Sponge Iron Rotary Kiln Design

2II. Rotary kiln: Operation and construction details A schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in Fig. 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

The hot gases may be generated in an external furnace or by a flame inside the kiln. Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation.

Fig. 2.5 Material balance in a rotary kiln sponge iron plant 2.4 FEATURES OF A ROTARY KILN SPONGE IRON PLANT Figure 2.4 indicates the essential features which are needed in the reduction kiln of a sponge iron rotary kiln plant. However, the air tubes indicated in this diagram can be substituted by a ported kiln design, which is discussed later ...

Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, 500 TPD) Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI).

3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

Rotary kiln is cylindrical in shape and is 80m long having 4.2m internal diameter. This is the reactor of the process where reduction as well as combustion reactions are carried out. The role of kiln is to convert the raw material (iron ore, coal and dolomite) into the sponge iron [8]. Detail reaction mechanism of the process is discussed below:

Dri Tunnel Kiln For Sponge Iron, Find Complete Details about Dri Tunnel Kiln For Sponge Iron,Tunnel Kiln,Construction Tunnel Kiln,Overall Design Tunnel Kiln from Industrial Furnace Supplier or Manufacturer-Henan Lite Refractory Material Co., Ltd.

Rotary kiln design calculations in sponge iron plant.Calculation of iron ore rotary kiln rockthecradle.Nl.Rotary kiln process of making sponge iron fig.2.5 material balance in a rotary kiln sponge iron plant substituted by a ported kiln design, design of high efficiency cyclone for tiny cement industry ce.View all rotary kiln foundation design.

Our cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Widely used for cement, pet coke calcination, sponge iron and other materials, it uses hot gases for the operation.

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 ...

Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials.

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The reduced iron ore i.e. SPONGE IRON from rotary Kiln with other contaminants like non magnetic char/stone pieces gets discharged into a Rotary Cooler at a temperature of 950-1000deg C. The rotary cooler is 2.2 meters in diameter and 50 meters long inclined at 2.5 percent and rotating at 0.8-1.2 rpmThe sensible heat of the matirials will be ...

Rotary kiln is the primary equipment in sponge iron industry, which is used to reduce iron ore to metallic iron i.e. Fe. It is called sponge iron. Rotary kiln is widely used in cement and steel industries. The production capacities of these industries depend significantly on the performance of rotary 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.

Directly reduced iron looks like sponge in texture due to pores and hence is called sponge iron. Iron Ore after due reduction inside the kiln is discharged to a rotary cooler of 3.5 mtr. Dia x 50 mtr long from DR1 and 3.8 x 50 mtr long from DR2 for cooling the DRI from 10000C.

6. The product i.e. Sponge Iron and semi burnt coal are discharged from the kiln through a rotary cooler. The cooler is 12M in length and water is sprayed directly as well as indirectly for cooling the material. The material is cooled down to 100oC and fed to magnetic separator for separating the sponge iron and non-magnetic (char). The Sponge ...

Sep 01, 2015· 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.

500 tpd rotary kiln tyre, capacity 100 to 600 tpd, rs. Kiln and cooler thrust roller for sponge iron plant, thrust roller for coal dryers, rotary kiln thrust roller, thrust roller for fertilizer plant, thrust roller for cement plant - 50 tpd, 100 tpd,175 tpd, 300 tpd, 350 tpd, 500 tpd, for sponge iron dri pla...

INTRODUCTION: The rotary kiln process is a commonly practiced method in India for producing coal based sponge iron. The iron ore along with coal is charged into the kiln and air tubes located along the length supply the air for combustion. In the industry, there have been many recent reports of premature failures of certain air tubes in a ...

For Sponge Iron production by Direct Reduction Process CUMI offers the following solutions. ... GAS BASED SPONGE IRON ROTARY KILN . Application: Recommended Products: BUSTLE PORT : CUMILOX 201 HF: REACTOR HOT FACE LINING: ... Design - ANGLER Technologies ...

Iron ore 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 inside the kiln at 950-1050 o C.

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 an angle 2.5 deg and rotated by

Jun 30, 2011· 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 comprehensively deals with the production of sponge iron in the rotary kiln. The book is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production ...

sponge iron manufacturer/supplier, China sponge iron manufacturer & factory list, find qualified Chinese sponge iron manufacturers, suppliers, factories, exporters & wholesalers quickly on Made-in-China.com. ... Customized Comfortable Design High Density Sponge Metal Iron Church Chair. ... Cement Rotary Kiln and Sponge Iron Rotary Kiln Manufacture.

Engineering design and construction of sponge iron production line by tunnel kiln method is operated by Aramico technical and engineering group. Application Sponge iron is an ideal charge in steelmaking industries and it is used for making different grades of steels like: stainless steels, tool steel, bearing steel, springs steel and other ...

large number of viable design and operating candidates. Introduction Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production.

Kiln Girth Gear for 100 TPD Sponge Iron Plant – Rotary KILN DRI PLANT: 2. Kiln Pinion Assembly for 100 TPD Sponge Iron Plant – Rotary KILN DRI PLANT · Kiln Pinion · Kiln Pinion With Shaft · Kiln Pinion Plumber Block (Bearing Housing – Assly.) · Kiln with Bearing (ZKL, Chinese, SKF) · Kiln End Plate & End Cover & Nut Bolts: 3.