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Sponge Iron Making Process Rotary Kiln Pdf

Oct 28, 2021

Sponge iron is the product generated by direct reduction of iron ore with aid of either carbon or natural gas under controlled temperatures and pressures within a rotary kiln. However the performance of rotary kilns is usually adversely affected by

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  • PRESENT STATE OF THE SL / RN PROCESS AND ITS
    PRESENT STATE OF THE SL / RN PROCESS AND ITS

    self-explanatory; under certain conditions sponge iron can actually compete with scrap for steel-making. 4. Description of a few SL/RN and Lurgi Rotary Kiln Plants The reduction plants based on natural gas built so far have in most cases been set up within PROCUCTION COST OF STEEL EOLLETS [OM J t) INFLUENCE OF SPONGE IRON AND POWER

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  • Energy Audit Methodology of Sponge Iron
    Energy Audit Methodology of Sponge Iron

    Jul 14, 2014 Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary

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  • DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A
    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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  • Sponge Iron - an overview | ScienceDirect Topics
    Sponge Iron - an overview | ScienceDirect Topics

    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 gaseous reductants (CO + H

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  • (PDF) i) Direct Reduced Iron: Production
    (PDF) i) Direct Reduced Iron: Production

    Mar 30, 2016 decades, a new route of ironmakin g has rapidly developed for direct reduction (DR) of iron ore to. metallic iron by using noncoking coal/n atural gas. This product is known as direct reduced iron

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  • Sponge Iron | Iron | Steelmaking - Scribd
    Sponge Iron | Iron | Steelmaking - Scribd

    Gas-Based Process: This process utilizes natural gas as the reducing agent. Natural gas is reformed to enrich with H2 and CO mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process

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  • Coal based Direct Reduction Rotary Kiln Process – IspatGuru
    Coal based Direct Reduction Rotary Kiln Process – IspatGuru

    Feb 14, 2017 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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  • material balance of gas based sponge iron
    material balance of gas based sponge iron

    What is material balance in sponge iron production. Material balance in sponge iron is nothing but calculating input chargeing material into the roatary kiln comparing to the outputOutput refers the DRI,Gases,Ash,Char,Dolo Char,Lumps,FinesBHQ if

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  • Energy survey of the coal based sponge iron industry
    Energy survey of the coal based sponge iron industry

    Sep 01, 2015 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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  • Sponge Iron Production In Rotary Kiln By Sarangi Arabinda
    Sponge Iron Production In Rotary Kiln By Sarangi Arabinda

    Sponge Iron Production In Rotary Kiln Pdf. Sponge iron production in rotary kiln The cooler is also inclined at 2 The largest improvements would be made by design modifications adopting a novel energy conservation scenario by process

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  • New Sponge Iron Rotary Kiln Design In Sponge Iron
    New Sponge Iron Rotary Kiln Design In Sponge Iron

    Sep 10, 2020 During the sponge iron manufacturing process, hot air enters through the air tube and air nozzle of the sponge iron kiln, providing heat for the reaction. The waste gas produced by the rotary kiln first enters the dust settling chamber, and the settled dust is finally discharged by the scraper. The treated exhaust gas can enter the waste heat

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  • SPONGE IRON FROM MAGNETITE – A NOVEL PROCESS
    SPONGE IRON FROM MAGNETITE – A NOVEL PROCESS

    Oct 12, 2021 Sponge Iron production usually employs the DRI Process, undertaking solid state reduction of hematite ores with equal proportions of coal. This is brought about by the use of a coal fired Rotary Kiln, with the environmental impact of the entire process putting Sponge Iron plants under ‘Red Category’ industries

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  • Development of energy conservations scenarios for sponge
    Development of energy conservations scenarios for sponge

    Jan 16, 2011 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 rotary kiln

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  • 2 D Model of Sponge Iron Rotary Kiln Developed Using
    2 D Model of Sponge Iron Rotary Kiln Developed Using

    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

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  • USE OF SPONGE IRON - NIT Jamshedpur
    USE OF SPONGE IRON - NIT Jamshedpur

    Problems of Rotary Kiln process a)Low productivity. b)Building up of accretions or ring formation. c)Erratic operation. d)Heat loss through exit gas. e)Sponge iron contains low carbon. Minimization of these problems: a)Low productivity-Productivity can be improved by: 1)High reactivity coal can be used. 2)Pick up of ore with high reducibility

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  • IS 15774 (2007): Sponge Iron/Directed Reduced Iron
    IS 15774 (2007): Sponge Iron/Directed Reduced Iron

    (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

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  • GODAWARI POWER & ISPAT LTD
    GODAWARI POWER & ISPAT LTD

    Scope & Areas for Energy Conservation in Sponge Iron Making Scope 4 Feed material as well as air enters the process (mainly rotary kiln) at ambient temperature and reduction reactions are taking place at 1080-1100 C. This requires feed to be heated up which needs the significant amount of heat generated from combustion of coal. This

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  • Recovery and utilization of waste heat in a coal based
    Recovery and utilization of waste heat in a coal based

    reduction technology has emerged as a potential process for iron and steel making. ∗ Corresponding radial author. Tel.: +91 661 2462267; fax: +91 661 2462999. ... Coal-based sponge iron process ... gas from ESP outlet to rotary kiln an insulated duct, which is a hollow cylinder of 43m length and 0.6m diameter, is used

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  • free download sponge iron production in rotary kiln book
    free download sponge iron production in rotary kiln book

    Rotary Kiln Process of Making Sponge Iron. Rotary Kiln Process of Making Sponge Iron … discussed later in this book. … Fig. 2.8 Another comparison of sponge iron production of India and World indicating More detailed

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  • Modelling and optimization of a rotary kiln direct
    Modelling and optimization of a rotary kiln direct

    The kiln model applied in this work was developed by Hatch over a number of years and has been used for several rotary kiln projects. It has its roots in a FORTRAN program that was developed by Venkateswaran (1978) to study the reduction of iron ore. The original software was used to model the operation of a 35 m pilot kiln at the Stellco company

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  • Direct Reduced Iron and its Production Processes –
    Direct Reduced Iron and its Production Processes –

    Mar 16, 2013 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 is drawn off from the bottom after cooling it

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  • SPONGE-IRON - Shakambhari Group
    SPONGE-IRON - Shakambhari Group

    Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with consistent chemical & physical characteristics

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  • Rotary Kiln Process of Making Sponge Iron C
    Rotary Kiln Process of Making Sponge Iron C

    10 // Advances in Rotary Kiln Sponge Iron Plant A typical process scheme for making sponge iron in a rotary kiln is presented in Fig. 2.1. While Fig. 2.1 shows only the key steps, a more detailed scheme, as it would appear for a typical operating plant, is presented in Fig. 2.2. 2.3 SPONGE IRON PILOT PLANT OF RDCIS SAIL

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  • OPERATIONAL ASPECTS OF SPONGE IRON
    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 iron

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  • SPONGE IRON PLANT
    SPONGE IRON PLANT

    The rotary kiln process chosen for the unit considers reduction of iron ore (5-20 mm) with solid carbonaceous material like coal heated up to a temperature of 950-10000c in rotary kiln and then. www.spongeitc.com 10. cooled in a rotary cooler with external water cooling system

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

    The sponge iron is produced in the form of lumps as well as fines. The production of sponge iron depends on metallization of iron ore. Fig. 1. Schematic of rotary kiln For the present work data of a typical industry of 527 T/day production capacity is collected for 25 days. The data of temperature T-1 to T-12, AT-1 to AT-3 and MF-1 and

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  • (PDF) Modeling of Rotary Kiln for Sponge Iron
    (PDF) Modeling of Rotary Kiln for Sponge Iron

    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 Under the supervision of

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  • (PDF) Operation of Coal-Based Sponge Iron Rotary
    (PDF) Operation of Coal-Based Sponge Iron Rotary

    Also, the process conditions in a sponge iron rotary kiln are dynamic in nature. Hence, the quality keeps fluctuating and is not a constant value. A mathematical mass

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  • A Thesis Submitted for Partial Fulfillment of the Degree
    A Thesis Submitted for Partial Fulfillment of the Degree

    3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

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  • SPONGE IRON PRODUCTION FROM ORE -COAL
    SPONGE IRON PRODUCTION FROM ORE -COAL

    However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns

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  • Coal based Direct Reduction Rotary Kiln Process –
    Coal based Direct Reduction Rotary Kiln Process –

    Feb 14, 2017 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

    Get Price
  • (PDF) Mathematical Modelling of Sponge Iron
    (PDF) Mathematical Modelling of Sponge Iron

    The mathematical model was customized and validated with data from one of the industrial scale rotary kilns at Tata Sponge Iron Limited (TSIL) and

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