rotary kiln sponge iron plant pdf

منتوجات جديدة

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …

This compendium by TERI reviews various energy-saving and low-carbon technologies for direct reduction of iron (DRI) plants in India. It covers waste heat recovery, coal …

منتوجات جديدة

Coal & Gas based DRI Plant

We manufacture Sponge Iron Plant on turn-key basis of different functional capacities i.e. 100 TPD, 300 TPD, 500 TPD plants.The equipment support provided for the plants include Kiln/cooler tyre, Kiln/cooler support roller, Kiln/cooler support roller shaft, Kiln/cooler support roller assembly with bearing housing, Kiln/cooler girth gear, Kiln/cooler pinions, …

منتوجات جديدة

[PDF] Simulation of Rotary Kiln Used in Sponge Iron …

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 different topologies are proposed for this data set to optimize the regression coefficients (R2).

منتوجات جديدة

Flow of materials in rotary kilns used for sponge iron …

Division of the "rata Iron and Steel Company Limited frISCO) set up a rotary kiln based direct reduction pilot plant in 1975. In this pilot plant, a totally indigenous technology for production of sponge iron has been developed in which non-coking coal is essentially used as the reductant. For easy

منتوجات جديدة

Pressure Measurement and Control in Rotary Kilns at TATA Sponge Iron

PDF | Pressure fluctuations inside a coal-fired rotary kiln for production of sponge iron affect the temperature distribution as well as the rate of... | Find, read and cite all the research you ...

منتوجات جديدة

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 …

منتوجات جديدة

OPERATIONAL ASPECTS OF SPONGE IRON …

ROTARY KILN—SOLID REDUCTANT PROCESSES 1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores …

منتوجات جديدة

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to ... 2.1 Raw Materials for Rotary Kiln 5 2.2 Waste Heat Sources and Uses 11 2.3 Grading Of Waste Heat 12 2.4 High Temperatures waste gases 13 2.5 Medium Temperatures waste gases 14 ...

منتوجات جديدة

(PDF) Simulation of Rotary Kiln Used in Sponge Iron …

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 different topologies are proposed for this data set to optimize the regression coefficients (R2).

منتوجات جديدة

Operation of Coal-Based Sponge Iron Rotary Kiln to …

Sponge iron is the final product of coal fired rotary kilns. The schematic diagram in Fig. 1 describes the unit processes involved in a sponge iron a production plant [1] .

منتوجات جديدة

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

منتوجات جديدة

Rotary Kiln Manufacturers | Electrotherm E&T

Download Rotary Kiln PDF to get more product information. Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more …

منتوجات جديدة

Decarbonisation Options for Rotary Kiln-Induction …

A schematic diagram of a typical rotary kiln-based sponge iron plant is shown in Figure 1. Figure 1: Schematic diagram of a rotary kiln-based sponge iron plant integrated with a captive power ...

منتوجات جديدة

Dolomite – Its Processing and Application in Iron and

Several different types of kilns are used for the calcination process. These kilns can be rotary kilns or shaft kilns. The type of the kiln to be selected strongly depend on the characteristics of the raw dolomite, anticipated production rate, cost of fuel, investment costs, available fuel, local conditions, infrastructure and other things.

منتوجات جديدة

Energy Conservation in Sponge Iron Production Process …

Index Terms— Capital cost, Coal consumption, Heat integration, Payback period, Sponge iron plant. I. INTRODUCTION Sponge iron is the metallic form of iron produced from direct reduction of iron oxide below the fusion temperature of iron ore (1535ºC) utilizing hydrocarbon gases or carbonaceous fuels such as coal. With the availability of raw

منتوجات جديدة

Everything You Need to Know on Rotary Kiln Refractory

This can be done by picking a spot on the rotary kiln shell, and holding a temperature gun in place. As the rotary kiln rotates, that spot should read the same temperature for the entire circumference of the shell. For example, a temperature reading of 400º, 400º, 700º, 400º would likely indicate a failure in refractory.

منتوجات جديدة

Direct Reduced Iron Industry in India — Problems and …

The rotary kiln sponge iron has lower metallisation (about 85 — 88% on the average) and low carbon content (0.1-0.2%) compared to gas based sponge iron (Metallisation of 92 — 94% and carbon content ... DRI producers as joint venture, as individual plant requirements are generally small, which will ensure availability of quality input at ...

منتوجات جديدة

Operation of Coal-Based Sponge Iron Rotary Kiln to …

Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation. AISTech 2019 — Proceedings of the Iron & …

منتوجات جديدة

An Investigation on the Cracking of Air Tubes of Rotary Kilns …

Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. The material of the air tube is ASTM A297 HK 40, a member of the heat-resistant cast alloy family (H series) steels widely used for enhanced high-temperature properties. Microstructural degradation occurring at high temperature …

منتوجات جديدة

Decarbonisation Options for Rotary Kiln-Induction …

This paper analyses a 350 t/day (tpd) sponge iron plant integrated with an induction furnace and a captive power plant. Several decarbonisation options, such as the use of …

منتوجات جديدة

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

(DRI) fines/briquettes for steel making' and IS 13905:1993 'Hot briquette sponge iron (HBI) for steel making'. With the formulation of this standard IS 10812: 1992, IS 13839: 1993 and IS 13905: 1993 stand withdrawn. In this revision, the carbon content for rotary kiln DRI/sponge iron has been modified to around 0.1 percent apart

منتوجات جديدة

Sponge Iron

Sponge iron means porous iron produced by direct reduction process.Direct reduction (DR) process is a solid-state reaction process (i.e. solid–solid or solid–gas reaction) by which removable oxygen is removed from the iron ore, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or …

منتوجات جديدة

Steel Exchange India Ltd

Sponge Iron and Coal Char are discharged from the kiln through a 12 meters long rotary cooler where water is sprayed directly as well as indirectly for cooling the material down to 100oC. The material is then fed to magnetic separator for separating the Sponge Iron and non-magnetic coal char after which the Sponge Iron is transported by way of ...

منتوجات جديدة

Direct Reduced Iron

DRI is a high-quality metallic iron product produced in a DRI kiln (either rotary or vertical shaft kiln) by removing oxygen from iron ore by means of heating and chemical reaction at temperatures below the melting point of iron. A relatively high grade of iron ore is needed as input, as the process retains the impurities.

منتوجات جديدة

A review of ironmaking by direct reduction processes: …

However, for coal-based DR the reductant is generated from non-coking coal and rotary kilns, rotary hearth furnaces and multi-hearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 65-75% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).

منتوجات جديدة

Modelling and optimization of a rotary kiln direct …

The kiln model applied in this work was developed by Hatch over a number of years and has been used for several rotary kiln projects. It has its roots in a FORTRAN program that was developed by Venkateswaran (1978) to study the reduction of iron ore. The original software was used to model the operation of a 35 m pilot kiln at the Stellco company

منتوجات جديدة

(PDF) Dynamic quality prediction and control in rotary sponge iron kilns

The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe.

منتوجات جديدة

Optimizing Waste Heat Recovery in the Post-combustion …

The iron ore is reduced to sponge iron inside the rotary kiln. The coal enters from both ends of the rotary kiln; one end is known as the feed side, and the other is the injection side. The iron ore, dolomite, and coal (nearly 50% of the total coal required) enter from the feed end of the rotary kiln, and coal (balance), in some cases raw ...

منتوجات جديدة

(PDF) Mathematical Modelling of Sponge Iron Production in …

This paper highlights how mathematical modelling of heat transfer and reaction kinetics in a rotary kiln processing iron ore to metallised iron can useful for …

منتوجات جديدة

(PDF) Environmental performance evaluation of sponge iron …

Figure III showsproduction pro cess of sponge iron in a co al based rotary kiln us ing customized/ indigenous t echnology a long w ith sour ces o f air emissio n, liquid eff luent and so lid waste ...

منتوجات جديدة

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

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 …

منتوجات جديدة

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

PDF | On Jan 1, 2019, S. Borah and others published Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation | Find, read and cite ...

منتوجات جديدة

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.

منتوجات جديدة

Direct Reduced Iron: Most Efficient Technologies for …

The employed fuels are natural gas and/or coal. The energy consumption is in the order of 10.4 GJ/t-DRI that is equivalent to 300 m 3 of natural gas per ton of reduced iron. The CO 2 emissions are quantified in the range 0.77–0.92 t of CO 2 per ton of steel. As a function of the employed reducing reactors, the systems are of four main types:

منتوجات جديدة

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

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 …

منتوجات جديدة

Flow of materials in rotary kilns used for sponge iron …

Division of the "rata Iron and Steel Company Limited frISCO) set up a rotary kiln based direct reduction pilot plant in 1975. In this pilot plant, a totally indigenous technology for …