Heat exchange in a rotary kiln may be by conduction, convection and radiation, in descending order of efficiency. Sponge iron production in rotary kiln bidyapati sarangi. The clarkdale plant is surrounded by hills that are rich with high quality limestone that is quarried on site the quarried rock contains both silica and calcium as well as deposits of volcanic material that provide alumina iron and additional silica all of these are necessary to make a. Us3096172a rotary furnace production of sponge iron. Sep 25 2017 the production of iron ore pellets is often performed in the socalled gratekiln process the aim of the process is to oxidize the magnetite fe3o4 to hematite. This book deals with the basics of sponge iron production in rotary kiln, describing the operational problems and control needed to produce a quality product. Simulation of rotary kiln used in sponge iron process. Modelling and optimization of a rotary kiln direct reduction. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. Pdf quality prediction and control in coalfired rotary. West midnapore, cse report peoples movement very strong against the sponge iron industry especially rashmi cement ispat in 2009, in west midnapore. Method for the production of low sulfur sponge iron buehl, russell c. The process of reducing the iron ore in solid form by reducing gases is called direct reduction. A wide variety of rotary kiln drawing options are available to you, there are 1,520 suppliers who sells rotary kiln drawing on, mainly located in asia.
Buy sponge iron production in rotary kiln book online at best prices in india on. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 c. 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. Steel sponge iron, rotary kiln for sponge iron plants, ashoka technologies india, standards can be made in electric arc furnace sponge iron rotary kiln simulator tata consultancy services.
However, very little work is available related to cfd analysis of rotary kiln of sponge iron process such as. Sponge iron units do not use the pollution control equipment. What is the cost to install the cement rotary kiln. A thesis submitted for partial fulfillment of the degree award of. Sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore non coking coal and dolomite as the raw materials the plant consists of the following sub divisions read the. Study on air tubes failure in sponge iron rotary kiln ankit1, t. 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. 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 plant kiln cooler equipment cooler pinion. We are a largescale manufacturer specializing in producing various mining machines including different types of sand and gravel equipment, milling equipment, mineral processing equipment and building materials equipment. Cold bonded orecoal composite pellets for sponge ironmaking. Rotary kiln is widely used in cement and steel industries.
This gas has a lot of sensible heat and can be used for energy integration. Simulation of rotary kiln used in sponge iron process using ann. Two five combinations of sponge iron tunnel kiln plant with an annual capacity of. Computational fluid dynamics analysis of sponge iron.
Rotary kiln process of making sponge iron the production of steel began in ancient times. Rotary kiln is the primary equipment in sponge iron industry, which is used to reduce iron ore to metallic iron i. Processes that produce iron by reduction of iron ore in solid state below. Recommended procedures for mechanical analysis of rotary kilns.
We are certified partner of eurokiln for afroasia region. For this purpose a case study of typical sponge iron production process is considered. In rotary kiln, carbon is charged from either end, in one end in the form of coal particles and in another in form of coal lumps. The cfd studies discussed above are mainly carried out for rotary kiln of cement industry. Certificate this is to certify that the thesis entitled, modeling of rotary kiln for sponge iron processing using cfd package ansys. Schematic flow sheet of coal based direct reduction process 1. We surya engineering works sew gears manufacturers, suppliers and exporters of 100 tpd sponge iron plant kiln and cooler in various domestic as well as international regions for sponge iron plant that have running capacities of. In lowtemperature processes, and in the cooler parts of long kilns lacking preheaters, the kiln is often furnished with internal heat exchangers to encourage heat exchange between the. Flow of materials in rotary kilns used for sponge iron manufacture. The present work identifies the basic features of burden movement in a rotary kiln.
Processes that produce iron by reduction of iron ore in solid state below the melting. Rotary kiln cement rotary kiln and sponge iron rotary kiln. Schematic of the sponge iron rotary kiln comparison of bed and gas temperature profiles. Flow of materials in rotary kilns used for sponge iron. Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. Pdf 2 d model of sponge iron rotary kiln developed using cfd. If you continue browsing the site, you agree to the use of cookies on this website. One of the major challenges for sponge iron plant is the accretion formation. Pollution in the coal based sponge iron industry in india.
In lowtemperature processes, and in the cooler parts of long kilns lacking preheaters, the kiln is often furnished with internal heat exchangers to encourage heat exchange between the gas and the feed. Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Limestone, in small quantities, is also required to scavenge the sulphur. Iron ore pelletization rotary kiln pdf travel mafia. Rotary kiln is a kind of large scale sintering device widely used in metallurgical. The direct reduction process uses pelletized iron ore or natural lump ore.
Pdf modeling of rotary kiln for sponge iron processing using. Pdf operation of coalbased sponge iron rotary kiln to reduce. Computational fluid dynamics analysis of sponge iron rotary kiln. The top countries of suppliers are china, india, from which the percentage of sponge iron plant supply is 99%, 1% respectively. Microstructural degradation occurring at high temperature affects mechanical and corrosionresistance. In this pilot plant, a totally indigenous technology for production of sponge iron has been developed in which noncoking coal is essentially used as the reductant. 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.
Cn1804049a tunnel kiln without exterior combustion. In the present work a system is designed to integrate the heat of waste gas in the sponge iron process. Rotary cooler the product come to the water cooled where its temperature reaches to 80100 c 11. Sponge iron is a mixture of reduced metallic iron, unreduced iron oxide and the associated with gangue constituents of the original ore. New technology tunnel kiln to make sponge iron, nov 22, 2011 case group has set up indias first dri sponge iron unit using tunnel kiln the kiln which is 194m in length, is the longest in india was successfully fire. Rotary kilns used for sponge iron plant, find complete details about rotary kilns used for iron rotary kiln,rotary kiln incinerator from cement making machinery supplier or delivery time. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. It our sponge iron rotary kiln simulator is a tool based on a the plant in an optimized manner. Sponge iron rotary kiln process anticorruption helpline. Rotary kiln is cylindrical in shape and is 80m long having 4. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Buy sponge iron production in rotary kiln book online at low. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. Us3096172a us27168a us2716860a us3096172a us 3096172 a us3096172 a us 3096172a us 27168 a us27168 a us 27168a us 2716860 a us2716860 a us 2716860a us 3096172 a us3096172 a us 3096172a authority us united states prior art keywords furnace discharge end sponge iron bed prior art date 19600505 legal status the legal status is an assumption and is not a legal conclusion.
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. Study on air tubes failure in sponge iron rotary kiln. Altekar abstract on the background of the imbalance in the occurrences of vast deposits of high grade iron. A thesis submitted for partial fulfillment of the degree. Material balance in a rotary kiln sponge iron plant. Get your kindle here, or download a free kindle reading app. 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. Xsm, one of the largest quarry machine manufacturers in. 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. In the first phase one 350 tpd rotary kiln and 8mw power plant have been missioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. Pdf the present paper deals with 2d cfd model of rotary kilns employed in sponge iron process. The rotary kiln is slightly inclined at an angle 2. This product is known as direct reduced iron dri or sponge iron. This is the reactor of the process where reduction as well as combustion reactions are carried out.
The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char. We are wellknown as a service provider, providing erection, cold kiln alignment and diagnostic maintenance services for cement kiln, sponge iron kiln, fertilizer plant, chemical plant, and carbon plant. A schematic diagram of the rotary kiln of sponge iron process. Rotary cooler the product is conveyed to the product separation and storage building the product is sponge iron and. Nov 12, 2012 advances in rotary kiln sponge iron plant free pdf free pdf free. An investigation on the cracking of air tubes of rotary. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. The performance of rotary kiln significantly affects the production capacities of these industries. Buy sponge iron production in rotary kiln book online at. In a typical embodiment of the preferred rotary kiln process for the production of the sponge iron a mixture of the raw. The largest improvements would be made by design modifiions adopting a novel energy conservation scenario by process integration and thereby decreasing the coal and water consumption and by decreasing the cold fresh air. Kumar 2 1indian institute of technology kharagpur, kharagpur, west bengal, india 2hsbc indiaformerly with iit kharagpur, bangalore, india abstract introduction. The production capacities of these industries depend significantly on the performance of rotary kiln.
Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production, commercially used dr direct reduction processes and physicochemical principles of sponge iron production. This book comprehensively deals with the production of sponge iron in the rotary kiln. Details of rotary kiln pdf file process detail henan. In order to promote public education and public safety, equal justice for all, a better informed citizenry, the rule of law, world trade and world peace, this legal document is hereby made available on a noncommercial basis, as it is the right of all humans to know and speak the laws that govern them.
Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. New technology tunnel kiln to make sponge iron ro7bx. Rotary furnace production of sponge iron download pdf info publication number us3096172a. Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. The performance of rotary kiln is affected by temperature profile. 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. Widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation. Modeling of rotary kiln for sponge iron processing using. The hot gases may be generated in an external furnace or by a flame inside the kiln. Maoist politics emerged solely due to pollution from sponge iron plants in west midnapore. Tunnel kiln for sponge iron production boucheriedujardinbe. Looking forward to the need of developing coalbased sponge iron technology in india, a country having no significant resources of either coking coal or natural gas, the research and development division of the tata iron and steel company limited tisco set up a rotary kiln based direct reduction pilot plant in 1975. An empirical equation correlating different operating variables has been derived on the basis of.
Nov 17, 2012 sponge iron units do not use the pollution control equipment. Chaeng cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Prasad and ray developed 2d model to simulate flow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant. Recommended procedures for mechanical analysis of rotary kilns top results of your surfing recommended procedures for mechanical analysis of rotary kilns start download portable document format pdf and ebooks electronic books free online rating news 20162017 is books that can provide inspiration, insight, knowledge to the reader. Cold bonded orecoal composite pellets developed on a laboratory scale part 1 of this two part paper were tested in a rotary kiln sponge iron plant. Rotary kiln is a rotating cylindrical vessel which is used for drying, calcination and sintering in a continuous process with the use of hot gases. Study on accretion formation on dri kiln during spong iron. In sponge iron industry rotary kiln is the primary equipment, which is used to reduce iron ore to metallic iron i. Sponge iron is a term given to the product obtained by reduction of iron ore in solid state. Of the different types of dryers that there are the most common is the rotary drum dryerkiln. Mining equipment free download rotary kiln handbook.
A coal based sponge iron plant was first built in 1980 at a place called paloncha in andhra pradesh which had a capacity of just 0. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. This plant had a 12 m length refractory lined rotary kiln of 8 tday iron ore throughput capacity. The role of kiln is to convert the raw material iron ore, coal and dolomite into the sponge iron 8. A wide variety of sponge iron plant options are available to you, there are 579 suppliers who sells sponge iron plant on, mainly located in asia. Sponge iron production in rotary kiln gases cooled to around deg c at the whrb discharge travel to pollution control equipment such as bag filters scrubber or electro static precipitator. The slrn process also uses rotary kiln for reducing iron ore. Raw dri process materials, partly coal, iron ore, after burn flue gas chamber fluxes enter the rotary kiln the remainder rotary kiln coal. Raw mix design in cement process download solustrid. Cost of tunnel kiln for sponge iron stone crushing process making sponge iron rotary kiln animation in south africa tunnel kiln process sponge iron in lineplant south africa plan a holiday in south africa, sas official tourism website. Superheated steam which is produced in the boiler is used to rotate a. The coal reacts with air to form carbon monoxide which then reduces iron oxide ore to iron.
An investigation on the cracking of air tubes of rotary kilns. Operation of coalbased sponge iron rotary kiln to reduce accretion formation and optimize quality and power generation. Sponge iron production in rotary kiln the cooler is also inclined at 2 the largest improvements would be made by design modifications adopting a novel energy conservation scenario by process integration and thereby decreasing the coal and water consumption and by decreasing the cold fresh air. Currently, coal as a reducing agent process for producing sponge iron are. Sponge iron production in rotary kiln the cooler is also inclined at 2. The top countries of supplier is china, from which the percentage of rotary kiln drawing supply is 100% respectively.