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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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TATA Sponge employs coal fired rotary kilns to produce sponge iron. Iron ore, coal, and dolomite are charged from one end of rotary kiln (schematic diagram in Fig. 1), and the coal for combustion is fired from the other end.Rotary kiln is slightly inclined so that material flows in forward direction.
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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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Ring formation and heavy build-up in an experimental rotary kiln for production of sponge iron using hematite pellets, bituminous coal and nut coke have been described. The build-up from …
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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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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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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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ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the R&D for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, ... 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 ...
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this study, the best results are obtained sponge iron has a metal content of 62.62% Fe and 95.31% metallization degree. Keywords: iron ore, pulverized coal burner, reduction, rotary kiln, sponge iron.
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This is due to process requirement as discussed in the work of Prasad [8]. The sponge iron is produced in the form of lumps as well as fines. The production of sponge iron depends on metallization of iron ore. Fig. 1. Schematic of rotary kiln For the present work data of a typical industry of 527 T/day production capacity is collected for 25 days.
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This is to certify that the thesis entitled, "Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0)" submitted by Tapash Ranjan Majhi in partial fulfilment of the requirements for the award of Master in Technology Degree in Chemical Engineering with specialization in "Chemical Engineering" at the National Institute of Technology, Rourkela …
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We design custom solutions to provide effective and low-maintenance rotary kilns operations for quality sponge iron production through our extensive knowledge and expertise.
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This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from ...
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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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After retention time of 8–10 h in the kiln, the sponge iron is discharged via a transfer chute into a cooler. Here, the material is cooled below 100 ℃ by indirect cooling in rotary cooler by water. ... This ironmaking process takes only 10 min against 10 h in BF process and 8 h in rotary kiln process. Iron and slag get separated, and ...
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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 lining. These rings narrow the kiln diameter thereby hindering efficient material flow and effect lowering production rate and ...
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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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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 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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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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Keywords: iron ore, pulverized coal burner, reduction, rotary kiln, sponge iron. ABSTRAK . Ketersediaan sumberdaya mineral yang melimpah menjadikan Indonesia sebagai negara yang .
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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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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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A 2D CFD model of rotary kiln for sponge iron process is developed in this work and simulated using ANSYS 14.5. The present study discusses the behavior of temperature profile …
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In this communication, OI methodology is used to study the operability characteristics of direct reduction of iron ore by coal in a rotary kiln using a rigorous process model.
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the largest producer of sponge iron. The Indian sponge iron industry is primarily rotary kiln based and integrated lant and a steel-making unit. This study investigates various decarbonisation options and their impact on the rotary kiln process for sponge iron production. The current process uses two different streams
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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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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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This produces highly metalized direct reduced iron using rotary kiln. Here solid, liquid and gaseous fuels are used directly in the kiln. The ACCAR process ... sponge iron production plant at Chandrapur, Maharastra. The OSIL process uses a rotary kiln of 3.5mtr diameter and 84mtr long. The output of this plant is 300 tons
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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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