rotary kiln furnace in sponge iron plant

Sponge Iron

The plant included two shaft reduction furnaces of 3.4 m inside diameter and had a total capacity of 300,000 tpa. The average energy consumption of this early plant was approximately 15 GJ/t of sponge iron . The Midrex Division became a subsidiary of Korf Industries in 1974. ... Discuss the principle of rotary kiln process for sponge iron ...

A review of ironmaking by direct reduction processes: …

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).

[PDF] Modeling of rotary kiln for sponge iron processing …

CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD …

Dolomite – Its Processing and Application in Iron and

In the iron and steel plant, in some of the places, raw dolomite is further processed. ... Rotary kilns, with or without preheaters, usually process raw dolomite with material size between 10 mm and 50 mm. ... During the production of iron by blast furnace (BF) route, dolomite is added either in the process of sintering or as a direct feed in ...

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A …

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. Further, the waste gas at reduced temperature is used to cool hot sponge iron which is previously carried out by water.

Decarbonisation Options for Rotary Kiln-Induction Furnace …

The rotary cooler and magnetic separator in a conventional sponge iron plant can be replaced with a gravimetric separator enabling hot charging of sponge iron to the steel-making furnace.

Coal & Gas based DRI Plant

We manufacture Sponge Iron Plant on turn-key basis of different functional capacities i.e. 100 TPD, 300 TPD, 500 TPD plants.The equipment support provided for the plants include Kiln/cooler tyre, Kiln/cooler support roller, Kiln/cooler support roller shaft, Kiln/cooler support roller assembly with bearing housing, Kiln/cooler girth gear, Kiln/cooler pinions, …

Rotary kiln process: An overview of physical mechanisms, …

The heat and mass transport occurring through a rotary kiln has many industrial applications, such as organic or mineral materials manufacturing. The …

Sponge iron: Uses, process formula, iron plant, and more

In the DRI plant, sponge iron is produced by using the solid reductant iron ore with carbonate materials such as coil. ... the reduction is carried out in a rotary kiln in which it is rotated at specific speed at the temperature of 800° to 1500° C. ... Improved furnace productivity: Users of DRI experience higher furnace productivity. The ...

350tpd Sponge Iron Production Plant Sponge Iron Rotary Kiln Furnace

2. Features and Factory Pictures of Sponge Iron Rotary Kiln Furnace 1. The structure of sponge iron rotary kiln is advanced. The preheater with low pressure loss in our company can effectively improve the preheating effect. After preheating, the decomposition rate of raw material into kiln can reach 30%. 2. Sponge iron rotary kiln can be ...

Decarbonizing Rotary Kiln–Induction Furnace based Sponge …

The rotary cooler and magnetic separator in a conventional sponge iron plant can be replaced with a gravimetric separator enabling hot charging of sponge iron …

Direct Reduced Iron: Most Efficient Technologies for …

The effect of raw materials properties on the sponge iron quality is underlined. The installation of DRI plants as a function of the natural resources availability is discussed. ... Rotary kilns. Rotary hearth furnaces. ... The gas is then employed in the shaft furnace. The plant leads to natural gas consumption reduction and to the lowering …

Decarbonizing rotary kiln–induction furnace based sponge …

This study evaluates major options for CO 2 abatement in the rotary kiln–induction furnace process for steel production. Based on the mass and energy balances of a typical sponge iron plant, this study evaluates the techno-economic potential of nine major …

Decarbonizing Rotary Kiln–Induction Furnace based Sponge Iron …

The rotary cooler and magnetic separator in a conventional sponge iron plant can be replaced with a gravimetric separator enabling hot charging of sponge iron to the steel-making furnace.

Rotary kiln

The rotary kilns are used to remove oxygen from the hematite iron ore through direct reduction process using non-coking coal as the fuel and reducing agent. Our rotary kilns are known to produce sponge iron rich in metallic iron (pure iron) with consistent chemical and physical characteristics which give steelmakers the needed flexibility to ...

Decarbonisation Options for Rotary Kiln-Induction …

This paper analyses a 350 t/day (tpd) sponge iron plant integrated with an induction furnace and a captive power plant. Several decarbonisation options, such as the use of …

Direct Reduced Iron Industry in India — Problems and …

Introduction of co-generation system has improved economics of the rotary kiln /induction furnace operation. However, the higher initial investment has slowed down the adoption of co-generation, ... The rotary kiln sponge iron has lower metallisation (about 85 — 88% on the average) and low carbon content (0.1-0.2%) compared to gas based ...

Process flow diagram of the sponge iron plant.

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). ... The rotary kiln furnace ...

An Investigation on the Cracking of Air Tubes of Rotary Kilns …

Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. The material of the air tube is ASTM A297 HK 40, a member of the heat-resistant cast alloy family (H series) steels widely used for enhanced high-temperature properties. Microstructural degradation occurring at high temperature …

(PDF) Operation of Coal-Based Sponge Iron …

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.

Optimizing Waste Heat Recovery in the Post-combustion

The hot gases from the rotary kiln used for sponge iron production enter the post-combustion chamber (PCC) placed next to the kiln. ... (PCC) of a sponge iron rotary kiln plant at TSLPL, Joda, is associated with a rotary kiln with a ... Davenport W (2020) Introduction to the blast furnace enthalpy balance, blast furnace ironmaking. Elsevier, …

Rotary Kiln Manufacturers | Electrotherm E&T

Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information. ... Coal based DRI plant; Rotary Kiln with SL/RN Process; ... Hereby we feel glad to have 4000 KW/ 10 Ton DTi Furnace set along with HSMC lX Caster. We have commissioned …

Innov Engineering Pvt. Ltd

ROTARY KILN (Coal-Based DRI Plant) ... We design custom solutions to provide effective and low-maintenance rotary kilns operations for quality sponge iron production through our extensive knowledge and expertise. ... and these gases either come from an external furnace or may be generated inside the kiln. ...

ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …

cope for energy-eficiency improvements by employing feasible WHR system. The WHR-based power generation, the most attractive among a. l, is economically viable for …

IS 15774 (2007): Sponge Iron/Directed Reduced Iron …

(DRI) fines/briquettes for steel making' and IS 13905:1993 'Hot briquette sponge iron (HBI) for steel making'. With the formulation of this standard IS 10812: 1992, IS 13839: 1993 and IS 13905: 1993 stand withdrawn. In this revision, the carbon content for rotary kiln DRI/sponge iron has been modified to around 0.1 percent apart

Decarbonisation Options for Rotary Kiln-Induction Furnace …

The rotary cooler and magnetic separator in a conventional sponge iron plant can be replaced with a gravimetric separator enabling hot charging of sponge iron to the …

LECTURE NOTES ON Sponge Iron & Ferro Alloys

1930-1950s Saggers in Tunnel Kilns- Small Shaft Furnace- Rotary Kilns- Hogganas- Wiberg- Krupp & Lurgi- Coal Based Coal Based Coal Based 1950-1960s Static Reactors- Fluid bed Reactors- ... TATA steel established a sponge iron plant in Keonjhar Dist. Of Odisha. The TDR technology uses a rotary kiln of 4.2mtr internal diameter and 72mtr …

WHRB in Sponge Iron Plant

We are pioneer in supplying waste heat recovery boilers for sponge iron plants and has over 184 installations to date. The boilers are designed to handle large amounts of dust from the flue gas generated in the rotary …

Decarbonizing rotary kiln–induction furnace based sponge iron

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 …