Rotary Kiln Process (ACCAR / SL – RN / Krupp CODIR)

in the Sponge Iron kiln can not be eliminated since it originates from the input constituents of the process. The extent of interaction appears to increase with the alumina content of the

Sponge Iron

Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & physical characteristics.

Decarbonizing rotary kiln–induction furnace based sponge iron

In a traditional rotary kiln process, sponge iron comes out of the rotary kiln at about 1020 °C and is then cooled to 110 °C in a rotary cooler before being separated from a solid mixture containing sponge iron, coal ash, and dolo-char mixture. Sponge iron is then stored and later used in the steel-making process.

Sponge Iron Production in Rotary Kiln

Sponge Iron Production in Rotary Kiln - Kindle edition by Sarangi, A. Sarangi, B.. Download it once and read it on your Kindle device, PC, phones or tablets. ... The process of reducing the iron ore in solid form by reducing gases is called direct reduction. This book deals with the basics of sponge iron production in rotary kiln, …

SPONGE IRON

The production process followed at Rashmi Group makes the Sponge Iron unique and superior than its competitors. Iron ore (Red Hematite) is extracted from the mines and taken to the DirectReduced Iron (DRI) Plant where it is charged with different sizes of Coal (Carbon) by conveyors from different stock houses into the Rotary Kiln.

Sponge Iron

Learn about sponge iron, also known as DRI, a product of reducing iron oxide into metallic iron below the melting point of iron. Find out its chemical composition, reduction …

Schematic diagram of plant and the rotary kiln (see arrow) …

The temperature profiles of the gas and charge in a coal-fired rotary sponge iron kiln affect both the iron ore reduction process and accretion formation. The temperature profile of charge is ...

IS 15774 (2007): Sponge Iron/Directed Reduced Iron …

In this revision, the carbon content for rotary kiln DRI/sponge iron has been modified to around 0.1 percent apart ... Direct reduction (DR) is a metallurgical process of producing iron from iron oxides (mainly in the form of lump ore or pellets) directly in the solid phase, that is without going through the molten stage as occurs in blast furnace

Advances in Rotary Kiln Sponge Iron Plant

Contents: IntroductionRotary Kiln Process of Making Sponge IronThermodynamic Considerations: Feasibility of ReactionAerodynamics inside a Sponge Iron Rotary KilnMathematical Modelling in Rotary Kiln Sponge Iron MakingPhysical Movement of Solids inside a Rotary Kiln: Charge Movement and Coal Throwing/SlingingRequirement, …

Process flow diagram of the sponge iron plant.

In the conventional process, the sponge iron leaving the rotary kiln at 1,020 °C (Dey et al., 2015) is cooled to 110 °C for two reasons: (i) to prevent re-oxidation of the sponge iron when ...

Innov Engineering Pvt. Ltd

Tunnel Kiln Technology Process for Sponge Iron . Crushing and screening of raw materials; Mixing iron ore, coal and limestone ; The mixed iron ore, coal and limestone are charged in storage bins in certain ratios. Raw materials mix is charged in SiC crucibles through an automatic charging system;

Direct Reduction Ironmaking

If sponge iron is used in steelmaking, it can be transported in a sealed container to the steelmaking workshop without cooling. The reducing gas can be produced by reforming natural gas in a heat exchanging catalytic conversion unit in which the shaft furnace top gas is used as oxidant. ... The industrialized process is rotary kiln process ...

SPONGE IRON PLANT

The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production can be classified into:-

Direct Reduced Iron: Most Efficient Technologies for …

Direct reduced iron (DRI) is also known as sponge iron (Hasambeigi et al. 2014). This high porous material has a metallization degree in the range 85–95% with a carbon content in the range 0.5–4% depending on the processing route. During the process, the iron oxides are reduced at the solid state.

Recovery and Utilization of Waste Heat in a Coal Based …

Kiln Feeding Iron ore: Feed coal: Dolomite All at 30 C Rotary Cooler Sponge iron (magnetic) At 110 oC Water: at 30 oC DSC 900 C 1020 C Dust: ABC Air: WHRB Waste gas Water: ESP Dust ... Coal-based sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non …

LECTURE NOTES ON Sponge Iron & Ferro Alloys

iron. ACCAR Process: (Allis Chalmers controlled Atmosphere Reactor) This produces highly metalized direct reduced iron using rotary kiln. Here solid, liquid and gaseous …

IS 15774 (2007): Sponge Iron/Directed Reduced Iron …

Recovery and utilization of waste heat in a coal based sponge iron process

Highlights Present work deals with two design modifications proposed for sponge iron plant. First design accounts for preheating of kiln air using waste gas exiting from ESP. For second design water is heated using hot sponge iron to preheat rotary kiln air. A model is developed to compute coal demand of process based on different …

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …

This compendium by TERI reviews various energy-saving and low-carbon technologies for the coal-based direct reduction of iron (DRI) process, also known as sponge iron, in India. It covers waste heat recovery, iron ore preheating, coal gasification, hydrogen use, and …

[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 …

(PDF) Environmental performance evaluation of sponge iron …

Another environmental issue of direct reduced iron kiln is the high greenhouse gases (GHGs) generation potential. ... Figure III: Process Flow Diagram of Coal Based Sponge Iron Plant alon g with ...

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

Schematic of optimised Rotary kiln sponge iron making process. Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge end of Rotary Kiln which is inclined at 2.5% of drum length. Coal is also injected through a Coal Throw Pipe at the discharge end of Kiln. Due to the inclination and rotation of Kiln the charge ...

Simulation of Rotary Kiln Used in Sponge Iron Process …

Index Terms—Sponge iron process, rotary kiln, temperature profile, artificial neural network. I. II. INTRODUCTION Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal.

Sponge Iron

Sponge iron is porous iron produced by direct reduction of iron ore in solid state using coal or natural gas. Learn about the different types of sponge iron …

Conventional and AI Models for Operational Guidance and …

TATA Sponge employs coal fired rotary kilns to produce sponge iron. Iron ore, coal, and dolomite are charged from one end of rotary kiln (schematic diagram in Fig. 1), and the coal for combustion is fired from the other end. Rotary kiln is slightly inclined so that material flows in forward direction.

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD …

2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters. Based on grid ...

(PDF) Operation of Coal-Based Sponge Iron …

In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.

Profitability analysis of power generation using waste heat of sponge …

The schematic of sponge iron process is shown in Fig. 1 where raw material enters to the kiln from feed end and moves toward the discharge end due to rotation and inclination of kiln. Sponge iron exits from discharge end. Air enters the kiln as primary and secondary air, which is due to the process requirement, as shown in Fig. …

Proposed expansion of Induction Furnace of capacity …

Sponge Iron Kiln to produce sponge iron from Coal based DRI kiln process from Iron Ore 30000 TPA (100 TPD X 1 No.) CTE 10/09/2003 CTO 27/07/2005 CTO 5/9/2018 2. Sponge Iron Kiln to produce sponge iron from Coal based DRI kiln process from Iron Ore 12 MT Induction Furnace to produce 36000 TPA MS Billets 30000 TPA (100 TPD X …

Sree Rengaraaj Steels

We supply Our Sponge Iron Products to various Induction Furnace, Foundry Division and also for Blast Furnace. Sponge Iron Rotary Kiln Process. In this process, a Refractory lined Rotary Kiln is used for reduction of iron ore in solid state. The Kiln is mounted with a slope of 2.5 % downwards from the feed end to discharge end.

Analysis of temperature profile and % metallization in rotary kiln …

The literature discussed above is based on CFD analysis of rotary kiln of cement plant. As the focus of the present work is to study the kiln of sponge iron process, literature related to it is discussed here: Prasad and Ray [9] simulated flow pattern of air using FLUENT software in rotary kiln of a typical 100 tpd sponge

Accretion Control in Sponge Iron Production Kiln using …

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 non-coking coal [Patra et al, (2005)]. …

Production of Sponge Iron through Tunnel Kiln Process

PDF | On Apr 1, 2010, Swaren Bedarkar and others published Production of Sponge Iron through Tunnel Kiln Process | Find, read and cite all the research you need on ResearchGate

Profitability analysis of power generation using waste heat of sponge …

The present paper proposes two energy integration options, Option-1 and Option-2, to compare power generation and preheating scheme in sponge iron process.Option-1 accounts power generation whereas in Option-2 preheating of feed material, slinger coal and kiln air is considered. These options utilize heat of waste gas …

Sponge Iron Production in Rotary Kiln

The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world. This book comprehensively deals with the production of sponge iron in the rotary kiln. The book is divided into 17 chapters. The initial chapters give a brief on the fundamental theories …

Introduction to Iron ore Pellets and Pelletizing …

Grate kiln process, Green pellets, Iron ore fines, iron ore pellets, Pelletization processes, Pelletizing disc, Straight travelling grate process, ... – What will be the impact on pellets during reduction …