The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1].The rotary kiln is a slightly inclined steel cylinder that rests …
quality and productivity of DRI in rotary kiln", Materials Today: Proceedings 56 (2022), pp. 1538-1541. [5] Dey N, "Energy Survey of coal based sponge iron industry", Science Direct, 6 (2015). [6] Choudhury, A. (2014) Energy Audit Methodology of Sponge Iron Manufacturing Units Using DRI Process.
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 …
India is the largest producer of direct reduction of iron (DRI), popularly known as sponge iron and accounted for about 39.3% of the global production in 2020. India's growing economy will require an increase in steel production to meet the demands of sectors …
Pig iron is produced through the smelting of iron ore in a blast furnace, while sponge iron is produced through the direct reduction of iron ore in a rotary kiln. Pig iron has a higher carbon content, making it brittle and heavy, while sponge iron has a lower carbon content, making it more ductile and lightweight.
The direct carbon dioxide (CO 2) emissions from the iron and steel sector are nearly 7 % of the global CO 2 emissions from energy use. India is the world's second-largest producer of steel and the largest sponge iron producer. India produces one-third of the global sponge iron, mostly from rotary kilns using coal as an energy source, resulting in higher energy …
The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon dioxide and entrained dust.
Sponge iron kiln's cylinder: The design of the sponge iron rotary kiln cylinder is more reasonable. The cylinder is rolled with a Q235-B steel plate to ensure five mechanical properties, usually with automatic welding. The wall thickness of the cylinder is generally 25 mm, and that of the firing zone is 32 mm. ...
Flow of Materials in Rotary Kilns Used for Sponge Iron Manufacture: Part I. Effect of Some Operational Variables AMIT CHATTERJEE, A. V. SATHE, M.P. SRIVASTAVA, and P.K. MUKHOPADHYAY ... TDR (Tisco Direct Reduction) process of sponge iron manu- facture. 3 In order to commercialize the TDR technology to plants of 300 to 500 tpd …
However, for coal-based DR the reductant is generated from non-coking coal and rotary kilns, rotary hearth furnaces and multi-hearth furnaces are used (Ghosh and Chatterjee, 2017). It has been estimated that approximately 65-75% of sponge iron production cost is attributed to the cost of raw materials (Indian Bureau of Mines, 2011).
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
This study evaluates major options for CO 2 abatement in the rotary kiln–induction furnace process for steel production. Based on the mass and energy balances of a typical …
2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters. Based on grid ...
Our lateritic nickel rotary kiln is mainly used to smelt lateritic nickel ores so as so get nickel pig iron. So far CITIC HMC Co., Ltd has successfully carried out many projects in China, such as Guangqing in Guangdong …
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 ...
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.
Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent …
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.
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 …
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 and gas (air) along the length of the kiln. These parameters are studied based on variation of input parameters such as angle of inclination, number of rotation and mass ...
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 waste ...
The present paper deals with 2D CFD model of rotary kilns employed in sponge iron process. Using this model the effects of variations of input parameters, …
Electrotherm E&T is the foremost manufacturer of Coal Based Rotary Kiln for Sponge Iron (100 TPD, 350 TPD). Download Rotary Kiln PDF to get more product information.
The formation of accretions or 'rings' in rotary kilns used for the manufacture of directly reduced iron (sponge iron) affects the residence time of the charge, kiln hold-up, and the kiln output to a great extent. In this part of the work, the effect of ring formation was simulated at room temperature in a scaled-down model of a rotary kiln by inserting …
sponge iron manufacturing process and suggested improvement in that [8, 10, 11]. Directly reduced iron (DRI, or called sponge iron) has been found an excellent feed in electric arc ... 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
(DRI) fines/briquettes for steel making' and IS 13905:1993 'Hot briquette sponge iron (HBI) for steel making'. With the formulation of this standard IS 10812: 1992, IS 13839: 1993 and IS 13905: 1993 stand withdrawn. In this revision, the carbon content for rotary kiln DRI/sponge iron has been modified to around 0.1 percent apart
Efforts to increase the degree of metallization of iron ore pellets to min. 90% in the reduction process in the rotary kiln with a continuous process has been carried out in 2012.
in the Sponge Iron kiln can not be eliminated since it originates from the input constituents of the process. The extent of interaction appears to increase with the alumina content of the
Sponge iron rotary kiln is professional equipment for smelting sponge iron. Due to its high degree of mechanization and low labor intensity, many sponge iron plants around the world use the rotary kiln process to …
`the quality requirements for the rotary kiln sponge iron process. The sponge iron fines generation is high and ranges from 15 — 30% depending upon the ore used due to high reduction degradation. This will not only reduce the sales realization of the product but also will lead to accretion formation in the
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