(PDF) i) Direct Reduced Iron: Production
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.
Steel Exchange India Ltd
Sponge Iron and Coal Char are discharged from the kiln through a 12 meters long rotary cooler where water is sprayed directly as well as indirectly for cooling the material down to 100oC. The material is then fed to magnetic separator for separating the Sponge Iron and non-magnetic coal char after which the Sponge Iron is transported by way of ...
Mathematical Modelling of Sponge Iron Production in a Rotary Kiln
We have applied predictive data analytics techniques for off-line optimization of granulation and sintering of iron ore fines, for on-line optimization of sponge iron production in a rotary kiln ...
Mass balance around main components of the plant on …
It resulted in the reduction of energy consumption from 5.57 to 4.9 times in comparison to the existing system. Prasad et al. (2011b) proposed design modifications for the sponge iron industry ...
Sponge 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 …
Computational fluid dynamics analysis of sponge iron rotary …
The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m internal diameter.For different production …
Sponge Iron Plant.pdf
The document describes the raw material requirements, manufacturing process, and basic components involved in a typical coal-based rotary kiln system for producing sponge iron. ... Sponge Iron Plant Rotary …
Computational fluid dynamics analysis of sponge iron rotary kiln
2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters.
[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 package (ANSYS 13.0). …
ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR DIRECT …
3.2 Iron Ore Preheating Rotary Kiln Using Waste Heat Recovery System 20 3.3 Coal Gasification for Partial Substitution in Rotary Kiln 22 3.4 Waste Heat Recovery-based Absorption Chiller 23 3.5 Decentralized Control of Shell Air Fans 25 3.6 Mullite-based Kiln Lining 26 3.7 Switch Over to Iron Ore Pellets 27
(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to …
Conference: AISTech 2019 — Proceedings of the Iron & Steel Technology Conference 6–9 May 2019, Pittsburgh, Pa., USA; At: Pittsburgh, USA
| Engineering & Consultancy
We designed and commissioned our first Sponge Iron plant of capacity 10,000 TPA near Hyderabad in 1995 and achieved rated production capacity from the first year onwards. ... We have proficiency in converting cement kilns for Sponge Iron production. ... (Rotary Kiln): 100 TPD 175 TPD 350 TPD DRI (Tunnel Kiln) : 30 TPD 50 TPD 100 TPD Iron Ore ...
Rotary kiln process: An overview of physical …
5 Figure 3: Granular flow regimes and the Froude number associated with each bed movement [13] Yin et al. [14] stated that the flow into the active layer depends mainly on both the Froude number (Fr = ω2R/g, where ω is the angular velocity of rotation and g the acceleration of gravity) and size ratio ( O= ã/, where ã is the particle diameter and the radius of the kiln cylinder).
Schematic diagram of plant and the rotary kiln (see arrow) …
It has been shown earlier that the sponge iron rotary kiln is a chaotic, dynamical (nonlinear, time-varying) system [4][5] [6] [7][8]. The present work is the first application of both OSAA and ...
Schematic diagram of plant and the rotary kiln (see arrow) …
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.
Ghugus (Chandrapur, Maharashtra)
Lloyds Metals and Energy Limited. (LMEL) is a unit of Lloyds Group which is in the manufacturing of Sponge Iron had initially set up its first 500 TPD (Tonnes per day) kiln with the rated capacity of 1,50,000 TPA by opting OSIL-Technology in the year 1994-95 at the village-Ghugus, District-Chandrapur (Maharashtra).
Direct Reduced Iron (DRI) | International Iron Metallics …
Direct Reduced Iron (DRI) is the product of the direct reduction of iron ore in the solid state by carbon monoxide and hydrogen derived from natural gas or coal. ... In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are ...
Rotary kilns & cooler spares (50 TPD-900 TPD) for cement, sponge iron
We are pleased to introduce Piyali Engineering Corporation, situated in Delhi, India. We are leading manufacturer and supplier specializing in the production of Sponge Plant DRI (Direct Reduced Iron) Rotary Kiln & Cooler equipment and vital components for steel plants, alongside catering to a diverse range of industries including sugar mills, cement plants, fertilizer plants, …
Quality Prediction and Control in Coal-Fired Rotary …
Quality Prediction and Control in Coal-Fired Rotary Kilns at Tata Sponge Iron Ltd. Sampurna Borah 1, Shubhajit Mondal 1, Puneet Choudhary 1, Brahma Deo 1, Susil Kumar Sahoo 2, Parimal Malakar 2,
Dynamic quality prediction and control in rotary sponge iron kilns
The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe.
Advances in Rotary Kiln Sponge Iron Plant
Annotation About the Book: Now that India is virtually the only player in this field, an elaboration is needed with respect to more fundamental understanding as well as future prospects and needs, which this edition has tried to fulfill. It can now fulfill the need of a reference textbook in alternate iron making area for undergraduate and post graduate students in Metallurgical, Production ...
New Sponge Iron Rotary Kiln Design In Sponge …
In the newly designed sponge iron rotary kiln system, a coarse coal branch pipe and fine coal branch pipe are added at the kiln head. The original way of adding coal at the kiln head is changed to 50-70% coal is added together with …
New Sponge Iron Rotary Kiln Design In Sponge Iron …
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.
Sponge Iron plant Equipment – 50 – 900 TPD with High …
Kiln Girth Gear (Spur / Helical Tooth):. Piyali Engineering Corporation is the best quality and top ranked manufacturer and supplier in India for Kiln Girth Gear, Cooler Girth Gear, Ring Gear, Rim Gear, Two Halve Gear, Split Gear, Large Cast Steel Gear, Fabricated Gear, Wheel Gear, Spur Gear, Helical Gear, Double Helical Gear etc. DRI Sponge Iron plant Rotary Kilns & Rotary …
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 affects mechanical and …
Energy Conservation in Sponge Iron Production Process …
gas exits the sponge iron plant at substantially higher temperature ranges ... rotary kiln FD fans are required. The number of FD fans depends on pressure drop available in the duct. Further, an effort is made to reduce the temperature drop of 3.78ºC for the inside diameter of …
(PDF) Rotary Kiln Handbook NEW
The ROTARY KILN HANDBOOK OPERATION | SIZING & DESIGN | CONSIDERATIONS | MAINTENANCE a product of Contents INTRO About FEECO 1 Intro to Rotary Kilns 3 ROTARY KILN OPERATION & PROCESSING How Rotary Kilns Work 5 Rotary Kiln Processes 8 SIZING & DESIGN Rotary Kiln Sizing & Design 11 Increasing Eficiency Through Customization 14 …
Sponge iron: Uses, process formula, iron plant, …
In the DRI plant, sponge iron is produced by using the solid reductant iron ore with carbonate materials such as coil. After, the reduction is carried out in a rotary kiln in which it is rotated at specific speed at the …
Rotary kiln process: An overview of physical mechanisms, …
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 on supports (bearing rollers) …
(PDF) Energy survey of the coal based sponge …
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). A separate conve yor collects ...
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