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case studies on sponge iron kiln

Computational fluid dynamics analysis of sponge iron

Mar 01, 2017· The CFD studies discussed above are mainly carried out for rotary kiln of cement industry. However, very little work is available related to CFD analysis of rotary kiln of sponge iron process such as: Prasad and Ray developed 2D model to simulate flow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant. They considered

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CASE STUDY ON THRESHOLD PROBLEM Sponge Iron

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. Kiln Feeding G-S HX Sponge iron At 110 C DSC Air ABC Water

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

Process Detail : Sponge Iron Plant The Rotary Kiln or Reduction Kiln is a very important part of any Sponge Iron plant. This is the place where The case study is about the repair of Kiln Shell crack of Kiln-2 of 350 TPD capacities. This was earlier repaired with E7018 alloy. During regular use a crack originated from the same repaired portion.

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Sponge Iron FirstEsco

Sponge Iron 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.

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(PDF) Computational fluid dynamics analysis of sponge iron

A rotary kiln, considered for the present study and shown in Fig. 1(a), is used in sponge iron industry. The rotary kiln consists of a rotating cyl indrical shell lined inside with refractory

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SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE

Keywords: Tunnel Kiln, Iron ore-coal composite pellets, Sponge iron, Thermal efficiency, Carbon utilization efficiency, Percentage metallic iron . 1. INTRODUCTION The tunnel kilns are mostly used by the ceramic industries for heating refractory and ceramic products [1-2]. In the year 1908 use of tunnel kiln started for iron oxide reduction. This

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brief process of al based sponge iron rotary kiln

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.

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Top PDF Sponge Iron 1Library

4) We have seen some sponge iron companies trying to reduce radiation loss by applying low-emissivity re- versible paint which brings down the emissivity level from 0.95 to 0.65. But study shows that ultimately this becomes counter-productive. Application of coating although reduces the radiation loss but at the same time it enhances the surface temperature which in turn increases the

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Modified approach of total site integration for energy

May 01, 2018· Results of these studies can be compared with that of Strategy-1 on the basis of %reduction in coal, water and waste gas and profit per ton of sponge iron to observe benefits of TS integration. Kumar and Khanam (2012) proposed preheating of kiln air to 80 °C by kiln

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sponge iron process

Jul 29, 2010· In general the gangue content in sponge iron varies from 4% to 8% . Carbon content: 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.

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

Process Detail : Sponge Iron Plant The Rotary Kiln or Reduction Kiln is a very important part of any Sponge Iron plant. This is the place where The case study is about the repair of Kiln Shell crack of Kiln-2 of 350 TPD capacities. This was earlier repaired with E7018 alloy. During regular use a crack originated from the same repaired portion.

More

brief process of al based sponge iron rotary kiln

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.

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Tata Consulting Engineers Engineering a better tomorrow

Tata Consulting Engineers carried out the studies from the environmental, commercial and technological angle and put forth recommended solution such as Tunnel Kiln technology, coal quality management, etc. The assessment report and recommendations are expected to benefit the state of West Bengal and the sponge iron industry sector here.

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

in the sponge iron process. 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.

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(PDF) "Sponge Iron Industry in Chhattisgarh : A Perspective

the rotary kiln first passes through pre-heating zone where . Considering a real data set obtained from the case study of a sponge iron industry, we analyze the crisp model first, then we go

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Case Study Shri JI Power & Automation

Case Study. Melt Shop Automation: LRF/MIF Sponge Iron Plants . The process to make steel on the fingertip control. Automatic weighing controls of Iron Ore, Lime and Coke. Automatic transfer to Kiln through various conveyors. Temperature and Pressure monitoring & control of the Kiln.

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Iron Ore Pellets Manufacturing Process By Tunnel Kiln

Iron Ore Sponge Iron 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.

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modeling of rotary kiln for sponge iron processing using

1/3/2017· The CFD studies discussed above are mainly carried out for rotary kiln of cement industry. However, very little work is available related to CFD analysis of rotary kiln of sponge iron process such as: Prasad and Ray developed 2D model to simulate flow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant.

More

A Case Study on Large-scale Grate-kiln Production of

Jun 21, 2018· (2019). A Case Study on Large-scale Grate-kiln Production of Fluxed Iron Oxide Pellets: Zhanjiang Pelletizing Plant of BaoSteel. Mineral Processing and Extractive Metallurgy Review: Vol. 40, No. 2, pp. 123-128.

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sponge iron.pptx Iron Steelmaking

Sponge iron is the product created when iron ore is reduced to metallic iron, in the presence of coal, at temperatures below the melting point of iron. The external shape of the ore is retained with 30% reduction in weight due to oxide reduction resulting in change in

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Iron and Steel Knowledge Exchange Platform

Resource Name: Best Practices adopted by TATA Sponge Iron Limited . Abstract: The resource presents benefits achieved by replacing of impeller of Kiln #2 ID fan motor (3.3 KV, 260 kW motor), replacing of under loaded LT motors with correct size motors of DE system of Kiln-1 & Kiln-3, VFDs for pump motors running in throttled condition, different VFD panels for odd & event set of SAB motors of

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Case study: Gear damage on rotary kiln SPM Instrument

This case study describes the detection of gear damage on an output shaft, detected during a capacity test involving a speed increase. The Södra Cell Värö pulp mill in southern Sweden uses the Intellinova online system with HD measurement technology to monitor the drives of its rotary kiln.

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Sponge Iron By Tunnel Process greenrevolution.org

sponge iron by tunnel process. CASE offers international standard DRI tunnel Kiln product through SKBIT Process. The sponge iron manufacturer in Delhi India offers DRI products produced though

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tunnel kiln process for sponge iron

Sponge Iron Production Process Arij Trading. Jul 29, 2010· The Fe total content in sponge iron purely depends on Fe con tent in iron ore and the degree of reduction achieved in the process Fe total content of 90%min is required for steel making requirement Fe metallic: Fe metallic content in sponge iron depends on the effective control of process. 24/7 Online] Tunnel Kiln Process Sponge

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