In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production, commercially used dr direct reduction processes and physicochemical principles of sponge iron production. This book deals with the basics of sponge iron production in rotary kiln, describing the operational problems and control needed to produce a quality product. Cement rotary kiln, lime rotary kiln, kaolin rotary kiln, magnesium rotary kiln, etc.
On average, their thermal efficiency is between 5065%, on average. This book deals with the basics of sponge iron production in rotary. Raw material preparation plant direct reduction plant raw material preparation plant. The fully integrated system boasts a burn rate if 1200kg per hour and accepts a variety of different waste streams that include, clinical waste, pharmaceutical waste, liquid waste that includes solvents, waste oil, shredded tyres and well as some.
Flow of materials in rotary kilns used for sponge iron. Sponge iron composition manufacturing process lloy. The cooler is 12m in length and water is sprayed directly as well. Pipe and ms billets bars at village samkhiyali, taluka. Rotary kiln manufacturers are those who manufacture cement. A number of paper manufacturers soon became aware of the savings that could be achieved by recovering the lime. Suitable unitplant size in terms of capacityproduction. The material of the air tube is astm a297 hk 40, a member of the heatresistant cast alloy family h series steels widely used for enhanced hightemperature properties. The process of reducing the iron ore in solid form by reducing gases is called direct reduction. This public version of the master thesis thermodynamic process evaluation of a rotary kiln unit at lkab includes only parts of the total work performed. These treatments can be applied to powders, granulates, suspensions and green bodies. The kiln is a long, cylindrical, slightly inclined, refractory lined furnace, through which the limestone and hot combustion gases pass counter currently. Potential pollution problems met with in sponge iron production.
Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. Combustion profile of a grate rotary kiln incinerator. India is the largest producer of dri in the world with total installed capacity of 35 mtpa. The feed is introduced together with reducing and desulphurizing agents limestone or raw dolomite into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge. The continuity of operation of a lime sludge kiln requires strict maintenance control. Installation of preheating furnace in the sponge iron plant can save 8251 mt of coal per year. Modeling of rotary kiln for sponge iron processing using. Rotary kiln incineration plant rotary incinerator case study. Presentation from tata sponge iron ltd was very much liked and lot of the people showed. The kiln is usually turned by means of a single girth gear surrounding a cooler part of the kiln tube, but sometimes it is turned by driven rollers. Rotary kiln has many advantages, such as great production capacity, high mechanization and automation, strong adaptability to raw material, high activity of its product, stable production operation, perfect environmental.
The prevalent type of kiln is the rotary kiln which accounts to about 90 percent of all lime production in the world ellis 1960. We are manufacturer of 50 tpd sponge iron plant, 100 tpd sponge iron plant, 350 tpd sponeg iron plant and 500 tpd spnoge iron plant equipment machinery manufacturer and exporters. Rotary kilns and rotating industrial drying ovens are used for a wide variety of. Sponge iron plant kiln cooler equipment cooler pinion. Rotary kiln cement rotary kiln and sponge iron rotary kiln. Siil was the first sponge iron plant in the country which was set up at paloncha in andhra pradesh in 1990 with an initial capacity of 0. We have introduced a new technology for producing sponge iron is known as itc preheating technology. Study on accretion formation on dri kiln during spong iron. This book comprehensively deals with the production of sponge iron in the rotary kiln. Since coal was adequately available in india, production of coalbased sponge iron plants was considered as. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. Iron ore and bauxite is crushed if more than 20 mm and stored in respective storage yards.
The bulk material is continuously fed into the elevated end of the tube and cascades down the length of the tube by the tubes continuous rotation. Sponge iron plant sponge iron plant or direct reduction plant drp is designed to produce 350tons of sponge iron per day in a rotary kiln using iron ore, non coking coal and dolomite as the raw materials. This paper aimed to understanding and improving the heat transfer in a rotary kiln and to provide a systematic basis for the efficient working of kiln in the modern of the cement factory. Analysis of temperature profile and % metallization in. A rotary kiln is a pyroprocessing device that raises materials to very high temperatures in a continuous process. A solid reductant is usually employed in the rotary kiln processes, but in the other. Kiln girth gear, cooler girth gear, kiln support roller, cooler support roller, kiln pinion and cooler pinion complete assembly. The rotary kiln is among the largest type of moving machines made and is subjected to extreme temperatures, power failures, atmospheric conditions, varying loads, and other operating conditions which affect its wear and alignment. Rotary kilns sometimes called calciners or rotary furnaces are used for thermal treatment processes such as calcination, sintering, pyrolysis and firing, as well as for oxidation and reduction. The rotary kiln heated chamber is a long horizontal tube that is rotated with one end slightly elevated. The following chemical reactions take place inside the kiln. Thermodynamic process evaluation of a rotary kiln unit at. Sponge iron plants sponge iron kiln plant vsk cement plant. Brief process of coal based sponge iron rotary kiln.
The carbon and oxygen combine together to form carbon monoxide which is used as a reducing. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a selectgrade of ironcoking coal little dolomite inside an inclined rotary kiln and control busted in the presence of air for about 12 hours. Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Sponge iron kiln plant, vsk cement plant tyre suppliers. Due to the confidential requirements from lkab, chapter 4. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process. Sponge iron and semi burnt coal are discharged from the kiln through a rotary cooler. Alibaba manufacturer directory suppliers, manufacturers.
Setting up of modalities for normative coal requirement in. A thesis submitted for partial fulfillment of the degree. C, carbon monoxide will combine with the oxygen in the iron ore forming. The xrd patterns were identified using powder diffraction files pdf. Dri is also known as sponge iron because of its spongy micro structure. Notably, in the mid1960s, following the merger of the sl and rn technologies, considerable. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. Rotary kiln incineration plant the r1200 plant was installed in the early 00s in macau.
India produces 65% of its iron through bf route and 35% through dri route. Ibutec the rotary kiln experts for trials and production. Microstructural degradation occurring at high temperature affects mechanical and corrosion. The gear is connected through a gear train to a variablespeed electric motor. Study on air tubes failure in sponge iron rotary kiln. Beginning in the 20s, efforts were directed toward lime recovery installations. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. This must have high starting torque to start the kiln with a large eccentric load. In 1954, more kilns came in operation in sweden and usa.
Rotary kilns transport phenomena and transport processes. There are only three existing power plants that combine whr, coal and grid electricity. It is used to create cement, lime, metakaolin, titanium dioxide, alumina, iron ore pellets, and more. Prasad and ray simulated flow pattern of air using fluent software in rotary kiln of a typical 100 tpd sponge iron process. In the year 1908 use of tunnel kiln started for iron oxide reduction. However, rotary kiln process suffers from serious limitations like low productivity and pollution. One of the major challenges for sponge iron plant is the accretion formation. The coal reacts with air to form carbon monoxide which then reduces iron oxide ore to iron. Support rollers with bearing housing for 350 tpd sponge. A rotary kiln consists of a cylindrical, rotating body mounted between stationary material feed and outlet housings. An investigation on the cracking of air tubes of rotary.
A wide variety of sponge iron options are available to you, there are 4,168 suppliers who sells sponge iron. Pdf quality prediction and control in coalfired rotary. Flame simulation and flow visualization inside rotary kilncfd with pdf. Part of the burning mass is constantly turned over and moved progressively along the 24foot length of the kiln as it slowly rotates.
The incinerator plant consists of drying and ignition grates where rubbish is ignited and moved continuously to a rotary kiln. As the focus of the present work is to study the kiln of sponge iron process, literature related to it is discussed here. Case introduces another first in india by introducing coal gasifier for dri rotary kiln saving tremendous coal used for reduction of iron ore. Material balance in a rotary kiln sponge iron plant. C, carbon monoxide will combine with the oxygen in the iron. Rotary kiln cement plant cement rotary kiln plant and. Presently it is more popular in china for sponge iron production from beneficiated iron ore fines cakes. The outlet of the rotating burning chamber drops the unburnable ash to. Procedure commissioning of the cement rotary kiln in. Pdf energy survey of the coal based sponge iron industry.
We, at industrial technical consultant itc in raipur, started in the year 2000. September 20121 chairmans message globally ninety percent iron is produced through bf route. Looking forward to the need of developing coalbased 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. The coal base dri rotary kiln used for the production of sponge iron with. Simulation of rotary kiln used in sponge iron process. The rotary kiln is slightly inclined at an angle 2. You have clicked a page that seems to be very popular. A survey is made on a typical coal based indian sponge iron plant of capacity 500 td in order to identify the largest energy losses and find ways to increase the efficiency. Us3096172a rotary furnace production of sponge iron. We execute the rotary kiln cement plant, cement rotary kiln plant, rotary kiln turnkey cement plant, rotary kiln cement project, rotary kiln cement manufacturing plant.
In this pilot plant, a totally indigenous technology for production of. T srinivasa rao, md, balajiswamy premium steels pvt ltd offered his 50tpd kiln for this purpose. Today, a proper rotary lime kiln operation is an integral part of all modern pulp mills. On the direct reduction of iron ore in rotary kiln email protected lahiri, a k 1973 on the direct reduction of iron ore in rotary kiln. Rotary kiln and 2 x 2 mw waste heat recovery boiler whrb. Symposium on science and technology of sponge iron and. Sponge iron rotary kiln process anticorruption helpline. We are a consulting firm providing services to the clients for the establishment of plants from steel and power sector in india and abroad. The rotary hearth furnace direct reduction process.100 913 372 155 1510 491 1473 1085 502 525 856 506 1050 1196 618 199 592 1052 1228 743 762 595 1588 1441 1002 587 1452 1255 933 255 50 71