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.
Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...
During the last four decades, a new route of ironmaking has rapidly developed for direct reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas. This product is known as ...
utility of sponge iron in other steel manufacturing processes like L.D. Converters, Open Hearth Furnaces (OHFs), Blast Furnaces (BFs) & Basic Oxygen Furnaces (BOFs), Induction Furnaces (IFs) and Cupolas. 1.2 Rotary Kiln Operation Generally in any sponge iron process, reduction is conducted in a refractory lined rotary kiln.
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
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 coal-based lining, support …
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 the formation of accretion. This accumulation of sintered solid particles which form rings
Sponge Iron Production in Rotary Kiln - Kindle edition by Sarangi, A. Sarangi, B.. Download it once and read it on your Kindle device, PC, phones or tablets. Use features like bookmarks, note taking and highlighting while reading Sponge Iron Production in Rotary Kiln.
(DRI). Sponge iron is produced primarily both by using non-coking coal and natural gas as reductant and therefore classified as coal based and gas based process respectively. Due to a promising availability of coal, the coal based sponge iron plants share the major amount of its production.
Direct-reduced iron (DRI), also called sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. The reducing gas is a mixture majority of Hydrogen (H2) and Carbon Monoxide (CO) which acts as reducing agent.
suffering because non availability of natural gas. These units are unable to use imported LNG ... Coal based Sponge Iron Industry is highly energy intensive industry. The thermal energy consumption ... Reduction of surface temperature of Rotary Kiln. 6. Efficiency of thermal processes can be optimized
This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is 'directly reduced' in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces ...
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, Kiln/cooler pinion shaft, Kiln ...
Tunnel Kiln – Electrotherm Engineering And Technologies [PDF]SPONGE IRON PRODUCTION FROM ORE COAL COMPOSITE tunnel kiln design for reduction of ores USA Equilibrium atmosphere tunnel kilns for [PDF]Energy Efficient Tunnel Kilns with Superlative Firing tunnel kiln technology Tunnel Kiln – Electrotherm – Engineering Technologies DRI (Tunnel Kiln) View Specifications Details of Tunnel ...
Simulation of rotary kiln for sponge iron process is based on combustion of coal particles and reduction of iron ore. The heat transfer inside the kiln is done through radiation. The model equations used for computation of desired parameters, such as temperature profile and …
Sponge iron production by tunnel kiln method was developed from 1911 as Höganäs method in Sweden. After many modifications, now this process is a sufficient and effective method for sponge iron production. ... using different grades of coal and natural gas as the process main fuel are advantages of sponge iron production in tunnel kiln.
Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3. Kiln temperature distribution for the base case The feed material (bed) enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard.
Abstract. Prediction models for temperature, pressure, and quality control in rotary sponge iron kilns are developed from operational data. The conventional and AI-based methods which are used to develop the models include extreme learning machine (ELM), artificial neural net (ANN), and multiple linear regression (MLR).
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 …
Nov 09, 2014· Sponge iron making process ... ROTARY KILN 9. ROTARY KILN 10. ROTARY COOLER The product come to the water cooled Where its temperature reaches to 80-100 C 11. ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot ...
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.
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.
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 ...
SPONGE IRON INDUSTRY - bankruna. 309 SL / RN Process (Outcompu), later natural gas is used to reduce the iron ore For coal based rotary Kiln ... Midrex ® Natural gas based, HYL ® Natural gas based, Rotary kiln and Rotary, The SL/RN ® rotary kiln process that was built in the .
steel plants. The gas based DRI plants started coming up with the availability of natural gas. As per the statistics available, in year 2011, 55 million ton DRI was produced through gas based plants and 19 million ton DRI through coal based rotary kilns. GAS Based DRI 76 % World DRI Production Coal-based COAL Based DRI 24%
Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, 500 TPD) Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI).
Sponge iron is made either by using coal or natural gas. It is coal based sponge iron that is still the primary method of obtaining sponge iron in India. This is because India has a shortage of natural gas while there is an abundance of coal in the country. ... A burner is used to heat the contents inside this rotary kiln.
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 around 80 m long with 4 m
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