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 ...
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Pressure inside a coal fired sponge iron rotary kiln depends on several operating parameters such as coal injection rate, ore feed rate, moisture, and primary and secondary air blow rates ...
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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 ...
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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 …
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clusters and agglomerates are common in both rotary kiln and shaft based processes. In the presence of context we cannot conceive of a reactor to manufacture sponge iron, which …
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The rotary kiln-based sponge iron unit consists of a rotary kiln, a rotary cooler, a magnetic separator, and a system of conveyors for material handling. The rotary kiln is a long cylindrical rotating drum slightly inclined to the horizontal, internally lined with refractories, and has several port holes located along its length for air ...
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Clients can also choose sponge iron rotary kiln specifications with different lengths, diameters, and sizes according to the required temperature and output of the fired materials. Reasonable design and unique redox principle. Sponge iron is a high-quality ore. It is eliminated by the principle of redox reaction and filtered by sediment removal.
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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 …
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Looking forward to the need of developing coal-based 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. In this pilot plant, a totally indigenous technology for …
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The hot gases from the rotary kiln used for sponge iron production enter the post-combustion chamber (PCC) placed next to the kiln. These gases (1023–1223 K) contain unused carbon monoxide (CO) and unburnt coal, along with other components. Since carbon...
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The company is able to manufacture 0.225 MTPA of Sponge Iron per annum. Each Rotary Kiln is 70 meters long, 4.4 meters wide and inclined at 2.5%. The kilns each have a thick 250mm refractory lining inside, 3 support rollers and a dual drive with two 155 kW DC Motors. Each Kiln also has seven shell air fans and air tubes for air supply inside ...
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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.
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The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital expenditure and no …
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DRI is also known as sponge iron. It refers to porous iron produced by the direct reduction (DR) process. It is the second most viable source of iron used in steelmaking after hot metal which is produced in the blast furnaces (BF). ... DRI is a high-quality metallic iron product produced in a DRI kiln (either rotary or vertical shaft ...
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Contents: IntroductionRotary Kiln Process of Making Sponge IronThermodynamic Considerations: Feasibility of ReactionAerodynamics inside a Sponge Iron Rotary KilnMathematical Modelling in Rotary Kiln Sponge Iron MakingPhysical Movement of Solids inside a Rotary Kiln: Charge Movement and Coal Throwing/SlingingRequirement, Generation and Transfer ...
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sponge iron rotary kiln, coal acts as the reducing agent. as well as the source of energy. Heat is supplied by. 10. VOL. 5 NO. 1 OCTOBER, 2010. STEEL TECH.
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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
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This book, earlier titled as Sponge Iron Production in Rotary Kiln, is revised as per the feedback from students, faculty members and professionals. It, now, covers broad spectrum of alternative routes of iron making, therefore, the book is renamed as Alternative Routes to Iron Making. In this revised edition of the book, three new chapters ...
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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 .
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We have provided engineering and consultancy services for more than 500 Sponge Iron Kilns of different modules / capacities ranging from 15,000 TPA to 100,000 TPA. ... DRI (Rotary Kiln): 100 TPD 175 TPD 350 TPD DRI (Tunnel Kiln) : 30 TPD 50 TPD 100 TPD Iron Ore Palletization : 500 TPD 1000 TPD 2000 TPD
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menjadi sponge iron dalam rotary kiln yang . dilakukan ditunjukkan pada Gambar 3. Bijih besi . Fe . Total<60%. Magnetik Separator. Bijih besi . Fe Total >60% Binder. Batubara . MIXER. PELLET IZER.
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The conventional rotary kiln-based sponge iron (SI) production process in India, which contributed to the manufacture of 33.88 million tons of SI in 2022 was depicted in Fig. 1 (Ministry of Steel, 2023). The SI production system of 100 ton per day (TPD) capacity comprised an inclined rotary kiln (3°), a rotary cooler, an after burning chamber ...
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Rotary Kiln Manufacturers in India. We, Classic Technomec Pvt. Ltd are specializing in the manufacture and supply of high-quality Rotary kilns for Sponge Iron Plants.We made our products with high-quality raw materials as per industry quality standards.
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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. The book comprehensively explains the process of selection and …
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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 of ...
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ROTARY KILN—SOLID REDUCTANT PROCESSES 1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets …
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Innov Engineering is a leading manufacturer and supplier of advanced and custom-made rotary kilns used to heat solids at high temperatures, ensuring durability, efficiency, and longevity. ... We design custom solutions to provide effective and low-maintenance rotary kilns operations for quality sponge iron production through our extensive ...
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Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, and 500 TPD) Solid-state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is …
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These rotary kiln-based sponge iron plants are often accompanied by a power plant to recover heat from the high-temperature kiln-off gases having low calorific value. In the …
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1.1 Image of a Sponge Iron Granule 2 1.2 Microscopic view of sponge iron 4 3.1 Material Balance in a Rotary Kiln sponge iron plant 14 3.2 Energy Balance in a Rotary Kiln sponge based iron making 14 3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24
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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 gaseous reductants (CO + H ...
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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 generate fugitive dust and ...
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Abstract: Direct reduction of iron ore with aid of either carbon or natural gas under controlled temperatures and pressures within a rotary kiln generates sponge iron as a product. However rotary kiln performance is adversely affected by the ring formation known as accretion. These accumulated sintered solid particles which
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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.
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This paper highlights how mathematical modelling of heat transfer and reaction kinetics in a rotary kiln processing iron ore to metallised iron can useful for scaling up a pilot kiln to...
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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, Kiln/cooler pinion shaft, Kiln ...
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Keywords: Sponge Iron, Heat Transfer, Rotary Kiln . 1. Introduction . 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 coal reacts with air to form carbon monoxide which then reduces iron oxide (ore) to iron. So, in a kiln,
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In recent years the production of sponge iron by direct reduction of iron ores has received con-siderable attention by metallurgists. Experiments for the production of sponge iron in a 34 feet long rotary kiln were successfully conducted at the National Metallurgical Laboratory using pellets made from Donimalai haematite ore and
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