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Process Making Sponge Iron Rotary Kiln

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A

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 iron.Simulation of Rotary Kiln Used in Sponge Iron Process,,Rotary kiln is cylindrical in shape and is 80m long having 4.2m internal diameter. This is the reactor of the process where reduction as well as combustion reactions are carried out. The role of kiln is to convert the raw material (iron ore, coal and dolomite) into the sponge iron [8]. Detail reaction mechanism of the process is discussed below:SPONGE IRON PLANT,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:- www.spongeitc.com 2 1) Physical requirements:- Strength and granulometry are the two,

sponge iron process

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. The mean particle size ratio of iron ore to feed coal shall be in the range of 1.2 to 1.5 depending up on the characteristicsSponge iron making process - SlideShare,09/11/2014· Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical CompositionA Thesis Submitted for Partial Fulfillment of the Degree,,clusters and agglomerates are common in both rotary kiln and shaft based processes. In the presence of context we cannot conceive of a reactor to manufacture sponge iron, which operate above 11000C, even though there have been prolonged attempts to produce sponge iron and semi-fused iron at higher temperature. It is very easy to reduce the higher oxides of iron to FeO

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. A temperature profile ranging fromCoal based Direct Reduction Rotary Kiln Process – IspatGuru,The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI). The reduced product having high degree of metallization shows aSponge 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

Simulation of Rotary Kiln Used in Sponge Iron Process,

Rotary kiln is cylindrical in shape and is 80m long having 4.2m internal diameter. This is the reactor of the process where reduction as well as combustion reactions are carried out. The role of kiln is to convert the raw material (iron ore, coal and dolomite) into the sponge iron [8]. Detail reaction mechanism of the process is discussed below:SPONGE IRON PLANT,The process proposed to be adopted is the rotary kiln proposes using Non-coking coal and iron ore. Iron are undergoes the following reduction reaction in all the processes Fe2o3+ 2 CO = 2 Fe + 3 Co2 As shown in above reactions, carbon monoxide is reducing gases.Rotary Kiln Process Of Making Sponge Iron,process of sponge iron by rotary kiln – Grinding Mill China. Posted at: January 5, 2013 . Rotary Kiln Process of Making Sponge Iron The production of steel began in ancient times; but because of the complexity…. Click & Chat Now

Sponge iron making process - SlideShare

Sponge iron making process 1. ALBERTUS SEPTYANTOKO 2712100014 2. IRON ORE • Iron = 65-67 % • SiO2 + Al2O3 = 2-3 % • CaO + MgO = 0,5-1 % • Sulphur = 0,02 % max • Phosphorus = 0,04 % max Chemical Composition • Size = 5-18 mm • Shatter Index = +95 % • Tumbler index = +88 % • Reducibility Index = +94 % • Thermal Degradation Index = 5 % Physical CompositionAccretion 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. A temperature profile ranging fromRotary Kiln Process Of Making Sponge Iron,Rotary kiln process of making sponge iron c. 2009-4-15rotary kiln process of making sponge iron 13 that the entire production by number 2 3 and 4 countries is through gas based route while in india more than half the production is by the coal based route 25 the indian scene situation in india. Accretion Control in Sponge Iron Production Kiln using . This study focuses on sponge iron kiln based,

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(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to,,Also, the process conditions in a sponge iron rotary kiln are dynamic in nature. Hence, the quality keeps fluctuating and is not a constant value. A mathematical mass Hence, the quality keeps,Modelling and optimization of a rotary kiln direct,,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.

Energy survey of the coal based sponge iron industry,

01/09/2015· 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 different production rates.SPONGE IRON PLANT,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 ore2 D Model of Sponge Iron Rotary Kiln Developed Using CFD,A schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in Fig. 1. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m internal diameter with nine different ports of secondary air. In general, the variation in length and diameter of the kiln is from 40 to 100 m and 2,

Rotary Kiln Process Of Making Sponge Iron

process of sponge iron by rotary kiln – Grinding Mill China. Posted at: January 5, 2013 . Rotary Kiln Process of Making Sponge Iron The production of steel began in ancient times; but because of the complexity…. Click & Chat NowMaking Sponge Iron With Rotary Kiln,Sponge Iron Composition Manufacturing Process. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of ironcoking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled magnetically separated screened and size wise in finishedModelling and optimization of a rotary kiln direct,,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.

(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to,

Also, the process conditions in a sponge iron rotary kiln are dynamic in nature. Hence, the quality keeps fluctuating and is not a constant value. A mathematical mass Hence, the quality keeps,Rotary Kiln Process Of Making Sponge Iron In Ethiopia-,Rotary Kiln Process Of Making Sponge Iron In Ethiopia. 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 desulphurizing agents limestone or raw dolomite into an inclined rota. Chat Online . Hot Products. New. Spring Cone Crusher Add to cart. New. Hydraulic,Energy survey of the coal based sponge iron industry,,01/09/2015· 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 different production rates.

DRI UPDATE - Sponge Iron Manufacturer India

during the steel making through the induction furnace route.,2. 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, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of,Direct Reduced Iron and its Production Processes –,DR process, DRI, HBI, Iron making. Metallization, reformed natural gas, residual elements, Rotary kiln, Direct Reduced Iron and its Production Processes. Direct reduced iron (DRI) is the product which is produced by the direct reduction of iron ore or other iron bearing materials in the solid state by using non-coking coal or natural gas. Processes which produce DRI by reduction of iron ore,,