Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.
Jul 16, 2017· There are many basic aspects, which need to be considered for making sponge iron in rotary kiln. The important are as follows. #Thermodynamics and kinetics of reduction and gasification reaction. Movement of solids in the rotary kiln and its residence time. Gas evolution and flow rate. Heat transfer and temperature profile.
Jul 29, 2010· Mean Particle Size: 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.
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
In the present work a system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 C.
ORISSA SPONGE IRON AND STEEL LTD. Plant facilities. Sponge Iron Plant. As on 31.03.2011, OSIL has the following production facilities at the plant: The main plant consists of a 4 mtr. Dia x 84 mtr. Long ported rotary kin (DR 1) and 4.8 mtr. Dia x 84 mtr.long ported rotary kin (DR 2) equipped with air injection system to provide for generation ...
In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850°C -1,500°C).
3.1 Material Balance in a Rotary Kiln sponge iron plant 14 3.2 Energy Balance in a Rotary Kiln sponge based iron making 14 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
May 18, 2016· sponge iron TCE NMD. 1. CONSULTING ENGINEERS LIMITED CHALLENGES IN SPONGE IRON MAKING USING ROTARY KILNS Asaman Prasad Patnaik, Dr M D Maheshwari, Jitendra Nath Rath & Raghunath V Deshpande TATA CONSULTING ENGINEERS LIMITED. 2. CONSULTING ENGINEERS LIMITED OUTLINE OF PRESENTATION TATA CONSULTING
+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.
Mar 10, 2011· Mass balance around main components of the plant on per hour basis ... Enthalpy change of waste gas in the rotary drier =required en- ... lection of Coals for Rotary Kiln Sponge Iron Plant ...
Sep 01, 2018· The location of Sponge Iron Plant should be at least 500 m away from National Highway and State Highway. The radial distance between two Sponge Iron Plants should be 5 km for plants having capacity 1000 TPD or more. Sponge Iron Plants can be established in designated industrial areas/Estates as notified by State Government.
The hot product discharged from the kiln is indirectly cooled in a rotary cooler by spraying water on the shell of the cooler. The discharge from the cooler is conveyed through a belt conveyor screened and magnetically separated. Sponge iron and non-magnetic components are separated and stored in separate bins for further transfer.
Sep 28, 2011· 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 affects mechanical and corrosion-resistance ...
DRI PLANT. Lloyds Metals and Energy Limited. (LMEL) is a unit of Lloyds Group which is in the manufacturing of Sponge Iron had initially set up its first 500 TPD (Tonnes per day) kiln with the rated capacity of 1,50,000 TPA by opting OSIL-Technology in the year 1994-95 at the village-Ghugus, District-Chandrapur (Maharashtra).
Weigh feeders are provided to draw various materials in the required proportion from the bins and deliver to the conveyors for feeding into the kiln. Rotary kiln and cooler. Rotary kiln of a certain dia and length are provided for reduction of iron ore into sponge iron using non-coking coal as reductant. Other main components of kiln are:
1.2.1 Sponge Iron (DRI) Refractory lined rotary kilns will be used for reduction of iron ore in solid state. A central Burner located at the discharge end will be used for initial heating of the kiln. Iron ore will be continuously fed into the kiln along with coal which has dual role of fuel as well as reductant.
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
A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process.Materials produced using rotary kilns include: Cement; Lime; Refractories; Metakaolin; Titanium dioxide; Alumina; Vermiculite; Iron ore pellets; They are also used for roasting a wide variety of sulfide ores prior to metal extraction.
Number of DRI processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world. Ashokas Sponge Iron Plants Manufacturing Capabilities:Sponge Iron Plant: 100 TPD to 600 TPD & Sponge Iron Plant Equipment
We supply Our Sponge Iron Products to various Induction Furnace, Foundry Division and also for Blast Furnace. Sponge Iron Rotary Kiln Process. In this process, a Refractory lined Rotary Kiln is used for reduction of iron ore in solid state. The Kiln is mounted with a slope of 2.5 % downwards from the feed end to discharge end.
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 designers lof industrial size plants in the near
based sponge iron plant, an incredible amount of heat is ... such savings is required. Although many plants have acquired ... The principal cost factor in direct reduction is energy cost as energy requirement for rotary kiln processes ranges between 14.63 GJ/t to 20.9 GJ/t . Based on above discussion, it was observed that for heat
Iron Ore and Coal are drawn with the help of weigh feeders in the required quantity and proportion and fed on to common conveyor. These raw materials enter into the rotary kiln through a feed chute. 4. The rotary kiln is 70 meters in length and 4.4 meter in diameter. This kiln
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 8001200 °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 ...
Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING Under the supervision of. Radhebihari Upadhyay. Related Papers. Rotary Kilns. By shoyab mohamed.
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
We are engaged in the manufacture and supply of best quality Kiln Shell specialy for Sponge iron plant. They are made using superior-grade raw materials in agreement to industry quality standards. They are highly acclaimed for their durable nature. They are easy to install and incur low maintenance costs.
Power has become an essential commodity all over world today, with rapid development in infrastructure and other aspects, Power has become the most sought out commodity. Globally conventional fuels are going to be exhausted. World wide all resource
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 ...
Because of the huge length of the kiln and to maintain the temperature profile, 40% coal is injected from the discharge end. Sponge iron produced by this plant is of high grade which contains 80% Fe, 12% FeO and 8% gangue ma-terial. After separation of sponge iron in the magnetic screen/pulley, the remains arecollected as char. Char
By Considering All The Requirements of The Global Market M/S Industrial Technical Consultant Introduced A New Technology For Producing Sponge Iron is Known as ITC Pre-Heating Technology. In This Technology The Iron Ore to be Fed in A Rotary Kiln Like Equipment, Known as Pre-Heater, Which Kept Above The Rotary Kiln.
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 different size fractions of coal for injection into the kiln with the help of pressurized air from discharge end side.
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.
Jan 16, 2011· 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.
There are over 300 DRI plants in India. Out of which at least 100 rotary kilns of the size are 350 TPD and above. Many of them have already started to produce at 400 TPD. Arguably these kilns can be expected to produce upto 500 TPD at lower specific coal consumption to meet/exceed BEE requirements. This canbe achieved by reducing waste gas volume,
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 ...
Jul 29, 2010· 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.
Oct 18, 2019· Extract more sponge iron to boost steel production, jobs. Production of steel is the biggest metallurgical industry in the world. The steel in different forms
Jan 01, 2011· The entire rotary kiln plant and its functionalities are explained with precision. The concluding chapters explicate the ways to store and handle sponge iron. The heat and mass balance calculation done meticulously shows how the waste heat can be utilized for power generation.