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Energy Audit Methodology of Sponge Iron

2014-7-14  Most of the plants in India use DRI process—a solid state direct reduction process by which iron ore is reduced to sponge without phase change (Figure 1). Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary

OPERATIONAL ASPECTS OF SPONGE IRON

2012-1-10  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 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

A Thesis Submitted for Partial Fulfillment of the Degree

2012-5-29  3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

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.

Recovery and utilization of waste heat in a coal based

2012-10-4  Coal-based sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking coal are fed to the kiln at controlled rates without pre-mixing and the charge moves through the kiln depending upon the rotation

(PDF) 2 D Model of Sponge Iron Rotary Kiln Developed

Nov 2016. Gajendra Kumar Gaurav. Shabina Khanam. 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

Coal based Direct Reduction Rotary Kiln Process IspatGuru

2017-2-14  Normally for rotary kiln process volatile matter is to be in the range of 25 % to 30 %. Coals for direct reduction in the rotary kiln need to have low swelling index. Normally swelling index is to be less than 1. The physical and chemical specifications of the non-coking coal are as follows. Size of

Energy survey of the coal based sponge iron industry

2015-9-1  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

New Sponge Iron Rotary Kiln Design In Sponge Iron

2020-9-10  During the sponge iron manufacturing process, hot air enters through the air tube and air nozzle of the sponge iron kiln, providing heat for the reaction. The waste gas produced by the rotary kiln first enters the dust settling chamber, and the settled dust is finally discharged by the scraper. The treated exhaust gas can enter the waste heat

SPONGE IRON PLANT

2018-9-24  Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by

SPONGE IRON PLANT

2018-9-24  Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by

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.

Energy survey of the coal based sponge iron industry

2015-9-1  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

New Sponge Iron Rotary Kiln Design In Sponge Iron

2020-9-10  During the sponge iron manufacturing process, hot air enters through the air tube and air nozzle of the sponge iron kiln, providing heat for the reaction. The waste gas produced by the rotary kiln first enters the dust settling chamber, and the settled dust is finally discharged by the scraper. The treated exhaust gas can enter the waste heat

(PDF) 2 D Model of Sponge Iron Rotary Kiln Developed

Nov 2016. Gajendra Kumar Gaurav. Shabina Khanam. 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

Direct Reduced Iron Industry in India — Problems and

2020-5-6  rotary kiln sponge iron process. Further, in the southern zone, Singareni being the only source, availability of linkage and coal quality are the constraints. The sponge iron plants, therefore, are using any non coking/steam coal available to them. Many of

ORISSA SPONGE IRON AND STEEL LTD.

2017-7-24  · OSIL is a development oriented company and OSIL owns many patents to its credit including the patent for OSIL process: “ A method of continuous manufacture of sponge iron and a ported rotary kiln therefore.”.

Energy Audit Methodology of Sponge Iron Manufacturing

2014-10-14  Conducting complete energy audit (both process and utility) of a sponge iron unit is challenging as there is no laid down procedure to audit the process side. Further, the average heat to power ratio (kW th /kW e ) of sponge iron plants ranges from (25:1) to (31:1). This shows that the manufacturing process mostly uses thermal energy and application of electrical energy is insignificant.

Sponge Iron Sambhv Steel

Sponge Iron. Sponge iron is a highly processed form of iron ore that contains metallic iron in the range of 83-88% obtained by direct reduction through reaction with carbon in the form of coal at approx. 1100 degree Celsius. Due to high porosity, the resulting iron is called sponge iron. Sponge iron is also referred to as direct reduced iron or

FE Techno Engineering & Power Solutions Iron and Steel

2019-8-28  Rotary kiln process is a well established process for production of sponge iron. In this process a refractory lined rotary kiln is used for reduction of iron ore in solid state. A central burner located at the discharge end is used for initial heating of the

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.

(PDF) 2 D Model of Sponge Iron Rotary Kiln Developed

Nov 2016. Gajendra Kumar Gaurav. Shabina Khanam. 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

Sponge iron from magnetite A novel process developed

2021-10-13  Sponge Iron production usually employs the DRI Process, undertaking solid-state reduction of hematite ores with equal proportions of coal. This is brought about by the use of a coal-fired Rotary Kiln, with the environmental impact of the entire process putting

Sponge iron Manufacturing process Simurgh Industrial

2021-11-12  Sponge iron is a metal product that is produced by a direct reduction of iron ore in solid-state. Sponge iron is a good alternative to waste and is mainly used in the manufacture of steel via secondary routes. The process of making sponge iron occurs by removing oxygen from the iron ore.

Modelling and optimization of a rotary kiln direct

2014-8-5  Modelling and optimization of a rotary kiln direct reduction process 55 Figure 3. Kiln temperature distribution for the base case The feed material (bed) enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard.

Direct Reduced Iron Industry in India — Problems and

2020-5-6  rotary kiln sponge iron process. Further, in the southern zone, Singareni being the only source, availability of linkage and coal quality are the constraints. The sponge iron plants, therefore, are using any non coking/steam coal available to them. Many of

ORISSA SPONGE IRON AND STEEL LTD.

2017-7-24  · OSIL is a development oriented company and OSIL owns many patents to its credit including the patent for OSIL process: “ A method of continuous manufacture of sponge iron and a ported rotary kiln therefore.”.

Direct Reduced Iron and its Production Processes

2013-3-16  Fig 2 Principle of direct reduction process. Gas based process. In the gas based reduction processes, a vertical shaft kiln is used in which iron ore is fed into the top of the kiln and finished sponge iron is drawn off from the bottom after cooling it so as

Sponge Iron Sambhv Steel

Sponge Iron. Sponge iron is a highly processed form of iron ore that contains metallic iron in the range of 83-88% obtained by direct reduction through reaction with carbon in the form of coal at approx. 1100 degree Celsius. Due to high porosity, the resulting iron is called sponge iron. Sponge iron is also referred to as direct reduced iron or

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2021-12-1  TOWCO,DRI,HBI,direct reduced iron,hot briquetted iron,Rotary Kiln,coal gas making,Gas-based reduction,Coal-based reduction,Tunnel kiln,Shaft