State the limitations of pelletization in agglomeration of iron ore.
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In a DR process, iron ore pellets and/or lump iron ores are reduced by a reducing gas to produce DRI or hot briquetted iron (HBI). Depending on the generation of the reducing gas, two different DR processes are commercially available: gas-based and coal/oil-based. In the gas-based DR process, the reducing gas is produced by chemically reforming a mixture of natural gas and off-gas from the reducing furnace to produce a gas that is rich in hydrogen and carbon monoxide. Typical examples of the gas-based DR process include MIDREX and HYL, which are often the preferred technology in countries where natural gas is abundant. However in the coal/oil-based DR process, the reducing gas is generated from hydrocarbons (primarily coal, but sometimes oil and natural gas) in the reduction zone of the furnace, which is typically a rotary kiln. Typical examples of the coal-based process include the SL/RN and ACCAR processes. The coal-based DR process is more popular in India and China. Different types of reactors, such as shaft furnaces, fluidized beds, rotary kilns, and rotary hearth furnaces, have been used in different variations of the processe to achieve the metallization required.
Based on statistics (Anon 3, 2014), India is the world leader in DRI production producing about 17.8 Mt of DRI in 2013, approximately one-forth of world DRI production. The gas-based DR processes are producing almost 80% of the world's DRI. MIDREX is the key variant of the gas-based DR processes accounting for about 63.2% of world DRI production in 2013, followed by HYL (15.4%). Therefore, the following discussion focuses mainly on the MIDREX process.
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In a DR process, iron ore pellets and/or lump iron ores are reduced by a reducing gas to produce DRI or hot briquetted iron (HBI). Depending on the generation of the reducing gas, two different DR processes are commercially available: gas-based and coal/oil-based. In the gas-based DR process, the reducing gas is produced by chemically reforming a mixture of natural gas and off-gas from the reducing furnace to produce a gas that is rich in hydrogen and carbon monoxide. Typical examples of the gas-based DR process include MIDREX and HYL, which are often the preferred technology in countries where natural gas is abundant. However in the coal/oil-based DR process, the reducing gas is generated from hydrocarbons (primarily coal, but sometimes oil and natural gas) in the reduction zone of the furnace, which is typically a rotary kiln. Typical examples of the coal-based process include the SL/RN and ACCAR processes. The coal-based DR process is more popular in India and China. Different types of reactors, such as shaft furnaces, fluidized beds, rotary kilns, and rotary hearth furnaces, have been used in different variations of the processe to achieve the metallization required.
Based on statistics (Anon 3, 2014), India is the world leader in DRI production producing about 17.8 Mt of DRI in 2013, approximately one-forth of world DRI production. The gas-based DR processes are producing almost 80% of the world's DRI. MIDREX is the key variant of the gas-based DR processes accounting for about 63.2% of world DRI production in 2013, followed by HYL (15.4%). Therefore, the following discussion focuses mainly on the MIDREX process.
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