Ramanaiah and S. Khanam, "Analyses of different modifications proposed for sponge iron process for best utilization of waste heat", Process Integration and Optimization for Sustainability, 2 (2018) 365–381.

Schematic of the sponge iron or direct reduced iron kiln model showing sub-models included and inputs and outputs of the model.

An improved mathematical model that can reproduce the kinetics of melting of a pellet of sponge iron immersed in a slag bath was successfully developed. The model is robust as it was validated with experimental and analytical results existing in the literature.

There have been a few attempts to model sponge iron manufacturing in a gas-fired RHF. Wu et al. [3] created a mathematical model for zinc-containing pellets and dem-onstrated that raising furnace temperature enhanced iron metallisation and dezincification rate.

In this work a mathematical model was developed to predict the melting kinetics of an isolated sponge iron pellet in a bath of non-reactive liquid slag. The model represents an incipient stage of ...

To improve the performance of EAF, a new initiative technique has been introduced in which sponge iron particles are preheated before entering the furnace. A heat exchanger is used to transfer waste energy from EAF flue gas to a neutral gas like nitrogen, which in turn preheats the sponge iron particles in the fixed bed.

The solid product, called direct reduced iron (DRI) or reduced sponge iron, is cooled in the lower part of the furnace, down to approximately 50 C, prior to being discharged.

Sponge iron is the product generated by direct reduction of iron ore with aid of either carbon or natural gas under controlled temperatures and pressures within a rotary kiln. However the performance of rotary kilns is usually adversely affected by the formation of …

Investigation of the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation finds that reduction gas temperature over 973°C (1246 K) is not recommended because the formation of sticky iron will be initiated. Numerical prediction …

A mathematical model has been developed to predict the operating behavior of an SL/RN direct reduction kiln from a knowledge of the main process variables. The model is based on steady state principles and is capable of quantitatively describing the different chemical reactions in the kiln such as reduction, Boudouard reaction, coal devolatilization, …

The formation of accretions or 'rings' in rotary kilns used for the manufacture of directly reduced iron (sponge iron) affects the residence time of the charge, kiln hold-up, and the kiln output to a great extent. In this part of the work, the effect of ring formation was simulated at room temperature in a scaled-down model of a rotary kiln by inserting …

Here we developed a mathematical model describing the kinetics of how iron, an essential transition metal, is "trafficked" into and within a eukaryotic cell, and how such a system might be regulated. The model was solved using a novel combination of mathematical methods combined with a modest amount of experimental data.

We presented the mathematical model in the iron reactor. The model was limited to Isobaric Zone and Cooling Zone termed as IZ and CZ, respectively. The simulation was done by adapting the heat and mass transfer equations. The main purpose of this paper is to estimate the temperature increasing effect of reduced-iron on sponge …

Based on the principles of mass, momentum and heat transfers between the reducing gas and the iron ore solid, a two-dimensional mathematical model for above two phases is established to study the influences of reducing gas composition on thermal and reduction conditions in pre-reduction shaft furnace with the temperature ranging from 1 …

Wu et al. [3] created a mathematical model for zinc-containing pellets and dem-onstrated that raising furnace temperature enhanced iron metallisation and dezincification rate.

The Rotary Hearth Furnace (RHF) has emerged as a promising alternative for sponge iron production from solid waste. This study developed a 3D computational fluid dynamics (CFD) model of a pilot ...

The present paper deals with 2D CFD model of sponge iron rotary kilns. Using this model the effects of variations of input parameters, such as angle of inclination, number of rotation and mass flow rate of iron ore are studied on output parameters like Fe content, temperature profile.

A few researchers focused on sponge iron process and suggested mathematical expressions to model the temperature profile, heat transfer, fuel combustion, reduction chemistry, etc., inside the rotary kiln.

Firstly, it selects the most effective input variables for the desired targets using Akaike information criterion followed by formulation of linear and nonlinear mathematical model of desired targets.

Semantic Scholar extracted view of "Computational fluid dynamics analysis of sponge iron rotary kiln" by G. Gaurav et al.

Iron ore direct reduction is an attractive alternative steelmaking process in the context of greenhouse gas mitigation. To simulate the process and explore possible optimization, we developed a systemic, multiscale process model. The reduction of the iron ore pellets is described using a specific grain model, reflecting the transformations from ...

This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO2 emissions from the steel industry. The shaft furnace is divided into three sections (reduction, …

Most shaft furnaces producing sponge iron, however, have been designed empirically up to the present. In order to optimize operations a mathematical model has been developed to be applied to shaft furnace design. The model, whose reduction rate equations are derived from the three-interface model, involves both mass and heat …

Central to this process is the shaft furnace, functioning as a counter-current moving bed reactor, wherein oxide pellets descend from above while the reduction gas ascends from the opposite direction, leading to the …

Heat and mass transfer through a wustite pellet during converting to sponge iron was investigated. Pellet was reduced by a gaseous mixture containing CO and H2. The grain model was considered to ...

The decreasing of sponge iron temperature in the isobaric and cooling zone is around 300 K and 600 K respectively. Keywords—Mathematical Model, Iron Ore Reactor, Cooling Zone, Isobaric zone.

Modeling of Rotary Kiln for Sponge Iron Processing Using CFD package (ANSYS 13.0) A Thesis Submitted for Partial Fulfillment of the Degree Award Of MASTER OF TECHNOLOGY In CHEMICAL ENGINEERING Under the supervision of

The aim of the present study is to investigate transient entropy generation during wustite pellet reduction to sponge iron. Grain model was used to simulate the reduction rate [9, 10] and the governing equations were given with some assumptions which are considerably simplify solution of the equations.

The mathematical model was customized and validated with data from one of the industrial scale rotary kilns at Tata Sponge Iron Limited (TSIL) and was utilized for process analysis and ...

The fundamental aspects of iron ore reduction. Symposium on Science and Technology of Sponge Iron and its Conversion to Steel