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Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3 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 At about 10 m into the kiln the volatiles in the coal are released resulting in a local temperature spike due to combustion of the volatiles in the freeboard.
Energy Audit Methodology Of Sponge Iron Jul 14 2014nbsp018332most of the plants in india use dri processa solid state direct reduction process by which iron ore is reduced to sponge without phase change figure 1 raw material mixiron ore dolomite and coal are fed to one end of rotary kiln and product sponge iron along with char is taken out from the other end apart from this primary.
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 desulphurizing 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.
The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace rotary kiln furnace or fluidised bed Sponge iron can be produced in the form of Direct Reduced Iron DRI Hot Briquetted Iron HBI and Cold Briquetted Iron CBI also Low Reduced Iron LRI which is prereduced iron ore with a reduction and metallisation degree lower.
Sponge Iron Production In Rotary Kiln Arabinda Sarangi As a leading global manufacturer of crushing equipment milling equipmentdressing equipmentdrying equipment and briquette equipment etc we offer advanced rational solutions for any sizereduction requirements including quarry aggregate grinding production and complete plant plan.
Sponge iron production by tunnel kiln method was developed from 1911 as H246gan228s method in Sweden After many modifications now this process is a sufficient and effective method for sponge iron production The main advantage of tunnel kiln process is the possibility to build small plants with low investment costs which are feasible economically.
1 Y FOLLOWED FOR SPONGE IRON This chapter describes the Generally in any sponge iron process reduction is conducted in a refractory lined rotary kiln The coal and iron ore are metered into the high end of the inclined kiln A CO with FeO to form CO2 and metallic iron.
Sponge Iron an overview ScienceDirect Topics 3331 Direct Reduced Iron 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 176C Iron oxide is charged into shaft furnace rotary kiln or fluidized beds in the form of pellet iron ore lumps or fines.
Iron ore and noncoking coal are the prime raw materials for the production of sponge iron These are charged into a rotary kiln in requisite proportion along with some dolomite Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 9501050 o C.
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 raised 35 up production has been increased 510 and heat consumption has been reduced 15 down.
discussion is restricted to the rotary kiln process only Normally the rotary kiln is 60125 m long L a n d 46 m in diameter D and the L D ratio is about 1520.
The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace rotary kiln furnace or fluidised bed Sponge iron can be produced in the form of Direct Reduced Iron DRI Hot Briquetted Iron HBI and Cold Briquetted Iron CBI also Low Reduced Iron LRI which is pre.
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 noncoking coal Patra et al 2005 The reduction process is carried out in an inclined horizontal rotary kiln which rotates at a programmed speed.
Index TermsSponge 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 carbonaceous fuels as coal The reduced iron having high.
MANUFACTURING PROCESS Coal based Direct reduction process is classified based on the reducing agent namely solid Most solid reduction process use noncoking coal as reducing agent due to abundantly available noncoking coal The process proposed to be adopted is the rotary kiln proposes using Noncoking coal and iron ore.
Mineral Processing Mining Excellence Awards 2018 This award recognises a mine or mining company or a project that has developed or carried out an innovative or unique minerals processing program that increased productivity and efficiency nomination criteria 1 program implemented between jan 1 and 31 dec 2018 2 demonstrable success in relation to productivity efficiency andor safety.
Use Of Fines For Sponge Iron Production In Coal Brief process of coal based sponge iron rotary kiln 2 d model of sponge iron rotary kiln developed variation in mass fraction of fe content in kiln outlet stream is observed based on kiln which consists of iron ore coal rotary kiln of sponge iron process get price and support online a.
Computational fluid dynamics analysis of sponge iron Simulation of rotary kiln for sponge iron process is based on combustion of coal particles and reduction of iron ore The heat transfer inside the kiln is done through radiation The model equations used for computation of desired parameters such as temperature profile and metallization are tabulated in Table 3.
Mar 16 2013nbsp018332The coal based process uses any one of the four types of reactors for the reduction reaction These reactors are i rotary kiln ii shaft furnace iii fluidized bed reactor and iv rotary hearth furnace Rotary kiln is the most popular reactor for the coal based process The principle of the direct reduction of iron ore is shown in Fig 1.
direct reduction of iron ore by coal in a rotary kiln using a rigorous process model Though the objective is not to quantify OI but to develop deeper understanding of the process the.
Market share About 23 of sponge iron total production 4 Tunnel furnace process This process is the oldest direct reduction method In this method Thermal coal is mixed with iron ore as a reducing agent Natural gas generates the required reduction temperature and reduction is performed on Silicon Carbide SiC Crucibles in a tunnel furnace.