rotary kiln process of making sponge iron chapter

DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 8001200 C. 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 ...

  • Sponge Iron an overview ScienceDirect Topics

    Sponge Iron an overview ScienceDirect Topics

    DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 8001200 C. 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 ...

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  • tunnel kiln process for sponge iron

    tunnel kiln process for sponge iron

    tunnel kiln process of iron ore reduction. SPONGE IRON PRODUCTION FROM ORE -COAL COMPOSITE In the year 1908 use of tunnel kiln started for iron oxide reduction. This process was invented by E.Sieurin as Hoganas process 3. In 1954, more kilns came in operation in

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  • Accretion Control in Sponge Iron Production Kiln

    Accretion Control in Sponge Iron Production Kiln

    This study focuses on sponge iron kiln based process. The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of non-coking coal Patra et al, (2005). The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

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  • SPONGEIRON Shakambhari Group

    SPONGEIRON Shakambhari Group

    Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with

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  • SPONGE IRON PRODUCTION FROM ORE COAL

    SPONGE IRON PRODUCTION FROM ORE COAL

    However, Rotary kiln process suffers from serious limitations like low productivity and pollution. In this respect fixed bed Tunnel kiln furnace are evolving as an alternative to Rotary kiln process. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns.

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  • The Effect of Reduction Time and Size Distribution of

    The Effect of Reduction Time and Size Distribution of

    Apr 29, 2016 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%. In this research, sponge iron is made of a mixture of Lampung iron ore ...

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  • ENERGY INTEGRATION IN SPONGE IRON PLANT

    ENERGY INTEGRATION IN SPONGE IRON PLANT

    sponge iron making was in 1972 presumably using a rotary kiln. More than 100 DR processes have been invented and operated since 1920. Most of these have died down but some of them have re-emerged in slightly different form. 6 Sponge iron is mainly produced from iron ore by two different routes (a) - by reducing gases (CO and H 2

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  • Project Proponent Ms BRGD Sponge and Iron Pvt Ltd

    Project Proponent Ms BRGD Sponge and Iron Pvt Ltd

    1,20,000 TPA sponge iron. Manufacturing Process The proposed plant uses the coal based process in which iron oxide in pellet/iron ore will be reduced with non coking coal in a rotary kiln to make sponge iron. The raw materials (Pellet/iron ore, coal and dolomite), in desired quantities and sizes, are fed into the rotary kiln

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  • DRI UPDATE Sponge Iron Manufacturer India

    DRI UPDATE Sponge Iron Manufacturer India

    2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the RampD for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed

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  • Direct Reduced Iron Industry in India Problems and

    Direct Reduced Iron Industry in India Problems and

    the quality requirements for the rotary kiln sponge iron process. The sponge iron fines generation is high and ranges from 15 30% depending upon the ore used due to high reduction degradation. This will not only reduce the sales realization of the product but also will lead to accretion formation in the kiln shortening the campaign life.

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  • Modelling and optimization of a rotary kiln direct

    Modelling and optimization of a rotary kiln direct

    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

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  • Sponge Iron Production By Direct Reduction Of Iron Oxide

    Sponge Iron Production By Direct Reduction Of Iron Oxide

    This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces ...

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  • Recovery and utilization of waste heat in a coal based

    Recovery and utilization of waste heat in a coal based

    Coal-based sponge iron process The process of the direct reduction of haematite in a rotary kiln is schematically described in the Fig. 1. Haematite and non-coking ... gas from ESP outlet to rotary kiln an insulated duct, which is a hollow cylinder of 43m length and 0.6m diameter, is used. To

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  • Sponge Iron Plant Rotary Kiln China Rotary Kiln Rotary

    Sponge Iron Plant Rotary Kiln China Rotary Kiln Rotary

    sponge iron plant rotary kiln 1..Brief description of clinker rotary kiln Our company owns the magnesium production line. As a kind of qualified material crushed by the crusher, the raw material-dolomite is calcined till it became white by rotary kiln, being cooled by the cooling machine and then mix it evenly with silicon powder (75%) and silica powder (including GaF2 fluorite95%).

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  • Direct Reduction Process an overview ScienceDirect Topics

    Direct Reduction Process an overview ScienceDirect Topics

    The basis of the direct reduction process is that solid sponge iron is produced by removing oxygen from the ore in a shaft furnace, rotary kiln furnace or fluidised bed. Sponge iron can be produced in the form of Direct Reduced Iron (DRI), Hot Briquetted Iron (HBI) and Cold Briquetted Iron (CBI) also Low Reduced Iron (LRI), which is pre ...

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  • CN1818081A Production of sponge iron Google Patents

    CN1818081A Production of sponge iron Google Patents

    The invention is about the producing method of the sponge iron. The process is (1) make the material into the double iron oxide ball (2) put the double iron oxide ball and the reductant into the reaction tank to get the sponge iron ball mass (3) put the mass into the thermal insulating flume to separate the reductant, to remove the C, S,O in the protection of the N2 or the H2 to produce the ...

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  • sponge iron process

    sponge iron process

    Aug 03, 2011 Wednesday, August 3, 2011. During the process of manufacture of sponge iron, coal injection plays a very vital role in maintaining the product quality. Due to highly endothermic nature of Boudouard reaction, heat has to be continuously supplied in entire reduction zone of rotary kiln. Generally the length of reduction zone is 60-70% of total ...

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  • Rotary Furnace And Lime Rotary Kiln Maintenance

    Rotary Furnace And Lime Rotary Kiln Maintenance

    Apr 27, 2020 Lime rotary kiln is an important and common type of rotary kiln.. Lime production is a relatively complicated thermal decomposition reaction process of calcium carbonate to calcium oxide. Due to different kiln types, different equipment configurations, different raw material quality and composition, and different fuel types and calorific values, each will appear Various problems and

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  • Sponge Iron Iron Steelmaking

    Sponge Iron Iron Steelmaking

    Gas-Based Process This process utilizes natural gas as the reducing agent. Natural gas is reformed to enrich with H2 and CO mixture and this enriched and reformed gas mixture is preheated in gas-based process. A vertical retort is used for the reduction of iron ore as against a rotary kiln in coal based sponge iron process.

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  • Sponge Iron Production In Rotary Kiln By Sarangi Arabinda

    Sponge Iron Production In Rotary Kiln By Sarangi Arabinda

    Rotary Kiln To Making Sponge Iron In India Binq Mining. Rotary Kiln Process of Making Sponge Iron New Age International Rotary Kiln Process of Making Sponge Iron 13 that the entire production by number 2 3 and 4 countries is. Get Price

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  • Sponge Iron Rotary KilnampRotary Kiln Process of Making

    Sponge Iron Rotary KilnampRotary Kiln Process of Making

    Sponge Iron Rotary Kiln, Lime Rotary Kiln, Cement Rotary Kiln manufacturer / supplier in China, offering Sponge Iron Rotary KilnampRotary Kiln Process of Making Sponge Iron, Widely Used Zz/Zj Series Cylindrical Gear Reducer for Building Materials Industry and Gear Box Reducer for Mine Machines and Construction Machines, Medium Hardness Material Crushing Equipment Fine Spring Cone

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  • US4676824A Process for generating heat and producing

    US4676824A Process for generating heat and producing

    Sponge iron is produced by a direct reduction of iron oxide containing materials in a rotary kiln, the material discharged from the rotary kiln is separated into sponge iron and material which contains surplus carbon, the carbon-containing material is burnt in a fluidized bed reactor containing a circulating fluidized bed, and the heat generated by the combustion is recovered and utilized to ...

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  • SPONGE IRON BHAGWATI POWER amp STEEL LIMITED

    SPONGE IRON BHAGWATI POWER amp STEEL LIMITED

    The overall process requires duration of approximately ten to twelve hours inside the kiln, during which iron ore is optimally reduced and discharged to a rotary cooler for cooling below 120 C., before coming out into the finished product circuit. The process of sponge iron making aims to remove oxygen from iron

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  • Manufacturer of SPONGE IRON BHAGWATI POWER

    Manufacturer of SPONGE IRON BHAGWATI POWER

    Due the inclination and the rotary motion of the kiln, the raw materials move from the feed end to the discharge end. In the process it gets pre-heated at temperature range of 200-800 oC and reduced to sponge iron. The materials discharged from the kiln is taken into a rotary cooler via transfer chute where the material is cooled.

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  • US4676824A Process for generating heat and producing

    US4676824A Process for generating heat and producing

    Sponge iron is produced by a direct reduction of iron oxide containing materials in a rotary kiln, the material discharged from the rotary kiln is separated into sponge iron and material which contains surplus carbon, the carbon-containing material is burnt in a fluidized bed reactor containing a circulating fluidized bed, and the heat generated by the combustion is recovered and utilized to ...

    read more
  • SPONGEIRON Shakambhari Group

    SPONGEIRON Shakambhari Group

    Sponge Iron, also known as Direct Reduced Iron is produced from Hematite Iron ore (5 to 18 mm size) by removing the oxygen by direct reduction process using non coking coal as the fuel and reducing agent in Rotary Kiln. Sponge iron is rich in Metallic Iron (Pure Iron) with

    read more
  • CN1818081A Production of sponge iron Google Patents

    CN1818081A Production of sponge iron Google Patents

    The invention is about the producing method of the sponge iron. The process is (1) make the material into the double iron oxide ball (2) put the double iron oxide ball and the reductant into the reaction tank to get the sponge iron ball mass (3) put the mass into the thermal insulating flume to separate the reductant, to remove the C, S,O in the protection of the N2 or the H2 to produce the ...

    read more
  • Development of energy conservations scenarios for sponge

    Development of energy conservations scenarios for sponge

    Jan 16, 2011 Coal based sponge iron plant a conventional process. The process flow diagram of conventional coal-based sponge iron plant is shown in Fig. 1. The operating data shown in Fig. 1 is taken from a typical Indian sponge iron plant. In the conventional process kiln feed, which consists of iron ore, feed coal, and dolomite, is fed to the rotary kiln.

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  • Convert your sponge iron plant into a cast iron plant and

    Convert your sponge iron plant into a cast iron plant and

    To convert the rotary kiln-based sponge iron plant into a pig iron plant, MAGMA smelter is installed in place of the rotary cooler, and all other existing infrastructures are utilized. A 100 TPD sponge iron plant can make 1,08,000 tons of pig iron per year a 200 TPD plant can make 1,72,000 tons of pig iron per year and a 350 TPD plant can make ...

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  • SPONGE IRON INDUSTRY

    SPONGE IRON INDUSTRY

    2.05 Historical Development of Sponge Iron Making Sponge iron provided the main source of iron for many centuries before the blast furnace was developed. In historic times, sponge iron was produced in shallow hearths, which used charcoal as reductant fuel. The product of these early smelting process was a sponge mass of coalesced granules of nearly

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  • Sponge Iron Production By Direct Reduction Of Iron Oxide

    Sponge Iron Production By Direct Reduction Of Iron Oxide

    This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces ...

    read more
  • ORISSA SPONGE IRON AND STEEL LTD

    ORISSA SPONGE IRON AND STEEL LTD

    ORISSA SPONGE IRON AND STEEL LTD. OSIL P amp E is capable of providing the following services. Preliminary engineering services including testing of raw materials for - Coal based DRI Plant of 350 amp 500 TPD. - Power generation facility from waste heat of DRI off gas. - Steel making through IF / EAF including secondary metallurgy.

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  • Sponge Iron Plant Manufacturers and Sponge Iron

    Sponge Iron Plant Manufacturers and Sponge Iron

    The coal base DRI rotary kiln process for production of DRI / Sponge Iron has its many parameters to increase the quality as well as productivity which need careful operations throughout the process. Number of DRI processes came up and rotary kiln process with solid coal as fuel found to be most acceptable process in the world.

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  • Sponge Iron Plant Rotary Kiln China Rotary Kiln Rotary

    Sponge Iron Plant Rotary Kiln China Rotary Kiln Rotary

    sponge iron plant rotary kiln 1..Brief description of clinker rotary kiln Our company owns the magnesium production line. As a kind of qualified material crushed by the crusher, the raw material-dolomite is calcined till it became white by rotary kiln, being cooled by the cooling machine and then mix it evenly with silicon powder (75%) and silica powder (including GaF2 fluorite95%).

    read more
  • Gypsum Rotary Kiln Gypsum Kiln AGICO

    Gypsum Rotary Kiln Gypsum Kiln AGICO

    Gypsum Rotary kiln Working Process . Put the raw material into a gypsum rotary kiln. raw material from the bottom of the raw material store divided into seven areas going to the raw material standard warehouse by a manual gate valve, electronically controlled pneumatic valve or

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  • Subhas Behera President PUSHPIT STEEL PRIVATE

    Subhas Behera President PUSHPIT STEEL PRIVATE

    Summary. 32years of experience in Sponge Iron, Steel and Power Industry. Coal based Rotary Kiln Process for DRI (Sponge Iron) making is the speciality as success in return. Product development ...

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