sponge iron kiln process

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

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;

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:-

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)]. …

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. …

Sponge Iron (DRI) | The Hira Group

In Energy conservation process in DRI plant we catch Process resultant fuel gases which is at high temperatures of around 950°C from the sponge iron kiln; constituting significant amount of heat energy. With WHRB, a modern Technology, We produces around 0.5 million TPA of Sponge Iron. Thus we have achieved about 85% recovery of waste heat from ...

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 …

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

(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 ...

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 …

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 …

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.

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

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 …

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

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 …

[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 …

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 …

Decarbonisation Options for Rotary Kiln-Induction …

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 ...

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 ...

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, …

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.

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 …

A study on the accretion formation in DRI kilns and …

sponge iron manufacturing process and suggested improvement in that [8, 10, 11]. Directly reduced iron (DRI, or called sponge iron) has been found an excellent feed in electric arc ... 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

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 …

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 ...

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, …

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

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.

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.