rotary kiln iron design sponge

Operational Guidance And Control Of Sponge Iron Rotary Kilns At TATA Sponge, Soft Computi ng for Problem Solving , SocProS 2017, Advances in intelligent sy stems and computing 816 , Ed. J

Coal Based Rotary Kiln for Direct Reduced Iron Sponge Iron 100 TPD, 350 TPD, 500 TPD Solid state reduction of Iron Ore using either coalgas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron DRI.

Direct reduced iron DRI, also called sponge iron,1 is produced from the direct reductionof iron ore in the form of lumps, pellets, or fines to iron by a reducing gas or elemental carbon

The coal base DRI rotary kiln process for production of DRI Sponge Iron has its many parameters to increase the quality as well as productivity which need careful operations throughout the process. Number of DRI processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world.

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.

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.

Iron ore and noncoking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 9501050 o C.

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 amp material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

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, commercially used DR direct reduction processes and physicochemical principles of sponge iron production.

Modeling of Rotary Kiln for Sponge Iron Processing ethesis 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 successfully manufactured in various parts of the world through either natural gas or coalbased lining, support tyres and rollers, drive

The results showed that the rotary kiln could be divided into three major functional zones reduction of hematite to wstite occurred at 10231163 K wstite transformed to fine metallic iron

Heat Recovery from Rotary Kilns Heat recovery system. A heat recovery system that captures heat lost from rotary kiln surfaces in cement, paper and sponge iron plants and putting it to useful work. The outside surface temperature of the kiln ranges from 200300C.

Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation.

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

The final induration is accomplished in a rotary kiln, wherein the principal heat transfer mechanism is radiation from the system39s main burner. There are two main processes for producing iron ore pellets The GrateKiln system and the straight grate system. In the straight grate system, a continuous parade of grate cars moves at the same speed

Rotary kiln is the primary equipment in sponge iron industry, which is used to reduce iron ore to metallic iron i.e. Fe. It is called sponge iron. Rotary kiln is widely used in cement and steel industries. The production capacities of these industries depend significantly on the performance of rotary kiln.

6. The product i.e. Sponge Iron and semi burnt coal are discharged from the kiln through a rotary cooler. The cooler is 12M in length and water is sprayed directly as well as indirectly for cooling the material. The material is cooled down to 100oC and fed to magnetic separator for separating the sponge iron and nonmagnetic char. The Sponge

2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the RampD for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed

In general sized iron ore of 518mm is used in the process of manufacture of sponge iron on all types of rotary kiln with 16mm not exceeding 1520.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.