The mathematical model was customized and validated with data from one of the industrial scale rotary kilns at Tata Sponge Iron Limited (TSIL) and was utilized …

Sponge Iron Plant Brahma Deo1, ... sponge iron kilns exit at a high temperature (800-950oC) ... complete the combustion resulting in formation of CO 2

Generally for the reduction of the iron ore a large rotary kiln is used, for instance 70-90 m long with an internal diameter of 4-5 m. Kilns present an inclination of 2.5 degrees and can rotate at ...

The data reveal that Midrex process is more prevalent as a process adopted for DRI / Sponge Iron production. In India, however, owing to limited resources of natural gas, coal based

The tunnel kiln has evolved as an alternative to rotary kiln process for production of sponge iron because of the limitations of the latter such as pollution and low productivity. Used directly for manufacturing of sponge iron in tunnel kilns are iron ore fines and the low grade beneficiated iron ore cake are directly.

iron. ACCAR Process: (Allis Chalmers controlled Atmosphere Reactor) This produces highly metalized direct reduced iron using rotary kiln. Here solid, liquid and gaseous …

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 ...

sponge iron has been developed in which non-coking coal is essentially used as the reductant. For easy scaling up of the T1SCO Direct Reduction (TDR) process to units of …

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 main kiln motor drive current Kiln drive (A) 21 1288 241.44 65.61 The speed of ID fan ID fan rotation (rpm) 86 995 879.62 83.68 Total of kiln fuel and pre-calciner Total fuel(lit/hr) 220 ...

Sponge Iron. Thermax is a pioneer in supplying waste heat recovery boilers for sponge iron plants and has over 150 installations to date. The boilers are designed to handle large amounts of dust from the flue gas generated in the rotary kilns. The steam generated from these boilers is typically used for power generation.

CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package …

Processes that produce iron by reduction of iron ore in solid state are generally classified as direct reduction (DR) processes and the products also referred to …

Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and …

The power consumption ranges from 45-130 Kw/tonne direct reduced iron. The amount of char generation on an average is 0.35 tonne/tonne of direct reduced iron and electrostatic precipitator dust is ...

P.V. Natekar. India is the largest producer of sponge iron or direct reduced iron (DRI) in the world. The important step in the manufacture of DRI is direct reduction of iron ore by coal or ...

Perhaps the very first patent in U.K. for sponge iron making was in 1792 presumably using a rotary kiln. More than 100 DR processes have been invented and… Expand. …

In the newly designed sponge iron rotary kiln system, a coarse coal branch pipe and fine coal branch pipe are added at the kiln head. The original way of adding coal at the kiln head is changed to 50-70% …

Sponge iron is produced using non-crushing coal through the iron ore reduction process in a rotary kiln. In this paper, the production process of sponge iron in rotary kilns from the perspective of mechanics and chemistry is investigated. Keywords: Sponge iron, rotary …

Sponge Iron Plant. We are pioneer in supplying waste heat recovery boilers for sponge iron plants and has over 184 installations to date. The boilers are designed to handle large amounts of dust from the flue gas …

The process flow diagram (PFD) of sponge iron production process, shown in Fig. 1, consists of a number of equipment namely rotary kiln, rotary cooler, DSC, ABC, WHRB, ESP, wet scrapper and chimney. As the aim of the present work is to correlate input and output parameters of the sponge iron process using

Expansion of existing Sponge Iron Plant capacity (DRI Kilns- 2x 100 TPD to 3x100 TPD and installation of WHRB based Power Plant 6 MW and AFBC based power plant 6 MW;Fly ash block (1 x 500M3/day) along with Sinter plant (100 TPD) and Ferro Alloys Plant (2x 9 MVA SAF; Si-Mn-27000 TPA or Fe-Si-27000 TPA or Fe-mn-42000 TPA) At

sponge iron manufacturing process or kiln operation with a view to finding out major energy sav- ing potential of the unit. In the research work we find that it is the incomplete reaction of coal that

3.1 MANUFACTURING PROCESS 3.1.1 SPONGE IRON PLANT M/s BSPL is now operating 2 DRI kilns, each of 100 TPD capacity for production of 60,000 TPA sponge iron. The company is now planning to install (1x200 +1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. …

Innov Engineering advanced tunnel kiln technology is arguably the most sufficient and effective method for sponge iron production which allows for economically feasible plants. The tunnel kilns enable continuous process in that as some materials are beginning to heat at one end of the device, others are being fired in the middle, and more are ...

AGICO GROUP mainly focuses on major and medium series of rotary kiln products such as cement kiln, lime rotary kiln, shaft kiln, and sponge rotary kiln. Located in Anyang of China, AGICO owns a large heavy industrial factory, it has more than 100 pieces of equipment such as large and medium mental process machines, riveting equipment, and ...

II. 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 coal based sponge iron plant where iron ore, feed coal and dolomite are fed to the rotary kiln. A separate conveyor collects

The main function of making Sponge Iron in the Kiln is to convert Iron ore into sponge iron by using Iron ore, coal and dolomite / limestone. ... The Sponge Iron is processed further for making liquid metal at Steel Melting Shop. The entire process of making Sponge Iron is associated with various Safety hazards. If not mitigated, it may lead to ...

Authors: Gajendra Kumar Gaurav. Brno University of Technology. Shabina Khanam. Indian Institute of Technology Roorkee. Abstract. Different processes of …

Sponge-iron is made in China by the Hoganas Process. Coal, limestone, and iron are put in saggers and heated in a special kiln and maintained at a tempera-ture of 2100'F for 80 hours. The sponge-iron produced has about 96 per cent iron, 2 per cent oxygen and 2 per cent other elements. The Japanese built installations at Penchihu, Man-