These industries face many challenges with respect to quality & productivity because of frequent variation in raw material quality (both physical and chemical) of Iron Ore, Coal and dolomite. This variation in the raw materials affect the chemical reactions inside the rotary kiln and which in turn impact the quality and thereby productivity.

Deposit formation in the coal-fired rotary kiln is frequently found in the production of fluxed iron ore pellets by the grate-kiln process and affects normal production. In this paper, the effects of pellet basicity (CaO/SiO 2 mass ratio) on the simulated deposit formation were investigated.

Accretion so called ring formation is the continuous production of thick layer of oxide and impurities on the inner portion of the DRI kiln during sponge iron production, the main reason behind this problem arises due to the softening of fluxing agents and impurities which amalgamate at specific temperature to form a low melting composition ...

Determination of surface moisture and particle size distribution of coal using on-line image processing: XIII mineral processing and recyling conference, Belgrade, Serbia, May 8-10 2019

This document summarizes a study on accretion formation in direct reduction iron (DRI) kilns and possible ways to reduce it. Accretion forms from the deposition of low-melting complex compounds on the …

Prediction models for temperature, pressure, and quality control in rotary sponge iron kilns are developed from operational data using conventional and AI-based methods, which greatly helps in chaos control inside the kiln.

This paper suggests the control of accretion formation in rotary kiln by increasing the fusion temperature of the complex compound which sticks to refractory wall by adding suitable additives.

To improve the performance of rotary kiln and maintaining the quality of sponge iron, there is a need to reduce the accretion formation in the kiln. However it is difficult to control accretion formation in the kiln due to the erratic nature of the reduction process dynamics.

Rhino horn formation mechanism: Clinker dust carried back to the kiln with the secondary combustion air loses velocity around the burner and that causes clinker dust to settle and build up on the top of the burner.

But this is counterproductive for coal consumption per ton of sponge and also for accretion formation. Low melting point materials are formed at high temperature during iron oxide reduction; FeO reacts with impurities like SiO2, Al2O3 to form low melting compounds which get deposited on the refractory lining of the rotary kiln.

h of the kilns. This is a regular phenomenon in the DRI rotary kiln. It narrows down the opening of the kiln and creates hind ance to material flow resulting ultimately in shutdown for cleaning. The formation of accretion at frequent intervals results in reduced campaign life, lo productivity, damage to kiln lining and ultimately

The International Institute for Science, Technology and Education (IISTE). Science, Technology and Medicine Journals Call for Academic Manuscripts. Read more. 1 of 12. Download now. Download to read offline. Accretion control in sponge iron production kiln using fuzzy logic - Download as a PDF or view online for free.

The article delves into the application of laser scanning within the realm of engineering, concentrating its examination on rotary kilns. Through an in-depth case study, this article meticulously assesses the advantages inherent in utilising laser scanning technology and draws comparisons with conventional measurement methods. The …

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 rests …

However the performance of rotary kilns is usually adversely affected by the formation of accretion. This accumulation of sintered solid particles which form rings along the length of the kiln hinders material flow, lowers productivity and life span of the kiln.

Although ring formation in rotary kiln applications has been widely studied, for the production of, e.g., ordinary Portland cement clinker, 4−8 calcium−aluminate cement clinker, 9 magnesite ...

Discover the four major problems in rotary kilns and the solutions provided by FTM Machinery engineers. Read to become an expert.

In the first section, the main wearing mechanisms acting on the lining og DRI rotary kilns are described. Second, the concept of double-layer lining is introduced.

Control of accretion growth in a coal fired rotary kiln for production of sponge iron is important to achieve a long campaign life. Temperature is measured at 11 locations with embedded ...

As the volume in kiln remains nearly constant, increasing the pressure will raise the temperature profile in the kiln (enhanced heat transfer), and hence more accretion.

Ring Formation in the Smelting of Saprolite Ni-ore in a Rotary Kiln for Production of Ferro-nickel Alloy: Examination of the Mechanism

Optimization problem discussed here for a coal-based rotary kiln to find the optimal operating conditions keeping desired targets like quality and accretion formation (temperatures of kiln) within ...

Increase in temperature and oxidizing atmosphere (because of CO2) promotes accretion formation. Thus, the control of pressure inside the kiln is the first requirement of an optimal operation of ...

To improve the performance of rotary kiln and maintaining the quality of sponge iron, there is a need to reduce the accretion formation in the kiln. However it is difficult to control accretion formation in the kiln due to the erratic nature of the reduction process dynamics.

PDF | Control of accretion growth in a coal fired rotary kiln for production of sponge iron is important to achieve a long campaign life.

Corrective steps to dislodge the accretion by manipulating process parameters have been developed at TATA sponge and they are working efficiently. The decisions to control accretion are however such that they are in line with increase in production of sponge iron and profitability. This is because enhanced accretion formation leads to premature …

However, deposition of oxide layers leads to accretion formation over the thermocouple and this causes inaccuracy in its measurement. This poses difficulties in control of rotary kiln dynamic ...

Thus, this paper aims at improving the kiln performance by analyzing the effect of variation of input variables, such as kiln inclination, kiln rotation speed, feed flow rate of iron ore and coal on realizing product % metallization level and estimation of accretion formation inside the rotary kiln, thereby facilitates longevity of kiln life ...

The temperature profiles of the gas and charge in a coal-fired rotary sponge iron kiln affect both the iron ore reduction process and accretion formation. The temperature profile of charge is…

PDF | On Aug 20, 2020, Indra Chakraborty published Accretion Build Up Resistant Refractories for Sponge Iron Kilns IREFCON 06 | Find, read and cite all the research you need on ResearchGate