Unnel Kiln Process For Sponge Iron Making

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

A: Solid iron output like HYL, MIDREX and rotary kiln-based sponge iron production COREX is the only smelting process to be deployed industrially on a scale comparable to the blast furnace HISMELT, FINEX, HISARNA, etc. - all in pilot-scale/trial stage till date

Coal, iron ore, and dolomite are used as raw materials. The iron ore is reduced to sponge iron inside the rotary kiln. The coal enters from both ends of the rotary kiln; one end is known as the feed side, and the other is the injection side. The iron ore, dolomite, and coal (nearly 50% of the total coal required) enter from the feed end of the ...

The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, the departing oxygen causes micro pores in the ore body making it porous. The final product, when observed under a microscope, resembles a honeycomb structure looking spongy in texture, hence the name sponge iron. ... Coal based Rotary Kiln process - Solid ...

The reduction process takes place in a gas fired tunnel kiln at around 1200°C for 60 hours producing a sponge iron cake that is crushed, milled and magnetically separated from …

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].

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:-

Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is ...

The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world. This book comprehensively deals with the production of sponge iron in the rotary kiln. The book is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and basic principles of sponge …

In the conventional process, the sponge iron leaving the rotary kiln at 1,020 °C (Dey et al., 2015) is cooled to 110 °C for two reasons: (i) to prevent re-oxidation of the sponge iron when ...

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

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 …

It is seen that the growth of sponge iron industry in last few years is unremarkable and today India is the largest producer of sponge iron as it covers 16% of global output. Sponge iron is used as feedstock and a recognized alternative to steel scraps in iron and steel making processes.

In sponge iron production plant by tunnel kiln method, after crushing and screening raw materials, iron ore, coal and limestone are mixed and charged in storage bins in certain ratios. By using an automatic charging system, raw …

Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is ...

In a traditional rotary kiln process, sponge iron comes out of the rotary kiln at about 1020 °C and is then cooled to 110 °C in a rotary cooler before being separated from a solid mixture containing sponge iron, coal ash, and dolo-char mixture. Sponge iron is then stored and later used in the steel-making process.

Manufacturing Process with Energy mapping. 4 4 Energy Management WITH WHAT (Philosophies & Tools) •Rotary Kiln equipment •Power plant equipment. ... Iron Ore Crusher Sponge Iron (DRI) Kiln MET Coke Cold Briquette Mn Fines Briquette Fluxesi.e. Dolomite, Quartz, Lime stone, etc. Blast Furnace Induction Furnace WHR Boiler AFBC Boiler

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Sponge Iron Industry - Download as a PDF or view online for free ... Oxidation of iron ore in the feeding area. process zone, kiln 2. Recuperator (in lieu of 3. Flue gas from the kiln WHRB) through the upper end. 4. Dust of char, unburnt lime, 3. Discharge end and cooler sulphur, alumina and others discharge.

production of sponge iron was investigated with calcium carbonate, sodium carbonate, and barium carbonate cata-lysts under different conditions using the tunnel kiln meth-od. The …

Sponge Iron Heat & Mass Balance - Free download as Excel Spreadsheet (.xls / .xlsx), PDF File (.pdf), Text File (.txt) or read online for free. The document provides information about the chemistry and properties of raw materials used in a coal-based direct reduction process. It includes the composition and analysis of iron ore, feed and discharge coal, sponge iron, …

the models were validated with data 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

Rotary Kiln Process of Making Sponge Iron - New Age International. EN. English Deutsch Français Español Português Italiano Român Nederlands Latina Dansk Svenska Norsk Magyar Bahasa Indonesia Türkçe Suomi Latvian Lithuanian česk ...

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.

1 1 Review of Sponge Iron Making Processes Historical Development. 2 Reasons for Rapid growth of DR Process 3 Chronological Evolutions of some of the DRI Processes 4 …

based reduction of iron ore into sponge iron is one of the proficient commercially efficacious carbo-thermal beneficiation processes. Sponge iron has gained popularity in steel making as a substitute for scrap due to its low content of sulphur and also high metallic content of iron. The rotary kiln is the back-bone of sponge iron production.

With a boom in the steel industry all over the world today, the demand of sponge iron has considerably increased as a feed (raw) material to steel making. The increase in the demand of sponge iron is also due to the fact that it is used for replacing coke making required for blast furnace processing. The primary objective of this book is to provide the basis, principles, …

In this study, the goal is to apply the methodology to production of direct reduced iron (DRI) or sponge iron using the model developed by Runkana et al. (2010). Direct reduction is an alternative ...

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 ...

sponge iron is produced in shaft furnaces using natural gas, 80.1 % of the sponge iron produced in India is from the coal-based process (Ministry of Steel, 2020). The rotary kiln process uses iron ...