Processes that produce iron by reduction of iron ore in solid state below the melting. Simulation of rotary kiln used in sponge iron process. Pdf operability analysis of direct reduction of iron ore. Study on accretion formation on dri kiln during spong iron. Iron oxide is charged into shaft furnace, rotary kiln, or fluidized beds in the form of pellet, iron ore lumps, or fines. Introduction in todays world, powering along the supply of raw materials, cement production is the most important factor. Rotary kiln china henan zhengzhou mining machinery co. Making process iron ore to sponge iron slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The original software was used to model the operation of a 35 m pilot kiln at the stellco company. One of the major challenges for sponge iron plant is the accretion formation. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. For the kiln gas in contact with the solid burden, gorog et al.
Ibutec the rotary kiln experts for trials and production. 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. New type slag rotary kiln china henan zhengzhou mining. Flow of materials in rotary kilns used for sponge iron. Boateng who outlines his decades of research and practical experience and his new book titled rotary kilns. From process development, to sizing and design, and even manufacturing a custom rotary kiln, we can guide you through every step of the way. All kinds of iron ore copper ore and nonferrous me tal ore etc. It is used to create cement, lime, metakaolin, titanium dioxide, alumina, iron ore pellets, and more. 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 iron ore rotary kiln is the equipment for calcining the mineral. They are also used for roasting a wide variety of sulfide ores prior to metal extraction. By using a 309 stainless steel liner and ceramic fiber insulation, we can shopassemble the largest systems without exceeding the weight and size restrictions of standard freight. There are many types of rotary kiln arrangements for producing cement clinker with each incremental design goal aimed at improving energy efficiency, ease of operation, and product quality and minimizing.
Energy balance in a rotary kiln sponge based iron making. Rotary kilns are a pyroprocessing device used to raise materials to a high temperature calcination in a continuous process. Rotary kiln,lime rotary kiln,clinker rotary kiln,indirect. Rotary kiln definition and meaning collins english. We own and maintain all of the latest equipment necessary for lining demolition and installation including, but not limited to. C, carbon monoxide will combine with the oxygen in the iron ore forming carbon. The new concept of process technology, which is proposed in this paper patent pending to produce hot metal pig iron.
A ce ment rotary kiln i s a nonlincar, illultivar i. Request pdf an investigation on the cracking of air tubes of rotary kilns in a sponge iron plant cracking of an air tube used for supplying air in rotary kiln of. Meaning, pronunciation, translations and examples log in dictionary. Rotary kiln and retorting rotary kiln manufacturers lcdri cn.
We start with the cement and lime processes and then move on to describe some of the carbothermic reduction processes that employ the rotary kiln as the primary device where we examine two processes, iron ore reduction the slrn acronym for steel making companies stelco, lurgi, and republic national process and ilmenite ore reduction the. Presently it is more popular in china for sponge iron production from. A rotary kiln is a type of furnace commonly used to heat solid materials in the form of a powder, lump, or other granular form. Cement production process is extremely timeconsuming 1 and the rotary kiln is the most important part of the. They are also an excellent way to optimize an existing process for maximum efficiency or in preparation of changes in production, with many beneficial outcomes possible. Modelling and optimization of a rotary kiln direct reduction process 55 figure 3. 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. Rotary kiln reduction process at nml the rotary kiln at nml fig. Cement kiln is used for making cement clinker and there are dry and wet methods to make cement clinker. Rotary kiln in sponge iron ore production buy activated. Rotary kiln can be divided into cement rotary kiln, retorting rotary kiln, metallurgical chemical kiln and lime kiln according to different processing materials. The rotary kiln consists of a cylinder made from steel plate, and lined with refractory brick. Compared with the traditional rotary kiln, the new type slag rotary kiln is an important improvement in the design and structure of the part, through a lot of data analysis and practical effect test, application, proved that the new rotary kiln equipment drying effect is quite good, energy saving and drying effect greatly improved, and a significant technological progress. Brazilian hematite iron ore was reduced successfully in a rotary kiln with a gaseous reactant which was.
Rotary kiln process audits are an essential tool in optimizing process performance, preventing unnecessary downtime and maintenance, and even avoiding premature equipment failure. Metallurgy chemical kiln is widely used for magnetic roasting of poor iron ore and oxidizing roasting of chrome and. Iron ore roasting rotary kiln for sale savona equipment is your supplier for new, used, and rebuilt ore roasting rotary kiln. 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. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets fig. An investigation on the cracking of air tubes of rotary kilns in a. They rotate slowly on an axis that is inclined a few.
Rotary kilns are synonymous with cement making, being the workhorses of this industry. Modelling and optimization of a rotary kiln direct. These kilnsup to 200 metres 660 feet long and six metres in diameter in wet process plants but shorter for the dry processconsist of a steel, cylindrical shell lined with refractory materials. Operability analysis of direct reduction of iron ore by coal in an industrial rotary kiln. Suitable unitplant size in terms of capacityproduction. What is the maximum continuous shell temperature a kiln stands without permanent damage to the shell. Reduction of iron ore pellets with domestic lignite coal in a rotary tube furnace. We have a large selection of trunnion rollers, thrust rollers, gears, tires and much more at a fraction of the cost of new. Potential pollution problems met with in sponge iron production. C, carbon monoxide will combine with the oxygen in the iron ore forming.
Rotary kiln in sponge iron ore production, find complete details about rotary kiln in sponge iron ore production,activated carbon rotary kiln,kiln,clinker kiln from cement making machinery supplier or manufacturerhenan yuhong heavy machinery co. A rotary kiln consists of a cylindrical, rotating body mounted between stationary. Raw material preparation section this section contains equipments such as vibrofeeders, crushers and screens. Rotary kilns are used for any number of purposes, from heating soil to remove volatile contaminants, to heating stones to remove moisture. Used riedhammer direct fired rotary kiln system consisting of, model dri 7. 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.
Brokk demolition robots, hydraulic lift tables, skidsteers with radius buckets, kiln bricking rigs several sizes. In this pilot plant, a totally indigenous technology for. Iron ore fines and the low grade beneficiated iron ore cake are directly used for manufacturing of sponge iron in tunnel kilns. Ikn supplies rotary kilns with two or three support piers. And the rotary kiln also has functions of environmental protection and energy conservation. These treatments can be applied to powders, granulates, suspensions and green bodies. Modeling of rotary kiln for sponge iron processing using. A rotary kiln is a pyroprocessing device that raises materials to very high temperatures in a continuous process. The effects of rotary kiln operating conditions and design. It is made up of a strong reinforced steel outer shell that is coated with a heatresistant inner lining, support rollers and a drive gear to keep the contents in a continuous rotating motion and internal heat exchangers capable of producing temperatures. Since a mode l descr ib il1 g tile whole il cal illg process is 1i0t available, separate control schellles,ire designed lu.
Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron. The most critical raw material for sponge iron making. A thesis submitted for partial fulfillment of the degree. Kiln plants with two and three station rotary kilns from khd humboldt wedag are top of the line. Iron ore as a raw material for the manufacture of iron and steel for its processing and utilization very economic value.
It is widely used for different materials with a processing capacity of 1801, 000 tons per day, a dimension of. Iron ore roasting rotary kiln for sale savona equipment. Our process experts work with our innovation center to develop a process around your materials. A rotary kiln is a device that supplies tremendous amounts of heat in order to change the chemical composition of an object. Operation and construction details a schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in fig. However, rotary kiln process suffers from serious limitations like low productivity and pollution. Slrn stelcolurgi rotary kiln with only recycle scrap charge to. We are a professional rotary kiln manufacturer in china, providing flowchart and installation service. Rotary kiln belongs to building material equipment, according to different materials, which can be divided into cement kiln, metallurgy chemical kiln and lime kiln. A rotary kiln is a pyroprocessing device used to raise materials to a high temperature calcination in a continuous process. Iron ore crushing is normally not needed since sized material 5 mm to 20 mm is generally procured.
The continuity of operation of a lime sludge kiln requires strict maintenance control. Coal based direct reduction rotary kiln process ispatguru. The rotary kiln is among the largest type of moving machines made and is subjected to extreme temperatures, power failures, atmospheric conditions, varying loads, and other operating conditions which affect its wear and alignment. What sets feeco systems apart from our competitors is the customized solutions we offer. The following equipments and facilities are needed for the coal based direct reduction rotary kiln process. Equipments and machinery in sponge iron manufacturing. The heat transfer coefficient on the outside of the kiln is estimated by assuming natural convection on a stationary horizontal. Rotary kiln for sponge iron dry process rotary kiln.
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. Iron oxide pellet an overview sciencedirect topics. Rotary kiln with the integration of the pyro activities of psp engineering in 2010, ikn carries on a tradition in the design and fabrication of rotary kilns, dating back to 1951. Heres a little bit about what a rotary kiln is and the seals we make for them. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. Rotary kilns no longer have to function as calciners which mean that they can be substantially smaller in size. What is the cost to install the cement rotary kiln. China manufacturing industries are full of strong and consistent exporters. China rotary kiln, rotary kiln manufacturers, suppliers. Request pdf reduction efficiency of iron orecoal composite pellets in tunnel kiln for. A few dr processes that use rotary kilns or rotary hearth furnaces use solid. 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. In terms of environmental protection, developed countries in the world use cement kiln to burn hazardous waste.
If you continue browsing the site, you agree to the use of cookies on this website. The hot gases may be generated in an external furnace or by a flame inside the kiln. For over 40 years we have performed work in many different types of kilns and related systems for customers throughout the united states. It has its roots in a fortran program that was developed by venkateswaran 1978 to study the reduction of iron ore. Rotary kiln is a hightemperature heat treatment system, so it is often the case that a pilot facility is manufactured to meet desired processing capacity and product quality and to develop an effective process. Reduction efficiency of iron orecoal composite pellets in tunnel. The principal raw materials for dri production are iron oxide concentrates, iron. According to different fuels, rotary kiln can be classified into gasfired rotary kiln, oilfired rotary kiln and coalfired rotary kiln. Rotary kiln zhengzhou dynnor industrial machinery co. 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. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of iron coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished. 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. Rotary kiln is the key equipment in rotary kiln process,rotary kiln refers to rotary calcining kiln which belongs to building material equipment.
Hitemp manufactures rotary kiln systems that will operate at 12 to 100 tons per day. Chaeng cement rotary kiln and sponge iron rotary kiln has been developed for performing drying, calcination and sintering work in a continuous process. Rotary kilns sometimes called calciners or rotary furnaces are used for thermal treatment processes such as calcination, sintering, pyrolysis and firing, as well as for oxidation and reduction. Simulation of rotary kiln used in sponge iron process using ann iacsit international journal of engineering and technology, vol. In this respect fixed bed tunnel kiln furnace are evolving as an alternative to rotary kiln process.
Rotary kiln process optimization feeco international inc. The coal consumption in 200 tpd sponge iron rotary kiln for various units in the cluster are given in. Ironmaking process alternatives screening study department of. This product is known as direct reduced iron dri or sponge iron. This is a data collection process required to design a rotary furnace of a suitable size in an application field. Coal is used as a reducent for sponge iron making in. Rotary kiln plant engineering company vietnam samshin. Rotary kiln is a rotating cylindrical vessel which is used for drying, calcination and sintering in a continuous process with the use of hot gases.