case studies on sponge iron kiln
case studies on sponge iron kiln
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case studies on sponge iron kiln

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production ...

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are assigned individual number and henceforth each stream will

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Case Studies in Thermal Engineering - ResearchGate

The kiln data were taken at production of sponge iron of capacity 453.875 t/d. The length of the kiln is 80 m and its internal and external diameters are 4.55 m and 5 m, respectively.

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case studies on sponge iron kiln - nko-sintniklaas

case group tunnel kiln sponge iron manufacturers india . Rotary Kiln Manufacturer India Rotary Kiln for Sponge Iron . Sponge Iron Kiln, Sponge Iron Kiln Suppliers and . Sponge Mill - Sponge Iron Plant Manufacturer from Greater Noida . sponge iron kiln - cheap sponge iron kiln Wholesalers .Cracking of Air Tubes of Rotary Kilns in a Sponge Iron Plant . Sponge

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

Case studies from the iron and steel industry on model-based optimization of production of direct reduced iron in a rotary kiln and induration of wet iron ore pellets on a moving packed bed ...

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CASE GROUP - casepl

CASE GROUP FINES TO SPONGE DRI (Direct Reduced Iron) Tunnel Kiln was commissioned on 24 November 2011. CASE gave this technology to India and this was also first of its kind in India. The process has been established now after earlier hiccups.

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(PDF) Different processes of Sponge Iron production – A Review

22.02.2013  November 2016 Case Studies in Thermal Engineering. Gajendra Kumar Gaurav; Shabina Khanam; 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of ...

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Sponge Iron - FirstEsco

Sponge iron kilns are energy intensive. 30% of the energy input to the kiln is lost to the atmosphere through flue gas. Many sponge iron plants with kiln capacity higher than 200 tons, the heat in the exhaust flue gas is already utilised to generate steam and generate power. However, sponge iron plants with a capacity less than 200 tons normally let out the flue gas

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sponge iron process

29.07.2010  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

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SPONGE IRON PLANT

The Rotary Kiln process is a well-established process for production of coal based sponge iron. Rotary kiln of certain dia and length is provided for reduction of Iron Ore into sponge iron using non-coking coal as reductant and Dolomite as sulphur scavenger; however the Diameter and Length are to be designed based on the Plant Capacities.

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Energy Conservation

•Therefore total heat supplied to the kiln in the process of making 1 Kg sponge iron is 3889.84 Kcal. •We have already seen that theoretical heat supplied to the kiln to produce 1 Kg of sponge iron is 2058.12 Kcal and actual is 3365.41 Kcal. Therefore, Thermal efficiency of the Kiln is 2058.12/3365.41 = 61.15%. MCJ ENERGY ENGINEERS PVT LTD

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CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production ...

CASE STUDY ON THRESHOLD PROBLEM Sponge Iron Production Process Process description This is the case study of typical coal based sponge iron plant of 500 tonne per day capacity. The process flow diagram (PFD) of the sponge iron process is shown in Fig. 1. Different streams in the PFD are assigned individual number and henceforth each stream will

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A STUDY OF RING FORMATION OF SPONGE IRON IN THE ROTARY KILN

A STUDY OF RING FORMATION OF SPONGE IRON IN THE ROTARY KILN M. R. K. RAO National Metallurgical Laboratory Jamshedpur, India Abstract Ring formation and heavy build-up in an experimental rotary kiln for production of sponge iron using hematite pellets, bituminous coal and nut coke have been described. The build-up from different parts of the kiln was

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case studies on sponge iron kiln - nko-sintniklaas

case group tunnel kiln sponge iron manufacturers india . Rotary Kiln Manufacturer India Rotary Kiln for Sponge Iron . Sponge Iron Kiln, Sponge Iron Kiln Suppliers and . Sponge Mill - Sponge Iron Plant Manufacturer from Greater Noida . sponge iron kiln - cheap sponge iron kiln Wholesalers .Cracking of Air Tubes of Rotary Kilns in a Sponge Iron Plant . Sponge

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN

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. Depending on its content of volatile matter, the coal is part-ly blown into the ...

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CASE GROUP - casepl

FINES TO SPONGE DRI (Direct Reduced Iron) Tunnel Kiln was commissioned on 24 November 2011. CASE gave this technology to India and this was also first of its kind in India. The process has been established now after earlier hiccups. The process of Tunnel Kiln uses fines of Iron ore and Coal which are mixed together in specified proportions to eventually make DRI having

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

Case studies from the iron and steel industry on model-based optimization of production of direct reduced iron in a rotary kiln and induration of wet iron ore pellets on a moving packed bed ...

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Case History on “Repair of Kiln Shell” At Ankit Metals ...

• Department : Sponge Iron • Machine : Rotary Kiln • Part : Kiln Shell • Make : Hari Machinaries, Rourkela • Capacity : 350 TPD • Base Material : Boiler Quality Steel • No. Of Kilns : 3 Nos. • Kiln Shell Length : 82 Meter • Shell Diameter : 4.2 Meter • Temperature : 800-1300 degree centigrade • Kiln RPM : 0.3-0.7 • Kiln tilt angle : 1.43 ˚ The case study is about the ...

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(PDF) Different processes of Sponge Iron production – A Review

22.02.2013  November 2016 Case Studies in Thermal Engineering. Gajendra Kumar Gaurav; Shabina Khanam; 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of ...

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sponge iron process

29.07.2010  FeS + Cao> FeO + CaS The reduced iron ore -SPONGE IRON with unburnt char from rotary kiln gets discharged into a Rotary Cooler. The heat will be dissipated indirectly by water spraying into the outside of Cooler Shell. The material gets cooled to around 1200C. The waste gases leaving rotary kiln pass through a dust settling chamber to an after burning

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Energy survey of the coal based sponge iron industry ...

01.09.2015  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. Throughout the length of the

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A STUDY OF RING FORMATION OF SPONGE IRON IN THE ROTARY KILN

A STUDY OF RING FORMATION OF SPONGE IRON IN THE ROTARY KILN M. R. K. RAO National Metallurgical Laboratory Jamshedpur, India Abstract Ring formation and heavy build-up in an experimental rotary kiln for production of sponge iron using hematite pellets, bituminous coal and nut coke have been described. The build-up from different parts of the kiln was

More

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

Case studies from the iron and steel industry on model-based optimization of production of direct reduced iron in a rotary kiln and induration of wet iron ore pellets on a moving packed bed ...

More

(PDF) Different processes of Sponge Iron production – A Review

22.02.2013  November 2016 Case Studies in Thermal Engineering. Gajendra Kumar Gaurav; Shabina Khanam; 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of ...

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ENERGY INTEGRATION IN SPONGE IRON PLANT USING HEAT OF ...

For this purpose a case study of typical sponge iron production process is considered. Waste gas from the rotary kiln of the sponge iron plant exits at a temperature around 900 C. This gas has a lot of sensible heat and can be used for energy integration. This heat is used for heating water in a boiler. Superheated steam which is produced in the boiler is used to rotate a prime

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Energy integration of sponge iron production process

For this purpose a case study of typical Indian sponge iron process of capacity 100 tpd is considered. After a complex reduction and combustion process waste gas exits the sponge iron plant at substantially higher temperature which is around 200-220 C. At this range of temperature waste gas carries a lot of sensible heat which directly goes to the atmosphere through

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Case History on “Repair of Kiln Shell” At Ankit Metals ...

• Department : Sponge Iron • Machine : Rotary Kiln • Part : Kiln Shell • Make : Hari Machinaries, Rourkela • Capacity : 350 TPD • Base Material : Boiler Quality Steel • No. Of Kilns : 3 Nos. • Kiln Shell Length : 82 Meter • Shell Diameter : 4.2 Meter • Temperature : 800-1300 degree centigrade • Kiln RPM : 0.3-0.7 • Kiln tilt angle : 1.43 ˚ The case study is about the ...

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE IRON

For this purpose a case study of typical sponge iron production process is considered. The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln. Further, the waste gas at reduced temperature is used to cool hot sponge iron which is previously carried

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(PDF) Energy survey of the coal based sponge iron industry

20.04.2015  A study on rotary kiln energy efficiency by Nishant et al. [29] identified the possible areas where energy is lost in the form of waste gas, cooling of

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STUDIES ON POLLUTION CONTROL IN IRON BASED PLANTS IN ...

In sponge Iron Plants the kiln, Coal and Iron ore crusher section, cooler discharge and product house are the major source sources of emissions. Fugitive dust emissions also occur during raw material and product handling, loading and unloading, storage, transportation of raw material and product, handling and disposal of char. Poor housekeeping is also causing air pollution in side

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Model-Based Optimization of Industrial Gas-Solid Reactors

Case studies from the iron and steel industry on model-based optimization of production of direct reduced iron in a rotary kiln and induration of wet iron ore pellets on a moving packed bed reactor are discussed here. Keywords: multiphase reactors, modeling, optimization, soft-sensors, iron and steel, pelletization 1. Introduction Production of many commodity chemicals, metals,

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