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process making sponge iron rotary kiln

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

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.

SPONGE IRON PLANT

The Rotary Kiln process is a well-established process for production of coal based sponge iron. Rotary kiln of certain dia and length is provided for reduction of Iron Ore into sponge iron using non-coking coal as reductant and Dolomite as sulphur scavenger; however the Diameter and Length are to be designed based on the Plant Capacities.

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing

Schematic of optimised Rotary kiln sponge iron making process. Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge end of Rotary Kiln which is inclined at 2.5% of drum length. Coal is also injected through a Coal Throw Pipe at the discharge end of Kiln. Due to the inclination and rotation of Kiln the charge

sponge iron process

Jul 29, 2010 In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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.

Sponge iron making process SlideShare

Nov 09, 2014 ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell 12.

SPONGE IRON PLANT

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 required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing

Schematic of optimised Rotary kiln sponge iron making process. Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge end of Rotary Kiln which is inclined at 2.5% of drum length. Coal is also injected through a Coal Throw Pipe at the discharge end of Kiln. Due to the inclination and rotation of Kiln

Sponge iron making process SlideShare

ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell.

sponge iron process

Jul 29, 2010 In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.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.

Rotary Kiln with SL/RN Process electrotherment

Rotary Kiln with SL/RN Process Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, and 500 TPD) Solid-state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI).

A Thesis Submitted for Partial Fulfillment of the Degree

3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

Making Sponge Iron With Rotary Kiln

Sponge Iron Composition Manufacturing Process. 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 finished

Accretion Control in Sponge Iron Production Kiln using

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 kiln, which rotates at a programmed speed.

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to

Also, the process conditions in a sponge iron rotary kiln are dynamic in nature. Hence, the quality keeps fluctuating and is not a constant value. A mathematical mass

Sponge Iron an overview ScienceDirect Topics

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 800–1200 °C. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H

New Sponge Iron Rotary Kiln Design In Sponge Iron

Sep 10, 2020 Sponge Iron Manufacturing Process of New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System. The iron concentrate, dolomite, and coal from the stockyard enter into three groups of metering pneumatic conveying devices of the feeding system for metering. The measured iron

SPONGE IRON PRODUCTION FROM ORE -COAL

However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns.

SL RN (Iron Making Rotary Kiln Process for DRI

(SL/RN) Stelco-Lurgi/Republic-National rotary kiln process

Modelling and optimization of a rotary kiln direct

The kiln model applied in this work was developed by Hatch over a number of years and has been used for several rotary kiln projects. It has its roots in a FORTRAN program that was developed by Venkateswaran (1978) to study the reduction of iron ore. The original software was used to model the operation of a 35 m pilot kiln at the Stellco company

SPONGE IRON PLANT

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 required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing

Schematic of optimised Rotary kiln sponge iron making process. Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge end of Rotary Kiln which is inclined at 2.5% of drum length. Coal is also injected through a Coal Throw Pipe at the discharge end of Kiln. Due to the inclination and rotation of Kiln

Accretion Control in Sponge Iron Production Kiln using

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 kiln, which rotates at a programmed speed.

Making Sponge Iron With Rotary Kiln

Sponge Iron Composition Manufacturing Process. 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 finished

SPONGE IRON PRODUCTION FROM ORE -COAL

However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns.

New Concept of Hot Metal Production using Rotary Kiln

Hot sponge iron from rotary kiln shall be smelted directly by continuously charging into smelting reduction furnace. The smelting furnace itself is equipped with stoves to preheat the hot blast air.

Modelling and optimization of a rotary kiln direct

The kiln model applied in this work was developed by Hatch over a number of years and has been used for several rotary kiln projects. It has its roots in a FORTRAN program that was developed by Venkateswaran (1978) to study the reduction of iron ore. The original software was used to model the operation of a 35 m pilot kiln at the Stellco company

Energy survey of the coal based sponge iron industry

Sep 01, 2015 In the sponge iron process concentrated and finely divided iron ore is reduced in solid phase into sponge iron at high temperatures in rotary kiln. The process is very energy demanding. In order to identify the largest losses and to find ways to increase the efficiency, an energy survey of the sponge iron plant was carried out for a number of

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

DRI UPDATE Sponge Iron Manufacturer India

2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the R&D for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed

China Rotary Kiln Process of Making Sponge Iron China

Model NO.: Rotary Kiln Process of Making Sponge Iron Type: Iron-Making Equipment Certification: ISO Lateritic Nickel Rotary Kiln: Rotary Kiln for Laterite Nickel Ore Calcining Output: 80-100 T/H(Roasted Sand) Application: Roasting Laterite Ores

Sponge Iron Plant Rotary Kiln Equipments China Rotary

sponge iron plant rotary kiln equipments 1..Brief description of clinker rotary kiln : Our company owns the magnesium production line. As a kind of qualified material crushed by the crusher, the raw material-dolomite is calcined till it became white by rotary kiln, being cooled by the cooling machine and then mix it evenly with silicon powder (75%) and silica powder (including GaF2 fluorite=95%).

first rotary kiln in zimbabwe to produce sponge iron from

MORE DETAILS: Conversion of Sponge Iron From Low Grade Iron ore. The process of DRI or sponge Iron making can be classified into different categories as given below 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

Simulation of Rotary Kiln Used in Sponge Iron Process

Index Terms—Sponge iron process, rotary kiln, temperature profile, artificial neural network. I. INTRODUCTION Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or