sponge iron making process rotary kiln pdf

  • ENERGY INTEGRATION IN SPONGE IRON PLANT USING …

    sponge iron making was in 1972 presumably using a rotary kiln. More than 100 DR processes have been invented and operated since 1920. Most of these have died down but some of them have re-emerged in slightly different form. [6] Sponge iron is mainly produced from iron ore by two different routes – (a) - by reducing gases (CO and H 2

  • [PDF] Simulation of Rotary Kiln Used in Sponge Iron ...

    In the present study, estimation of actual output 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 ...

  • Sponge Iron

    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 + H ...

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

    The present work identifies the basic features of burden movement in a rotary kiln. The cold model study was conducted with iron ore as the feed material to determine the influence of length to diameter ratio (L/D) of a rotary kiln on the filling degree, hold-up, and residence time of the charge. An empirical equation correlating different operating variables has been derived on the basis of ...

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

    Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN IACSIT International Journal of Engineering and Technology, Vol. 6, No. 2, April 2014 DOI: 10.7763/IJET.2014.V6.673 95 Abstract—In the present study, estimation of actual output parameters is carried out for a sponge iron production process

  • Rotary Kiln Maintenance Procedures

    rotary kiln operations. Regardless of rotary kiln size or configuration the basic principles outlined in this manual govern the reliable operation of every rotary kiln, calciner, dryer, incinerator, digester and cooler application. For questions or problems with your specific application please contact North American Kiln …

  • Effect of Quality of Raw Materials on the Quality of ...

    Amongst direct reduction processes utilizing solid reduction agents for sponge iron production, the rotary kiln process, the SL/RN process by Lurgi and the Codir process by Krupp all developed in Germany, are predominant throughout the world. In the meantime two installation have been built in Venezuela (HB and Fior Process) working

  • Sponge Iron | Iron | Steelmaking

    Gas-Based Process: This process utilizes natural gas as the reducing agent. Natural gas is reformed to enrich with H2 and CO mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process.

  • (PDF) Development of energy conservations scenarios for ...

    Download Free PDF. Download Free PDF. Development of energy conservations scenarios for sponge iron industry using process integration. Energy Efficiency, 2011. Radha Prasad. Shabina Khanam. Anil Prasad R. Radha Prasad. Shabina Khanam. Anil Prasad R. Download PDF. Download Full PDF Package. This paper.

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

    3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

  • 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.

  • Study on Air Tubes Failure in Sponge Iron Rotary Kiln

    Abstract: The rotary kiln process is a commonly practiced method in the industry for producing sponge iron using coal. In the industry, there have been recent reports of premature failures of certain air tubes in a rotary kiln. Most of those cases have concentrated on those air tubes which

  • ORISSA SPONGE IRON AND STEEL LTD.

    - Steel making through IF / EAF including secondary metallurgy. ... · OSIL is a development oriented company and OSIL owns many patents to its credit including the patent for OSIL process: A method of continuous manufacture of sponge iron and a ported rotary kiln therefore. .

  • [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 …

  • Accretion Control in Sponge Iron Production Kiln using ...

    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)]. The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

  • The Making of Iron & Steel

    The BOS process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal (and scrap is used for temperature control). The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Compared to the BOS process, the EAF requires

  • DRI UPDATE

    2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the R&D for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed

  • Development of energy conservations scenarios for sponge ...

     · Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coal-based sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.

  • Proceedings of the World Congress on Engineering 2011 Vol ...

    II. COAL BASED SPONGE IRON PLANT: A CONVENTIONAL PROCESS The process flow diagram of conventional coal based sponge iron plant is shown in Fig. 1. The operating data, shown in Fig. 1, is taken from a typical Indian coal based sponge iron plant where iron ore, feed coal and dolomite are fed to the rotary kiln. A separate conveyor collects

  • Energy Audit Methodology of Sponge Iron Manufacturing ...

    Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary

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

     · 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 ...

  • Direct Reduced Iron and its Production Processes – IspatGuru

     · Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as to prevent its re-oxidation.

  • SPONGE IRON – Lloyd''s Metals

    Process. Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a ''select'' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in ...

  • sponge iron process

     · In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.

  • US4490168A

    Sponge iron produced by direct reduction is melted in an electric arc furnace, in which a pool of liquid metal is maintained. To ensure that liquid carbon-containing iron for forming the pool is available in adequate quantities and that the process can be carried out with the highest possible economy, the sponge iron is reacted in an electric arc furnace on a bath of liquid carbon-containing ...

  • (PDF) Spontaneous burning of sponge iron | varun suri ...

    As touched upon earlier, sponge iron is mainly produced from ore by two different routes -(a) By reducing gases (CO and H 2 ) in a shaft furnace (b) Through direct treatment with coal in a rotary kiln.Sponge Iron:-Sponge iron is the metallic product formed by the reduction (removal of oxygen) of iron ore at temperature below the fusion point of ...

  • OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN …

    1. Krupp Sponge Iron Process The Krupp. 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 ...

  • SPONGE IRON PLANT

    The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore. Iron are undergoes the following reduction reaction in all the processes Fe2o3 + 2 CO = 2 Fe + 3 Co2 As shown in above reactions, carbon monoxide is reducing gases. These reducing gases can be obtained by controlled combustion

  • PROSES REDUKSI BIJIH BESI LAMPUNG MENJADI SPONGE …

    - Rotary kiln (panjang 10 m dan diameter dalam 54 cm) - Mesh ukuran 100 - Thermocouple - Mixer - Timbangan Desain rotary kiln yang digunakan ; Gambar 1. Rotary kiln tampakdepan 10 m 0,7 m Gambar 2. Rotary kiln tampaksamping Prosedur Percobaan Prosedur percobaan meliputi tiga tahapan yaitu persiapan bahan baku, persiapan alat dan pengambilan data

  • Sponge iron making full process_Coal base DRI

    Direct reduced iron (DRI), also called sponge iron,[1] is produced from the direct reductionof iron ore (in the form of lumps, pellets, or fines) to iron by ...

  • (PDF) Rotary Kiln Manufacture | Gary Li

    Dajia rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Widely used for cement, pet coke calcination, dolomite, bauxite, sponge iron and other materials, it uses hot gases for the operation. Integrated with variable speed drive, process automation and ...

  • Bhagwati Sponge Private Limited

    +1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.

  • 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

  • 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

  • Sponge iron making process

     · 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

  • Study on Air Tubes Failure in Sponge Iron Rotary Kiln

    : The rotary kiln process is a commonly practiced method in India for producing coal based sponge iron. In the industry, there have been many recent reports of premature failures of certain air tubes in rotary kilns. This work aims at developing a temperature profile by modelling the heat transfer phenomena happening inside the kiln ...