water cooling system. Feed raw materials such as iron ore, coal and limestone of the desired calibrated size are fed into the rotary kiln in predetermined proportions by electronic weighing equipment through a feed pipe which is inclined and rotated in the desired speed range.

The oven has five shell fans installed in the top which blow air in different areas to maintain the desired temperature profile.

The material and the hot gases move in the countercurrent direction so that the iron ore is preheated and gradually reduced as it reaches the discharge end.

Due to the tilting and rotating motion of the kiln, the raw material moves from the feed end to the outlet end. During this process, it is preheated and reduced to sponge iron in the temperature range of 200-800 C. The material discharged from the furnace enters the rotary cooler through the conveyor chute, where the material is cooled.

The cooled product temperature is around 80oC. It is discharged from the cooler and fed to the product separation and handling system by the cooler outlet conveyor. The hot end of the conveyor is provided with a diversion groove which is used to divert the material in case of failure during the product separation process.

In a product separation system consisting of a double-layer sieve, the material is sieved into 0.3 mm and 3-20 mm size fractions. The product is composed of non-magnetic substances such as sponge iron and carbon, which are shielded into parts of different sizes and then magnetically separated by a magnetic separator.

The sponge iron was brought to a storage box for shipping. Charcoal is non-magnetic and contains a certain amount of carbon which is placed in separate containers and can be recycled if found suitable or sold as fuel for applications such as brickmaking.

K B sponge iron ltd company

Many sponge iron factories are looking for a place in the steel industry but K B ltd company has a shot in this line of work because of the potential they have.

The National Steel Policy (revised in 2008) expects the country’s domestic steel production to reach 180 million tons per annum by 2019-20. This situation calls for the corresponding development and expansion of iron-making facilities and an adequate supply of raw materials to meet the needs of the Indian steel industry.

Iron ore is the basic raw material for the production of metallic iron. The pig iron and sponge iron industry accounts for about 98% of the total domestic consumption of iron ore. Lumpy iron ore (-30+10 mm) and agglomerates such as sinter and pellets constitute the raw material for blast furnace production of pig iron, while scrap, iron lumps (-18+6 mm) or pellets are the raw material for sponge iron production.

Blast furnaces remain the traditional route and will continue to dominate ironmaking in India. However, given the high investment, limited supply of metallurgical coke and associated negative environmental concerns, there is a growing awareness that the blast furnace route needs to be supplemented by alternative ironmaking processes.

Over the last two decades, coal and natural gas-based alternative technologies for the production of solid iron in the form of sponge iron, also known as direct reduced iron (DRI), and the production of molten iron (liquid) without the use of high-grade through the Reduction Smelting Route (SR ) of coke has played an important role in ironmaking technology in India. It is worth noting that today India is the largest DRI (sponge iron) producer in the world.

NSP assumes that 60% of the new steel capacity will be delivered through the blast furnace route, 3-3% through the sponge iron and EAF/IF routes and 7% through other routes.

K B sponge iron ltd company

Iron making processes can be broadly categorized/classified as:

  1. Traditional blast furnace/small blast furnace
  2. Alternative processes

Smelting is the process or combination of processes that produce molten metal. Iron smelting in blast furnaces is an example of reductive smelting, where coke is used both as a fuel and as a source of reducing agent. In the presence of excess carbon monoxide, iron oxide can be completely reduced at approx.

900°C, but the metal has a melting point of 1535°C. Therefore, the iron produced by the original furnace was always solid, low carbon, soft in nature and malleable. Our current operation to produce sponge iron is merely an improvement on the original iron manufacturing.

The iron-made blast furnace is a circular shaft furnace with a height of about 30m and a maximum internal diameter of about 10m. The hearth is a steel shell lined with refractory materials, almost all of which are clay bricks. The bricks used for the hearth and crucible are fire clay bricks of the highest quality – a hard and dense super material.

Some furnace liners are made from carbon blocks. The thickness of the refractory brick layer is about 1m at the belly and about 1-2m at the upper part of the shaft. The bottom of the crucible is made of high-quality refractory clay bricks, with tight seams to prevent molten metal from seeping up from the bottom, with a thickness of 2-4m.

There are 10 to 16 fans equally spaced along the circumference under the belly, through which preheated air (1000-1100 °C) enters the furnace at a pressure of 2 kg/sq.cm. The hearth is the part of the furnace placed between the mantle and the upper part of the crucible; it is the melting zone and is the hottest part of the furnace (1900-2000°C). As the hot reducing gas moves up, it heats the solid charge and participates in different reactions in different areas of the furnace.

Under the belly is the hearth or crucible where the molten metal and slag are collected. Near the bottom of the furnace is the tap hole through which molten iron is discharged, and approx. 1.5 m above the tap hole is the slag grate through which molten slag or slag is discharged.

K B sponge iron ltd company

K B sponge iron ltd

Direct reduction of iron (DRI) forms an important sub-sector of the Indian steel sector, accounting for about 33% of the total steel production, which is about 34.15 million tons of steel produced in 2020-21.

The substantial growth of DRI sector in India can be mainly attributed to the easy availability of non-coking coal and limited access to natural gas. This has led to the establishment of around 300 low-capacity DRI plants using non-coking coal available in the country with average capacity utilization of 60%.

The coal-based DRI kilns in India suffer from low-energy efficiency (about 37%) due to high-energy losses through off-gases (41%).

However, a large number of DRI plants with an installed capacity of 200 tons per day (tpd) or more have mostly installed waste heat recovery (WHR)-based power generation systems. This has not only helped in meeting the internal electricity needs but also led to additional energy credit of about 40%, thereby lowering the overall specific energy consumption in DRI production.

Further, the excess power generation from WHR system, which is about 60%, helps in generating additional revenues for the plants. One of the key performance indicators of coal-based DRI plants is the specific energy consumption (SEC) in DRI production, which is observed to be in the range of 4.10–5.26 Giga calories (Gcal) per ton DRI.

An analysis of input thermal energy utilization clearly indicates that there is significant scope for energy efficiency improvements by employing a feasible WHR system. The WHR-based power generation, the most attractive among all, is economically viable for plants with a capacity of 200 tpd and above.

K B sponge iron ltd

Smaller capacity plants of 100 tpd or less can adopt other WHR options such as iron ore preheating and coal drying for improving their energy performance.

Adoption of plant-specific energy-efficiency options, for instance, switch over to iron ore pellets, an artificial neural network for accretion control, and a decentralized variable frequency drive (VFD) for shell air fans, would help in reducing the SEC level by as high as 2.3 Gcal/t-DRI. This technology compendium provides techno-economic details for a range of energy-efficient technologies for rotary kiln-based DRI industries.

It will enable DRI industries to select and implement the technologies based on their prioritization. The compendium also discusses the potential of futuristic technologies such as coal gasification and hydrogen-based processes, which are either already commercialized or under development to enable their adoption in the future.

Steel is the most important part of a country’s infrastructure construction. Besides supplementing the machines and tools inseparable from industrialization, it also contributed to the growth of the construction sector that drives urbanization.

K B sponge iron ltd

The steel industry’s contribution to a country’s GDP is well known. It has been observed that no country has achieved a high level of income per capita. per capita without significantly increasing steel consumption per inhabitant.

Your comment submitted.

Leave a Reply.

Your phone number will not be published.