The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge. Sponge iron production in rotary kiln kindle edition by sarangi, a. Operation and construction details a schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in fig. The present work identifies the basic features of burden movement in a rotary kiln. A muffle rotary kiln is indirect combustion kiln, it applies to high grade iron ore and mill scale, in the condition of reducing atmosphere and high temperature, the iron ore is reduced and volumn shrink, to become high density of dri hddri. The results showed that the rotary kiln could be divided into three major functional zones. However, rotary kiln process suffers from serious limitations like low productivity and pollution. Rotary kiln process of making sponge iron c rotary kiln process of making sponge iron that the entire production by number 2. Direct reduction processes are classified, the process to be adopted is the rotary kiln process using lowgrade, process flow of sponge iron making. Primary and secondary airs are supplied to the kiln to initiate combustion and reaction processes choudhury, 2014. Expired lifetime application number us700181a inventor john p riott original assignee john. Hatch has developed a proprietary onedimensional kiln model to. They are also used for roasting a wide variety of sulfide ores prior to metal extraction.
A rotary klin process rotary kiln method is very important for sponge iron production using noncoking coal as a reluctant the iron ore is charged from one end with noncoking coal which is in the lump form or pellets and heated from. Once we have a rough design of the rotary kiln, rotary kiln process of making sponge iron c pdf dateirotary kiln process of making sponge iron substituted by a ported kiln design, fig. Rotary kiln process of making sponge iron new age international. Rotary kilns figure 1 are used for a range of mineral processing operations. Two of the most common applications are for cement production and sponge iron production. Industrial rotary kilns used in iron making are complex reactors having several functions. The material is cooled down to 100oc and fed to magnetic separator for separating the sponge iron and nonmagnetic char.
Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of. Sponge iron production in rotary kiln pdf rotary kiln process of making sponge iron sponge get price f cover sponge iron india sep 10 2012 and induction furnace for steel. Sponge iron rotary kiln, sponge iron rotary kiln, alibaba offers 587 sponge iron rotary kiln products about 71 of these are cement making machinery, 8 are other mining machines, and 1 are industrial furnace. Im nikhil chaurasiya from government polytechnic college satna branch cement technology. Coal based direct reduction rotary kiln process ispatguru. The cold model study was conducted with iron ore as the feed material to determine the influence of length to diameter ratio ld of a rotary kiln on the filling degree, holdup, and residence time of the charge. The cooler is 12m in length and water is sprayed directly as well as indirectly for cooling the material. A thesis submitted for partial fulfillment of the degree. Coal, dolomite and iron ore or pellets are fed into one end of a rotary kiln, while sponge iron and char are withdrawn from the other end. Rotary kiln cement rotary kiln and sponge iron rotary kiln.
The original software was used to model the operation of a 35 m pilot kiln at the stellco company. Modelling and optimization of a rotary kiln direct. T srinivasa rao, md, balajiswamy premium steels pvt ltd offered his 50tpd kiln for this purpose. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Iron ore iron 6567 % sio2 + al2o3 23 % cao + mgo 0,51 % sulphur 0,02 % max phosphorus 0,04 % max chemical composition size 518 mm shatter index +95 % tumbler index +88 % reducibility index +94 % thermal degradation index 5 % physical composition. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same.
Presentation from tata sponge iron ltd was very much liked and lot of the people showed. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process. We are here to bring together china factories that supply manufacturing systems and machinery that are used by processing industries including but not limited to. The iron ore along with coal is charged into the kiln and air tubes located along the length supply the air for combustion. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production, commercially used dr direct reduction processes and physicochemical principles of sponge iron production. Sponge iron coal based in tunnel kiln grinding mill china.
China manufacturing industries are full of strong and consistent exporters. In the industry, there have been many recent reports of premature failures of certain air tubes in a. Direct reduction process an overview sciencedirect topics. Kilnrotary kilnsponge iron division kiln350tpd kilnsupport rollertyregirth gearkiln maindrive duration. It has its roots in a fortran program that was developed by venkateswaran 1978 to study the reduction of iron ore. Use features like bookmarks, note taking and highlighting while reading sponge iron production in rotary kiln. Sponge iron production in rotary kiln pdf rotary kiln process of making sponge iron the production of steel began in ancient times but because of the complexity and.
Sponge iron production in rotary kiln foticrociere. Coal based rotary kiln for direct reduced iron sponge iron 100 tpd, 350 tpd, 500 tpd solid state reduction of iron ore using either coalgas as a medium of reduction to produce a substitute raw material for steel making is termed as direct reduced iron dri. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed. Pdf operability analysis of direct reduction of iron ore. Rotary kiln process of making sponge iron the production of steel began in ancient times.
Genetic algorithms based multiobjective optimization of. An empirical equation correlating different operating variables has been derived on the basis of. Sarangi, b download it once and read it on your kindle device, pc, phones or tablets. The process of dri or sponge iron making can be classified into different categories as given below. China rotary kiln, rotary kiln manufacturers, suppliers. Dri is also known as sponge iron, it is a solidstate direct reduction process fig. Us2462900a reduction accelerator for the sponge iron. The rotary kiln process is a commonly practiced method in india for producing coal based sponge iron. Sponge iron rotary kiln process anticorruption helpline. Iron and steel making machines pioneers in the industry, we offer induction melting furnace, rotary kiln coal based dri plant, tunnel kiln coal based dri plant, modular billet caster, electric arc furnace and vibro feeder from india. 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 iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Boudouard reaction, dolomite, dri, iron ore, metallization, non coking coal, pellets, reduction, rotary kiln, sponge iron, sulphur, coal based direct reduction rotary kiln process.
Flow of materials in rotary kilns used for sponge iron. An investigation on the cracking of air tubes of rotary. Iron and steel making machines induction melting furnace. Sponge iron composition manufacturing process lloy. In coal based sponge iron technology, the furnace rotary kiln fulfils various functions. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. The maximum recommended kiln shell temperature varies by plant, by country and by kiln manufacturer, despite the fact that most kiln shells are made of low alloy carbon steel. Kilns range in size from 26 m in diameter and can be 50225 m long with an operating mass of up to 3000 t. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. Consequently, they were replaced by the high production rate indirect process, and the development of modern dr process did not begin until the middle of 19th century. This book comprehensively deals with the production of sponge iron in the rotary kiln.
The material of the air tube is astm a297 hk 40, a member of the heatresistant cast alloy family h series steels widely used for enhanced hightemperature properties. The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the. A rotary kiln is a pyroprocessing device used to raise materials to a high temperature calcination in a continuous process. The kiln model applied in this work was developed by hatch over a number of years and has been used for several rotary kiln projects. Study on accretion formation on dri kiln during spong iron. The rotary kiln is slightly inclined at an angle 2. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. One of the major challenges for sponge iron plant is the accretion formation. China rotary kiln for sponge iron making equipment products. What is the maximum continuous shell temperature a kiln stands without permanent damage to the shell. Simulation of rotary kiln used in sponge iron process.
The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation. Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The zenith mining machine is custom designed to reduce your operating costs and increase your mine production by. Study on air tubes failure in sponge iron rotary kiln. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a selectgrade of ironcoking coal little dolomite inside an inclined rotary kiln and control busted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished product. It is used as a conveying, mixing and charring unit, as a heat exchanger and as a reactor for coal. Microstructural degradation occurring at high temperature affects mechanical and corrosion. More than 100 dr processes have been invented and operated since 1920. Because of their regular size and shape, and their hard, dense nature, pellets were considered an ideal feed material for.
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