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 Non-coking coal is required in sponge iron production, since the MAJOR PLANT FACILITIES
Because of the separation of iron reduction and iron melting/coal gasifying in two steps, a high degree of flexibility is achieved and a wide variety of coals can be used.
SPONGE IRON PRODUCTION IN A ROTARY KILN B. L. SENGUPTA A. B. CHATTERJEA, G. P. MATHUR In the two ways of meeting the thermal requirements, the alteration in the temperature profile was marginal. The retention time was 90 to 110 minutes. The SL-RN process also uses rotary kiln for reducing iron ore. The plant, as shown in Fig. 2
Maintenance of Sulphur level in steel by its removal during Sponge iron production** Lower refining requirements of steel produced; It allows steelmaking to dilute metallic residuals in scrap; Main Components of the Rotary Kiln are Raw Material Handling & Storage; Rotary Kiln; Rotary Cooler; Magnetic Separators (MS) Dust Settling Chamber
sponge iron plant dri mining machinery kiln cooler. Kiln Girth Gear for 100 TPD DRI Coal Based Sponge Iron Plant rotary kiln 50 TPD 600 TPD; Cooler Girth Gear for 100 TPD DRI Coal Based Sponge Iron Plant; Kiln Pinion Assembly For 100 Tpd Dri Coal Based Sponge Iron Plant Rotary Kiln 50 Tpd 600 Tpd
In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850°C -1,500°C).
Number of DRI processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world. Ashoka’s Sponge Iron Plants Manufacturing Capabilities:Sponge Iron Plant: 100 TPD to 600 TPD & Sponge Iron Plant Equipment
For this, Prakash Industries Ltd setup Sponge Iron Kilns at Champa (Chattisgarh) in technical collaboration with Lurgi Germany. In the solid reduction process iron ore is converted into DRI in a rotary kiln fired by non-coking coal. Sponge iron and non-magnetic components are separated and stored in separate bins for further transfer.
Most plants employ reduction process which is carried out in rotary kilns. These plants use wide variety of raw materials and non-coking coal. The quality of these materials has direct bearing on the process as well as the product. Some plants do not use iron ore directly. These plants use iron ore pellets in the rotary kiln.
As only oxygen can be removed from the iron ore during the process of making sponge iron iron,ores rich in iron content of 65percent and above is preferred. We source iron ore from our group company from Barbil mineral rich area of Odisha state.
The coal base DRI rotary kiln process for production of DRI / Sponge Iron has its many parameters to increase the quality as well as productivity which need careful operations throughout the process. Number of DRI processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world.
The hot product discharged from the kiln is indirectly cooled in a rotary cooler by spraying water on the shell of the cooler. The discharge from the cooler is conveyed through a belt conveyor screened and magnetically separated. Sponge iron and non-magnetic components are separated and stored in separate bins for further transfer.
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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.
Rotary Kiln Process of Making Sponge Iron. Rotary Kiln Process of Making Sponge Iron 2.1 HISTORICAL BACKGROUND The production of steel began in ancient times; but because of the complexity and slow. Get Price » Chat Online ; rotary kiln iron ore pellet process Solution for Mining Quarry. three dimensional flow chart of iron pellet plant
Components Required For Rotary Kiln For Sponge Iron Plant. Sponge iron production line in rotary kiln by dahua sponge iron dri rotary kiln the introduction of rotary kiln a rotary kiln is the main equipment for sintering cement clinker b the rotary kilns produced by our company can be divided into dry process and wet process compared to been
Plant facilities: Sponge Iron Plant. The main plant consists of a 4 mtr. Dia x 84 mtr. Long ported rotary kin (DR 1) and 4.8 mtr. Dia x 84 mtr.long ported rotary kin (DR 2) equipped with air injection system to provide for generation of necessary heat and reducing atmosphere required for the process.
Rotary Kiln Plant: We manufacture high quality low setup cost Rotary Kiln Plants on turnkey basis, including design, upgrade rotary kiln, and complete cement plant. Contact at [email protected] or call +91 9811141400
in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln.
+1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.
3.1 Material Balance in a Rotary Kiln sponge iron plant 14 3.2 Energy Balance in a Rotary Kiln sponge based iron making 14 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
Oct 03, 2011· The first coal based sponge iron plant was set up at Paloncha in Andhra Pradesh in 1980, which had a capacity of just 0.039 million tones per annum. In the next nine years, five more coal-based were set up and to-day there are 19 coal-based plants in India using various technologies like SL/RN, ACCR, Krupp, Codir, TDR, Jindal etc. the present estimated capacity is nearly 4.5 million
parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the
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.
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.
Aug 30, 2020· In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and dolomite, is fed to the rotary kiln (RK).
Components Required For Rotary Kiln For Sponge Iron Plant. Sponge iron production line in rotary kiln by dahua sponge iron dri rotary kiln the introduction of rotary kiln a rotary kiln is the main equipment for sintering cement clinker b the rotary kilns produced by our company can be divided into dry process and wet process compared to been
Plant facilities: Sponge Iron Plant. The main plant consists of a 4 mtr. Dia x 84 mtr. Long ported rotary kin (DR 1) and 4.8 mtr. Dia x 84 mtr.long ported rotary kin (DR 2) equipped with air injection system to provide for generation of necessary heat and reducing atmosphere required for the process.
3.1 Material Balance in a Rotary Kiln sponge iron plant 14 3.2 Energy Balance in a Rotary Kiln sponge based iron making 14 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
in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln.
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 it so as to prevent its re-oxidation.
Typical examples of the coal-based process include the SL/RN and ACCAR processes. The coal-based DR process is more popular in India and China. Different types of reactors, such as shaft furnaces, fluidized beds, rotary kilns, and rotary hearth furnaces, have been used in different variations of the processe to achieve the metallization required.
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.
+1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.
Rotary Kiln Plant: We manufacture high quality low setup cost Rotary Kiln Plants on turnkey basis, including design, upgrade rotary kiln, and complete cement plant. Contact at [email protected] or call +91 9811141400
Oct 03, 2011· The first coal based sponge iron plant was set up at Paloncha in Andhra Pradesh in 1980, which had a capacity of just 0.039 million tones per annum. In the next nine years, five more coal-based were set up and to-day there are 19 coal-based plants in India using various technologies like SL/RN, ACCR, Krupp, Codir, TDR, Jindal etc. the present estimated capacity is nearly 4.5 million
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.
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.
SPONGE IRON PLANT. rotary kiln is slightly inclined at an angle 25 deg and rotated by ac variable speed motor at a steeples variable speed ranging form 0210 rpm Due to inclination and rotary motion of the kiln the material. More Details What is the kiln formula of kiln inclination Answers
Rotary kiln sponge iron plant pdf sponge iron plant by the rotary kiln process are sized graded iron ore and noncoking coal limestone in small quantities is also required to scavenge the sulphur iron ore the quality requirement of sized ore for sponge iron production can be classified into spongeitc 2 1 physical requirements.
Directly reduced iron looks like sponge in texture due to pores and hence is called sponge iron. Iron Ore after due reduction inside the kiln is discharged to a rotary cooler of 3.5 mtr. Dia x 50 mtr long from DR1 and 3.8 x 50 mtr long from DR2 for cooling the DRI from 10000C.
Oct 03, 2011· The first coal based sponge iron plant was set up at Paloncha in Andhra Pradesh in 1980, which had a capacity of just 0.039 million tones per annum. In the next nine years, five more coal-based were set up and to-day there are 19 coal-based plants in India using various technologies like SL/RN, ACCR, Krupp, Codir, TDR, Jindal etc. the present estimated capacity is nearly 4.5 million
Rotary Kiln Plant: We manufacture high quality low setup cost Rotary Kiln Plants on turnkey basis, including design, upgrade rotary kiln, and complete cement plant. Contact at [email protected] or call +91 9811141400
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.
+1x350) TPD DRI Kilns for production of 1,65,000 TPA Sponge Iron. So, the final will be 2,25,000 TPA Sponge Iron. Manufacturing Process The plant uses the coal based process in which pellet is reduced with non-coking type imported coal in a rotary kiln to make sponge iron.
in the sponge iron process. For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln.
We Piyali Engineering Corporation based at capital city New Delhi in India. We are dealing in Sponge Iron (DRI) and Cement plants and Equipment and supplying
Sep 10, 2020· The water in the mixture, the carbon dioxide in the dolomite, and the volatile components in the coal enter the upper space of the sponge iron rotary kiln, forming reducing gas. Then the mixture enters the reduction zone of sponge iron rotary kiln, and the iron concentrate is reduced by carbon monoxide to form iron elements.
rotary kiln operations. Regardless of rotary kiln size or configuration the basic principles outlined in this manual govern the reliable operation of every rotary kiln, calciner, dryer, incinerator, digester and cooler application. For questions or problems with your specific application please contact North American Kiln
Iron ore fines are usually subject to beneficiation and/or pelletisation thereby converting them back into hard rock-like shapes (pellets) with a proper tumbler index. These pellets are then used for making sponge iron. Rotary kilns have a drawback upon the size and quality of iron ore that can be used.