(PDF) Mathematical Modelling of Sponge Iron Production in …
This paper highlights how mathematical modelling of heat transfer and reaction kinetics in a rotary kiln processing iron ore to metallised iron can useful for scaling up a pilot kiln to...
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(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln …
In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.
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An Investigation on the Cracking of Air Tubes of Rotary Kilns …
Abstract 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 ...
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Analysis of temperature profile and % metallization in rotary kiln …
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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Rotary kiln process: An overview of physical …
The rotary kiln is a slightly inclined steel cylinder that rests on supports (bearing rollers) with an interior lining; it is equipped with a rotating motor that induces a turning motion.
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Computational fluid dynamics analysis of sponge iron rotary …
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 output …
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(PDF) Analyses of Different Modifications Proposed for the Sponge Iron …
Prasad et al. (2013) designed a gas carrying duct and rotary drier for utilization of waste heat in a sponge iron plant, which reduced the load on the kiln by 13.15% in comparison to the existing one to produce 1 tonne DRI. Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury ...
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[PDF] Simulation of Rotary Kiln Used in Sponge Iron …
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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An Investigation on the Cracking of Air Tubes of Rotary Kilns …
Abstract. 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 ...
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OPERATIONAL ASPECTS OF SPONGE IRON …
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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ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …
India is the largest producer of direct reduction of iron (DRI), popularly known as sponge iron and accounted for about 39.3% of the global production in 2020. India's growing …
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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 reduction takes place using …
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Coal & Gas based DRI Plant
Approx. Rs 12 Lakh / Number Get Latest Price. 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 ...
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Conventional and AI Models for Operational Guidance and
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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A review of ironmaking by direct reduction processes: …
However, for coal-based DR the reductant is generated from non-coking coal and rotary kilns, rotary hearth furnaces and multi-hearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 65-75% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
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Operation of Coal-Based Sponge Iron Rotary Kiln to …
Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation. AISTech 2019 — Proceedings of the Iron & …
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Sponge Iron Production in Rotary Kiln
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 …
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Rotary kiln process: An overview of physical mechanisms, …
The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1].The rotary kiln is a slightly inclined steel cylinder that rests …
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(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to …
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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Rotary kiln process: An overview of physical …
1. Introduction. The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1].
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SPONGE IRON PLANT
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 ac variable speed motor at a steeples variable speed ranging form 0.2-1.0 rpm. Due to inclination and rotary motion of the kiln, the material moves form feed end to discharged end in about 7-8 hrs.
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[PDF] Modeling of rotary kiln for sponge iron processing …
CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD …
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CARBON RECOVERY FROM SPONGE IRON PLANT DUST
CARBON RECOVERY FROM SPONGE IRON PLANT DUST. Mar 17, 2013 • Download as PPT, PDF •. 8 likes • 5,199 views. RADE INITIATIVE. India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP …
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Evaluation of new equipments for utilization of waste heat in sponge …
The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the present energy integration investigations, two scenarios: 1 and 2 are proposed and compared with the existing one. During the operation in coal-based sponge iron plant, …
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OPERATIONAL ASPECTS OF SPONGE IRON …
ROTARY KILN—SOLID REDUCTANT PROCESSES 1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores …
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Schematic diagram of plant and the rotary kiln (see arrow) …
It has been shown earlier that the sponge iron rotary kiln is a chaotic, dynamical (nonlinear, time-varying) system [4][5] [6] [7][8]. The present work is the first application of both OSAA and ...
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Steel Exchange India Ltd
The company is able to manufacture 0.225 MTPA of Sponge Iron per annum. Each Rotary Kiln is 70 meters long, 4.4 meters wide and inclined at 2.5%. The kilns each have a thick 250mm refractory lining inside, 3 support rollers and a dual drive with two 155 kW DC Motors. Each Kiln also has seven shell air fans and air tubes for air supply inside ...
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An Investigation on the Cracking of Air Tubes of Rotary Kilns …
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 …
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Sponge iron manufacturing process pdf
Sponge iron making process pdf – WordPress. Sponge iron making process pdf Rotary Kiln Process of Making Sponge Iron. The production of steel began in ancient times but because of the complexity and. Rotary The process flow diagram of conventional coal based sponge iron plant is shown in figure 1.
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Flow of materials in rotary kilns used for sponge iron …
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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