NRDC Technology offer-ELECTROLYTIC IRON POWDER FROM SPONGE IRON FINES

PLANT PARAMETERS
Capacity	2000 kg/per day
No.of Shifts per day	2
Working days per Year.	300
Land Area, m²	3000
Covered Area, m²	2500
MANPOWER
Technicall	15
Skilled	20
Unskilled	20
RAW MATERIAL/DAY
Sponge iron fines, 2500 kg Hydrochloric acid 25000 ltrs
Ammonium Chloride (commercial)
Nylon/Polypropylene cloth
Chemicals required for washing
Ammonia or NaOh to control pH
Chemicals for analysis
UTILITIES/DAY
Power	4400 KWH
Water, Steam etc.	80 m³
PLANT & MACHINERY
Rectifier 5000 A-60 with substation
Centrifuge, Furnace
Concrete tanks with FRP lining
FRP support for anodic bag
Electrolyte filtration unit, Scrappers
Overhead crane to handle electrodes
Weighing machine
Ameter 0-5000A

INTRODUCTION

Iron powder is mainly produced by the reduction of its oxide using Hoganas and Pyron process, water atomization of low-carbon iron, QMP process, Domfer process, carbonyl vapor metallurgy process, by electrolysis process, fluidised-bed reduction process and by H-iron ONIA process. The iron powder applications comprise for cutting and scarfing, making welding electrodes, the manufacture of powder metallurgy and for food enrichment.

USES The Product is used for automotive and other industries, welding electrode, flame cutting and scarfing, in chemical industries, frictional materials, abrasive wheel and cutting tubes etc.

PROCESS

The production of Electrolytic Iron powder from sponge iron fines involves using sponge iron fines – 3 mm size typically comprising Fe:88-91%; Fe0:5.0-6.0%; C:0.20-0.25%; S:0.02-0.03%; P:0.05-0.07%; Mn:Trace;SiO2 + Al2 O3 :5.0 -6.0% as soluble anode placed inside a porous diaphragm made of nylon or poly-propylene. The electrolyte of the cell consists of a novel composition of ferrous chloride and ammonium chloride (commercial grade). The proposed combination of the chemicals helps attain higher electrical conductivity of the electrolyte. The current drawn from a DC source is passed through the specially designed anode. The cell electrodes comprise an anode of sponge iron fines placed inside a porous diaphragm nylon or polypropylene mentioned as above and fastened with an insoluble multiple titanium strips (CP grade) for contact and cathode of stainless steel onto which the EIP gets deposited during the electrolysis process.

SPECIFICATIONS

Carbon : 0.005%; Silica:0.020%; Manganese: Trace; Sulphur:0.003%; Phosphorus:0.003%; Acid Insolubles:0.02-0.08%; Hydrogen Loss:0.08 – 0.15%. The physical properties of the powder exhibits Apparent density as 2.2 – 3.1g/cm3 ; flow rate as 25/30; Compressibility (4.2t/cm2) as 6.8 – 7.0; Green Strength as 24-25 (2.45 cm OD x 1.8cm ID Bush).

The sieve analysis of the powder conforming to BS is as given below:

BS SieveNo.	+100	+150	+240	+300	+350	20
Percentage	Nil	20	25	20	-350	15

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