Energy Survey of the Coal-Based Sponge Iron Industry

In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and dolomite, is fed to the rotary kiln (RK).

ENERGY INTEGRATION IN SPONGE IRON PLANT USING …

2012-5-12 · Table 2.1: Raw Materials for Production of Sponge Iron Material Size Iron Ore 5-18 mm Coal 3-20 mm Dolomite 2-6 mm Air - 2.1.3. Theory In any rotary kiln process based on coal, the reduction of iron oxide takes place by the carbon monoxide produced from coal. The following reactions involved are as …

Modelling and optimization of a rotary kiln direct ...

2015-6-11 · of iron ore reduction in a generic rotary kiln. Rotary kiln model Kiln modelling consists of two steps. Firstly, an Excel®-based calculation is used to determine the kiln bed profile and residence time based on specific operating conditions and the kiln configuration. This is followed by a calculation of the kiln operating character-

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 ...

Process of producing sponge iron by a direct reduction of ...

What is claimed is: 1. In a process of producing sponge iron by a direct reduction of iron oxide-containing materials including prereducing a charge in a fluidized bed and final reducing the charge below the melting point of the charge in a rotary kiln, the improvement which comprises prereducing fine-grained materials which contain iron oxide and have an iron content in a fluidized bed to ...

Sponge Iron | Iron | Steelmaking

2017-7-31 · 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.

Rotary Dryer Design & Working Principle

2016-6-1 · Rotary Dryer – Kiln. For evaporating moisture from concentrates or other products from plant operations, Rotary Dryers are designed and constructed for high efficiency and economy in fuel consumption. Whenever possible to apply heat direct to …

Computational fluid dynamics analysis of sponge iron ...

2017-3-1 · The geometry of rotary kiln of sponge iron process is developed using GAMBIT 2.4.6. Dimensions of kiln are 80 m length and 4 m internal diameter. The kiln is inclined to 2.5 degree to the horizontal and rotated with 4.3 rpm. Bed material consists of iron ore, coal and dolomite, enters the kiln through feed end.

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. A temperature ...

Benefits of oxygen enrichment in sponge iron rotary kiln ...

2018-5-29 · These conditions resulted in a reduction of specific coal consumption by 6%, an enhancement in the sponge iron production by 6% and an increase in the rotary kiln campaign life from 50 to 100 days. Keywords: Sponge iron rotary kiln, Oxygen enrichment, Data-driven model, Optimisation, Genetic algorithm, Artificial neural network

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN …

2012-1-10 · priately called the Malza-Bharati Process of producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the

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

Fig 3 – Process flow diagram for coal based sponge iron The hot reduced sponge iron along with semi-burnt coal, discharged from kiln is cooled in water-cooled cylindrical rotary …

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 [5].

Preparation of Direct Reduction Sponge Iron (DRI) Using ...

It contains abundant iron, such as Fe 2 O 3 and Fe 3 O 4, and nonferrous metals, such as zinc, lead and copper. In order to try and recycle this material as a source of Fe units, preparation of direct reduction iron (DRI) using pyrite cinder was investigated by coal-based grate rotary kiln process. This process includes chloridizing and ...

Sponge Iron Production in Rotary Kiln

2011-6-30 · 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 and basic principles of sponge iron production ...

(PDF) Rotary Kiln Handbook NEW | Ahmad Reza Jamali ...

Sizing is a complex process Increasing Eficiency not easily explained in brief; the process of sizing a rotary kiln is one that combines engineering principles through Customization Rotary kilns are extremely customizable, and can be with the thermal and chemical …

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, Kiln/cooler pinion shaft, Kiln ...

Energy integration of sponge iron production process

2012-10-19 · rotary kiln. About 40% of total 5.958 tph coal i.e 2.429tph of slinger coal is also injected pneumatically from the discharge end of the kiln. Compressed air (24.807 tph) is injected along the length of the rotary kiln at various places with the help of blowers which can be adjusted separately. Figure 1: Flow Sheet of Typical Sponge Iron Plant ...

Brief Process Of Ore Based Sponge Iron Rotary Kiln

Sponge Iron Rotary Kiln Process Cement. 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 ...

Sponge Iron Production In Rotary Kiln Bidyapati Sarangi

Sponge Iron Production In Rotary Kiln Arabinda Sarangi. Sponge Iron Production In Rotary Kilnsarangi Bidyapati. 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 and basic principles of sponge iron production commercially used dr direct reduction processes and ...

Analysis of temperature profile and % metallization in ...

2016-6-1 · 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 simulated flow pattern of air using …

(PDF) 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 ... (Georgakis et al., 2003). ... the process conditions in a sponge iron ...

DRI production | International Iron Metallics Association

The Midrex® and Energiron gas-based processes use predominantly iron ore pellets as feedstock, but sometimes with inclusion of lump ore in the furnace charge. The Finmet / Finored gas-based process utilizes iron ore fines as feedstock. The SLRN coal-based rotary kiln process uses lump ore and, increasingly, pellets as feedstock.

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

The new concept of process technology, which is proposed in this paper (patent pending) to produce hot metal / pig iron. is the combination of rotary kiln and lower part of blast furnace (smelting ...

Modelling and optimization of a rotary kiln direct ...

2014-8-5 · Illustrative examples are included for the case of a generic rotary kiln iron-ore reduction process. Rotary kiln model Kiln modelling consists of two steps. An Excel®-based calculation is used to determine the kiln bed profile and residence time based on specific operating conditions and the kiln configuration, followed by a calculation of the ...

Study on Air Tubes Failure in Sponge Iron Rotary Kiln

2015-12-4 · Keywords: Sponge Iron, Heat Transfer, Rotary Kiln . 1. Introduction . In Rotary kiln, carbon is charged from either end, in one end in the form of coal particles and in another in form of coal lumps. The coal reacts with air to form carbon monoxide which then reduces iron oxide (ore) to iron. So, in a kiln,

Sponge Iron Production in Rotary Kiln: Sarangi, Bidyapati ...

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 …

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

2017-2-2 · in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. 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 preheat the air entering to kiln. Further, the waste gas at reduced ...

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 ...

2019 SPONGE IRON PRODUCTION IN ROTARY KILN on …

Rotary kiln process of making sponge iron chapter 3. Rotary Kiln Process of Making Sponge Iron 13 that the entire production by number 2, 3 and 4 countries is through gas based route while in India, more than half the. Iron Production In Rotary Kiln. Sponge iron production in rotary kiln …

PROCESS FOR PRODUCING SPONGE IRON

We claim 1. A process for producing sponge iron, comprising the steps of preparing a sinter mix including iron ore and sponge iron, sintering the sinter mix by utilizing for at least part of the heat required for sintering the heat liberated by burning of the sponge iron in said mix, changing the product of the step of sintering into sponge iron, separating the minus 3 millimeter size fraction ...

Study on Air Tubes Failure in Sponge Iron Rotary Kiln

2015-12-4 · : 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 ...

Sponge Iron Production in Rotary Kiln, Sarangi, A. Sarangi ...

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. Use features like bookmarks, note taking and highlighting while reading Sponge Iron Production in Rotary Kiln.

Types of Sponge Iron Technology

2014-10-24 · Rotary kiln and vertical kiln are used for producing sponge iron under this process. The saving of energy is high in comparison to other process. But the control mechanism is comparatively complex. The use of sponge iron for producing steel and foundry grade pig iron created new opportunities in the iron and steel sector.