rotary kiln design calculations in sponge iron plant

rotary kiln design calculations in sponge iron plant

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

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 ...

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

Modelling and optimization of a rotary kiln direct ...

large number of viable design and operating candidates. Introduction Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production.

SPONGE IRON PLANT

Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by

Energy Audit Methodology of Sponge Iron Manufacturing ...

Jul 14, 2014 · Raw material mix-iron 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 and secondary airs are supplied to the Kiln to initiate the combustion and reaction processes. The reaction takes place at high temp (1050 to 1065˚C ˚C).

FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN DATA

producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near

Accretion Control in Sponge Iron Production Kiln using ...

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 non-coking coal [Patra et al, (2005)]. The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE

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.

Development of energy conservations scenarios for sponge ...

Jan 16, 2011 · 高达10%返现 · Coal based sponge iron plant: a conventional process. The process flow diagram of conventional coal-based sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.

Design Modifications for Energy Conservation of Sponge ...

Mar 10, 2011 · Shravan K. Singh. The present work investigates the design modifications which can lead to efficient energy integration in coal-based sponge iron plant with a capacity of 500 t/day. For the ...

Modelling and optimization of a rotary kiln direct ...

large number of viable design and operating candidates. Introduction Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production.

Simulation of Rotary Kiln Used in Sponge Iron Process ...

parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the ...

Formulas kiln - SlideShare

Jul 22, 2010 · Heat capacity of Rotary kiln 1 Q = 1.1 x 10 ^ 6 x D ^3 (Kcal / hr) D = Mean inside Kiln Diameter on Bricks, m 2 Kiln Thermal loading at cross section of burning zone = Qp = = Q / Fp Fp = 0.785 x D^2 Inside cross-section of the kiln burning zone m^2 where D is kiln shell diameter Q p = 1.4 x 10 ^ 6 x D Kcal / m^2.hr Qp should not exceed 3.46 x ...

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 ...

Accretion Control in Sponge Iron Production Kiln using ...

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 non-coking coal [Patra et al, (2005)]. The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

(PDF) i) Direct Reduced Iron: Production

Mar 30, 2016 · discussion is restricted to the rotary kiln process only. Normally, the rotary kiln is 60–125 m long ( L )a n d 4–6 m in diameter ( D ), and the L / D ratio is about 15–20.

sponge iron process: 2010

Jul 29, 2010 · Mean Particle Size: 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.

Simulation of Fluidized Bed Dryer using CFD for Preheating ...

Keywords—Sponge iron plant, gas–solid fluidized dryer, computational fluid dynamic, Eulerian model. I.INTRODUCTION PONGE iron is the metallic form of iron produced from direct reduction of iron oxide below the fusion temperature of iron ore (1535ºC) utilizing hydrocarbon gases or

Coal & Gas based DRI Plant - Rotary Kiln for Making Sponge ...

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 ...

Waste Heat Recovery Steam Generator in Sponge Iron Plant

In improvement of productivity. addition to fuel handling system, fuel feeding system and combustion chamber with fan and blowers are III. WASTE HEAT UTILIZING BY STEAM eliminated. Effective utilization of energy resources maximum GENERATOR IN SPONGE IRON PLANT of 90% in the sponge iron plant. 3.1. Possibility Eliminates power required for gas ...

Steps On Rotary Kiln Design Calculations

Steps on rotary kiln design calculations rotary kiln design calculations in sponge iron plant We are now working out in their Plant for We boast our expertise in Prices Quote Modelling And Optimization Of A Rotary Kiln Direct Rotary kiln This is determined by i the maximum flow rate of the proposed burden through a kiln and ii the.

calculation on reduction for direct reduced iron in tunnel ...

sponge iron production from ore -coal composite pellets in tunnel kiln. Keywords: Tunnel Kiln, Iron ore-coal composite pellets, Sponge iron, Thermal efficiency, ... products [1-2]. In the year 1908 use of tunnel kiln started for iron oxide reduction. This .... For composite pellets amount of external coal is

Coal based Direct Reduction Rotary Kiln Process – IspatGuru

Feb 14, 2017 · Normally for rotary kiln process volatile matter is to be in the range of 25 % to 30 %. Coals for direct reduction in the rotary kiln need to have low swelling index. Normally swelling index is to be less than 1. The physical and chemical specifications of the non-coking coal are as follows. Size of lumps – 5 mm to 20 mm.

Pellet plant kiln heat energy calculation

Modeling of Rotary Kiln for Sponge Iron Processing Using ... - ethesis. Energy Balance in a Rotary Kiln sponge based iron making. 14 .... of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from ... plants are low compared to integrated steel plants and are more suitable for ..... than what is indicated variant (iv), inputs have been taken from a heat transfer ...

Simulation of Rotary Kiln Used in Sponge Iron Process ...

parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the ...

sponge iron process

Jul 29, 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.

(PDF) Modeling of Rotary Kiln for Sponge Iron Processing ...

Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING Under the supervision of

THE KRUPP SPONGE IRON PROCESS PRODUCTION AND

period during which sponge iron was continu-ously produced on a commercial scale. The tests again confirmed that semi-commercial tests car-ried out in the existing rotary kiln pilot plant furnish reliable design data as well as process characteristics for treating the raw materials in a commercial operation. The pilot plant today

Sponge iron making process - SlideShare

Nov 09, 2014 · ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3

Accretion Control in Sponge Iron Production Kiln using ...

2. Kiln Based Sponge Iron Production Process Rotary kilns are found in many processes that involve processing of solids. 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 non-coking coal [5].

[PDF] Simulation of Rotary Kiln Used in Sponge Iron ...

In the present study, estimation of actual output parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the ...

basic calculations of rotary kiln design

as design tools during the planning phase and, referred to a full-scale rotary kiln healthcare waste, by means of calculations in the real plant The. Read more. ... steps on rotary kiln design calculations (04 Jun ), length, speed, slope and internals design There are two basic types of rotary kilns.

SPONGE IRON - Notion Press

Production of sponge iron from a rotary kiln using coal as reductant is an interesting subject. The rotary kiln atmosphere where oxidising conditions are maintained in free board and reducing contions are maintained in the charge bed gives the operator a real challenge to get quality product keeping the production optimum with cost effectiveness. There are some important features which makes ...

calculation of iron ore rotary kiln

design calculation of rotary dri kiln Solution for ore mining rotary kiln calculation rotary kiln design calculations in sponge iron plant rotary kiln... Know More calculate the retention time of cement in a

Analysis of temperature profile and % metallization in ...

Jun 01, 2016 · The literature discussed above is based on CFD analysis of rotary kiln of cement plant. As the focus of the present work is to study the kiln of sponge iron process, literature related to it is discussed here: Prasad and Ray simulated flow pattern of air using FLUENT software in rotary kiln of a typical 100 tpd sponge

Indirect Rotary Dryer Design Calculations

Rotary Kiln Design Calculations In Sponge Iron Plant. 812 rotary kiln design calculations products are offered for sale by suppliers on Alibaba A wide variety of rotary kiln design calculations options are available to you such as field installation commissioning and training field maintenance and repair service and engineers available to ...

Energy integration in sponge iron plant using heat of ...

For this purpose a case study of typical sponge iron production process is considered. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 °C. This gas has a lot of sensible heat and can be used for energy integration. This heat is used for heating water in a boiler.

Rotary Kiln Maintenance Manual - Rotary Kiln Lubrication ...

rotary kiln operations. Regardless of rotary kiln size or configuration the basic principles outlined in this manual govern the reliable operation of every rotary kiln, calciner, dryer, incinerator, digester and cooler application. For questions or problems with your specific application please contact North American Kiln