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The document describes the raw material requirements, manufacturing process, and basic components involved in a typical coal-based rotary kiln system for producing sponge iron.
Sponge iron means porous iron produced by direct reduction process. Direct reduction (DR) process is a solid-state reaction process (i.e. solid–solid or solid–gas reaction) by which removable oxygen is removed from the iron ore, using coal or reformed natural gas as reductants, below the melting and fusion point of the lump ore or …
The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital expenditure and no requirement of coking coal. The metallic iron in this process is produced by the reduction of iron oxide below the …
Proses reduksi bijih besi menjadi sponge besi dimulai dengan proses pengumpanan bijih besi, batubara dan batu kapur ke unit pencampuran (mixing). Campuran homogen dari ketiga bahan ini kemudian diumpan secara kontinyu ke dalam rotary kiln dari sisi feed end. Akibar putaran dan kemiringan tanur, semua material padatan bergerak ke arah …
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...
The charge of SL / RN process, us ually consists of lump iron ore or pellets, coal, recycled char. and lime / dolomite, if sulphur removal is required. Counter-flowing gases heat the feed material ...
Prediction models for temperature, pressure, and quality control in rotary sponge iron kilns are developed from operational data using conventional and AI-based methods, which greatly helps in chaos control inside the kiln.
The geometry of rotary kiln of sponge iron process is developed using GAMBIT 2.4.6. Dimensions of kiln are 80 m length and 4 m internal diameter. The kiln …
The present paper deals with 2D CFD model of sponge iron rotary kilns. Using this model the effects of variations of input parameters, such as angle of inclination, number of rotation and mass flow rate of iron ore are studied on output parameters like Fe content, temperature profile.
g plant determines the type of control strategy to be implemented. Sponge iron production process equires accurate monitoring and control of the process parameters. The …
The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon …
temperatures and pressures within a rotary kiln generates sponge iron as a product. However rotary kiln performance is adversely affected by the ring formation known as …
Chapter 1 Review of Sponge Iron Making Process Historical Development. r – 1Review of Sponge Iron Making ProcessHistorical Development:Sponge iron was the main source of iron for many centu. ies before the blast furnace technology of iron making got developed. During that time sponge iron was developed in s.
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 …
Sponge iron is a raw material that is used to make steel and other metals. It can be produced by direct reduction of iron ore or through an electric arc furnace. The process produces less carbon dioxide than blast furnaces.
lns are found in many processes that involve processing of solids. 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 …
PDF | On Jan 1, 2019, Chaitanya Shah and others published Conventional and AI Models for Operational Guidance and Control of Sponge Iron Rotary Kilns at TATA Sponge: SocProS 2017, Volume 1 | Find ...
Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING Under the supervision of
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 physico-chemical principles of sponge iron …
The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also …
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The metallization zone is where the final reduction to metallic iron takes place with most CO2 reduced to CO. A lot of emissions are generated during this stage from combustion reactions in the kiln [2]. After the reduction process, a mixture of sponge iron and char is discharged from the kiln into the cooler where cooling takes.
Dey et al. (2015) analysed the energy aspects of the rotary kiln process for sponge iron production and discussed the possibilities of energy conservation through heat integration.
Keywords Tunnel kiln Iron ore–coal composite pellets Sponge iron Energy efficiency Carbon utilization efficiency 1 Introduction The tunnel kilns are mostly used by the industries for heating refractory and ceramic products [1, 2]. In the year 1908 use of tunnel kiln started for iron oxide reduction.
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 iron. Depending on its content of …
Conventional and AI techniques are used for prediction of temperature along the length of kiln and also quality of sponge iron produced.
Chapter 1 Review of Sponge Iron Making Process Historical Development. r – 1Review of Sponge Iron Making ProcessHistorical Development:Sponge iron was the main source …
Process Making Sponge Iron Rotary Kiln cz eueurotary kiln process of making sponge iron. Complete Process Of Sponge Iron Kilns A Thesis Submitted for Partial Fulfillment of the Degree have been able to complete my 33 Schematic of optimised Rotary kiln sponge iron making process Get Price And Support Online Ppt For Rotary Kiln …
As such it is called Sponge Iron. Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process.
Many investigators considered the process of sponge iron manufacturing and suggested improvement in that [1], [2]. It is found that during the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and a significant part of this heat associated with the waste gas, remains unutilized.
Iron ore feed rate: maintained at 31tons/hr.3) Coal feed rate:Around 390 kg of fixed. ton of DRI.4) C/Fe ( carbon/ Iron ) ratio:The C/Fe ratio is 0.4-0.46 which indicates t. at the quantity of carbon feed to the kiln. The higher the C/Fe ratio indicates excess coal consumption …
Sponge iron is a form of iron that is produced by heating iron ore in the absence of oxygen and the heat recovery methods for sponge iron are methodically studied and deployed by us. During the production process, a significant amount of heat is generated by the exothermic reaction of reducing iron ore. This heat is usually wasted, but with the ...
Abstract. Pressure fluctuations inside a coal-fired rotary kiln for production of sponge iron affect the temperature distribution as well as the rate of reduction of iron oxides. The fluctuations ...
The tunnel kilns are mostly used by the industries for heating refractory and ceramic products [ 1, 2 ]. In the year 1908 use of tunnel kiln started for iron oxide reduction. This process was invented by Sieurin as Hoganas process [ 3 ]. In 1954, more kilns came into operation in Sweden and USA. Presently it is more popular in China for sponge …
present work to take care of dynam ic process conditions inside the rotary sponge iron kiln, rotating at a very low RPM.
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 …
The critical step in this process is the reduction of iron ore by coal in the rotary kiln. In coal-based sponge iron rotary kilns, iron ore, coal and dolomite are fed to the kiln as separate ...
