process making sponge iron rotary kiln quot

process making sponge iron rotary kiln quot

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 ...

The role of kiln is to convert the raw material (iron ore, coal and dolomite) into the sponge iron. Detail reaction mechanism of the process is discussed below: There are two reduction reactions. First reaction converts iron ore to iron oxide which further reacts with CO to produce metallic iron (Fe) which is called sponge iron.

Sponge iron making process - SlideShare

09-11-2014  ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell. 12. SCREENING + 10 mm 3-10 mm -

2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

II. Rotary kiln: Operation and construction details 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

A 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

SPONGE IRON PLANT

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

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

Sponge iron is a type of iron produced by coal based or gas-based reduction of iron ore. It is difficult to measure and control the degree of reduction or quality of the iron ore at intermediate ...

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

Most solid reduction process use non-coking coal as reducing agent due to abundantly available non-coking coal. 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

sponge iron process

The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

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.

first rotary kiln in zimbabwe to produce sponge iron from ...

The process of DRI or sponge Iron making can be classified into different categories as given below 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. More Detail

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.

Sponge Iron - an overview ScienceDirect Topics

The process involves heating the naturally occurring iron oxide in the presence of carbon, which produces “ sponge iron.” In this process, the oxygen is removed without melting the ore. Iron oxide ores extracted from the Earth are allowed to absorb carbon by a reduction process.

New Concept of Hot Metal Production using Rotary Kiln ...

Hot sponge iron from rotary kiln shall be smelted directly by continuously charging into smelting reduction furnace. The smelting furnace itself is equipped with stoves to preheat the hot blast...

Direct Reduced Iron and its Production Processes –

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 to prevent its re-oxidation.

Coal based Direct Reduction Rotary Kiln Process – IspatGuru

The main raw materials for the production of DRI by the rotary kiln process are (i) sized graded iron ore or iron ore pellets, (ii) non-coking coal, and (iii) dolomite in small quantities to scavenge the sulphur. Iron ore of the right quality is the basic input for the coal based direct reduction process.

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

sponge iron process

The carbon content in sponge iron produced by coal based rotay kiln processes are generally low and is in the range og 0.08% to 0.20%.The carbon content in gas based processes can be controllrd to a level of 1.5% to 2.0% based on requirement for steel making.

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. Hatch has developed a proprietary one-dimensional kiln model to

SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE

However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns.

SPONGE IRON – Lloyd’s Metals

Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a ‘select’ grade of iron-coking 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 finished product bunkers prior to dispatch.

Making Sponge Iron With Rotary Kiln

Accretion Control in Sponge Iron Production Kiln u 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 noncoking coal Patra et al 2005 The reduction process is carried out in an inclined horizontal rotary kiln which rotates at a programmed speed

New Concept of Hot Metal Production using Rotary Kiln ...

Hot sponge iron from rotary kiln shall be smelted directly by continuously charging into smelting reduction furnace. The smelting furnace itself is equipped with stoves to preheat the hot blast...

Direct Reduced Iron and its Production Processes –

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 to prevent its re-oxidation.

Coal based Direct Reduction Rotary Kiln Process – IspatGuru

Since the rotary kiln process requires around 7 hours to 8 hours of reduction time, the productivity of the process is limited and is usually in a range between 30,000 tons/year to

Rotary Kiln For Carbon In Rotary Kiln Industry

New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System AGICO GROUP is devoted to be the No.1 rotary kiln manufacturer and professional enterprise of import and export trade.Our main business is rotary kiln equipment such as cement kiln, lime rotary kiln and shaft kiln.