Dynamic quality prediction and control in rotary sponge iron kilns
The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe. In order to adhere to this ...
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Advances in rotary kiln sponge iron plant
Title Advances in rotary kiln sponge iron plant [electronic resource] / K.K. Prasad, Hem Shankar Ray.
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Direct Reduced Iron Industry in India — Problems and …
The rotary kiln sponge iron has lower metallisation (about 85 — 88% on the average) and low carbon content (0.1-0.2%) compared to gas based sponge iron (Metallisation of 92 — 94% and carbon content ... DRI producers as joint venture, as individual plant requirements are generally small, which will ensure availability of quality input at ...
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Advances in Rotary Kiln Sponge Iron Plant
Advances in Rotary Kiln Sponge Iron Plant. Krishna Kant Prasad, Hem Shankar Ray. ... It can now fulfill the need of a reference textbook in alternate iron making area for undergraduate and post graduate students in Metallurgical, Production, Manufacturing, Chemical, Materials and to a minor extent Mechanical Engineering …
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Advances in Rotary Kiln Sponge Iron Plant.
Introduction -- 1.1 What is Spongs Iron and What is DRI? -- 1.2 History of Modern Sponge Iron Making -- 1.3 Iron Ore Reduction at a Glance -- 1.4 Multiple Role of a Rotary Kiln - …
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Advances in Rotary Kiln Sponge Iron Plant by K K Prasad and
Advances in Rotary Kiln Sponge Iron Plant by Hem Shankar Ray K.K. Prasad and a great selection of related books, art and collectibles available now at AbeBooks.
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A study on the accretion formation in DRI kilns and possible …
264,535 million tonnes the coal based sponge iron plants share the major amount of its production [5]. At present, there are 118 large and small sponge iron plants operating in India, among them only 3 are natural gas based and the remaining 115 plants are coal based. Among all the available options, rotary kilns have been
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Good Practices Manual
4.1 Brief description of sponge iron plant process 40 4.2 Technological options for coal based plants 42 5.0 Status of Sponge Iron Plants in India 67 5.1 Questionnaire Survey 67 5.2 Identified stakeholders for consultations 67 5.3 Questionnaire Survey Analysis 68 5.4 General outlook of green house emission measures and practice ...
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Generation of Energy Conservation Measures for Sponge …
Conventional sponge iron plant flow diagram Coal injector, Air: 2500m3/h, Injection coal:6.13 t/h, all at 300C Rotary Kiln (10200C) 8 shell air fan at 48000 m3/h, 300C Flue gas Fly ash Fines of iron ore 108.94 t/h Kiln Feeding Iron ore: 30 t/h Feed coal: 14.297 t/h Dolomite (Lime stone): 0.5 t/h All at 300C Rotary Cooler At 1200C Sponge iron:
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(PDF) Operation of Coal-Based Sponge Iron Rotary …
Operation of Coal-Based Sponge Iron Rotary Kiln to Reduce Accretion Formation and Optimize Quality and Power Generation. …
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Sponge Iron | SpringerLink
For coal-based sponge iron plant, iron ore requirement to produce sponge iron with different rates is shown in Fig. ... This ironmaking process takes only 10 min against 10 h in BF process and 8 h in rotary kiln process. Iron and slag get separated, and product is called nuggets. Iron nuggets can be fed directly into BOF or EAF as pure iron ...
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Dynamic quality prediction and control in rotary sponge iron kilns
The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe.
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Rotary kiln process: An overview of physical mechanisms, …
The rotary kiln is used in many solid processes, including drying, incineration, heating, cooling, humidification, calcination and reduction. This widespread application can be attributed to factors such as the ability to handle varied loads, with large variations in particle size [1]. The rotary kiln is a slightly inclined steel cylinder that ...
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Computational fluid dynamics analysis of sponge iron rotary kiln
Computational fluid dynamics analysis of sponge iron rotary kiln. 2D CFD model is developed for simulation of rotary kiln of sponge iron process. Effects of …
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Introduction to Iron ore Pellets and Pelletizing processes
There are four stages involved in the production of iron ore pellets. These stages consist of (i) raw material preparation, (ii) formation of green balls or pellets, (iii) induration of the pellets, and (iv) cooling, storage and transport of pellets. Raw material preparation – During the process for pelletization iron ore concentrate from ...
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(PDF) Conventional and AI Models for Operational
The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon dioxide and entrained dust.
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Advances in rotary kiln sponge iron plant
Dry kiln operator's manual / by: Rasmussen, Edmund Frederick, 1903- Published: (1961) Use of kiln samples in operating a lumber dry kiln. Published: (1954) A guide to the deep-water sponges of the Aleutian Island archipelago by: Stone, Robert P.
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Sponge Iron | Manufacturer of Sponge Iron
JSWAION possesses considerable expertise in the manufacture of sponge iron. The sponge iron exhibits superior quality characteristics with excellent metallic content and an impeccable consistency in chemical and physical characteristics and low sulphur and phosphorus content. The production process also ensures that the sponge is free from …
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Profitability analysis of power generation using waste heat of sponge
The present paper proposes two energy integration options, Option-1 and Option-2, to compare power generation and preheating scheme in sponge iron process.Option-1 accounts power generation whereas in Option-2 preheating of feed material, slinger coal and kiln air is considered. These options utilize heat of waste gas …
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(PDF) i) Direct Reduced Iron: Production
Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR processes. Based on the types of reductant used, DR processes can be ...
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Mechanical rotary kiln
entrepreneurs and plant operators has not only been retained; it has been elaborated. Further, the basic aspects have been ... [10] The kiln shell. 130 Sponge Iron Production in Rotary Kiln. (American Society of Mechanical Engineers,1969) Scientific Canadian Mechanics' Magazine and Patent Office
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Schematic diagram of plant and the rotary kiln (see …
It has been shown earlier that the sponge iron rotary kiln is a chaotic, dynamical (nonlinear, time-varying) system [4][5] [6] [7][8]. The present work is the first application of both OSAA and ...
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SPONGE-IRON
In the Direct Reduced Iron (DRI) plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material such as coal. The reduction is carried out in a …
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Recovery and Utilization of Waste Heat in a Coal Based …
Rotary Kiln (1050 C) Kiln air at 30 C Flue gas Fly ash Fines of iron ore at 900 oC Kiln Feeding Iron ore: Feed coal: Dolomite All at 30 C Rotary Cooler Sponge iron (magnetic) At 110 oC Water: at 30 oC DSC 900 C 1020 C Dust: ABC Air: WHRB Waste gas Water: ESP Dust Wet scraper waste gas Dusty gas Chimney Steam Water: at 34.5 oC Fe …
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Pressure Measurement and Control in Rotary Kilns at TATA …
equations on the basis of plant operational data. 1. INTRODUCTION Pressure inside a coal fired sponge iron rotary kiln depends on several operating parameters such as coal injection rate, ore feed ...
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Advances In Rotary Kiln Sponge Iron Plant [PDF] [2h3h9g6epd0g]
Sponge Iron, Direct Reduced Iron (DRI) = Iron produced by the reduction of iron oxide (ore) in solid state. Since the process is accompanied by large reduction in volume (53%), a lot of pores appear in the metallic product, which looks like sponge under the microscope.
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Brahma DEO | MGM Chair Professor | Ph.D., DIC
The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe.
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Understanding the co-relationships of variables and
Direct Reduced Iron (DRI) is produced when sized Iron Ore from Iron Ore Mines are subjected to a high temperature of about 1070 °C (below the fusion temperature of Ore, which is about 1535 °C) [6] in a rotary Kiln along with Coal & Dolomite. As shown in Fig. 1.1, raw materials like Coal, Ore and dolomite are fed in a controlled environment …
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ENERGY-EFFICIENT TECHNOLOGY OPTIONS FOR …
3.2 Iron Ore Preheating Rotary Kiln Using Waste Heat Recovery System 20 3.3 Coal Gasification for Partial Substitution in Rotary Kiln 22 3.4 Waste Heat Recovery-based Absorption Chiller 23 3.5 Decentralized Control of Shell Air Fans 25 3.6 Mullite-based Kiln Lining 26 3.7 Switch Over to Iron Ore Pellets 27
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Dynamic quality prediction and control in rotary sponge iron kilns
Abstract. The quality of sponge iron produced in the coal-fired rotary kilns at TATA Steel Long Products Limited (TSLPL) is permitted to vary in a small window of 80-83% Fe. In order to adhere to this window, the expected quality in the next hour is predicted, and appropriate actions are taken if changes or rates of change that take place are ...
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