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 rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge.
2. ed, sima requested the participants to volunteer to spare their rotary kiln for carrying out the ramp;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 the people showed.
8 products available. kiln pinion assembly for 100 tpd dri coal based sponge iron plant rotary kiln 50 tpd 600 tpd; cooler girth gear for 100 tpd dri coal based sponge iron plant.
A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process. when the gases are traveling upwards the charge moves downward by gravity. gasbased sponge iron is not subjected for magnetic separation, as no contamination with nonemagnetic is possible either it can be cooled indirectly or.
The location of sponge iron plant should be at least 500 m away from national highway and state highway. the radial distance between two sponge iron plants should be 5 km for plants having capacity 1000 tpd or more. sponge iron plants can be established in designated industrial areasestates as notified by state government.
This paper presents the potential for energy savings in various capacity sponge iron plants by estimating heat transfer rates using stabilized and optimized temperature data within the rotary kilnreactor. some design aspects of pneumatic coal injector for coal based direct reduction process in rotary kiln ), pp. 145 – 152. 7.
Boudouard reaction, dolomite, dri, iron ore, metallization, non coking coal, pellets, reduction, rotary kiln, sponge iron, sulphur, coal based direct reduction rotary kiln process . the coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials.
Coal based rotary kiln for direct reduced iron sponge iron (100 tpd, 350 tpd, and 500 tpd) solidstate 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). since dri is produced by removing oxygen from iron ore, its structure is just like a sponge with a network of connecting pores.
Coal based rotary kiln: technology : itc (industrial technical consultants) representatives : principal : mr. mukesh bhandari (chairman) email: bhandarimuki: alternate : mr. harish mukati: contact no 91 9879204107 email: hm.
Consequently, sponge iron making in rotary kiln flourished first in south africa, and now india produces over 70 of coal based sponge iron in the world. it is very easy to reduce the higher oxides of iron to feo stage. one only needs to meet the heat demand, the.
Design of waste heat recovery system in a sponge iron plant 2.1 raw materials for rotary kiln 5 2.2 waste heat sources and uses 11 promising availability of coal, the coal based sponge iron plants share the major amount of its production. at present, there are 118 large and small sponge iron plants operating in india,.
Directreduced iron (dri), also called sponge iron, is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas or coal. the reducing gas is a mixture majority of hydrogen (h2) and carbon monoxide (co) which acts as reducing agent.
During lite up there is a start up burner at the kiln discharge end which is oil fired to heat up the rotary kiln. to ignite the injected coal from outlet of the kiln. when the desired temp. is reached, iron ore, coal amp; lime stone or dolomite are fed from kiln feed end and also.
In sponge iron making process, coal is the prime source of energy utilised. about 98 of energy input in the process is coal and 2 electrical energy is consumed in the process. sponge iron making process sponge iron is produced by direct reduction of iron ore carried out in rotary kiln, which involves following chemical reactions:.
These plants use iron ore pellets in the rotary kiln. raw material mix consisting of iron ore, dolomite and noncoking coal is fed at the one end of the rotary kiln and is heated by coal burners to produce dri. the product dri along with char (sometimes called dolo.
In the direct reduced iron (dri) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumpspellets) with a carbonaceous material such as coal. the reduction is carried out in a rotary kiln (which is inclined and rotates at a predetermined range of speeds) at a stipulated temperature (850 c 1,500 c).
In the dri plant, production of sponge iron using a solid reductant involves reducing iron ore (lumpspellets) with a carbonaceous material like coal or lignite. the reduction is carried out in a rotary kiln (which is inclined and rotates at a predetermined range of speed) at a.
In the sponge iron production serves as the motivation of the present research work to propose some better alternative than waste heat recovery boiler to utilize waste heat. along with the energyaspectthepresentworkalsoconsidersbetterutilization of water. 2. coalbased sponge iron process the process of the direct reduction of haematite in a rotary kiln.
It supplies coal based sponge iron to steel plants across the country. process of making coal based sponge iron. galaxy enterprise manufactures coal based sponge iron by treating iron ore with coal in a rotary kiln. this rotating cylindrical vessel has blowers and air pipes mounted upon it and it is lined using firebricks. a burner is used to.
At present, there are 118 large and small sponge iron plants operating in india, among them only 3 are natural gas based and the remaining 115 plants are coal based. among all the available options, rotary kilns have been widely used as a reactor in coal based plants and the important processes applying this technology include: slrn, codir.
Due to promising availability of coal of 264,535 million tonnes the coal based sponge iron plants share the major amount of its production 2. at present, there are 118 large and small sponge iron plants operating in india, among them only 3 are natural.
The increase in the demand of sponge iron is also due to the fact that it is used as a substitute for coking coal which is available in scarcity in the world. this book comprehensively deals with the production of sponge iron in the rotary kiln. the book is divided into 17 chapters. the initial chapters give a brief on the fundamental theories and basic principles of sponge iron production.
Kiln tyre ₹ 1275000 number. cooler pinion with shaft assembly for 50 tpd, 100 tpd, 350 tpd, sponge iron plant ₹ 275000 set. kiln pinion with shaft assembly for 50 tpd, 100 tpd, 350 tpd, sponge iron plant ₹ 410000 set. kiln cooler support roller with shaft assembly ₹ 790000 set. kiln support rollers ₹ 215000 number.
Laboratory using a rotary kiln of 10.46 m long with 0.76 m internal diameter having a production capacity of 34 tonnes oil sponge iron per day. the details of pilot plant experiments using various types of ore lumps, heat hardened and green pellets with nonmetallurgical coals as solid reductant are presented. rotary kilnsolid reductant.
Looking forward to the need of developing coalbased sponge iron technology in india, a country having no significant resources of either coking coal or natural gas, the research and development division of the tata iron and steel company limited (tisco) set up a rotary kiln based direct reduction pilot plant in 1975. in this pilot plant, a totally indigenous technology for production of.
Decades, a new route of ironmakin g has rapidly developed for direct reduction (dr) of iron ore to. metallic iron by using noncoking coaln atural gas. this product is.
Sponge iron (si): dri is also known as sponge iron because of its spongy micro structure. ore lumps or iron ore pellets with the help of noncoking coal in rotary kiln (in coal based plants) .. but usually iron content of ores ranges between 506567 (rich ores) and 3035 (lean ores); . sinter plant cement industry more detailed.
Safety guidelines for iron amp; steel sector ministry of steel, direct reduction govt. of india plant (coal based) doc. no: sg32 rev no. : 00 effective date: 1. objective: the main function of making sponge iron in the kiln is to convert iron ore into sponge iron by using iron ore, coal and dolomite limestone. the sponge iron is processed.
In conventional coal based sponge iron plant, fig. 1, kiln feed (stream no. 1), which consists of iron ore, feed coal and dolomite, is fed to the rotary kiln (rk). a separate conveyor collects different size fractions of coal (stream no. 5) for injection into the kiln with the help of pressurized air (stream no. 4) from discharge end side.
The failure analysis of air tubes of rotary kilns in a coalbased sponge iron plant has been presented in this paper. the sponge iron plant has a production capacity of 390,000 tannum with two kilns of 300 tday and one kiln of 500 tday production capacities.