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.
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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.
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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, …
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Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by
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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.
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(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 With the formulation of this standard IS 10812: 1992, IS 13839: 1993 and IS 13905: 1993 stand withdrawn.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
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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 …
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In sponge iron plant, rotary kiln is used to manufacture iron billets from combustion of coal and iron ore. Waste flue gas emitted from the rotary kiln has a temperature of 700°C and above. Gas cooler is required to cool the gas to the acceptable level.
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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
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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 …
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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
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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 …
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PDF | The present paper deals with 2D CFD model of rotary kilns employed in sponge iron process. Using this model the effects of variations of input... | Find, read and cite all the research you ...
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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 ...
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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 …
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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.
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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 ...
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We designed and commissioned our first Sponge Iron plant of capacity 10,000 TPA near Hyderabad in 1995 and achieved rated production capacity from the first year onwards. ... DRI (Rotary Kiln): 100 TPD 175 …
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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 ...
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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.
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equations on the basis of plant operational data. 1. INTRODUCTION Pressure inside a coal fired sponge iron rotary kiln depends on several operating parameters such as coal injection rate, ore feed ...
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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 ...
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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 …
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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 …
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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 …
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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:
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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 ...
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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.
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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).
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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 ...
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