We designed and commissioned our first Sponge Iron plant of capacity 10,000 TPA near Hyderabad in 1995 and achieved rated production capacity from the first year onwards. ... DRI (Rotary Kiln): 100 TPD 175 TPD 350 TPD DRI (Tunnel Kiln) : 30 TPD 50 TPD 100 TPD Iron Ore Palletization : 500 TPD 1000 TPD 2000 TPD
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, …
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 bearing housing, Kiln/cooler girth gear, Kiln/cooler pinions, …
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 ...
A typical sponge iron plant has been investigated to find out the potential areas where energy is being wasted. To recover heat from these ... gas from ESP outlet to rotary kiln an insulated duct, which is a hollow cylinder of 43m length and 0.6m diameter, is used. To
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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 ... 2.1 Raw Materials for Rotary Kiln 5 2.2 Waste Heat Sources and Uses 11 2.3 Grading Of Waste Heat 12 2.4 High Temperatures waste gases 13 2.5 Medium Temperatures waste gases 14 ...
•Rotary Kiln equipment •Power plant equipment. •220KV System equipment •Right Mix of Coal Procurement •TPM Methodology/ Statistical Tools INPUTS ... Sponge Iron (DRI) Kilns 2007-2010 2 x 23 m 3 Micro Blast Furnace 2010-2011 Cold Briquetting Unit 2017-2018 6 MW Power Plant based on WHRB & AFBC 2017-2018 3 nos.
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 …
Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron …
IACSIT International Journal of Engineering and Technology, Vol. 6, No. 2, April 2014 Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN Anil K. Poonia and Shabina Khanam, Member, IACSIT These parameters include temperature profile inside the Abstract—In the present study, estimation of actual output main units of the process ...
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 ...
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 …
5 Figure 3: Granular flow regimes and the Froude number associated with each bed movement [13] Yin et al. [14] stated that the flow into the active layer depends mainly on both the Froude number (Fr = ω2R/g, where ω is the angular velocity of rotation and g the acceleration of gravity) and size ratio ( O= ã/, where ã is the particle diameter and the …
The employed fuels are natural gas and/or coal. The energy consumption is in the order of 10.4 GJ/t-DRI that is equivalent to 300 m 3 of natural gas per ton of reduced iron. The CO 2 emissions are quantified in the range 0.77–0.92 t of CO 2 per ton of steel. As a function of the employed reducing reactors, the systems are of four main types:
1. Less capital cost: The capital cost per tonne of installed capacity, in case of coal-based plants, is 1.8–2 times as high as in the gas-based plants.. 2. High productivity: The throughput rates for gas-based sponge iron plants are much higher than in coal-based plants.The productivity for gas-based plants can be as high as 11 t/m 3 /day as against …
Figure III showsproduction pro cess of sponge iron in a co al based rotary kiln us ing customized/ indigenous t echnology a long w ith sour ces o f air emissio n, liquid eff luent and so lid waste ...
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 package …
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 …
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 …
In sponge iron plant, rotary kiln is used to manufacture iron billets from combustion of coal and iron ore. Waste flue gas emitted from the rotary kiln has a temperature of 700°C and above. Gas cooler is required to cool the gas to the acceptable level.
The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon dioxide and entrained dust.
The rotary cooler and magnetic separator in a conventional sponge iron plant can be replaced with a gravimetric separator enabling hot charging of sponge iron to the steel-making furnace.
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 …
The rotary kiln sponge iron has lower metallisation (about 85 — 88% on the average) and low carbon content (0.1-0.2%) compared to gas based sponge iron (Metallisation of 92 — 94% and carbon content ... DRI producers as joint venture, as individual plant requirements are generally small, which will ensure availability of quality input at ...
(DRI) fines/briquettes for steel making' and IS 13905:1993 'Hot briquette sponge iron (HBI) for steel making'. With the formulation of this standard IS 10812: 1992, IS 13839: 1993 and IS 13905: 1993 stand withdrawn. In this revision, the carbon content for rotary kiln DRI/sponge iron has been modified to around 0.1 percent apart
This produces highly metalized direct reduced iron using rotary kiln. Here solid, liquid and gaseous fuels are used directly in the kiln. The ACCAR process started in ... TATA steel established a sponge iron plant in Keonjhar Dist. Of Odisha. The TDR technology uses a rotary kiln of 4.2mtr internal diameter and 72mtr long. The temperature of ...
Download scientific diagram | Schematic flowsheet of rotary-kiln sponge iron process. from publication: Comprehensive Utilization of Iron-Bearing Converter Wastes | …
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.
Sponge Iron and Coal Char are discharged from the kiln through a 12 meters long rotary cooler where water is sprayed directly as well as indirectly for cooling the material down to 100oC. The material is then …
