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components required for rotary kiln for sponge iron plant

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

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Flow of materials in rotary kilns used for sponge iron

this pilot plant which has resulted in the development of the TDR (Tisco Direct Reduction) process of sponge iron manu- facture. 3 In order to commercialize the TDR technology

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Amit Chatterjee, A. V. Sathe, M. P. Srivastava, P. K. Mukhopadhyay

Computational fluid dynamics analysis of sponge iron rotary kiln

2017/3/1  The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m internal diameter.For different

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Gajendra Kumar Gaurav, Shabina Khanam

Schematic diagram of plant and the rotary kiln (see arrow) for ...

It has been shown earlier that the sponge iron rotary kiln is a chaotic, dynamical (nonlinear, time-varying) system [4][5] [6] [7][8]. The present work is the first application

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

1. Krupp Sponge Iron Process The Krupp. 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

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Flow of materials in rotary kilns used for sponge iron manufacture ...

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

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Simulation of Rotary Kiln Used in Sponge Iron Process Using

parameters is carried out for a sponge iron production process by designing a Multilayer Perceptron model that uses a momentum learning algorithm. For this purpose data of

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Sponge Iron Production in Rotary Kiln - Google Books

2011/6/30  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

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Rotary Kiln - an overview ScienceDirect Topics

The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be

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Flow of materials in rotary kilns used for sponge iron

rotary kilns. The present study, on cold models, was under- taken to assess the importance of various parameters influ- encing the flow of materials in sponge iron rotary kilns. B In rotary kiln based direct reduction processes, it is essen- tial to identify the optimized flow conditions which give rise

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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 for sponge iron production can be classified into:-

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Energy survey of the coal based sponge iron industry

2015/9/1  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.

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Computational fluid dynamics analysis of sponge iron rotary kiln

2017/3/1  The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m internal diameter.For different production capacities of the plant the variation in length and diameter of the kiln is from 40 to 100 m and from 2 to 5 m, respectively.The kiln is inclined with horizontal at 2.5 degree

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Engineering Consultancy

We designed and commissioned our first Sponge Iron plant of capacity 10,000 TPA near Hyderabad in 1995 and achieved rated production capacity from the first year onwards. ... We have proficiency in converting cement kilns for Sponge Iron production. ... (Rotary Kiln): 100 TPD 175 TPD 350 TPD DRI (Tunnel Kiln) : 30 TPD 50 TPD 100 TPD Iron Ore ...

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Rotary kilns cooler spares (50 TPD-900 TPD) for cement, sponge iron

We are pleased to introduce Piyali Engineering Corporation, situated in Delhi, India. We are leading manufacturer and supplier specializing in the production of Sponge Plant DRI (Direct Reduced Iron) Rotary Kiln Cooler equipment and vital components for steel plants, alongside catering to a diverse range of industries including sugar mills, cement

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

2019/6/4  Conference: AISTech 2019 — Proceedings of the Iron Steel Technology Conference 6–9 May 2019, Pittsburgh, Pa., USA; At: Pittsburgh, USA

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New Sponge Iron Rotary Kiln Design In Sponge Iron

The water in the mixture, the carbon dioxide in the dolomite, and the volatile components in the coal enter the upper space of the sponge iron rotary kiln, forming reducing gas. Then the mixture enters the reduction zone of sponge iron rotary kiln, and the iron concentrate is reduced by carbon monoxide to form iron elements.

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Sponge Iron plant Equipment – 50 – 900 TPD with High Quality

Kiln Girth Gear (Spur / Helical Tooth):. Piyali Engineering Corporation is the best quality and top ranked manufacturer and supplier in India for Kiln Girth Gear, Cooler Girth Gear, Ring Gear, Rim Gear, Two Halve Gear, Split Gear, Large Cast Steel Gear, Fabricated Gear, Wheel Gear, Spur Gear, Helical Gear, Double Helical Gear etc. DRI Sponge Iron plant

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Mathematical Modelling of Sponge Iron Production in a Rotary Kiln

2010/1/1  We have applied predictive data analytics techniques for off-line optimization of granulation and sintering of iron ore fines, for on-line optimization of sponge iron production in a rotary kiln ...

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(PDF) Rotary Kiln Handbook NEW - Academia

Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING Under the supervision of ... are available: chain and sprocket, gear drive, friction drive, and direct drive assembly. Unlike most

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Innov Engineering Pvt. Ltd

ROTARY KILN (Coal-Based DRI Plant) ... We design custom solutions to provide effective and low-maintenance rotary kilns operations for quality sponge iron production through our extensive knowledge and expertise. Sponge iron, also called Direct-reduced iron (DRI) is produced from direct reduction of iron ore by a reducing gas produced from coal ...

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Steel Exchange India Ltd - SEIL

Sponge Iron and Coal Char are discharged from the kiln through a 12 meters long rotary cooler where water is sprayed directly as well as indirectly for cooling the material down to 100oC. The material is then fed to magnetic separator for separating the Sponge Iron and non-magnetic coal char after which the Sponge Iron is transported by way of ...

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Mass balance around main components of the plant on per

In the present work, an effort is made for best utilization of waste heat to reduce energy requirements in sponge iron plants. For this purpose, based on the principles of process integration ...

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(PDF) Rotary Kiln Handbook NEW - Academia

The ROTARY KILN HANDBOOK OPERATION SIZING DESIGN CONSIDERATIONS MAINTENANCE a product of Contents INTRO About FEECO 1 Intro to Rotary Kilns 3 ROTARY KILN OPERATION PROCESSING How Rotary Kilns Work 5 Rotary Kiln Processes 8 SIZING DESIGN Rotary Kiln Sizing Design 11 Increasing Eficiency

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Innov Engineering Pvt. Ltd

ROTARY KILN (Coal-Based DRI Plant) ... We design custom solutions to provide effective and low-maintenance rotary kilns operations for quality sponge iron production through our extensive knowledge and expertise. Sponge iron, also called Direct-reduced iron (DRI) is produced from direct reduction of iron ore by a reducing gas produced from coal ...

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Steel Exchange India Ltd - SEIL

Sponge Iron and Coal Char are discharged from the kiln through a 12 meters long rotary cooler where water is sprayed directly as well as indirectly for cooling the material down to 100oC. The material is then fed

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Mass balance around main components of the plant on per

It resulted in the reduction of energy consumption from 5.57 to 4.9 times in comparison to the existing system. Prasad et al. (2011b) proposed design modifications for the sponge iron industry ...

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2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

2014/10/12  Selection of coals for rotary kiln sponge iron plant. ... gas temperature, and gas components in a cement rotary kiln were obtained by numerical simulation of a 3000 t/d rotary kiln with a four ...

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Pressure Measurement and Control in Rotary Kilns at TATA

Pressure inside a coal fired sponge iron rotary kiln depends on several operating parameters such as coal injection rate, ore feed rate, moisture, and primary and secondary air blow rates ...

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(PDF) i) Direct Reduced Iron: Production - ResearchGate

2016/3/30  In book: Encyclopedia of Iron, Steel, and Their Alloys (pp.pp 1082-1108) Chapter: i) Direct Reduced Iron: Production; Publisher: CRC Press, Taylor and Francis Group, New York.

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Energy Conservation in Sponge Iron Production Process

gas exits the sponge iron plant at substantially higher temperature ranges ... rotary kiln FD fans are required. The number of FD fans depends on pressure drop available in the duct. Further, an effort is made to reduce the temperature drop of 3.78ºC for the inside diameter of 0.309m. It is done by

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Ghugus (Chandrapur, Maharashtra) - Lloyds Metals Energy Ltd

Lloyds Metals and Energy Limited. (LMEL) is a unit of Lloyds Group which is in the manufacturing of Sponge Iron had initially set up its first 500 TPD (Tonnes per day) kiln with the rated capacity of 1,50,000 TPA by opting OSIL-Technology in the year 1994-95 at the village-Ghugus, District-Chandrapur (Maharashtra).

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[PDF] Modeling of rotary kiln for sponge iron processing using

2012/5/29  CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package

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Direct Reduced Iron – IspatGuru

2013/12/14  DRI is a high-quality metallic iron product produced in a DRI kiln (either rotary or vertical shaft kiln) by removing oxygen from iron ore by means of heating and chemical reaction at temperatures below the melting point of iron. A relatively high grade of iron ore is needed as input, as the process retains the impurities.

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Operation of Coal-Based Sponge Iron Rotary Kiln to

Sponge iron is the final product of coal fired rotary kilns. The schematic diagram in Fig. 1 describes the unit processes involved in a sponge iron a production plant [1] .

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Schematic diagram of plant and the rotary kiln (see arrow) for ...

The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon dioxide and entrained dust.

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Rotary kiln process: An overview of physical mechanisms, models

2023/2/25  The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1].The rotary kiln is a slightly inclined steel cylinder that rests

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