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VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coal-based sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron ore
However, for coal-based DR the reductant is generated from non-coking coal and rotary kilns, rotary hearth furnaces and multi-hearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 65-75% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
Sponge iron kiln's cylinder: The design of the sponge iron rotary kiln cylinder is more reasonable. The cylinder is rolled with a Q235-B steel plate to ensure five mechanical properties, usually with automatic welding. The wall thickness of the cylinder is generally 25 mm, and that of the firing zone is 32 mm. ...
In book: Encyclopedia of Iron, Steel, and Their Alloys (pp.pp 1082-1108) Chapter: i) Direct Reduced Iron: Production; Publisher: CRC Press, Taylor and Francis Group, New York.
in the Sponge Iron kiln can not be eliminated since it originates from the input constituents of the process. The extent of interaction appears to increase with the alumina content of the
sponge iron manufacturing process and suggested improvement in that [8, 10, 11]. Directly reduced iron (DRI, or called sponge iron) has been found an excellent feed in electric arc ... The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the
Efforts to increase the degree of metallization of iron ore pellets to min. 90% in the reduction process in the rotary kiln with a continuous process has been carried out in 2012.
2D CFD model is developed for simulation of rotary kiln of sponge iron process. Effects of varying inclination angle, rotation and iron ore flow rate are studied. …
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. …
1. Krupp Sponge Iron Process 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 ...
Our lateritic nickel rotary kiln is mainly used to smelt lateritic nickel ores so as so get nickel pig iron. So far CITIC HMC Co., Ltd has successfully carried out many projects in China, such as Guangqing in Guangdong …
quality and productivity of DRI in rotary kiln", Materials Today: Proceedings 56 (2022), pp. 1538-1541. [5] Dey N, "Energy Survey of coal based sponge iron industry", Science Direct, 6 (2015). [6] Choudhury, A. (2014) Energy Audit Methodology of Sponge Iron Manufacturing Units Using DRI Process.
The formation of accretions or 'rings' in rotary kilns used for the manufacture of directly reduced iron (sponge iron) affects the residence time of the charge, kiln hold-up, and the kiln output to a great extent. In this part of the work, the effect of ring formation was simulated at room temperature in a scaled-down model of a rotary kiln by inserting …
Sponge iron rotary kiln is professional equipment for smelting sponge iron. Due to its high degree of mechanization and low labor intensity, many sponge iron plants around the world use the rotary kiln process to …
The formation of accretions or 'rings' in rotary kilns used for the manufacture of directly reduced iron (sponge iron) affects the residence time of the charge, kiln hold-up, and …
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. 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 operated since 1920.
Sponge Iron or Direct Reduction Iron (DRI) refers to a porous metallic substance that is produced by the direct reduction of iron ore, where oxygen is removed from the iron oxide using coal or natural gas as reductants and dolomite as a desulphurizing agent . Raw materials are fed into the rotary Kiln by a conveyor to …
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 …
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 dioxide and entrained dust.
Index Terms—Sponge iron process, rotary kiln, temperature profile, artificial neural network. I. II. 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 carbonaceous fuels as coal.
The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1].The rotary kiln is a slightly inclined steel cylinder that rests …
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 …
A 2D CFD model of rotary kiln for sponge iron process is developed in this work using ANSYS 14.5. The present study discusses the behavior of temperature profile of the bed and gas (air) along the length of the kiln. These parameters are studied based on variation of input parameters such as angle of inclination, number of rotation and mass ...
The direct carbon dioxide (CO 2) emissions from the iron and steel sector are nearly 7 % of the global CO 2 emissions from energy use. India is the world's second-largest producer of steel and the largest sponge iron producer. India produces one-third of the global sponge iron, mostly from rotary kilns using coal as an energy source, resulting in higher energy …
The 2D geometry of rotary kiln of sponge iron process is developed using ANSYS 14.5 and shown in Fig. 2. Feed, a mixture of iron ore, coal and dolomite, enters to the kiln as indicated in Fig. 2. In this figure primary air enters from discharge end whereas, secondary air enters the kiln through different nozzles placed at the periphery of the ...
Schematic representation showing the process involved in rotary kiln-based sponge iron production (This figure showcases each step involved in direct reduction …
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 …
Figure III showsproduction pro cess of sponge iron in a co al based rotary kiln us ing customized/ indigenous t echnology a long w ith sour ces o f air emissio n, liquid eff luent and so lid waste ...
In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.
In the conventional process, the sponge iron leaving the rotary kiln at 1,020 °C (Dey et al., 2015) is cooled to 110 °C for two reasons: (i) to prevent re-oxidation of the sponge iron when ...