rotary kiln based sponge iron plant process pdf

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 ...

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coal based sponge iron process - dmschaatssport.nl

coal based sponge iron process in south africa Description : Chapter 11, ... Sponge iron plant process pdf Rotary kiln based sponge iron plant process pdf. Iron ore pelletizing DR pellets are used in the direct reduction processes to produce. Chat Online; Sponge Iron - Manufacturing Process - …

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Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce ...

Sponge iron is the final product of coal fired rotary kilns. The schematic diagram in Fig. 1 describes the unit processes involved in a sponge iron a production plant [1] .

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Simulation of Fluidized Bed Dryer using CFD for Preheating ...

The process flow sheet of a typical coal-based sponge iron plant with material and energy balanced operating data is shown in the figure. 1. The overall production capacity of the plant is 100tpd. In this process screened iron ore (6.5tph), coal (3.529tph) and …

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Coal based Direct Reduction Rotary Kiln Process – IspatGuru

Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials.

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Plant Details - MGM

SPONGE IRON PLANT Sponge iron plant or Direct Reduction Plant (DRP) is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. ... Based on the process requirement, the received coal is crushed and screened in to three size fractions 0-4mm.4-18mm,4-20mmin the coal ...

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F ocus - YesJersey

2. Process Description: Sponge iron is produced using non-coking coal by the process of reduction of iron are in a rotary kiln. The reduction is carried out in a rotary kiln of a pre-determined temperature and controlled atmospheric pressure. The input raw material such as iron ore, non-coking coal (with high reactivity) and the fluxing materials

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Case Studies in Thermal Engineering

The CFD studies discussed above are mainly carried out for rotary kiln of cement industry. However, very little work is available related to CFD analysis of rotary kiln of sponge iron process such as: Prasad and Ray [9] developed 2D model to simulate ﬂow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant.

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DRI UPDATE - Sponge Iron Manufacturer India

GAS BASED 1. Clean Technology. 2. Energy Requirement is 20% less than that of rotary kiln based plant. 3. Product suits best steel making qualities. 4. DRI fines (-5mm) generated is 5%. Thus, Loss in SMS are less due to low % of fines. 5. - Sulphur content in DRI is in range of 0.003-0.01% which is very low. 6. Average Metallization is 92-94% ...

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[PDF] Simulation of Rotary Kiln Used in Sponge Iron ...

In the present study, estimation of actual output 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 ...

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ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …

3.0 Energy-efficient Technologies in Direct Reduction of Iron Process 17 3.1 Waste Heat Recovery for Power Generation 18 3.2 Iron Ore Preheating Rotary Kiln Using Waste Heat Recovery System 20 3.3 Coal Gasification for Partial Substitution in Rotary Kiln …

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

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 ...

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SPOTLIGHT - SAIMM

Theperformance ofIscor'sfour-kiln plant, whichwillbe the largest coal-based plant in the world producing sponge iron, will undoubtedly bewatched with great interest bysteelmakers throughout theworld. Thetechnical andeconomic reasons forIscor'sdecision toinstall the 100percentcoal-based rotary-kiln direct-reduction process aredescribed ...

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sponge iron process

The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

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Status of Sponge Iron Plant in Orissa - Vasundhara

3 Raw Material for sponge iron plant Coal: Non-coking coal having certain important parameters is being used for the direct reduction of iron ore . Important factors determining coal quality are: • Chemical properties such as fixed carbon, ash content, volatile matter, etc.: & • Physical properties viz, reactivity and ash fusion temperature. In Orissa scenario, all most all the sponge iron ...

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Sponge iron making process - SlideShare

ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3 …

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Sponge Iron Industry - SlideShare

Raw DRI Process materials, partly coal, iron ore, After Burn Flue gas Chamber fluxes enter the rotary kiln The remainder Rotary kiln coal in = 2.5% Slo and 0.47 rp pe powdered form m sp e e d and hot air is charged Preheating Solid iron and zone or unburnt char, combustion zone lime is where coal is heated discharged Cooler discharge and ...

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Computational fluid dynamics analysis of sponge iron ...

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.

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Tpd Sponge Iron Kiln Dimensions, Rotary Kiln

Rotary Kiln Based Sponge Iron Plant Process Pdf. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore non coking coal and dolomite as ...

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN …

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 ...

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WORLD DIRECT REDUCTION STATISTICS

productivity gains of the rotary kilns, which were able to use higher quality coal imported from South Africa and Indone-sia, according to the Sponge Iron Manufacturers Association (SIMA). Rotary kilns saw a 27.9% jump from 2018, which was already a 35% increase from 2017. Gas-based DRI plants ben -

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Simulation of Rotary Kiln Used in Sponge Iron Process ...

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 ...

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2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

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

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Modelling and optimization of a rotary kiln direct ...

Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production. Hatch has developed a proprietary one-dimensional kiln model to

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1. Identification of Project

The coal based rotary kiln process of making sponge iron is the focus of the present write up. Although many different processes and process concepts have been emerging in this area, there were rapid births and deaths of these processes and process concepts in the middle of the twentieth century. But those operating

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Sponge Iron Production in Rotary Kiln - Arabinda Sarangi ...

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 ...

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SPONGE IRON PLANT

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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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 of ...

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE …

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(PDF) Modeling of Rotary Kiln for Sponge Iron Processing ...

Simulation of Rotary Cement Kilns Using a One-Dimensional Model By Vivek Ranade 523-1 Designing of an Intelligent Fuzzy Logic System for Accretion Prevention in Sponge Iron SL/RN Rotary Kiln Based 100TPD Dri Process

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