Sarangi, b download it once and read it on your kindle device, pc, phones or tablets. Rotary kiln to making sponge iron in india binq mining. Fluorite ore sponge iron rotary kiln meipaly heavy. The reduction is carried out in a rotary kiln of a predetermined temperature and controlled atmospheric pressure. Iron ore the quality requirement of sized ore for sponge iron production can be classified into. Rotary kiln reduction process at nml the rotary kiln at nml fig. T srinivasa rao, md, balajiswamy premium steels pvt ltd offered his 50tpd kiln for this purpose.
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. Study on air tubes failure in sponge iron rotary kiln. More than 100 dr processes have been invented and operated since 1920. A simplified flow diagram of sponge iron making in rotary kilns is given in fig51. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. The production capacities of these industries depend significantly on the. The present work identifies the basic features of burden movement in a rotary kiln. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. Rotary kiln cement rotary kiln and sponge iron rotary kiln.
The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. 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. Generally in any sponge iron process, reduction is conducted in a refractory lined rotary kiln. Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper.
Modeling of rotary kiln for sponge iron processing using. Based on the types of reductant used, dr processes can be broadly classified into two groups. Analysis of temperature profile and % metallization in rotary. Normally, the rotary kiln is 60125 m long l a n d 46 m in diameter d, and the l d ratio is about 1520. The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the. Presentation from tata sponge iron ltd was very much liked and lot of the people showed. Sponge iron rotary kiln process anticorruption helpline. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. Boudouard reaction, dolomite, dri, iron ore, metallization, non coking coal, pellets, reduction, rotary kiln, sponge iron, sulphur, coal based direct reduction rotary kiln process. Simulation of rotary kiln used in sponge iron process using ann. In all coalbased dr processes using rotary kilns, sized. Flow of materials in rotary kilns used for sponge iron.
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. The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform fe metallic of all grain size fraction of the product. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. 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. 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. The major raw materials required for production of sponge iron by the rotary kiln process are. Us2462900a reduction accelerator for the sponge iron rotary. The rotary kiln is slightly inclined at an angle 2. Schematic flow sheet of coal based direct reduction process 1. Pdf operability analysis of direct reduction of iron ore by. Expired lifetime application number us700181a inventor john p riott original assignee john. If you continue browsing the site, you agree to the use of cookies on this website.
Sponge iron composition manufacturing process lloy. 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. 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. 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. The quality of sponge iron is primarily ascertained by the percentage of metallization removal of oxygen, which is the ratio of metallic iron to the total iron present in the product. 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. Sponge iron rotary kiln process in this process a refractory lined rotary kiln is used for reduction of iron ore in solid state the kiln is mounted with a slope of 25 downwards from the feed end to discharge end sized and weighed iron ore is continuously fed. Our cement 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, sponge iron and other materials, it uses hot gases for the operation. Process making sponge iron rotary kiln aircondicoz. Prasad and ray simulated flow pattern of air using fluent software in rotary kiln of a typical 100 tpd sponge iron process. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr processes.
Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of ironcoking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in. Abstractin the present study, estimation of actual output parameters is carried out for a sponge iron production process by designing a multilayer perceptron. Coal based direct reduction rotary kiln process ispatguru. Microstructural degradation occurring at high temperature affects mechanical and corrosion. Raw material general the major raw materials required for. An investigation on the cracking of air tubes of rotary kilns. A thesis submitted for partial fulfillment of the degree award of. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. Modelling and optimization of a rotary kiln direct reduction. 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. Sponge iron is produced using noncoking coal by the process of reduction of iron are in a rotary kiln.
Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of. The literature discussed above is based on cfd analysis of rotary kiln of cement plant. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. An empirical equation correlating different operating variables has been derived on the basis of. 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. The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. China rotary kiln, rotary kiln manufacturers, suppliers. Microstructural degradation occurring at high temperature affects mechanical and corrosionresistance.
Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. The product of direct reduction processes known as sponge iron is used mainly as high quality melting stock for steelmaking. Rotary kiln cement rotary kiln and sponge iron rotary kiln our cement rotary kiln and sponge iron rotary kiln has been developed for integrated with variable speed drive process automation and instrumentation this kiln annular gap by cooling air fan using distribution nozzle ring made of pipes. The kiln of suitable size, generally inclined at 2. Rotary kiln process of making sponge iron new age international rotary kiln process of making sponge iron that the entire production by number 2 3 and 4 countries is. Operation and construction details a schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in fig. 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, screened and size wise in finished product. Walk by inspection of a sponge iron kilnyes guys kiln in cement and sponge iron isnt the samesee it to believe it. The rotary kiln process is a commonly practiced method in india for producing coal based sponge iron. Sand making machine sponge iron making process rotary kiln. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process. Schematic of optimised rotary kiln sponge iron making process. Coal is used as a reducent for sponge iron making in.
Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds. The process of sponge iron making aims to remove the oxygen from iron ore. Rotary kiln is a rotating cylindrical vessel which is used for drying, calcination and sintering in a continuous process with the use of hot gas the hot gases may be generated in an external furnace or by a flame inside the kiln our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and. The iron ore along with coal is charged into the kiln and air tubes located along the length supply the air for combustion. The input raw material such as iron ore, noncoking coal with high reactivity and the fluxing materials. Use features like bookmarks, note taking and highlighting while reading sponge iron production in rotary kiln. However, rotary kiln process suffers from serious limitations like low productivity and pollution. 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. 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. Computational fluid dynamics analysis of sponge iron rotary kiln. One of the major challenges for sponge iron plant is the accretion formation. Dryers sponge iron rotary kiln processhenan mining. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Process making sponge iron rotary kiln animation in south africa.
Rotary kiln process of making sponge iron the production of steel began in. Study on accretion formation on dri kiln during spong iron. Simulation of rotary kiln used in sponge iron process using. Sponge iron manufacture is highly sensitive to raw material characteristics. Operability analysis of direct reduction of iron ore by coal in an industrial rotary kiln. Sponge iron production in rotary kiln kindle edition by sarangi, a.
The process of dri making aims to remove oxygen from iron ore pellets lumps. Rotary kiln process of making sponge iron discussed later in this book. Tunnel sponge iron kiln process ketel service nederland. A rotary klin process rotary kiln method is very important for sponge iron production using noncoking coal as a reluctant the iron ore is charged from one end with noncoking coal which is in the lump form or pellets and heated from. Limestone, in small quantities, is also required to scavenge the sulphur. 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. Rotary kiln process of making sponge iron the production of steel began in ancient times. Tunnel kiln the latest technology in the dri sponge iron making is utilizing. Study on accretion formation on dri kiln during spong iron production.
Nov 12, 2012 rotary kiln process of making sponge iron. This product is known as direct reduced iron dri or sponge iron. A system and continuous process of manufacturing of sponge iron from iron ore fines as composite pellets in a tunnel kiln is disclosed. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. 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. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. In the industry, there have been many recent reports of premature failures of certain air tubes in a. Process making sponge iron rotary kiln animation mining. China rotary kiln manufacturers select 2020 high quality rotary kiln products in best price from certified chinese drying equipment manufacturers, china burner suppliers, wholesalers and factory on. As the focus of the present work is to study the kiln of sponge iron process, literature related to it is discussed here. Pdf operation of coalbased sponge iron rotary kiln to reduce. Sponge iron production in rotary kiln pdf rotary kiln process of making sponge iron sponge get price f cover sponge iron. Operation of coalbased sponge iron rotary kiln to reduce accretion.