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sponge iron production in rotary kiln
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India is the largest producer of direct reduction of iron (DRI), popularly known as sponge iron and accounted for about 39.3% of the global production in 2020. India’s growing Computational fluid dynamics analysis of sponge iron rotary kiln. 2D CFD model is developed for simulation of rotary kiln of sponge iron process. Effects of Computational fluid dynamics analysis of sponge iron
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(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. Conference: AISTech 2019 — Proceedings of the Iron & Steel...In the sponge iron industry rotary kiln is the primary equipment, which is used to reduce iron ore to metallic iron i.e. Fe. Though sponge iron is a hard solid Analysis of temperature profile and % metallization in
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Dynamic quality prediction and control in rotary sponge iron kilns
The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% The present paper deals with 2D CFD model of sponge iron rotary kilns. Using this model the effects of variations of input parameters, such as angle of Analysis of temperature profile and % metallization in rotary kiln
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Mathematical Modelling of Sponge Iron Production in a Rotary Kiln
Tata Sponge Iron Limited (TSIL) operates three large industrial rotary kilns for producing DRI through the TISCO direct reduction (TDR) process (Fig. 1)1). The critical step in this A. Sarangi, Sponge Iron Production in Rotary Kiln, PHI Learning Private Limited, 2011, pp. 90–241. Google Scholar [4] S. Mondal, Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation, 2012, pp. 727–732.Understanding the co-relationships of variables and improving
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New Sponge Iron Rotary Kiln Design In Sponge Iron
In the newly designed sponge iron rotary kiln system, a coarse coal branch pipe and fine coal branch pipe are added at the kiln head. The original way of adding 100% coal at the kiln head is changed to 50-70% Shabina Khanam. 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output 2 D Model of Sponge Iron Rotary Kiln Developed
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Mathematical Modelling of Sponge Iron Production in a Rotary Kiln
VOL. 5 NO. 1 OCTOBER, 2010 STEEL TECH 11 from an industrial coal-based sponge iron rotary kiln process. We have developed a fairly comprehensive mathematical model for the direct reduction of iron oreFe. Though sponge iron is a hard solid material, it is called sponge iron due to its honeycomb structure. Rotary kiln is also widely used in cement industry. The performance of rotary kiln significantly affects the production capacities of Analysis of temperature profile and % metallization in rotary kiln
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A simulation study of reduction kinetics for sponge iron production
A simulation study of reduction kinetics for sponge iron production in a rotary hearth furnace. Étude de simulation de la cinétique de réduction pour la production d'éponge de fer dans un four à sole tournante. Sooraj Saleem Department of 2 The total thermal energy content of in the fuel (coal) feed is 2488150.00 Kcal/hr. 3 The difference in the energy content input and utilized is 11075573.8 Kcal/hr. goes out of the kiln as :-. (a) Heat value carried by the unburnt V.M. of the coal fed. (b) Carbon in flue dust. (c) Carbon going to sponge iron. (d) Heat Value of Coal char.Sponge Iron Heat & Mass Balance PDF Iron Boiler Scribd
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Sustainability Enhancement of the Coal Based Direct Reduction of Iron
3.5 Impact of Waste from Sponge Iron Production. Wastes generated from the DRI process have adverse effect on the environment and Modelling and optimisation of direct reduction of iron ore by coal in a rotary kiln Optimal glucose control View project Digital Twins View project (2010) Google Scholar Samal, S.K ., Sahoo, P.KThe present paper proposes two energy integration options, Option-1 and Option-2, to compare power generation and preheating scheme in sponge iron process.Option-1 accounts power generation whereas in Option-2 preheating of feed material, slinger coal and kiln air is considered. These options utilize heat of waste gas Profitability analysis of power generation using waste heat of sponge
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ALTERNATIVE ROUTES TO IRON MAKING, 2nd Ed. Google Books
The primary objective of this book is to provide the basis, principles, fundamentals and theory of sponge iron production.This book, earlier titled as Sponge Iron Production in Rotary Kiln, is revised as per the feedback from students, faculty members and professionals. It, now, covers broad spectrum of alternative routes of iron makingComprehensively deals with the production of sponge iron in the rotary kiln. It is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production, commercially used DR (direct reduction) processes and physico-chemical principles of sponge iron production. The book then goes on Sponge Iron Production in Rotary Kiln Google Books
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Energy survey of the coal based sponge iron industry
In the sponge iron process concentrated and finely divided iron ore is reduced in solid phase into sponge iron at high temperatures in rotary kiln. The process is very energy demanding. In order to identify the largest losses and to find ways to increase the efficiency, an energy survey of the sponge iron plant was carried out for a number of Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. The reduction takes place using gaseous reductants (CO + H 2 ) which are generated through partial oxidation of coal (Reaction 3.3.1 ), reforming of methane by CO 2 /H 2 O (Reactions 3.3.2 and 3.3.3 ), or partial combustion of natural gas Sponge Iron an overview ScienceDirect Topics
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Schematic diagram of plant and the rotary kiln (see arrow) for
Download scientific diagram Schematic diagram of plant and the rotary kiln (see arrow) for production of sponge iron. from publication: Conventional and AI Models for Operational Guidance andIn the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850°C -1,500°C).SPONGE-IRON Shakambhari Group
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Recovery and utilization of waste heat in a coal based sponge iron
However, for Case-2 initially water is heated using hot sponge iron exiting rotary kiln and further hot water is used to preheat air. To compute coal demand of modified designs a model is developed based on heat of reactions, feed preheating, sensible and radiation losses, etc. Preheating of air up to 170 °C for Case-1 reduces coal consumption Discuss the principle and process for production of sponge iron by coal-based process. 3. (i) Discuss the principle of rotary kiln process for sponge iron production. (ii) What are the problems of rotary kiln process and how to overcome them? 4. Discuss the salient features of rotary kiln process. 5. Why coal-based sponge iron Sponge Iron SpringerLink
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Sponge Iron Rotary Kiln DRI Rotary Kiln Contact for Price
Highlights of sponge iron rotary kiln. Compared with the shaft kiln, the sponge iron rotary kiln has the characteristics of environmental protection, energy saving, less labor, high output, and quick profit. Clients can achieve the production goal in the shortest time and recover the investment cost.Sponge iron making process Download as a PDF or view online for free. Production of Direct Reduced Iron in Rotary Hearth Furnace Sateesh Kumar. POST COMBUSTION CHUMBER To maintain temperature in Sponge iron making process PPT SlideShare
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Generation of Energy Conservation Measures for Sponge Iron Plants
Conventional sponge iron plant flow diagram Coal injector, Air: 2500m3/h, Injection coal:6.13 t/h, all at 300C Rotary Kiln (10200C) 8 shell air fan at 48000 m3/h, 300C Flue gas Fly ash Fines of iron ore 108.94 t/h Kiln Feeding Iron ore: 30 t/h Feed coal: 14.297 t/h Dolomite (Lime stone): 0.5 t/h All at 300C Rotary Cooler At 1200C Sponge iron:
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