Sponge iron production in rotary kiln kindle edition by sarangi, a. A thesis submitted for partial fulfillment of the degree. 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 8001200 c. This process utilizes natural gas as the reducing agent. Nov 09, 2014 making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The rotary kiln process is a commonly practiced method in the industry for producing sponge iron using coal. Fluorite ore sponge iron rotary kiln meipaly heavy.
Dri is also known as sponge iron, it is a solidstate direct reduction process fig. Flow of materials in rotary kilns used for sponge iron. The process of reducing the iron ore in solid form by reducing gases is called direct reduction. Process making sponge iron rotary kiln the process of sponge iron making aims to remove oxygen from iron ore the reduction of iron ore as against a rotary kiln in coal based sponge iron process get price full text pdf jstage journals click to view rotary kiln electrotherm. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Consequently, they were replaced by the high production rate indirect process, and the development of modern dr process did not begin until the middle of 19th century. Pdf operability analysis of direct reduction of iron ore by. Expired lifetime application number us700181a inventor john p riott original assignee john.
Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Pdf the present paper deals with 2d cfd model of rotary kilns employed in. Raw material mixiron 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. Rotary kiln is widely used in cement and steel industries. In lowtemperature processes, and in the cooler parts of long kilns lacking preheaters, the kiln is often furnished with internal heat exchangers to encourage heat exchange between the gas and the feed.
The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Sponge iron production in rotary kiln pdf free download. Microstructural degradation occurring at high temperature affects mechanical and corrosionresistance. The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. Misra and ipicol 3, 4 examined the sponge iron manufacturing process and observed. Most of those cases have concentrated on those air tubes which. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a selectgrade of ironcoking coal little dolomite inside an inclined rotary kiln and control busted in the presence of air for about 12 hours before the products are air cooled magnetically separated. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. Coal is used as a reducent for sponge iron making in.
The rotary kiln process is a commonly practiced method in india for. Sponge iron production in rotary kiln foticrociere. Alibaba offers 587 sponge iron rotary kiln products about 71% of these are cement making machinery, 8% are other mining machines, and 1% are industrial furnace. Sponge iron production in rotary kiln pdf rotary kiln process of making sponge iron sponge get price f cover sponge iron india sep 10 2012 and induction furnace for steel. Us2462900a us700181a us70018146a us2462900a us 2462900 a us2462900 a us 2462900a us 700181 a us700181 a us 700181a us 70018146 a us70018146 a us 70018146a us 2462900 a us2462900 a us 2462900a authority us united states prior art keywords reduction sponge iron iron rotary kiln sponge prior art date 19460930 legal status the legal status is. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. Energy survey of the coal based sponge iron industry sciencedirect. The cold model study was conducted with iron ore as the feed material to determine the influence of length to diameter ratio ld of a rotary kiln on the filling degree, holdup, and residence time of the charge. In the industry, there have been recent reports of premature failures of certain air tubes in a rotary kiln. Scribd e il piu grande sito di social reading e publishing al mondo.
Operation of coalbased sponge iron rotary kiln to reduce accretion formation and. Chamber fluxes enter the rotary kiln the remainder rotary kiln coal in 2. Energy audit, dri process, sponge iron, kiln efficiency, sankey rotary kiln and product sponge iron along with char is taken out from the other end to the kiln in the process of making 1 kg sponge iron is 388984 kcal. Rotary kiln process of making sponge iron new age international. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from the other end. Kumar 2 1indian institute of technology kharagpur, kharagpur, west bengal, india 2hsbc indiaformerly with iit kharagpur, bangalore, india abstract introduction. Energy balance in a rotary kiln sponge based iron making. Nov 23, 2017 walk by inspection of a sponge iron kiln yes guys kiln in cement and sponge iron isnt the samesee it to believe it. Study on air tubes failure in sponge iron rotary kiln ankit1, t. Process making sponge iron rotary kiln aircondicoz.
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 integration and thereby decreasing the coal and water consumption and by decreasing the cold fresh air. An investigation on the cracking of air tubes of rotary. Widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation. One of the major challenges for sponge iron plant is the accretion formation. A thesis submitted for partial fulfillment of the degree award of. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes choudhury, 2014. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. This book deals with the basics of sponge iron production in rotary kiln, describing the operational problems and control needed to produce a quality product. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. Sarangi, b download it once and read it on your kindle device, pc, phones or tablets.
The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. An investigation on the cracking of air tubes of rotary kilns. Pdf 2 d model of sponge iron rotary kiln developed using cfd. Coal is used as a reducent for sponge iron making in the furnace. An empirical equation correlating different operating variables has been derived on. The material of the air tube is astm a297 hk 40, a member of the heatresistant cast alloy family h series steels widely used for enhanced hightemperature properties. Pdf quality prediction and control in coalfired rotary. Sponge iron production in rotary kiln pdf rotary kiln process of making sponge iron the production of steel began in ancient times but because of, sponge iron thermocon sipl is operating 4 x 100 tpd direct reduced iron rotary kilns for production of 2000 tpa sponge iron at purulia, using the. Study on accretion formation on dri kiln during spong iron. Rotary kiln cement rotary kiln and sponge iron rotary kiln. An empirical equation correlating different operating variables has been derived on the basis of. The availability of scrap of required quantum is unlikely and therefore scraps needs to be. Because of their regular size and shape, and their hard, dense nature, pellets were considered an ideal feed material for.
Books about hand book of sponge iron making in rotary kilns by p c pradhan. Sep 28, 2011 cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. Operation of coalbased sponge iron rotary kiln to reduce accretion formation and optimize quality and power generation. Operability analysis of direct reduction of iron ore by coal in an industrial rotary kiln. New technology tunnel kiln to make sponge iron ro7bx. Process making sponge iron rotary kiln ore crusher. Us3096172a rotary furnace production of sponge iron. Operation and construction details a schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in fig. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. In the present work, several challenges faced in sponge iron production have. Natural gas is reformed to enrich with h2 and co mixture and this enriched and reformed gas mixture is preheated in gasbased process. Generally, an ebook can be downloaded in five minutes or less.
In the industry, there have been many recent reports of premature failures of certain air tubes in a. Direct reduction process an overview sciencedirect topics. Sponge iron rotary kiln process anticorruption helpline. In this pilot plant, a totally indigenous technology for production of sponge iron has been developed in which noncoking coal is essentially used as the reductant. The reduction is carried out in a rotary kiln of a predetermined temperature and controlled atmospheric pressure. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Modelling and optimization of a rotary kiln direct. Walk by inspection of a sponge iron kilnyes guys kiln in cement and sponge iron isnt the samesee it to believe it.
Sand making machine sponge iron making process rotary kiln. 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. Modeling of rotary kiln for sponge iron processing using. Advances in rotary kiln sponge iron plant free pdf free pdf free download free pdf ebooks with advances in rotary kiln sponge iron plant free pdf free ipad and nook in pdf format for free download. Method for the production of low sulfur sponge iron buehl, russell c. Pollution in the coal based sponge iron industry in india. Rotary kiln is the key equipment in rotary kiln process,rotary kiln refers to rotary calcining kiln which belongs to building material equipment. Nov 12, 2012 hand book of sponge iron making in rotary kilns. The iron ore along with coal is charged into the kiln and air tubes located along the length supply the air for combustion. In sponge iron industry rotary kiln is the primary eq uipment. Study on air tubes failure in sponge iron rotary kiln. More than 100 dr processes have been invented and operated since 1920. If you continue browsing the site, you agree to the use of cookies on this website.
Operation of coalbased sponge iron rotary kiln to reduce accretion formation. Rotary kiln is cylindrical in shape and is 80m long having 4. This is the reactor of the process where reduction as well as combustion reactions are carried out. Tunnel kiln for sponge iron production boucheriedujardinbe. Rotary furnace production of sponge iron download pdf info publication number us3096172a. Pdf operation of coalbased sponge iron rotary kiln to reduce. New technology tunnel kiln to make sponge iron, nov 22, 2011 case group has set up indias first dri sponge iron unit using tunnel kiln the kiln which is 194m in length, is the longest in india was successfully fire. Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. In sponge iron industry rotary kiln is the primary equipment. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio.
Also, the process conditions in a sponge iron rotary kiln are dynamic in nature. Computational fluid dynamics analysis of sponge iron rotary kiln. Annual sponge iron production for sample sponge iron plants. Rotary kiln reduction process at nml the rotary kiln at nml fig. Most of the plants in india use dri processa solid state direct reduction process by which iron ore is reduced to sponge without phase change figure 1. Typical 3d image of accretions in kiln 3 at tata sponge, developed from the model which uses inputs thermocouple. In a typical embodiment of the preferred rotary kiln process for the production of the sponge iron a mixture of the raw. Us2462900a reduction accelerator for the sponge iron. Sponge iron rotary kiln, sponge iron rotary kiln, alibaba offers 587 sponge iron rotary kiln products about 71 of these are cement making machinery, 8 are other mining machines, and 1 are industrial furnaceponge iron production in rotary kiln pdf free download.
Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. Pdf operability analysis of direct reduction of iron ore. The product of direct reduction processes known as sponge iron is used mainly as high quality melting stock for steelmaking. Simulation of rotary kiln used in sponge iron process using ann. The rotary kiln is slightly inclined at an angle 2. Us2462900a reduction accelerator for the sponge iron rotary. Between 200405 and 200910, the dri production in india has increased by 24% as. Free download sponge iron production in rotary kiln book. The rotary kiln process is a commonly practiced method in india for producing coal based sponge iron. New technology tunnel kiln to make sponge iron ro7bx mine. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process. The role of kiln is to convert the raw material iron ore, coal and dolomite into the sponge iron 8. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler.
Rotary kiln process of making sponge iron the production of steel began in ancient times. Sponge iron is produced using noncoking coal by the process of reduction of iron are in a rotary kiln. Pdf modeling of rotary kiln for sponge iron processing using. Hence, the quality keeps fluctuating and is not a constant value.
Flow of materials in rotary kilns used for sponge iron manufacture. Heat exchange in a rotary kiln may be by conduction, convection and radiation, in descending order of efficiency. The present work identifies the basic features of burden movement in a rotary kiln. Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. The production capacities of these industries depend significantly on the.
Modelling and optimization of a rotary kiln direct reduction. Jun 19, 20 rotary kiln process of making sponge iron new age international. Use features like bookmarks, note taking and highlighting while reading sponge iron production in rotary kiln. The input raw material such as iron ore, noncoking coal with high reactivity and the fluxing materials.
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