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advances in rotary kiln sponge iron plant pdf

Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN IACSIT International Journal of Engineering and Technology, Vol. 6, No. 2, April 2014 ... sponge iron plant, which correlate four air inlets and twelve ... along the length of the kiln. To produce sponge iron, iron ore and coal are used as raw material. In the kiln coal is

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Simulation of Rotary Kiln Used in Sponge Iron Process

Simulation of Rotary Kiln Used in Sponge Iron Process

Simulation of Rotary Kiln Used in Sponge Iron Process Using ANN IACSIT International Journal of Engineering and Technology, Vol. 6, No. 2, April 2014 ... sponge iron plant, which correlate four air inlets and twelve ... along the length of the kiln. To produce sponge iron, iron ore and coal are used as raw material. In the kiln coal is

THE KRUPP SPONGE IRON PROCESS PRODUCTION

THE KRUPP SPONGE IRON PROCESS PRODUCTION

from the kiln consists of a mixture of sponge iron, surplus fuel, desulphurizing agent and ash, and is cooled down in a rotary cooler, mainly by ... ried out in the existing rotary kiln pilot plant furnish reliable design data as well as process characteristics for treating the raw materials in

Direct Reduced Iron Industry in India Problems and

Direct Reduced Iron Industry in India Problems and

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

PDF Spontaneous burning of sponge iron varun suri

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 ...

Advances in Rotary Kiln Sponge Iron Plant K K Prasad

Advances in Rotary Kiln Sponge Iron Plant K K Prasad

Advances in Rotary Kiln Sponge Iron Plant K. K. Prasad, Hem Shankar Ray on Amazon.com. *FREE* shipping on qualifying offers. Advances in Rotary Kiln Sponge Iron Plant

Energy survey of the coal based sponge iron industry

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.

Development of energy conservations scenarios for sponge

Development of energy conservations scenarios for sponge

Jan 16, 2011 Cost of sponge iron production varies with different inputs such as iron ore, coal, dolomite, fuel, maintenance, depreciation, power, etc. Costs of these inputs, taken directly from the plant, for 1 tonne production of sponge iron are drawn in Fig. 4, which shows that a significant component of total cost, i.e., 31.8% is due to coal.

Sponge Iron Iron Steelmaking

Sponge Iron Iron Steelmaking

Sponge iron is the product created when iron ore is reduced to metallic iron, in the presence of coal, at temperatures below the melting point of iron. The external shape of the ore is retained with 30% reduction in weight due to oxide reduction resulting in change in

PDF Industrial Applications of Rotary Kiln in Various

PDF Industrial Applications of Rotary Kiln in Various

CONCLUSION Rotary kiln is widely used in the production of cement clinker, Calcination of limestone, producing activated carbon, sponge iron production, metallurgical, minerals, food and sugar industries, it can also used as an incinerator and heat treatment system (dryer) for the process of liquid and solid hazardous and medical waste, drying ...

Direct Reduction Process an overview ScienceDirect Topics

Direct Reduction Process an overview ScienceDirect Topics

The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace, rotary kiln furnace or fluidised bed. Sponge iron can be produced in the form of Direct Reduced Iron (DRI), Hot Briquetted Iron (HBI) and Cold Briquetted Iron (CBI) also Low Reduced Iron (LRI), which is pre ...

PDF Aerodynamics inside a SpongeIron Rotary Kiln and

PDF Aerodynamics inside a SpongeIron Rotary Kiln and

Abstract. Sponge iron is being increasingly made using coal in a rotary kiln in India. In the design and operation of the kiln, aerodynamics plays an important role. So far, all adjustments of ...

Simulation of Rotary Kiln Used in Sponge Iron Process

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 ...

ENERGY INTEGRATION IN SPONGE IRON PLANT

ENERGY INTEGRATION IN SPONGE IRON PLANT

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.

Modelling and optimization of a rotary kiln direct

Modelling and optimization of a rotary kiln direct

Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 26 m in diameter and can be 50225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production. Hatch has developed a proprietary one-dimensional kiln model to

Project Proponent Ms BRGD Sponge and Iron Pvt Ltd

Project Proponent Ms 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.

Sponge Iron Review Iron Coal

Sponge Iron Review Iron Coal

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

Modelling and optimization of a rotary kiln direct

Modelling and optimization of a rotary kiln direct

In the case of a generic iron ore reduction kiln (Figure 1), Table I provides an overview of the parameters (and ranges) that are considered. Modelling and optimization of a rotary kiln direct reduction process by H.P. Kritzinger* and T.C. Kingsley* Synopsis Rotary kilns are used for a variety of mineral processing operations. Hatch

sponge iron Iron Coal

sponge iron Iron Coal

Iron ore tubes 12 // Advances in Rotary Kiln Sponge Iron Plant Fig. 2.5 Material balance in a rotary kiln sponge iron plant 2.4 FEATURES OF A ROTARY KILN SPONGE IRON PLANT Figure 2.4 indicates the essential features which are needed in the reduction kiln of a sponge iron rotary kiln plant.

status of sponge iron plant Orissa

status of sponge iron plant Orissa

3 Raw Material for sponge iron plant Coal Non-coking coal having certain important parameters is being used for the direct reduction of iron ore . Important factors determining coal quality are Chemical properties such as fixed carbon, ash content, volatile matter, etc. amp Physical properties viz, reactivity and ash fusion temperature. In Orissa scenario, all most all the sponge iron ...

PDF Rotary Kiln Manufacture Gary Li Academiaedu

PDF Rotary Kiln Manufacture Gary Li Academiaedu

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.

STUDIES ON POLLUTION CONTROL IN IRON BASED

STUDIES ON POLLUTION CONTROL IN IRON BASED

Sponge Iron plants. Since non coking coal is available in India, the sector largely depends on coal based sponge iron which contributes about 80 per cent of the total capacity in the country. Today, India has an installed capacity of 36.7 MTPA of sponge iron. Leading states in sponge iron production are Odisha, Chhattisgarh, West Bengal and ...

CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN

CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN

The ASL Sponge Iron unit at present consists of one rotary kiln of 500 TPD and the flue gas generated from the kiln is about 120,000 Nm3/hr at 950-10000C. Flue gas with high heat content is generated in the Rotary kiln in the Sponge iron plant during conversion of Iron Ore into Sponge Iron. The entire

rotary kiln design calculation pdf

rotary kiln design calculation pdf

Modelling and optimization of a rotary kiln direct . Rotary kilns are used for a range of mineral processing operations Kilns range in size from 26 m in diameter and can be 50225 m long with an operating mass of up to 3000 t Two of the most common applications are cement production and sponge iron production Hatch uses a proprietary onedimensional kiln model to evaluate designs for ...

rotary kiln spong iron Paula Rilke und Rodin

rotary kiln spong iron Paula Rilke und Rodin

Advances In Rotary Kiln Sponge Iron Plant Ebook 2009. Mathematical modellingin rotary kiln sponge iron making 51 what is a model 52 what is a mathematical model 53 how can we make a useful mathematical model 54 example of a small mathematical model 55 roal of coal in rotary kiln sponge iron making process 56 quantity of protective char 57 ...

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.

Sponge Iron Industry SlideShare

Sponge Iron Industry SlideShare

Nov 17, 2012 Raw DRI Process materials, partly coal, iron ore, After Burn Flue gas Chamber fluxes enter the rotary kiln The remainder Rotary kiln coal in 2.5% Slo and 0.47 rp pe powdered form m sp e e d and hot air is charged Preheating Solid iron and zone or unburnt char,combustion zone lime is where coal is heated discharged Cooler discharge and product ...

SPONGE IRON UNIT SEIL

SPONGE IRON UNIT SEIL

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 non-magnetic (char). The Sponge ...

Production of Iron amp Ferro Alloys Metallurgical and

Production of Iron amp Ferro Alloys Metallurgical and

K. K. Prasad amp H.S. Ray, Advances in Rotary Kiln Sponge Iron Plant Robert L. Stephenson, Direct reduced iron Technology amp Economics of production and use, 1980, Iron amp Steel Society of AMIE C. K. Gupta and A. K. Suri, Ferroalloys Technology in India, C. K. 1982, Milind Pub., New Delhi

Production of Direct Reduced Iron in Rotary Hearth Furnace

Production of Direct Reduced Iron in Rotary Hearth Furnace

Sep 23, 2011 This furnace has a capacity of 500,000 tons of sponge iron a year and is the largest such furnace in the world.5 br / At present India is the largest producer of sponge iron at 17 million tones/annum.4* br / 16.

Direct Reduced Iron and its Production Processes IspatGuru

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.

Integrated Steel Plant TMT Bar Manufacturing Plants

Integrated Steel Plant TMT Bar Manufacturing Plants

The inclination and the rotary motion of the kiln ensure that the raw materials move from the feed end to the discharge end of the kiln and during this movement the actual reduction of iron ore to iron takes place. The material discharged from the kiln is taken to a rotary cooler for cooling and the cooled product is separated from the coal char.

Dissolution of heavy metals from electrostatic

Dissolution of heavy metals from electrostatic

Sponge iron (Direct reduced iron) has a major role in the global steel industry. Over the past few years India has been the largest producer of sponge iron, majority of which are coal based. The manufacturing processes involve reduction of iron ore by using non-coking coal with small quantity of dolomite in a rotary kiln.

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