complete process of sponge iron kilns

(PDF) 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). A separate conve yor collects ...

The Aerodynamics of an Iron Ore Pelletizing Rotary Kiln

This paper summarizes more than a decade of systematic studies of the flow field in an iron ore pelletizing rotary kiln using computational fluid dynamics (CFD) on simplified models of a real kiln. Physical, laser-based experiments have been performed to validate part of the numerical results. The objective is a better understanding of the kiln …

Recovery and utilization of waste heat in a coal based sponge iron process

Highlights Present work deals with two design modifications proposed for sponge iron plant. First design accounts for preheating of kiln air using waste gas exiting from ESP. For second design water is heated using hot sponge iron to preheat rotary kiln air. A model is developed to compute coal demand of process based on different …

Chapter 1 Review of Sponge Iron Making Process Historical …

sponge iron production plant at Chandrapur, Maharastra. The OSIL process uses a rotary kiln of 3.5mtr diameter and 84mtr long. The output of this plant is 300 tons per day. The …

Direct Reduced Iron Industry in India — Problems and …

`the quality requirements for the rotary kiln sponge iron process. The sponge iron fines generation is high and ranges from 15 — 30% depending upon the ore used due to high reduction degradation. This will not only reduce the sales realization of the product but also will lead to accretion formation in the kiln shortening the campaign life.

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 production process of sponge iron in rotary kilns from the

In this paper, the production process of sponge iron in rotary kilns from the perspective of mechanics and chemistry is investigated. Keywords: Sponge iron, rotary kilns, alloying, iron ore reduction. International Research Science and Development Journal Vol. 1, No. 2, 2020, pp. 48-60.

A Case Study on Accretion Formation in Rotary Kiln of DRI Process

Literature on the coal-based rotary kiln DRI process is not sparse but not many have focussed on the accretion formation [1, 2]. A comprehensive study on the accretion formation in DRI kiln during sponge iron production has been published by Shrives and Shrives . Rao outlined the accretion formation in an experimental rotary kiln …

Analysis of temperature profile and % metallization in rotary kiln of

DOI: 10.1016/J.JTICE.2016.02.035 Corpus ID: 101865191; Analysis of temperature profile and % metallization in rotary kiln of sponge iron process through CFD @article{Gaurav2016AnalysisOT, title={Analysis of temperature profile and % metallization in rotary kiln of sponge iron process through CFD}, author={Gajendra Kumar Gaurav …

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR …

4.1 Direct Reduction of Iron Production Using Solid Coal 39 4.2 Direct Reduction of Iron Production Using Coal Gasification 43 4.3 Direct Reduction of Iron Production Using Gas …

Flow of materials in rotary kilns used for sponge iron …

For easy scaling up of the T1SCO Direct Reduction (TDR) process tounits of300 to 400 tpd capacity, it was thought necessary toexplore someof the fundamental aspects of material …

Sponge Iron Plant Equipment and Spare Parts high quality 3669

Sponge Iron Plant Equipment. We are the best and top level company in India for manufacturer supplier of Kiln Shell with Tyre and Support Rollers Assembly. We have executed Sponge Iron Plant Equipment more than 5000 Sets of Support Roller Assembly. We have executed lots of projects Kiln Shell with complete drive system.

Flow of materials in rotary kilns used for sponge iron …

TDR (Tisco Direct Reduction) process of sponge iron manu- facture. 3 In order to commercialize the TDR technology to plants of 300 to 500 tpd capacity, a need was felt to under- ... encing the flow of materials in sponge iron rotary kilns. B In rotary kiln based direct reduction processes, it is essen- tial to identify the optimized flow ...

Control of Post Combustion to Stabilize Power Generation in …

sponge iron kilns exit at a high temperature (800- ... complete the combustion resulting in formation ... A large number of process parameters affect

Energy survey of the coal based sponge iron industry

Due to chemical reactions and combustion the heat generated inside the kiln is 64.98 Gcal/h and the heat value of coal input is 118.6 Gcal/h resulting in a thermal efficiency of the process to be 51.31%. Considerable amount of heat is lost in the waste gas which is about 43.5% of the heat generated in the kiln.

The SL/RN Process For Production of Metallized Burden

Both used the rotary kiln as reactor and fixed carbon as reducing agent whereas the treatment of ores was different. In its original design, the SL process was utilized exclusively for the production of sponge iron from high-grade iron ores for use in steelmaking furnaces. As far as low grade iron ores are concerned, the

(PDF) Environmental performance evaluation of sponge iron …

The power consumption ranges from 45-130 Kw/tonne direct reduced iron. The amount of char generation on an average is 0.35 tonne/tonne of direct reduced iron and electrostatic precipitator dust is ...

Recent Trends in the Technologies of the Direct Reduction

The blast furnace and direct reduction processes have been the major iron production routes for various iron ores (i.e. goethite, hematite, magnetite, maghemite, siderite, etc.) in the past few decades, but the challenges of maintaining the iron and steel-making processes are enormous. The challenges, such as cumbersome production …

Analysis of temperature profile and % metallization in rotary kiln of

In the present work 2D model of the rotary kiln, employed in sponge iron process, is developed. The 2D model of the kiln with nine different ports for secondary …

Schematic diagram of plant and the rotary kiln (see …

Context 1 ... sponge employs 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 coal for...

(PDF) Rotary Kiln Handbook NEW | Ahmad Reza …

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 …

Sponge Iron

Sponge Iron. Thermax is a pioneer in supplying waste heat recovery boilers for sponge iron plants and has over 150 installations to date. The boilers are designed to handle large amounts of dust from the flue gas generated in the rotary kilns. The steam generated from these boilers is typically used for power generation.

Computational fluid dynamics analysis of sponge iron rotary kiln

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.

International Journal of ChemTech Research

The process flow diagram (PFD) of sponge iron production process, shown in Fig. 1, consists of a number of equipment namely rotary kiln, rotary cooler, DSC, ABC, WHRB, ESP, wet scrapper and chimney. As the aim of the present work is to correlate input and output parameters of the sponge iron process using

WHRB in Sponge Iron Plant

Sponge Iron Plant. We are pioneer in supplying waste heat recovery boilers for sponge iron plants and has over 184 installations to date. The boilers are designed to handle large amounts of dust from the flue gas generated in the rotary kilns. The steam generated from these boilers is typically used for power generation.

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR …

4.1 Direct Reduction of Iron Production Using Solid Coal 39 4.2 Direct Reduction of Iron Production Using Coal Gasification 43 4.3 Direct Reduction of Iron Production Using Gas Route 49 4.4 Hydrogen Use in Indian Iron and Steel Sector 54 5.0 Conclusion 57 Technology Vendors – Energy-efficient Equipment and Systems 60 References 65

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing Using …

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 By Tapash Ranjan Majhi (210CH1204) Under the supervision of Dr. Shabina Khanam DEPARTMENT OF CHEMICAL …