rotary kiln based sponge iron plant process

SPONGE IRON PLANT

The major Raw Materials required for production of Sponge Iron by the rotary kiln process are: sized graded Iron Ore and Non-Coking coal. Limestone, in small quantities, is also required to scavenge the sulphur. IRON ORE The quality requirement of Sized ore for sponge iron production can be classified into:- spongeitc 2 1) Physical requirements:- Strength and granulometry are the two ...

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(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to ...

Operation of Coal-Based Sponge Iron Rotary Kiln ... A graphic user interface is used by the operator to control the process. Results of plant trials are described. Minimum response time of a large ...

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sponge iron process

29/07/2010  In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product. The mean particle size ratio of iron ore to feed coal shall be in the range of 1.2 to 1.5 depending ...

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Accretion Control in Sponge Iron Production Kiln using ...

processing plant determines the type of control strategy to be implemented. Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the accumulation of semi-molten material which form rings along kiln ...

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A Thesis Submitted for Partial Fulfillment of the Degree ...

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 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air material flow in ...

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Sponge Iron - an overview ScienceDirect Topics

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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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN

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 iron. Depending on its content of volatile matter, the coal is part-ly blown into the ...

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Accretion Control in Sponge Iron Production Kiln using ...

processing plant determines the type of control strategy to be implemented. Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the accumulation of semi-molten material which form rings along kiln ...

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A Thesis Submitted for Partial Fulfillment of the Degree ...

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 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air material flow in ...

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Energy survey of the coal based sponge iron industry ...

01/09/2015  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 different production rates.

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Process Description and flow diagram of Coal Based DRI

07/08/2016  Process Description and flow diagram of Coal Based DRI Plant. Description of Sponge Iron Manufacturing Process . Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change. Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln as well as some fine coal also fed from discharge

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Sponge iron making process - SlideShare

Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical Composition

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Coal Gas based DRI Plant - Rotary Kiln for Making

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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DRI UPDATE - Sponge Iron Manufacturer India

ABOUT US- A MICRO INTEGRATED STEEL PLANT 2002-2004 3 x 50 TPD Sponge Iron (DRI) Kilns 2007-2010 2 x 23 m 3 Micro Blast Furnace 2010-2011 Cold Briquetting Unit 2017-2018 6 MW Power Plant based on WHRB AFBC 2017-2018 3 nos. Induction Furnace 2019-2020 Continuous Caster-Hot charging-Rolling Mill 2

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Development of energy conservations scenarios for

16/01/2011  When unutilized energy of the process is properly integrated, energy demand from outside sources can be reduced. It decreases coal consumption as coal is the only source of energy in this plant. For energy integration in sponge iron process pinch is applied on the actual data of plant. Based on this data, seven energy conservation ...

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ORISSA SPONGE IRON AND STEEL LTD.

- Coal based DRI Plant of 350 500 TPD. - Power generation facility from waste heat of DRI off gas. - Steel making through IF / EAF including secondary metallurgy. Know how and Basic Engineering Services for : - Coal based DRI Plant - Steel Plant through IF / EAF - Power generation by utilizing the waste heat Plant Engineering for : - Coal based DRI Plant - Steel Plant Designer’s ...

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SPONGE-IRON - Shakambhari Group

In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850°C -1,500°C). The inclination and the rotary motion of the kiln ensures ...

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Flow of materials in rotary kilns used for sponge iron ...

Looking forward to the need of developing coal-based sponge iron 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 for production of ...

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SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE

Abstract: Today India stands as the largest producer of coal based sponge iron through rotary kiln process using calibrated ore and non coking coal. However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated ...

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Sponge Iron - MSPSteel

In the DRI plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. The reduction is carried out in a rotary Kiln (which is inclined and rotates at a pre-determined range of speed) at a stipulated temperature ( 850 °C – 1050°C). The inclination and the rotary motion of the Kiln ensure that the raw ...

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Sponge iron making process - SlideShare

Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical Composition

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SPONGE IRON – Lloyd’s Metals

Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a ‘select’ grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished product bunkers prior to dispatch.

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Direct Reduced Iron and its Production Processes –

The coal based rotary kiln process combines the Republic Steel-National Lead (RN) process developed in 1920s for beneficiating low grade ores, and the Stelco-Lurgi (SL) process conceived in the early 1960s for producing high-grade DRI. DRI production process. The DRI production process involves the intimate mixing of prepared (sized) iron ore with a reductant, which is also generally used

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about us - ORISSA SPONGE IRON AND STEEL LTD.

It was the fi rst 100,000 TPA commer cial scale coal based Sponge Iron Plant in our Country and one of the first few in the World. ... Two nos. Rotary Kiln based Sponge Iron plants : One of production capacity 100,000 TPA and the other having 150,000 TPA capacity. Two nos. Waste Heat Recovery Power Plants : One with 15 MVA capacity and another having 30 MVA capacity. One Steel Billet Plant

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Development of energy conservations scenarios for

16/01/2011  When unutilized energy of the process is properly integrated, energy demand from outside sources can be reduced. It decreases coal consumption as coal is the only source of energy in this plant. For energy integration in sponge iron process pinch is applied on the actual data of plant. Based on this data, seven energy conservation ...

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kiln for sponge iron - Alibaba

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 3-5% up, production has been increased 5-10% and heat consumption has been reduced 15% down.

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