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SPONGE IRON PLANT

Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are 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

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

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

A Thesis Submitted for Partial Fulfillment of the Degree

3.1 Material Balance in a Rotary Kiln sponge iron plant 14 3.2 Energy Balance in a Rotary Kiln sponge based iron making 14 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

Rotary Kiln Maintenance Procedures

rotary kiln operations. Regardless of rotary kiln size or configuration the basic principles outlined in this manual govern the reliable operation of every rotary kiln, calciner, dryer, incinerator, digester and cooler application. For questions or problems with your specific application please contact North American Kiln

Simulation of Rotary Kiln Used in Sponge Iron Process

parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. 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

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to

Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is

DRI UPDATE Sponge Iron Manufacturer India

2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the R&D 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

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN DATA

producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near

ENERGY INTEGRATION IN SPONGE IRON PLANT USING HEAT

In the present work a system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 C.

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

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

II. 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 around 80 m long with 4 m

Energy Audit Methodology of Sponge Iron Manufacturing

Jul 14, 2014 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 and secondary airs are supplied to the Kiln to initiate the combustion and reaction processes. The reaction takes place at high temp (1050 to 1065˚C ˚C).

ENERGY INTEGRATION IN SPONGE IRON PLANT USING

In the present work a system is designed to integrate the heat of waste gas in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 C.

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN

producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near

Project Proponent M/s BRGD Sponge and Iron Pvt. Ltd.

5.1 SPONGE IRON PLANT There is a plan to install 4x100 TPD DRI kilns for production of 1,20,000 TPA sponge iron. Manufacturing Process The proposed plant uses the coal based process in which iron oxide in pellet/iron ore will be reduced with non coking coal in a rotary kiln to make sponge iron.

EDITORIAL Sponge Iron Manufacturer India

kilns using pellets give higher throughput compared to kilns using iron ore. Reduced fines and uniform size together create a condition that allows kilns to be filled more and faster. Arguably, iron ore feeds can achieve equally high throughput, if the iron ore is good in strength and more uniform in size.

Accretion Control in Sponge Iron Production Kiln using

This study focuses on sponge iron kiln based process. The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of non-coking coal [Patra et al, (2005)]. The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

Bhagwati Sponge Private Limited

+1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.

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.

sponge iron process

Jul 29, 2010 In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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.

Sponge Iron Prakash Industries Limited

Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel

(PDF) Rotary Kiln Manufacture Gary Li Academia.edu

Dajia 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, dolomite, bauxite, sponge iron and other materials, it uses hot gases for the operation.

SPONGE IRON UNIT SEIL

Iron Ore and Coal are drawn with the help of weigh feeders in the required quantity and proportion and fed on to common conveyor. These raw materials enter into the rotary kiln through a feed chute. 4. The rotary kiln is 70 meters in length and 4.4 meter in diameter. This kiln

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Detailed operation of this plant is discussed in the work of Prasad et al. [2011]. The operating parameters for this process are shown in Table 1. Fig. 1 Process flow diagram of the sponge iron process with material and energy balanced data ROTARY KILN (RK) (900 C) (1020 C) Total air Flue gas Kiln Feed RC Sponge iron Water Hot Water

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

II. 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 around 80 m long with 4 m

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN

producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near

Study on Air Tubes Failure in Sponge Iron Rotary Kiln

Keywords: Sponge Iron, Heat Transfer, Rotary Kiln . 1. Introduction . In Rotary kiln, carbon is charged from either end, in one end in the form of coal particles and in another in form of coal lumps. The coal reacts with air to form carbon monoxide which then reduces iron oxide (ore) to iron. So, in a kiln,

EDITORIAL Sponge Iron Manufacturer India

kilns using pellets give higher throughput compared to kilns using iron ore. Reduced fines and uniform size together create a condition that allows kilns to be filled more and faster. Arguably, iron ore feeds can achieve equally high throughput, if the iron ore is good in strength and more uniform in size.

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

Detailed operation of this plant is discussed in the work of Prasad et al. [2011]. The operating parameters for this process are shown in Table 1. Fig. 1 Process flow diagram of the sponge iron process with material and energy balanced data ROTARY KILN (RK) (900 C) (1020 C) Total air Flue gas Kiln Feed RC Sponge iron Water Hot Water

Krishna Iron Steel & Power Pvt. Ltd.

1.2.1 Sponge Iron (DRI) Refractory lined rotary kilns will be used for reduction of iron ore in solid state. A central Burner located at the discharge end will be used for initial heating of the kiln. Iron ore will be continuously fed into the kiln along with coal which has dual role of fuel as well as reductant.

(PDF) Spontaneous burning of sponge iron varun suri

As touched upon earlier, sponge iron is mainly produced from ore by two different routes -(a) By reducing gases (CO and H 2 ) in a shaft furnace (b) Through direct treatment with coal in a rotary kiln.Sponge Iron:-Sponge iron is the metallic product formed by the reduction (removal of oxygen) of iron ore at temperature below the fusion point of

Bhagwati Sponge Private Limited

+1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.

Sponge Iron Prakash Industries Limited

Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel

sponge iron process

Jul 29, 2010 In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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.

Energy survey of the coal based sponge iron industry

Sep 01, 2015 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.

sponge iron flowchart pdf capecoralferienhausverwaltung.de

status of sponge iron plant, Orissa. Fig. 1 Process Flow Chart For Sponge Iron Unit Raw material feeding at ground hopper (Coal, Ore) Coal Sized Iron ore Crushing Crushing Screening Screening Over size Over size Coal bin Iron ore bin Setting up of Production of mixed raw materials for kiln feed Dolomite bin Processed in rotary kiln at 10000C Indirect cooling in rotary cooler with water spray

Direct Reduced Iron and its Production Processes IspatGuru

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 so as to prevent its re-oxidation.

[PDF] Simulation of Rotary Kiln Used in Sponge Iron

In the present study, estimation of actual output parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. 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