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Sponge iron roller kiln reduction technology

  • Direct reduced iron - Wikipedia

    Direct reduced iron (DRI), also called sponge iron, is produced from the direct reduction of iron ore (in the form of lumps, pellets, or fines) into iron by a reducing gas or elemental carbon produced from natural gas or coal. Many ores are suitable for direct reduction.

  • sponge iron process

    Aug 03, 2011· During the process of manufacture of sponge iron, coal injection plays a very vital role in maintaining the product quality. Due to highly endothermic nature of Boudouard reaction, heat has to be continuously supplied in entire reduction zone of rotary kiln. Generally the length of reduction zone is 60-70% of total kiln length.

  • Industrial Training Report on Direct Reduced Iron Plant(DRI)

    Jul 16, 2017· Industrial Training Report on Direct Reduced Iron Plant(DRI) 1. 1 P a g e 20 days Industrial Training Report File On DRI (18/02/2017-09/03/2017) Submitted To Submitted By Mr. MK Pyasi Shani Kumar Singh General Manager Roll No-1344948 Direct Reduced Iron Plant-2 Branch-Mechanical Jindal Steel and Power Ltd, Raigarh Semester-8th College-CGC-COE, Mohali Signature-

  • Some Studies on Energy Savings in Sponge Iron Plants

    Aug 29, 2003· 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 kiln/reactor. Process Characteristics and Industrial Application of Rotary Kiln Iron Ore Reduction, Technology from Lurgi at ISCOR, 1983

  • Sponge Iron Production in Rotary Kiln - Arabinda Sarangi

    Jun 30, 2011· 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

  • Direct Reduced Iron and its Production Processes IspatGuru

    Mar 16, 2013· 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.

  • RESEARCH & DEVELOPMENT - ITC PRE-HEATING TECHNOLOGY

    A. Lower Cost of Production - The Cost of Production as Compared With Normal Technology is Low, Almost rs 800 1000 Per Ton of Sponge Iron Less. B. High Productivity - Since The Heating Zone of Kiln is Shifted to The Pre-Heater The Reduction Atmosphere

  • A Thesis Submitted for Partial Fulfillment of the Degree

    In Sponge Iron industry Rotary kiln is the key equipment used to reduce iron ore to sponge iron form. For design and optimization of rotary kiln, it is necessary to

  • Energy survey of the coal based sponge iron industry

    Sep 01, 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.

  • Simulation of Rotary Kiln Used in Sponge Iron Process

    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: 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.

  • DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE

    Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535 oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced product having high degree of metallisation exhibits a honeycomb structure due to which it is named as sponge iron.

  • German Kiln Technology: Technical ceramics

    German Kiln Technology (GKT) is a major supplier of sintering lines and kilns for producing all kinds of technical ceramics, such as: For the firing process GKT offers the most diverse selection of equipment, dependant on capacity and procedure, operating electrically or with fossil fuels:

  • SPONGE IRON PLANT

    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.

  • Flow of materials in rotary kilns used for sponge iron

    Looking forward to the need of developing coal-based 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

  • Working of kiln rotary for making sponge iron in

    Jan 11, 2021· Sponge Iron Rotary Kiln-Zhengzhou Taida Rotary Kiln Supplier. Sponge Iron Rotary Kiln. Specifications´╝Ü Sponge iron is a kind of superior iron ore. It can be got by oxidation-reduction reaction. In sponge iron rotary kiln, vertical furnace and other reactor, iron ore and other iron ore concentrates are reduced in low temperature condition and .

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

    Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation June 2019 Conference: AISTech 2019 Proceedings of the Iron & Steel

  • Simulation of Heat-Transfer Phenomena in a Rotary Kiln

    Characterization and drying kinetics of iron ore pellet feed and sinter feed. Drying Technology 2020,, 1-12. DOI: 10.1080/07373937.2020.1747073. Gajendra Kumar Gaurav, Shabina Khanam. Computational fluid dynamics analysis of sponge iron rotary kiln. Case Studies in Thermal Engineering 2017, 9, 14-27. DOI: 10.1016/j.csite.2016.11.001.

  • sponge iron process: 2010

    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.

  • New Concept of Hot Metal Production using Rotary Kiln

    Sep 27, 2013· The idea of this technology is to utilize the heat or energy contained in sponge iron (temperature of sponge iron > 1000 o C) at the end of rotary kiln before it is cooled by rotary

  • Kiln Support Roller - Kiln Support Roller Bearing - AGICO

    Dec 05, 2019· Own to the rotary kiln such as cement kiln, lime rotary kiln and shaft kiln is widely used in building materials, chemical industry, nonferrous metallurgy industry, black metallurgy, and refractory materials.Rotary kilns support roller is an important module, and it has the character of large bearing load, poor working environment, constant running, and complex maintenance.

  • (PDF) Production of Sponge Iron through Tunnel Kiln Process

    With reduction temperature increasing, the metallization ratio of produced sponge iron is proportionally increasing, and the outer diameter of the sponge iron ring is gradually decreasing.

  • Direct Reduced Iron Industrial Efficiency Technology

    Direct Reduced Iron (DRI), also known as Sponge Iron, offers an alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron ore is reduced in its solid state unlike BF process where a liquid metal is formed during reduction. DRI can then be transformed to steel in electric arc furnaces. DRI production is common in Middle East, South America, India and Mexico.

  • STUDY ON REDUCTION OF IRON ORE CONCENTRATE IN

    STUDY ON REDUCTION OF IRON ORE CONCENTRATE IN ROTARY KILN TO PRODUCE DIRECT REDUCED IRON STUDI REDUKSI KONSENTRAT BIJIH BESI DALAM TUNGKU PUTAR MENGHASILKAN DIRECT REDUCED IRON NURYADI SALEH and SITI ROCHANI Research and Development Centre for Mineral and Coal Technology Jalan Jenderal Sudirman 623 Bandung 40211

  • WORLD DIRECT REDUCTION STATISTICS

    IN DIRECT REDUCTION TECHNOLOGY. 2 TABLE OF CONTENTS 2019 World Direct Reduction Statistics Page 2 < > productivity gains of the rotary kilns, which were able to use higher quality coal imported from South Africa and Indone-sia, according to the Sponge Iron Manufacturers Association (SIMA). Rotary kilns saw a 27.9% jump from 2018, which was

  • 2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

    2 D Model of Sponge Iron Rotary Kiln Developed Using CFD Gajendra Kumar Gaurav* and Shabina Khanam *Research Scholar and Assistant professor Department of Chemical Engineering, Indian Institute of Technology Roorkee, Roorkee - 247 667, India _____ Abstract: The present paper deals with 2D CFD model of rotary kilns employed in sponge iron process.

  • SPONGE-IRON - Shakambhari Group

    Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron

  • Environmental Control Measures in Sponge Iron Industry

    Environmental Control Measures in Sponge Iron Industry with Particular Reference to Tata Sponge Iron Limited B. M. SARANGI, BABU KESAV and M. K. SHESHADRI Tata Sponge Iron Limited, Joda, Orissa ABSTRACT Direct reduced iron or sponge iron technology was developed as an alternate route for steel making and is considered as a clean technology.

  • STUDY ON REDUCTION OF IRON ORE CONCENTRATE IN ROTARY KILN

    In this reduction process of iron oxide would be reduced by CO to metallic iron (Fe). The experimental results showed that the metallization without oxygen injection produced the best metallization at 1,100°C and the ratio of carbon/iron (FC/Fe) of 0.52 to result 84.54%, contained 74.68% Fe and 88.34% Fe total .

  • Direct Reduction Technologies SAIL

    May 07, 2021· Direct reduction processes are of significance and can form an alternative to a conventional Blast furnace. Solid sponge iron ( direct reduced iron or DRI) is produced by removing oxygen from the ore .The technique of Direct reduction varies according to the type of reducing agents employed and the metallurgical vessel in which they are reduced.

  • Sponge Iron (DRI) The Hira Group

    As such it is called Sponge Iron. Sponge Iron is a substitute of scrap in steel melting. Although the reduction in the kiln is not direct, the CO gas reduces the impurities and oxides of hematite and the resultant DRI is in the solid form, this process is known as Direct Reduction Process.

  • Direct Reduced Iron Industrial Efficiency Technology

    Direct Reduced Iron (DRI), also known as Sponge Iron, offers an alternative steel production route to BF-BOF and Scrap-EAF routes. In DRI, iron ore is reduced in its solid state unlike BF process where a liquid metal is formed during reduction. DRI can then be transformed to steel in electric arc furnaces. DRI production is common in Middle East, South America, India and Mexico.

  • comparative study of particulate matter emission reduction

    Sponge iron industries study shows continuous improvement in technologies for better precautionary measures. This study depicts how the kiln size plays a pivotal role in emission control by reduction of particulate matter of existing sponge iron plants without any change in operational technology.

  • Direct Reduced Iron (DRI) International Iron Metallics

    In India there are many small rotary kiln furnaces producing DRI, known locally as sponge iron, using coal as energy and reductant source. Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, India producing 57% of

  • Sponge iron Manufacturers & Suppliers, China sponge iron

    sponge iron manufacturer/supplier, China sponge iron manufacturer & factory list, find qualified Chinese sponge iron manufacturers, suppliers, factories, exporters & wholesalers quickly on Made-in-China. Boomjoy Cleaning Roller Squeezing Hands-Free Sponge PVA Mop Rotary Kiln, Rotary Drum Kiln for Sponge Iron Reduction.

  • Rotary Kiln Maintenance Procedures

    Roller positions must be consistent with minimum ovalities, low support roller thrust loads, and a straight kiln axis. The preferred procedure to assure those conditions is a hot kiln alignment, where all alignment measurements are taken when the kiln is under normal operating conditions.

  • Welcome to SIPC Services- Pioneer in Sponge Iron

    By this time the iron ore comes to the inlet end of the main kiln the temperature of the iron ore reaches about 550 degree centigrade to 600 degree centigrade. With the introduction of preheating kiln for utilising the sensible heat in the kiln off gases for the following benefits could be acheived: 10-15% reduction in coal consumption.

  • Low-Carbon Production of Iron & Steel: Technology Options

    Mar 08, 2021· Direct Reduction of Iron (DRI) EAF also consumes the products of direct reduction of iron (DRI), also referred as sponge iron. DRI is as pure as pig iron and is an ideal feedstock to EAF efficiency gains. As a feedstock, EAF can take any fraction of sponge iron (zero to ).

  • Sponge Iron - HIRA - Godawari Power & Ispat Limited

    With such dimension of notion WE in our Sponge Iron Manufacturing process through 4 Kilns (1 * 350T and 3 * 500T) laid up the best DRI making process of India. It is Coal Fuel based DRI. Coal based Sponge-iron is a metallic product produced through direct reduction of iron ore in the solid state .As such it is also known as Direct Reduced Iron

  • DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A

    Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535 oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced product having high degree of metallisation exhibits a honeycomb structure due to which it is named as sponge iron.

  • Sponge Iron Production By Direct Reduction Of Iron Oxide

    This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces

  • sponge iron process

    Jul 29, 2010· In general sized iron ore of 5-18mm is used in the process of manufacture of sponge iron on all types of rotary kiln with +16mm not exceeding 15-20%.The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform Fe metallic of all grain size fraction of the product.

  • Accretion Control in Sponge Iron Production Kiln using

    2 KILN BASED SPONGE IRON PRODUCTION PROCESS Rotary kilns are found in many processes that involve processing of solids. 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

  • Simulation of Rotary Kiln Used in Sponge Iron Process

    Sponge iron is the metallic form of iron produced from reduction of iron oxide below the fusion temperature of iron ore (1535oC) by utilizing hydrocarbon gases or carbonaceous fuels as coal. The reduced iron having high degree of metallization exhibits a honeycomb structure, due to which it is named as sponge iron.

  • Sponge Iron Prakash Industries Limited

    Sponge iron is a highly processed form of iron ore which contains metallic iron in the range of 83-88% obtained by direct reduction without melting it. Due to high porosity, the resulting iron is called sponge iron. It is used as a raw material for manufacturing steel

  • Project Proponent M/s BRGD Sponge and Iron Pvt. Ltd.

    Direct Reduced Iron / Sponge Iron Process (DRI) The process of reduction takes place inside the rotary kiln, which is mounted on tyres and supported by support rollers. The transverse motion of the kiln is controlled with the help of hydro thruster and thrust rollers. The kiln is rotated at

  • Tunnel Kiln Technology - Ironmaking Technology

    Main Feature Of Rapid Reduction Technology To Compare With Traditional Tunnel Kiln Technology: 1. Not chang formula and method of loading and unloading; 2. Reduction speed 2-3 times faster; 3. Lower 1/3 reducer consumption; 4. Lower 1/3 energy consumption; 5. Recycle coking coal from tailing powder. Picture Of Products: Prepressing Sponge Iron

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