Hot products used for rotary impact mill pdf rotary mill utiliing an impact reduction chamber and a vertical air flow classification. Rotary kiln presentation in microsoft grinding mill china. To conclude the kiln modeling, the design of a 50mwth rotary receiver for a solar tower plant that operates in continuous mode was optimized, achieving an efficiency greater than 83%. Sponge iron plant kiln cooler equipment cooler pinion. 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. Energy audit methodology of sponge iron manufacturing. In india there are many small rotary kiln furnaces producing dri, known locally as sponge iron, using coal as energy and reductant source. Flow of materials in rotary kilns used for sponge iron.
A wide variety of sponge iron plant options are available to you, there are 579 suppliers who sells sponge iron plant on, mainly located in asia. The maximum recommended kiln shell temperature varies by plant, by country and by kiln manufacturer, despite the fact that most kiln shells are made of low alloy carbon steel. This book comprehensively deals with the production of sponge iron in the rotary kiln. Details of rotary kiln pdf file process detail henan. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. Raw material mix iron ore, dolomite and coal are fed to one end of rotary kiln and product sponge iron along with char is taken out from the other end. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. Raw dri process materials, partly coal, iron ore, after burn flue gas chamber fluxes enter the rotary kiln the remainder rotary kiln coal in 2. As the focus of the present work is to study the kiln of sponge iron process, literature related to it is discussed here. Characteristics requirement i inherent moisture content, percent by mass, max 4 ii ash, percent by mass, max 24 iii volatile matter percent by mass 2535 iv. China rotary kiln, rotary kiln manufacturers, suppliers. In this pilot plant, a totally indigenous technology for production of. In the first phase one 350 tpd rotary kiln and 8mw power plant have been commissioned and are operating smoothly 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. The reaction takes place at high temp 1050 to 1065.
Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Raw material mixiron ore, dolomite and coal are fed to one end of rotary kiln and product sponge iron along with char is taken out from the other end. Rotary kiln cement rotary kiln and sponge iron rotary kiln. Nov 17, 2012 raw dri process materials, partly coal, iron ore, after burn flue gas chamber fluxes enter the rotary kiln the remainder rotary kiln coal in 2. Lump iron ore in the size range of 520mm can be used in all coal based rotary kiln processes. 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. In rotary kiln, carbon is charged from either end, in one end in the form of coal particles and in another in form of coal lumps. Basic operation the basic operation is going to include two modes. The coal reacts with air to form carbon monoxide which then reduces iron oxide ore to iron. Iron ore and bauxite is crushed if more than 20 mm and stored in respective storage yards. Pdf industrial applications of rotary kiln in various. The literature discussed above is based on cfd analysis of rotary kiln of cement plant.
To make our solution easily understandable, we have splitted it into three sections. Some of the sponge iron plants are captive to steel mills, but there is a significant domestic merchant market, india producing 57% of. Nov 23, 2017 walk by inspection of a sponge iron kiln yes guys kiln in cement and sponge iron isnt the samesee it to believe it. What is the maximum continuous shell temperature a kiln stands without permanent damage to the shell. Modelling and optimization of a rotary kiln direct reduction. A separate conveyor collects different size fractions of coal stream no. In sponge iron industry rotary kiln is the primary equipment which is used to reduce iron ore to metallic iron ie fe which is called sponge iron the performance of rotary kiln significantly affects the production capacities of these industries the performance of rotary kiln is. Characteristics requirement i inherent moisture content, percent by mass, max 4 ii ash, percent by mass, max. In gas based processes 70% iron ore pellets and 30% lump iron ore of 1030mm are being used. Cpg has an experience of successfully executing numerous complete rotary kiln cement green field projects, cement rotary kiln plant and rotary kiln turnkey cement plant. Walk by inspection of a sponge iron kilnyes guys kiln in cement and sponge iron isnt the samesee it to believe it. 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. One of the major challenges for sponge iron plant is the accretion formation. Pdf file generated from united nations industrial feasibility of establishing a sponge iron plant in nepal based on phulchoki ores.
The millard lime plants five existing rotary kilns range in age from over 65 years for no. Analysis of temperature profile and % metallization in. Apart from this, primary and secondary airs are supplied to the kiln to initiate the combustion and reaction processes. In this pilot plant, a totally indigenous technology for. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process. A schematic of this kind of rotary kiln incinerator is shown here. 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. The lime plant is arranged in two separate lime producing areas.
Operation and construction details a schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in fig. The millard lime plant s five existing rotary kilns range in age from over 65 years for no. Pdf quality prediction and control in coalfired rotary. Kilns 1 to 4 comprise one lime production area, and kiln 5. Prasad and ray simulated flow pattern of air using fluent software in rotary kiln of a typical 100 tpd sponge iron process.
Operational guidance and control of sponge iron rotary kilns at tata sponge, soft computi ng for problem solving, socpros 2017, advances in intelligent sy stems and computing 816, ed. Setting up of modalities for normative coal requirement in. 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. Rotary kilns are similar to cement kilns, but the main difference is the reverse flow of gypsum. However, rotary kiln process suffers from serious limitations like low productivity and pollution. Energy survey of the coal based sponge iron industry. Sponge iron being magnetic gets attracted and gets separated from non magnetic char. The drum consists of a rotary body which is refractory lined using a highly heat resistant type of refractory adapted to requirements of. Study on air tubes failure in sponge iron rotary kiln. China manufacturing industries are full of strong and consistent exporters.
Simulation of rotary kiln used in sponge iron process. Learn more rotary kiln design calculations in sponge iron plant we are now working out in contact supplier. Rotary kiln cement plant cement rotary kiln plant and. China rotary kiln manufacturers select 2020 high quality rotary kiln products in best price from certified chinese drying equipment manufacturers, china burner suppliers, wholesalers and factory on. Old kilns shells have been exposed to creep for a long time and are more prone to develop fatigue cracks than newer shells. 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. Introduction in todays world, powering along the supply of raw materials, cement production is the most important factor. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. The top countries of suppliers are china, india, from which the percentage of sponge iron plant supply is 99%, 1% respectively.
Cracking of an air tube used for supplying air in rotary kiln of a sponge iron plant is investigated in this paper. 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. The cold model study was conducted with iron ore as the feed material to determine the influence of length to diameter ratio ld of a rotary kiln on the filling degree, holdup, and residence time of the charge. For this purpose data of temperature profile of rotary kiln are collected from typical sponge iron plant, which correlate four air inlets and twelve temperatures measured at different lengths of the. From storage yard these materials fed to raw mill hopper. Requirements for coal for sponge iron industry in case direct reduction in rotary kiln and in other reactors is 11860. Energy audit methodology of sponge iron manufacturing units. The rotary kiln allows incineration of almost all types of material safely and efficiently. Manufacturing process the proposed plant uses the coal based process in which iron oxide in pellet will be reduced with non coking coal in a rotary kiln to make sponge iron. We are here to bring together china factories that supply manufacturing systems and machinery that are used by processing industries including but not limited to. The rotary kiln was invented in 1873 by frederick ransome kiln shell. Details of rotary kiln pdf file process detail henan fumine. Erection of chain systems in a rotary kiln pdf and ppt pdf procedure for erection of kiln mill 2.
Kiln temperature distribution for the base case the feed material bed enters the kiln at ambient temperature and rapidly heats up due to the hot gas in the freeboard. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. Simulation of rotary kiln used in sponge iron process using ann. Analysis of temperature profile and % metallization in rotary. The process of reducing the iron ore in solid form by reducing gases is called direct reduction. Jun 19, 20 rotary kiln process of making sponge iron new age international. Cement production process is extremely timeconsuming 1 and the rotary kiln is the most important part of the. An empirical equation correlating different operating variables has been derived on the basis of. The rotary kiln is slightly inclined at an angle 2. Modelling and optimization of a rotary kiln direct. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in predetermined ratio. The present work identifies the basic features of burden movement in a rotary kiln. Kilns 1 to 4 comprise one lime production area, and kiln 5 is the second lime production area. 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.
Rotary kiln the hot gases may be generated in an external furnace or by a flame inside the kiln. The longer the rotary kiln shell span, the less it will resist high temperatures without sagging. Coal based rotary kiln for direct reduced iron sponge iron 100 tpd, 350 tpd, 500 tpd solid state reduction of iron ore using either coalgas as a medium of reduction to produce a substitute raw material for steel making is termed as direct reduced iron dri. However, the feasibility of developing the corex process to produce pig iron was also assessed. Processes that produce iron by reduction of iron ore in solid state below the melting point are generally classified as dr. Rotary kiln body, with drive gear and 2 tyres riding rings a rotary kiln is a pyroprocessing device used to raise materials to a high temperature calcination in a continuous process. 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. A thesis submitted for partial fulfillment of the degree award of. This is made from rolled mild steel plate, usually between 15 and 30 mm thick, welded to form a cylinder which may be up to 230 m in length and up to 6 m in diameter upper limits on diameter are set by the tendency of the shell to deform under its own weight to an oval cross section, with consequent. Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. A thesis submitted for partial fulfillment of the degree.