Natural gas and its Usage in Iron and Steel Industry...

Natural gas and its Usage in Iron and Steel Industry Natural gas (NG) is an environmentally friendly non-renewable gaseous fossil fuel which is extracted from deposits in the earth. It is a clean and green fuel with a high efficiency and plays a major role in helping many industries cut emissions and improve the overall air quality. It is normally supplied as (i) piped natural gas (PNG), (ii) compressed natural gas (CNG), and (iii) liquefied natural gas (LNG). Natural gas is a mixture of hydro-carbons consisting primarily of methane (CH4), generally in a percentage of over 85 % by volume. Other hydro-carbons in NG include varying amounts of various higher alkanes such as ethane, propane, and butane etc. It also contains water vapour (H2O) at varying degrees of saturation, or condensed water. It may also contain some small percentage of nitrogen (N2), carbon dioxide (CO2) and hydrogen sulphide (H2S) and helium (He) etc. NG burns with a clean blue luminous flame when mixed with the requisite amount of air and ignited. It is considered one of the cleanest burning fuels. On burning, it produces primarily heat, CO2, and water vapour. NG is a fuel found in deposits in its gas phase. It is colourless and odourless, non-toxic, and lighter than air. It does not contain olefins (hydrocarbons produced during the process of destructive distillation or reforming). It is a highly flammable and combustible gas. Its CAS number is 8006-14-2 and UN number is 1971. Quantities of natural gas are measured in normal cubic meters (corresponding to 0 deg C and 1 atmosphere pressure) or standard cubic feet (corresponding to 16 deg C and 14.73 pounds per square inch absolute pressure). The higher heat value of one cubic meter of natural gas varies from around 9500...

Energiron Direct Reduction Technology Sep08

Energiron Direct Reduction Technology...

Energiron Direct Reduction Technology Energiron direct reduction technology is a gas based direct reduction technology. Energiron process converts iron ore pellets or lumps into metallic iron. It uses the HYL direct reduction technology developed jointly by Tenova and Danieli and is a competitive and environmentally clean solution for lowering the liquid steel production cost. It uses a simple plant configuration, has flexibility for using different sources of reducing gases and has a very efficient and flexible use of iron ores. A key factor in many of the process advantages is directly related to its pressurized operation. Energiron is the name of the direct reduced iron (DRI) product produced by the Energiron direct reduction technology. The product is so named since it carries substantial energy with it which is realized during the steel making process. Energiron is a highly metallized product with the carbon (C) content which is controllable in the range of 1.5 % to 5.0 %. The higher C content of Energiron generates chemical energy in the electric arc furnace (EAF) melting process. The uniquely stable characteristic of Energiron DRI makes it a product which can be safely and easily transported without briquetting, following standard IMO (International Maritime Organization) guidelines. The process is flexible to produce three different product forms, depending on the specific requirements of each user. The three forms of Energiron DRI are cold DRI, HBI (hot briquetted iron) or hot DRI (‘Hytemp’ iron with discharge temperature greater than 700 deg C). Cold DRI discharge is normally used in an adjacent steel melt shop close to the direct reduction plant. It can also be shipped and exported. HBI is the DRI which is discharged hot, briquetted, and then cooled. It is a merchant product usually meant for overseas export. Hytemp Energiron...

Natural Gas- its Characteristics and Safety Requirements...

Natural Gas- its Characteristics and Safety Requirements Natural gas (NG)  is a fuel gas which is used in steel plants as an auxiliary fuel for injection in blast furnace, for the production of gas based direct reduced iron, and for heating in various furnaces subject to local availability and the cost. NG is an environmentally friendly non renewable fossil fuel which is found in underground deposits in its gas phase. It exists as a gas under atmospheric conditions. It is basically a hydrocarbon gas mixture consisting primarily of methane. It is a clean fuel with a high efficiency. NG is normally supplied as (i) piped natural gas (PNG),  (ii) compressed natural gas (CNG), and (iii) liquefied natural gas (LNG). Modes of handling natural gas is given in Fig 1. Fig 1 Modes of handling natural gas NG is transported normally to long distances (up to 5000 kms) through a pipeline net work. The pressure of NG in the pipeline depends on several factors which include (i) quantity of gas to be transported, (ii) diameter of the pipeline,  (iii) the distances involved, and (iv) the safety of the gas pipeline and environment. However at the consumer end the pipeline pressure is generally less than 16 atmosphere. CNG is a form of natural gas which undergoes compression (200 to 250 kg/sq cm) into containers wherefrom it is relayed to consumers who, due to geographic and other reasons are incapable of connecting into the NG pipeline. CNG is storable. Unlike NG conveyed via pipelines and immediately consumed (similarly to electricity), CNG can be used for storage and for discontinuous utilization. NG compression into containers raises risk levels. LNG is made by cooling natural gas to a temperature of minus 162 deg C. At this temperature, natural gas becomes...

Types of Energy used in a Steel Plants and Energy Conservation...

Types of Energy used in a Steel Plants and Energy Conservation Energy is needed to do any work. Energy can be in the form of potential energy or it can be in the form kinetic energy. Potential energy is stored energy and for doing the work it is to be released from the storage.  Common example of potential energy are fuel energy, chemical energy and  pressure energy etc. Kinetic energy is energy due to motion and example of kinetic energy is electric energy which is the movement of electrons. Energy conservation activities are the efforts made towards reduction in energy consumption for doing a work. These efforts can be in the form of reduction of energy wastages, recovery and recycling of waste energy, and/or by improving the energy efficiency of the processes. Various forms of energy used in an integrated steel plant are described below.  Fuel energy Fuel energy is the potential energy which constitutes the major component of all the form of energies used in the steel plant. Fuel energy is used in the form of primary fuels and the byproduct fuels. Primary fuels used in steel plant are (i) solid fuels, (ii) liquid fuels, and (iii) gaseous fuels. Byproduct fuels are mainly coke oven gas recovered during coking process of metallurgical coals, blast furnace gas recovered from blast furnace during the production of hot metal, converter gas recovered during the production of steel in the basic oxygen furnace process, and coal tar fuel produced during the cleaning of the raw coke oven gas produced while coking of the metallurgical coals. Solid fuels used in the steel plant are coal and/or coke. Solid fuels constitute the highest percentage of energy consumed in steel plant. Both metallurgical (coking) coals and non coking coals are...

Fuel gases used in steel industry...

Fuel gases used in steel industry Fuel gas is a fuel which under ordinary conditions is in the form of gas. Fuel gases are used in steel plants for different applications which include (i) a source of heat (ii) as a reductant and (iii) cutting and welding application. Fuel gases usually used in steel industry are natural gas (NG), liquefied petroleum gas (LPG), acetylene, by product gases (blast furnace gas, coke oven gas and converter gas). Natural gas Natural gas is a gaseous fossil fuel which is extracted from deposits in the earth. It is a mixture of hydro carbons consisting primarily of methane (generally greater than 80 %) but includes varying amounts of other higher alkanes such as ethane, propane and butane etc. It may even contain some small percentage of nitrogen, carbon dioxide and hydrogen sulphide. It is an odorless, colourless, tasteless and non toxic gas. Natural gas is lighter than air and it burns with a clean blue flame when mixed with the requisite amount of air and ignited. It is considered one of the cleanest burning fuels. On burning it produces primarily heat, carbon dioxide and water. Quantities of natural gas are measured in normal cubic meters (corresponding to 0 deg C and I Kg/Sq cm pressure) or standard cubic feet (corresponding to 16 deg C and 14.73 psia pressures). The higher heat value of one cubic meter of natural gas varies from around 9500 Kcal to 10,000 Kcal. Its density is around 0.85 Kg/Cum. The main usage of natural gas in the steel industry is in iron making. For production of direct reduced iron it is reformed to produce reducing gases which are then used for the reduction of iron ore. The main reforming reactions are as follows. 2CH4...