OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN B L SENGUPTA A B CHATTERJEA, , Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets Fig 1 , verised coal, oil or both or natural gas as fuel...
Abstract 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...
India is largest producer of Sponge Iron in the world Most of this production comes from secondary steel industry using rotary kiln process The design was initially introduced by Germany but later has been almost completely altered by Indian consultants and technology providers...
A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process Gas-based sponge iron is not subjected for magnetic separation DRC...
Major DRI production processes are either gas based or coal based Feed material in a DRI process is either iron ore sized to 10 to 30mm or iron ore pellets produced in an iron ore pellet plant In the gas based plant the reactor, the reduction reaction takes place is a shaft furnace...
sponge iron sl/rn rotary kiln based 100tpd dri process T Garikayi 1 , L Nyanga 2 , T Mushiri 3 , S Mhlanga 4 , PK Kuipa 5 1 Department of Manufacturing and Industrial Engineering...
and utilization of waste heat in a coal based sponge iron process Vivek , natural gas as reductant and therefore classified as coal based , gas from ESP outlet to rotary kiln an insulated duct, which is a hollow cylinder of 43m length and 06m diameter, is used To...
present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the remaining 115 plants are coal based Among all the available options, rotary kilns ,...
Rotary Kilns are commonly used for heat processing of minerals and aggregates such as lime, cement, and iron ore To achieve consistent quality results, it is important to maintain a uniform product temperature at the kiln entry, mid zone, and discharge...
Simulation of rotary kiln for sponge iron process is based on combustion of coal particles and reduction of iron ore The heat transfer inside the kiln is done through radiation The model equations used for computation of desired parameters, such as temperature profile and metallization, are tabulated in Table 3...
Iron ore tubes 12 // Advances in Rotary Kiln Sponge Iron Plant Fig 25 Material balance in a rotary kiln sponge iron plant 24 FEATURES OF A ROTARY KILN SPONGE IRON PLANT Figure 24 indicates the essential features which are needed in the reduction kiln of a sponge iron rotary kiln ,...
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 rata Iron and Steel Company Limited frISCO set up a rotary kiln based direct , encing the flow of materials in sponge iron rotary ....
During this time, the government also encouraged gas based sponge iron industry as there was surplus natural gas From 1985 to 1995, apart from few coal based plants, three large gas-based plants of Essar Steel Ltd with capacity of 360 MTPA, Vikram Ispat Ltd 090 MTPA Ispat Industries Ltd 160 MTPA also come into existence...
Sourcing Guide for Rotary Kiln China manufacturing industries are full of strong and consistent exporters We are here to bring together China factories that supply manufacturing systems and machinery that are used by processing industries including but not limited to kiln, drying equipment, cement machinery...
S Khanam et al/IntJ ChemTech R 2016,9 2 ,pp 20-34 21 parameters based on the desired output of the industry remains untouched These parameters include temperature profile inside the main units of the process which is kiln and flow rate of sponge iron production...
Direct-reduced iron DRI , also called sponge iron, is produced from direct reduction of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal The process of reducing the iron ore in solid form by reducing gases is called direct reduction...
11 Image of a Sponge Iron Granule 2 12 Microscopic view of sponge iron 4 31 Material Balance in a Rotary Kiln sponge iron plant 14 32 Energy Balance in a Rotary Kiln sponge based iron making 14 33 Schematic of optimised Rotary kiln sponge iron making process 21 41 Industrial view of Sponge Iron making Rotary Kiln 24 42 Schematic view of ....
The quality of sponge iron is dependent upon quality of raw materials used in the rotary kiln The optimum size of the ore used in the kiln is 8-20 mm The ore ,...
In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, India producing 57 of ,...
of energy in the coal based sponge iron industry by heat , coal and natural gas as reductant and therefore classified as , Further, waste gas from ESP is brought to the rotary kiln through a duct and a return duct is used to carry the waste...
Mar 20, 2007 The Comprehensive Industry Document on Sponge Iron Industry is one in the series that the Central namely coal based rotary kilns and gas based shaft furnace reactors The Retort/Tunnel Process...
Modelling and optimization of a rotary kiln direct reduction process HP Kritzinger and TC Kingsley , for cement production and sponge iron production , A calculation method was developed that allows for the prediction of the bed profile and residence time in a rotary kiln The method is based on the principle of granular movement in a ....
Dec 25, 2014 0183 32 Coal based DRI Sponge Iron plant using Rotary Kiln from Electrotherm...
natural gas as reductant and therefore classified as coal based and gas based processes, respectively Due to a promising , based sponge iron plant, an incredible amount of heat is , energy requirement for rotary kiln processes ranges between 1463 GJ/t to 209 GJ/t 7...
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 conveyor collects different size fractions of coal Stream no 5 for injection into the kiln with the help of pressurized air Stream no 4 from discharge end side...
The contribution of coal based sponge iron to the total production in India has remained above 60 per cent since 2004-05 The contribution of coal based sponge iron has been on the rise...
Ankit Metals Power Limited, Jorehira Prepared By - ARGHOJYOTI DEY APS - Asansol , Process Detail Sponge Iron Plant The Rotary Kiln or Reduction Kiln is a very important part of any Sponge Iron plant This is the place where , the form of reformed natural gas...
A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In , 32 Energy Balance in a Rotary Kiln sponge based iron making 14 , of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal The reducing gas is a mixture majority of hydrogen H 2...
Direct-reduced iron DRI , also called sponge iron, is produced from the direct reduction of iron In most cases the DRI plant is located near natural gas source as it is more cost effective to ship the ore rather than the Midrex Technologi...
According to different fuels, rotary kiln can be classified into gas-fired rotary kiln, oil-fired rotary kiln and coal-fired rotary kiln It is widely used for different materials with a processing capacity of 180-1, 000 tons per day, a dimension ofφ25 40m-φ48 68m and cement production capacity of 50-1000t/d, being easy to operate and ....