processing iron sand to sponge iron by rotary kiln

OPERATIONAL ASPECTS OF SPONGE IRON …

2012-1-10 · 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 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 ...

Processing Iron Sand To Sponge Iron By Rotary Kiln

OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN A ROTARY KILN

Sponge iron from magnetite

2021-10-13 · Sponge Iron production usually employs the DRI Process, undertaking solid-state reduction of hematite ores with equal proportions of coal. This is brought about by the use of a coal-fired Rotary Kiln, with the environmental impact of the entire process putting Sponge Iron plants under ''Red Category'' industries.

Direct reduction process in a rotary kiln ...

We claim: 1. In a process for directly reducing iron oxide-containing material to produce sponge iron in a rotary kiln by treatment with solid carbonaceous reducing agent having a high content of volatile combustile components, in which the charge is moved through the rotary kiln opposite to the direction of flow of the kiln atmosphere, oxygen-containing gases are blown at controlled …

rotary kiln for iron sand processing

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 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 ...

DRI PLANT – Lloyd''s Metals

DRI PLANT. 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).

TMT Bar Manufacturing Plants and Process with Latest ...

The inclination and the rotary motion of the kiln ensure that the raw materials move from the feed end to the discharge end of the kiln and during this movement the actual reduction of iron ore to iron takes place. The material discharged from …

The Ironmaking Process | New Zealand Steel

The char is burnt at a predetermined rate by the air blown in through the fans mounted on the kiln shell. The hot gases generated during combustion raise the temperature of the kiln refractory lining (bricks) and as the kiln rotates (at one …

SPONGE IRON PLANT

2018-9-24 · Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at …

Welcome to SIPC Services

2021-1-16 · Sponge Iron Background:: DRI Process:: The majority of DRI units in India are coal based. In a coal based DRI unit, non-coking coal and iron ore along with limestone or dolomite in the required size range and quantity are continuously fed into the feed – end of an inclined rotary kiln through a feed pipe.

Processing Iron Sand To Sponge Iron By Rotary Kiln

Rotary kiln for iron sand processing. 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

WELSPUN STEEL LIMITED

For the direct reduction of iron ore the main furnace used is rotary kiln. The rotary kiln is the refractory lined cylindrical vessel on which blowers are mounted & the air pipes, to provide combustion air to the inside of the kiln. During lite up there is a start up burner at the kiln discharge end which is oil fired to heat up the rotary kiln.

spong iron industries based on tunnel klin technology in …

Ball Segregation In An Industrial Ball Mills. Cost Of Tunnel Kiln Sponge Iron Mining equipment cost of tunnel kiln for sponge iron process making sponge iron rotary kiln animation in south africa tunnel kiln iron ore technology pakistan crusherstone crusher get price direct reduced iron tunnel kiln direct reduction of iron ore from tunnel kiln process 390 views the zenith is the professional ...

MAKING OF IRON NUGGET FROM CONCENTRATED IRON …

In this study, reduction process of iron sand concentrates with coal as the reductant was accomplished in a mini-sized rotary kiln (0.6 m diameter and 6 m length). The process of iron nugget making from iron sand concentrate was conducted in two (2) stages, namely oxidation and reduction processes.

Sponge Iron :: Shri-Bajrang

The material discharged from the kiln is taken to a rotary cooler and cooled product is separated from coal char. Sponge iron Ranging from 3mm to 18mm. Advantages: Sponge iron produced by us has high iron content and has high degree of metallization. It has less Sulphur and Phosphorous content and has uniform and consistent quality.

Production Process Of Sponge Iron In Rotary Kiln Grinding

Process For Production Of Sponge Iron. Process for production of sponge iron by direct reduction of iron ore wherein iron ore admixed with a carbonaceous reducing agent is passed through a rotary kiln countercurrent to a gas stream, and wherein granular coking high volatile coal is injected co-current to said gas stream as a solid reducing agent by means of oxygen …

Energy Audit Methodology of Sponge Iron …

2014-7-14 · Energy Audit, DRI Process, Sponge Iron, Kiln Efficiency, Sankey Diagram of Kiln, Coal Balancing 1. Background of This Study Sponge iron industries in India have mandatory energy performance target in terms of specific energy consump-tion (SEC). They shall have to achieve the target SEC by 31st March, 2015. The non-performing industries are

Sponge ITC, Sponge Iron,India Iron Consultant

2018-9-24 · Non-coking coal is used as reluctant in the rotary kiln process. The major quality requirements of coal for Sponge iron production are-1) Non-coking characteristics 2) Low ash content 3) Low sulphur content 4) Good reactivity 5) High ash fusion temperature 6) …

The Effect of Reduction Time and Size Distribution of ...

2016-4-29 · A rotary kiln is a tool used to reduce low-grade iron ore and produce sponge iron with a high metallization. This process is in accordance with the Indonesian government policies that regulate the minimum value of percentage of sponge iron metallization for export, i.e. 85%.

Sponge Iron – A-One Gold Steel

Grades of sponge iron - 82+ / 80+. Process used to manufacture - Rotary kiln DRI. Specifications - C-0.15, S-0.035, P-0.045. Size 5-20mm with processing to fast melting. Low-cost process and can use wide range of Raw materials like Coal & Iron Ore.

Energy survey of the coal based sponge iron industry ...

2015-9-1 · 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 ...

Super Refractories

2019-8-26 · For Sponge Iron production by Direct Reduction Process CUMI offers the following solutions. COAL BASED SPONGE IRON ROTARY KILN. svenska casino spel. Application. Recommended Products. AFTER BURNING …

Analysis of temperature profile and % metallization in ...

2016-6-1 · A 2D CFD model of rotary kiln for sponge iron process is developed in this work using ANSYS 14.5. The present study discusses the behavior of temperature profile of the bed and gas (air) along the length of the kiln. These parameters are studied based on variation of input parameters such as angle of inclination, number of rotation and mass ...

Sponge iron making process

2014-11-9 · ROTARY COOLER The product is conveyed to the product separation and storage building The product is Sponge iron and char Place that spraying a controlled amount of water directly into hot solids and by spraying additional …

SPONGE IRON

2010-9-21 · SPONGE IRON. Iron ore (haematite) and non-coking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature ...

A Thesis Submitted for Partial Fulfillment of the Degree ...

2012-5-29 · 3 sponge iron processing 10 4 rotary kiln design & operation 23 5 computational fluid dynamics (cfd) & its application 31 6 model development 37 7 result & discussion 43 8 conclusion 54 9 reference 56 . list of figures figure no. figure caption page …

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 …

Modelling and optimization of a rotary kiln direct ...

2014-8-5 · The kiln model applied in this work was developed by Hatch over a number of years and has been used for several rotary kiln projects. It has its roots in a FORTRAN program that was developed by Venkateswaran (1978) to study the reduction of iron ore. The original software was used to model the operation of a 35 m pilot kiln at the Stellco company

Accretion Control in Sponge Iron Production Kiln using ...

processing plant determines the type of control strategy to be implemented. Sponge iron production process requires accurate monitoring and control of the process parameters. The performance of rotary kiln sponge iron based processes is normally affected by accretion build up along the kiln linings. Accretion build up is the