Rotary Kiln Based Sponge Iron Plant Process Pdf

SPONGE IRON PLANT

Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A …

Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime- stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge iron.

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

Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accre tion Formation and Optimize Quality and Power Generation Shubhajit Mondal 1 , Puneet Choudhary 1 …

Simulation of Rotary Kiln Used in Sponge Iron Process ...

parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the kiln. Four

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

2II. Rotary kiln: Operation and construction details A schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in Fig. 1. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m

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

clusters and agglomerates are common in both rotary kiln and shaft based processes. In the presence of context we cannot conceive of a reactor to manufacture sponge iron, which operate above 11000C, even though there have been prolonged attempts to produce sponge iron and semi-fused iron at higher temperature. It is very easy to reduce the higher oxides of iron to FeO

Accretion Control in Sponge Iron Production Kiln using ...

processing plant determines the type of control strategy to be implemented. Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the accumulation of semi-molten material which form rings along kiln ...

Modelling and optimization of a rotary kiln direct ...

Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production. Hatch has developed a proprietary one-dimensional kiln model to

Sponge Iron - an overview | ScienceDirect Topics

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO

DRI UPDATE - Sponge Iron Manufacturer India

2. Adding Valueto Waste-Injection of char with prime coal. • Mixingfreshcharwith injectioncoal(Asimported coalcharcontainsaround40%FC) • Charaddedup-to 4% (of total injection coal) in yard in a mechanizedway to reduce moisture contentininjectioncoalfrom10.8%to 8.3%.

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing ...

Fig: 3 . 1 .31Material Balance in a Rotary Kiln sponge iron plant[15]. representation of overall reactions happening in a kiln based sponge iron making. Reaction 5 representation of Overall reactions occurring in reduction zone. Reaction 6 representation of Overall reactions for the RKDR process. These are highly endothermic heat required reactions. The energy demand for these endothermic ...

[PDF] Modeling of rotary kiln for sponge iron processing ...

CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package (ANSYS 13.0). This kiln is of length 80m. and inner …

SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE …

However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. The material bed in Tunnel kiln being stationary, it does not require high

Modelling and optimization of a rotary kiln direct ...

Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production. Hatch has developed a proprietary one-dimensional kiln model to

ENERGY INTEGRATION IN SPONGE IRON PLANT USING HEAT …

Sponge iron is mainly produced from iron ore by two different routes – (a) - by reducing gases (CO and H 2) in a shaft furnace, and (b) through direct treatment with coal in a rotary kiln. The conventional route for making steel consists of sintering or pelletization plants, coke ovens, blast furnaces, and basic oxygen furnaces. Such plants require high capital expenses and raw

(PDF) i) Direct Reduced Iron: Production

discussion is restricted to the rotary kiln process only. Normally, the rotary kiln is 60–125 m long ( L )a n d 4–6 m in diameter ( D ), and the L / D ratio is about 15–20.

Sponge Iron - an overview | ScienceDirect Topics

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO

Prospects for Coal-based Direct Reduction Process

rotary kilns and increases the reduction rate and productivity. The process is also characterized by flexibility regarding various raw materials, including iron ore fines, steel mill waste and non-coking coal. This paper outlines the features and development status of Kobe Steel's coal-based reduction processes,

Coal based Direct Reduction Rotary Kiln Process – …

The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital expenditure and no requirement of coking coal. The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron …

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

01.09.2015· In the sponge iron process concentrated and finely divided iron ore is reduced in solid phase into sponge iron at high temperatures in rotary kiln. The process is very energy demanding. In order to identify the largest losses and to find ways to increase the efficiency, an energy survey of the sponge iron plant was carried out for a number of different production rates. The energy usage in processing industries can be reduced by changing the process or …

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing ...

Fig: 3 . 1 .31Material Balance in a Rotary Kiln sponge iron plant[15]. representation of overall reactions happening in a kiln based sponge iron making. Reaction 5 representation of Overall reactions occurring in reduction zone. Reaction 6 representation of Overall reactions for the RKDR process. These are highly endothermic heat required reactions. The energy demand for these endothermic ...

[PDF] Modeling of rotary kiln for sponge iron processing ...

CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package (ANSYS 13.0). This kiln is of length 80m. and inner …

ENERGY INTEGRATION IN SPONGE IRON PLANT USING HEAT …

Sponge iron is mainly produced from iron ore by two different routes – (a) - by reducing gases (CO and H 2) in a shaft furnace, and (b) through direct treatment with coal in a rotary kiln. The conventional route for making steel consists of sintering or pelletization plants, coke ovens, blast furnaces, and basic oxygen furnaces. Such plants require high capital expenses and raw

Top PDF Sponge Iron - 1Library

In the process for the production of sponge iron, the raw materials viz., iron ore, coal and dolomite are charged into rotary kiln from the inlet end by means of a feed tube in a pre-determined ratio by electronic weighing equipment. The Rotary kiln is of 3.00 mts.

Making Sponge Iron With Rotary Kiln

2 KILN BASED SPONGE IRON PRODUCTION PROCESS Rotary kilns are found in many processes that involve processing of solids This study focuses on sponge iron kiln based process The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of noncoking coal Patra et al 2005 The

Prospects for Coal-based Direct Reduction Process

rotary kilns and increases the reduction rate and productivity. The process is also characterized by flexibility regarding various raw materials, including iron ore fines, steel mill waste and non-coking coal. This paper outlines the features and development status of Kobe Steel's coal-based reduction processes,

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

01.09.2015· In the sponge iron process concentrated and finely divided iron ore is reduced in solid phase into sponge iron at high temperatures in rotary kiln. The process is very energy demanding. In order to identify the largest losses and to find ways to increase the efficiency, an energy survey of the sponge iron plant was carried out for a number of different production rates. The energy usage in processing industries can be reduced by changing the process or …

Sponge iron making process - SlideShare

09.11.2014· Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical Composition

Rotary kiln - Wikipedia

A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process.Materials produced using rotary kilns include: Cement; Lime; Refractories; Metakaolin; Titanium dioxide; Alumina; Vermiculite; Iron ore pellets; They are also used for roasting a wide variety of sulfide ores prior to metal extraction.

Tpd Sponge Iron Kiln Dimensions, Rotary Kiln

Rotary Kiln Based Sponge Iron Plant Process Pdf. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore non coking coal and dolomite as the raw materials . Online Chat Kiln Tyre Riding ...

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