Sponge Iron Roller Kiln Reduction Technology

New Concept of Hot Metal Production using Rotary Kiln ...

2013-09-27· The idea of this technology is to utilize the heat or energy contained in sponge iron (temperature of sponge iron > 1000 o C) at the end of rotary kiln before …

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to ...

Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...

SPONGE IRON PLANT

High ash leads to under utilization of the kiln volume available for reduction. It also increases the consumption of fixed carbon, since additional energy is consumed in heating the inert ash . www.spongeitc.com 5 mass to reaction temperature. An ash content of 20 percent maximum is the practicable limit for normal operation. 3) Low sulphur content:- To control the sulphur in sponge iron, …

RESEARCH & DEVELOPMENT - ITC PRE-HEATING …

The Iron Ore is Being Passed to The Rotary Kiln (Reduction Kiln) Through Pre-Heater. The Reduction Kiln is Mounted With A Slop of 2-5 Degree Down Words From The Feed End to The Discharge End. A Central Burner Located at The Discharge End is Used For Initial Heating of The Kiln. Sized Iron Ore is Continuously Fed in Kiln Through The Pre-Heater ...

Accretion Control in Sponge Iron Production Kiln using ...

Accretion Control in Sponge Iron Production Kiln using Fuzzy Logic Edwell.T Mharakurwa1* G. N. Nyakoe 2 B.W. Ikua 3 1. Department of Electrical Engineering, Pan African University Institute of Basic Science and Technology (PAUISTI), P. O. Box 62000-00200, City Square, Nairobi, Kenya. 2. Department of Mechatronic Engineering, Jomo Kenyatta University of Agriculture and Technology …

Direct reduced iron - Wikipedia

Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) to iron by a reducing gas or elemental carbon produced from natural gas or coal.Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting ...

Computational fluid dynamics analysis of sponge iron ...

2017-03-01· The assumptions for the present work are: (1) 2D geometry of the kiln is considered, (2) Bed material, a mixture of iron ore, coal and dolomite, is supplied as inlet stream at atmospheric temperature (300 K), (3) Outlet stream is considered as sponge iron, (4) Secondary air injected from discharge end as shown in Fig. 3(a), and (5) reduction and combustion reactions take place in the …

sponge iron roller kiln reduction technology

Sponge Iron Roller Kiln Reduction Technology. tunnel kiln sponge iron new technology. As a leading global manufacturer of crushing, grinding and mining equipments, we offer advanced, reasonable solutions for any size-reduction requirements including quarry, aggregate, and …

sponge iron roller kiln reduction technology

Home / News & Article / sponge iron roller kiln reduction technology 2018/07/05 Author:SKM Chat Online Zenith high gradient magnetic separators and higher gradient magnetic filters are designed to recover weakly magnetic material from non-magnetic matter and can be used for many applications including the processing of iron ores, uncommon earths and industrial minerals.

RESEARCH & DEVELOPMENT - ITC PRE-HEATING …

The Iron Ore is Being Passed to The Rotary Kiln (Reduction Kiln) Through Pre-Heater. The Reduction Kiln is Mounted With A Slop of 2-5 Degree Down Words From The Feed End to The Discharge End. A Central Burner Located at The Discharge End is Used For Initial Heating of The Kiln. Sized Iron Ore is Continuously Fed in Kiln Through The Pre-Heater ...

A Comparative Study of Particulate Matter Emission ...

Sponge Iron Kilns at Raipur Ankur Sahu1, Mallika Jain 2 1PG Student, ... any change in operational technology. The reduction proposed in this study can be achieved by the modification of existing ESP’s. The particulate matter level from various sponge iron plants situated at Siltara and Urla industrial area can be reduced significantly in Raipur district for safe and healthy environment. AIM ...

Accretion Control in Sponge Iron Production Kiln using ...

Accretion Control in Sponge Iron Production Kiln using Fuzzy Logic Edwell.T Mharakurwa1* G. N. Nyakoe 2 B.W. Ikua 3 1. Department of Electrical Engineering, Pan African University Institute of Basic Science and Technology (PAUISTI), P. O. Box 62000-00200, City Square, Nairobi, Kenya. 2. Department of Mechatronic Engineering, Jomo Kenyatta University of Agriculture and Technology …

Direct reduced iron - Wikipedia

Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) to iron by a reducing gas or elemental carbon produced from natural gas or coal.Many ores are suitable for direct reduction. Direct reduction refers to solid-state processes which reduce iron oxides to metallic iron at temperatures below the melting ...

Direct Reduction Process - an overview | ScienceDirect …

The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace, rotary kiln furnace or fluidised bed. Sponge iron can be produced in the form of Direct Reduced Iron (DRI), Hot Briquetted Iron (HBI) and Cold Briquetted Iron (CBI); also Low Reduced Iron (LRI), which is pre-reduced iron ore with a reduction and metallisation ...

comparative study of particulate matter emission …

Sponge iron industries study shows continuous improvement in technologies for better precautionary measures. This study depicts how the kiln size plays a pivotal role in emission control by reduction of particulate matter of existing sponge iron plants without any change in operational technology. The reduction proposed in this study can be achieved by the modification of existing ESP’s. The ...

Sponge Iron – Prakash Industries Limited

Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel through electrical arc furnace and the induction furnace routes. Considering the fact that large quantity scrap required for ...

Direct Reduction Technologies | SAIL

2021-03-22· Direct reduction processes are of significance and can form an alternative to a conventional Blast furnace. Solid sponge iron ( direct reduced iron or DRI) is produced by removing oxygen from the ore .The technique of Direct reduction varies according to the type of reducing agents employed and the metallurgical vessel in which they are reduced. The reducing agents used normally …

A Thesis Submitted for Partial Fulfillment of the Degree ...

Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING By Tapash Ranjan Majhi (210CH1204) Under the supervision of Dr. Shabina Khanam DEPARTMENT OF CHEMICAL ENGINEERING NATIONAL INSTITUTE OF TECHNOLOGY, …

Energy survey of the coal based sponge iron industry ...

2015-09-01· Sponge iron is a metallic mass with honeycomb structure. It is produced by direct reduction of iron ore in the presence of coal and air. Since last few years, sponge iron has emerged as an alternate raw material for steel making. The Indian Government has recognized sponge iron as a vital sector for growth of Indian steel industries. At present ...

RESEARCH & DEVELOPMENT - ITC PRE-HEATING …

The Iron Ore is Being Passed to The Rotary Kiln (Reduction Kiln) Through Pre-Heater. The Reduction Kiln is Mounted With A Slop of 2-5 Degree Down Words From The Feed End to The Discharge End. A Central Burner Located at The Discharge End is Used For Initial Heating of The Kiln. Sized Iron Ore is Continuously Fed in Kiln Through The Pre-Heater ...

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE IRON …

Sponge iron is produced by direct reduction of iron ore (DRI process) and is popular because of use of non-coking coal. The conventional blast furnace process uses coking coal. The DRI process doesn‟t require coking coal and therefore is advantageous. In the present work waste heat recovery system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a ...

comparative study of particulate matter emission …

Sponge iron industries study shows continuous improvement in technologies for better precautionary measures. This study depicts how the kiln size plays a pivotal role in emission control by reduction of particulate matter of existing sponge iron plants without any change in operational technology. The reduction proposed in this study can be achieved by the modification of existing ESP’s. The ...

Tunnel Kiln Technology - Ironmaking Technology

Main Feature Of Rapid Reduction Technology To Compare With Traditional Tunnel Kiln Technology: 1. Not chang formula and method of loading and unloading; 2. Reduction speed 2-3 times faster; 3. Lower 1/3 reducer consumption; 4. Lower 1/3 energy consumption; 5. Recycle coking coal from tailing powder. Picture Of Products: Prepressing Sponge Iron . Cold Pressed Sponge Iron . Sponge Iron ...

Flow of materials in rotary kilns used for sponge iron ...

Looking forward to the need of developing coal-based sponge iron technology in India, a country having no significant resources of either coking coal or natural gas, the Research and Development Division of the Tata Iron and Steel Company Limited (TISCO) set up a rotary kiln based direct reduction pilot plant in 1975. In this pilot plant, a totally indigenous technology for production of ...

A Comparative Study of Particulate Matter Emission ...

Sponge Iron Kilns at Raipur Ankur Sahu1, Mallika Jain 2 1PG Student, ... any change in operational technology. The reduction proposed in this study can be achieved by the modification of existing ESP’s. The particulate matter level from various sponge iron plants situated at Siltara and Urla industrial area can be reduced significantly in Raipur district for safe and healthy environment. AIM ...

Sponge Iron – Prakash Industries Limited

Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel through electrical arc furnace and the induction furnace routes. Considering the fact that large quantity scrap required for ...

Some Studies on Energy Savings in Sponge Iron Plants ...

2003-08-29· This paper presents the potential for energy savings in various capacity sponge iron plants by estimating heat transfer rates using stabilized and optimized temperature data within the rotary kiln/reactor. Air jet seal instead of mechanical seal arrangements at specific locations in the rotary kiln and cooler are proposed and this is shown to reduce the power consumption and the size of the ...

Direct Reduction Technologies | SAIL

2021-03-22· Direct reduction processes are of significance and can form an alternative to a conventional Blast furnace. Solid sponge iron ( direct reduced iron or DRI) is produced by removing oxygen from the ore .The technique of Direct reduction varies according to the type of reducing agents employed and the metallurgical vessel in which they are reduced. The reducing agents used normally …

Direct Reduced Iron (DRI) | International Iron Metallics ...

In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, India producing 57% of …

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