This document discusses challenges in producing sponge iron using rotary kilns. It outlines various technological options for direct reduced iron (DRI) making, including coal-based and gas-based processes. Coal-based DRI uses rotary kilns while gas-based uses shaft furnaces with synthesis gas. Factors affecting productivity and emissions from each process are presented. Opportunities for cleaner technologies like using beneficiated coal or synthesis gas from coal gasification in rotary kilns or shaft furnaces are discussed along with challenges. The MIDREX and HYL gas-based shaft furnace processes and use of synthesis gas in these furnaces are also summarized.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
India is the world's largest Sponge Iron producer and mostly uses the Coal based process. The down-side of this industry is that it generates significant amounts of solid waste in the form of ESP Flyash and Bag House Filter Dust. Now as this Flyash contains considerable unburned carbon ( 10% and above), it cannot be utilized in cement manufacturing. Likewise the Bag Filter dust contains upto 25% unburned carbon and above 70% ash which again doesn't allow it to be reused viably as a fuel. Meanwhile, reducing the carbon content by the Carbon-burnout method is too expensive and polluting just to convert the wastes into usable Flyash.
As a result most of these wastes go into landfill, where they again contribute to ground and water pollution.
Surprisingly there are technologies which can not only effectively convert these wastes into usable items like recovered fuel and low carbon Flyash, but at the same time clean up the environment and save the companies great expenses. Its is called Carbon-Ash Separation and there are several ways of doing the same.
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Reheating Furnace in Rolling Mill IndustriesVikas Yadav
In steel plants reheating furnaces are used in hot rolling mills to heat the steel stock (Billets, blooms or slabs) to temperatures of around 1200 deg C which is suitable for plastic deformation of steel and hence for rolling in the mill.
A presentation on furnaces and refractories by stead fast engineerssteadfast123
A presentation on furnaces and refractories by stead fast engineers. Stead Fast Engineers Pvt Ltd one of the Leading manufacturers of Induction Furnace in India. find here Induction heater,Induction Melting furnace,
Induction heating system,Induction Billet heater for your sourcing needs.
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
In this file basic information regarding a sintering plant is shared.
sintering plant produce sinter for blast furnace feed.
Fine iron ore isn't usable for blast furnace .
So,it feeds to sintering plant.
Then sinter feeds to blast furnace as a charging material in addition to coke,additive,iron ore.
Reheating Furnace in Rolling Mill IndustriesVikas Yadav
In steel plants reheating furnaces are used in hot rolling mills to heat the steel stock (Billets, blooms or slabs) to temperatures of around 1200 deg C which is suitable for plastic deformation of steel and hence for rolling in the mill.
A presentation on furnaces and refractories by stead fast engineerssteadfast123
A presentation on furnaces and refractories by stead fast engineers. Stead Fast Engineers Pvt Ltd one of the Leading manufacturers of Induction Furnace in India. find here Induction heater,Induction Melting furnace,
Induction heating system,Induction Billet heater for your sourcing needs.
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
Pelletization of iron ores and the type of wear liners used in thier eqipmentsGulshan Kumar Singh
Now a days about 60% of iron ore converted to fines during mining, handling and transporting so pellet is a process of utilizing iron ore fines up to size of 0.15 microns. i investigate its process,equipment used in process, wear and other problems in them and its future scope
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
High level introduction
Mainstream syngas = steam reforming processes
Ammonia; methanol; hydrogen/HyCO
Town gas
Steam reforming; low pressure cyclic
Direct reduction iron (DRI)
HYL type processes; Midrex type processes
Production of Syngas from biomass and its purificationAwais Chaudhary
This project includes production of syngas from biomass and its purification. Firstly we discuss feasibility and availability of raw material. Then we have literature survey. A lot of techniques are there to produce syngas, we have discuss process selection. Environmental considerations are also have been discussed. Piping and instrumentation (P&ID) diagrams also have been attached. At the end we've our conclusion and our recommendations.
1. CONSULTING ENGINEERS LIMITED
CHALLENGES IN SPONGE IRON
MAKING USING ROTARY KILNS
Asaman Prasad Patnaik, Dr M D Maheshwari,
Jitendra Nath Rath & Raghunath V Deshpande
TATA CONSULTING ENGINEERS LIMITED
2. CONSULTING ENGINEERS LIMITED
OUTLINE OF PRESENTATION
TATA CONSULTING ENGINEERS LIMITED
1. Introduction
2. Present Technological Options in DRI Making
a. Gas Based DRI Making
b. Coal Based DRI Making
3. Factors affecting Productivity & Emission
4. Cleaner Technology Options -Opportunities & Challenges
a. Using Low Grade Coal
b. Using Coal Bed Methane
5. Conclusions
6. Acknowledgement
3. CONSULTING ENGINEERS LIMITED
INTRODUCTION
TATA CONSULTING ENGINEERS LIMITED
In Direct Reduction route, Ore is reduced at a temperature of 900-1050 oC, in
the solid state (below the melting point) by :
Carbon Monoxide (Coal Based).
Or
Hydrogen & Carbon Monoxide (Gas Based)
The reducing gas, diffuses through the pores of the ore, reacts to reduce the
ore. As the ore is reduced, the porosity increases. Hence, it is called as
Sponge Iron.
DRI is produced as a result of removal of oxygen from the iron ore, and
hence has a higher porosity and is reactive with atmospheric air.
The gaunge (SiO2 and Al2O3 etc) present in the ore is not removed and
remain as such in the product (unlike in case of hot metal making where the
gaunge is separated as Slag)
4. CONSULTING ENGINEERS LIMITED
TATA CONSULTING ENGINEERS LIMITED
Reduction Reactions:
First, Haematite is reduced to Magnetite:
3Fe2O3 + H2 = 2Fe3O4 + H2O
3Fe2O3 + CO = 2Fe3O4 + CO2
Then, Magnetite is reduced to Wustite:
Fe3O4 + H2 = 3 FeO + H2O
Fe3O4 + CO = 3 FeO + CO2
Most of the Wustite (FeO) is reduced to Iron (Fe):
FeO + H2 = Fe + H2O
FeO + CO = Fe + CO2
Carburisation Reactions:
3Fe + CO + H2 = Fe3C + H2O
3Fe + CH4 = Fe3C + 2H2
5. CONSULTING ENGINEERS LIMITED
PRESENT TECHNOLOGICAL OPTIONS IN DRI MAKING
TATA CONSULTING ENGINEERS LIMITED
COAL BASED DRI UPTO 0.15
MTPA
GAS BASED DRI 0.20 MTPA TO 2.0 MTPA
6. CONSULTING ENGINEERS LIMITED
GAS BASED DRI MAKING
TATA CONSULTING ENGINEERS LIMITED
• MIDREX and HYL processes using a Shaft furnace.
• Uses Natural Gas. Can also use Synthesis Gas from Coal
Gasification
• The CO and H2 required for reduction produced by reforming of
Natural Gas in a Reformer (MIDREX or Hyl III) or by direct
injection of Natural Gas into the shaft furnace (HYLZR).
Steam Reforming (MIDREX/HYL):
CH4 + H2O = CO + 3 H2
CO2 Reforming (MIDREX):
CH4 + CO2 = 2 CO + 2 H2
• The gas based processes have a higher annual capacity ranging
from 0.2 MTPA (minimod) to 2.5 MTPA (Super Megamod).
• Product can be cold DRI/ hot DRI/ Hot Briquetted Iron (HBI)
7. CONSULTING ENGINEERS LIMITED
COAL BASED DRI MAKING
TATA CONSULTING ENGINEERS LIMITED
• Uses Rotary Kiln
• Use Coal as the fuel & reductant
• At a bed temp of about 1050 oC.
• Air flow into the kiln:
• Radial Air -Using a series of radial ports (ACCAR/OSIL process)
• Axial Air – Using Axial Air Fans (Lurgi Process etc)
• Standard sizes of economic importance are 300 / 350 TPD (100000
TPA) and 450 / 500 TPD (150000 TPA) modules
• Coal is charged from both feed end as well as discharge end
• Limestone or Dolomite is added to remove sulphur from DRI
• DRI is separated from non-magnetics like ash and char and
bagged.
8. CONSULTING ENGINEERS LIMITED
AXIAL AIR PROCESS
TATA CONSULTING ENGINEERS LIMITED
Variation of GasTemp along Length in Axial air Kiln
0
200
400
600
800
1000
1200
1400
0 10 20 30 40 50 60 70 80 90
Length from Feed End
Temp
Air tubes for Air
AXIAL AIR KILN WITH AIR TUBES
Axial Air
9. CONSULTING ENGINEERS LIMITED
RADIAL AIR PROCESS
TATA CONSULTING ENGINEERS LIMITED
Gas Temperature along the length of a radial air Kiln
-
200
400
600
800
1,000
1,200
1,400
0 10 20 30 40 50 60 70 80
Length from FE
Temp
Ported Section for air to kiln
PORTED KILN OF OSIL PROCESS
Radial Air
10. CONSULTING ENGINEERS LIMITED
RADIAL AIR PROCESS
TATA CONSULTING ENGINEERS LIMITED
Rotary Kiln
Air Manifold with 8
no of Fans
Port Air Distribution System
11. CONSULTING ENGINEERS LIMITED
TATA CONSULTING ENGINEERS LIMITED
FACTORS AFFECTING PRODUCTIVITY & POLLUTION
Iron Ore Coal
Design
Spec.
Being Used Design
Spec.
Being Used
Fe T 65% min 60 % - 63% FC (dry) 45 % min 30% -36%
SiO2 +
AL2O3
5% max More Ash (dry) 29-31 % 34-40%
LOI 1- 1.5% 3- 4% Volatile
Matter (dry)
24-26% 28-30%
Tumbling
Index
88% min. 75- 80% Cal Value
kCal/kg
5500-6000 4500-5000
13. CONSULTING ENGINEERS LIMITED
ENVIRIONMENTAL IMPACT
TATA CONSULTING ENGINEERS LIMITED
ORE AND COAL AS PER DESIGN
SPECIFICATION
Material IN per t
MATERIAL
OUT per t
Ore 1.50DRI 1.00
Coal 1.02Char 0.25
Dolomite 0.03Dust 0.15
Accretion 0.01
Loss in
process
and to gas 1.15
Unaccount
able 0.00
Total 2.55Total 2.55
SPEC ENERGY CONS.* Gcal/ t 4.6-4.8
CO2 EMMISSION** t/ t DRI 2.2
INFERIOR QUALITY ORE AND COAL
Material IN per t
MATERIAL
OUT per t
Ore 1.67DRI 1.00
Coal 1.44Char 0.26
Dolomite 0.04Dust 0.51
Accretion 0.02
Loss in
process
and to gas 1.36
Unaccount
able 0.00
Total 3.14Total 3.14
SPEC ENERGY CONS.* Gcal/ t 5.2-5.5
CO2 EMMISSION** t/ t DRI 2.8
*After taking credit for WHR Power generation.
** Process related GHG emission including power consumption and credit for WHR
Power
14. CONSULTING ENGINEERS LIMITED
CLEANER TECHNOLOGY OPTIONS -OPPORTUNITIES &
CHALLENGES
TATA CONSULTING ENGINEERS LIMITED
CONCERN AREAS
• Natural Gas availability limited to western India.
• Restriction in supply of Natural Gas for DRI Making
• Pollution Aspects in Rotary Kiln process
OPPORUNITIES
• Availability of Non-coking Coal Resources
- Beneficiation
- Coal Gasification
• Availability of Coal Bed Methane
CHALLENGES
• Use of Synthesis Gas from Coal in Rotary Kiln/ Shaft Furnace
• Use of CBM in Rotary Kiln/ Shaft Furnace
15. CONSULTING ENGINEERS LIMITED
CLEANER TECHNOLOGY OPTIONS –COAL
BENEFICIATION
TATA CONSULTING ENGINEERS LIMITED
INFERIOR QUALITY ORE AND BENEF.
COAL
Material IN per t
MATERIAL
OUT per t
Ore 1.67DRI 1.00
Coal 1.28Char 0.26
Dolomite 0.04Dust 0.36
Accretion 0.01
Loss in
process
and to gas 1.34
Unaccount
able 0.00
Total 2.98Total 2.98
SPEC ENERGY CONS.* Gcal/ t DRI 4.95
CO2 EMMISSION* * t/ t DRI 2.50
• With coal beneficiation reduction in ash
upto 10% possible.
• Productivity improves by 7.5%.
• Reduction in dust generation by 25%
• Reduction in Sp Energy Cons by 10%.
• Reduction in CO2 emission by 2%
*After taking credit for WHR Power
generation.
** Process related GHG emission including
power consumption and credit for WHR
Power
16. CONSULTING ENGINEERS LIMITED
CLEANER TECHNOLOGY OPTIONS –USE OF SYNTHESIS
GAS
TATA CONSULTING ENGINEERS LIMITED
• Synthesis Gas Obtained by Coal Gasification.
• Most Suitable is Entrained Bed (Shell, GE, Conoco Phillips) or Fixed Bed Dry Bottom
type (SASOL Lurgi)
Gas Composition : CO : 32%, H2 : 52%, CH4: 12%, CO2: 3%
Gas Quality (H2 + CO/ H2O + CO2) More than 10.
H2/CO ratio All acceptable. (> 0.5 prefered)
Shaft Furnace Rotary Kiln
Syn Gas
requirement
Nm3/t 600 1100
Spec Energy
Consumption
Gcal/ t DRI 5.25* 5.99*+
CO2 emission*** t/ t DRI 0.10 1.05
• Considering Coal Gasification also.
+ After taking credit for WHR Power generation.
** Process related GHG emission including power consumption and credit for WHR
Power
17. CONSULTING ENGINEERS LIMITED
CLEANER TECHNOLOGY OPTIONS –USE OF CBM
TATA CONSULTING ENGINEERS LIMITED
• CBM contains about 96-98% Methane.
• CBM can be used as an alternative to Natural Gas.
• CBM availability in Asansol Coal belt in West Bengal is promising
Shaft Furnace Rotary Kiln
CBM requirement Nm3/t 250 400
Spec Energy
Consumption
Gcal/ t DRI 2.75 3.35
CO2 emission t/ t DRI 0.55 0.95
18. CONSULTING ENGINEERS LIMITED
GASEOUS REDUCTION IN ROTARY KILNS
TATA CONSULTING ENGINEERS LIMITED
• Use of natural gas in a ported
(radial air type) Rotary Kiln
(80% gas and 20% oil) has
been established by a pilot
plant at Niagra Falls, Ontario,
Canada (1960s).
• A 233,000 TPA Commercial
Plant was also set up by
ACCAR at Sudbury, Ontario
using 80% Natural Gas and
20% HSD (1973).
21. CONSULTING ENGINEERS LIMITED
MIDREX PROCESS
TATA CONSULTING ENGINEERS LIMITED
Shaft Furnace is at 1 bar g pressure .
Module Capacity : 0.5 MTPA ( 5m dia) to 2.5 MTPA
I : Reduction :
• Ore/ Pellet charged through a proportioning hopper at top.
• Dynamic seal legs at top and bottom of the furnace.
• Reduction Gas (called as Reformed Gas) at 850-900 oC is introduced at
bustle at the bottom of reduction zone.
H2: 56-61%, CO : 33-38% balance H2O & CO
H2/CO ratio : 1.5 to 1.8:1, H2+CO/H2O+CO2 : 10 to 12:1
• Natural Gas is also injected at the bottom of cooling zone (conical section)
for carburization and quenching.
• Cooling gas is re-circulated through a scrubber – compressor.
• The hot product can be briquetted/ hot discharged/ cooled as cold DRI.
• Top Gas leaving furnace at 400 oC(contains 90% CO2 & H2O) is sent to a
Scrubber. Around 2/3rd of Top Gas is recycled as process gas (used in
reforming) and the rest as fuel in reformer.
22. CONSULTING ENGINEERS LIMITED
MIDREX PROCESS
TATA CONSULTING ENGINEERS LIMITED
II : Reforming
• Reformer is a refractory lined furnace containing alloy steel tubes with Ni-Fe
Catalyst.
• Process Gas is compressed to 2 bar g and mixed with Natural Gas (feed
gas mixture) and preheated in a Recuperator and sent to Reformer.
• Preheated Air is used to burn Fuel Natural Gas to maintain the temperature
at 950oC.
• Reforming is carried out by CO2 and Steam present in the process gas.
• Reformed Gas is sent to the Shaft Furnace.
III: Heat Recovery
• Sensible heat is recovered from Reformer Flue Gas to preheat Feed Gas
mixture, and combustion air in the Recuperator.
24. CONSULTING ENGINEERS LIMITED
HYL PROCESS
TATA CONSULTING ENGINEERS LIMITED
Shaft Furnace is at 6-10 bar g pressure .
Module Capacity : 0.2 MTPA ( 2.5m dia) to 2.5 MTPA (6.5 m)
I : Reduction :
• Ore/ Pellet charged through four pressurised bins with charging legs with
hydraulically operated valves
• Production rate controlled by discharge rotary valve at bottom.
• Reduction Gas (Called as Process Gas) at 900-950 oC passes through a
refractory lined transfer line where O2 (for partial combustion) is injected and
then introduced at the bottom of reduction zone.
H2: 56-61%, CO : 33-38% balance H2O & CO
H2/CO ratio : 1.8 to 2.5:1, H2+CO/H2O+CO2 : 10 to 12:1
• Natural Gas is also injected for carburization and quenching.
• Cooling gas is re-circulated through a scrubber – compressor.
• The hot product can be briquetted/ hot discharged/ cooled as cold DRI.
• Top Gas leaving furnace at 450 oC(contains 90% CO2 & H2O) is sent to a
Top Gas Recuperator (energy recovered as Steam) and then Scrubber.
25. CONSULTING ENGINEERS LIMITED
HYL PROCESS
TATA CONSULTING ENGINEERS LIMITED
II : Process Gas System:
• Top Gas leaving furnace at 450 oC(contains 90% CO2 & H2O) is sent to a
Top Gas Recuperator (energy recovered as Steam) and then Scrubber.
• Steam generated is used in regeneration of absorbent in CO2 absorption
system.
• Water generated during reduction is removed in scrubbing.
• Process Gas is then sent to PG Compressor followed by PG aftercooler.
Then to CO2 absorption system.
• After removal of CO2. the Process Gas is sent to PG Heater and mixed with
reformed gas and sent back to shaft furnace.
III: Reforming:
• Natural Gas is reformed using excess steam.
• After reforming the excess steam is removed by cooling.
• The reformed gas is sent to the Process Gas Heater.
IV: PG Heater
• The recycled Process Gas and the reformed gas is heated to 900-950 oC
and sent to the reactor.