Research Article …
quality and capacity of sponge iron products through mathematical modeling arrangement and simulation. Simultaneous mass and energy balances along the reactor lead to a set of ordinary ...
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(PDF) Modeling of Rotary Kiln for Sponge Iron Processing …
All process simulations were done by developing mathematical models form these governing equations. The three basic governing transport laws are the following: 1. ... Fig.6.2: 2D & 3D model of Sponge iron Rotary Kiln To facilitate the function of lobe blower to kiln similar faces for material input were developed by method of Face imprint with ...
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(PDF) Operation of Coal-Based Sponge Iron Rotary Kiln to …
Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is ...
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Conventional and AI Models for Operational Guidance and …
TATA Sponge employs coal fired rotary kilns to produce sponge iron. Iron ore, coal, and dolomite are charged from one end of rotary kiln (schematic diagram in Fig. 1), and the coal for combustion is fired from the other end.Rotary kiln is slightly inclined so that material flows in forward direction.
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Mathematical Modeling of the Melting of Sponge …
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...
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Mathematical model of direct reduction shaft furnace and …
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 balances.
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Analyses of Different Modifications Proposed for the Sponge Iron …
Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...
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Modelling and optimisation of directreduction of iron ore …
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 ...
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Low Emission Sponge Iron Production in RHF: A CFD Study
Recycling iron-bearing solid wastes generated during iron and steelmaking processes is crucial for optimizing resource utilization and mitigating carbon emissions. 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 …
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Transformation of Indian Sponge Iron Industry Vis-à-vis …
Since the last 30 years, the Indian Sponge Iron (SI) industry has grown by leaps and bounds. Though the sector has undergone rapid growth in recent past, the growth graph is not likely to be sustained due to multiple geo-political and other related factors. Besides, the opening up of the economy has given unprecedented importance to the issues pertaining to …
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Arsenic removal by iron oxide coated sponge
Therefore, a material namely iron oxide coated sponge (IOCSp) has been developed by coating iron oxide on polyurethane sponge [17], [18]. Our earlier pilot study found that a 180 g of IOCSp packed in a bucket (200 mm in diameter and 350 mm in height) could reduce arsenic concentration of 480 μg/L in 1500 L contaminated natural water to below ...
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Detailed Modeling of the Direct Reduction of Iron Ore in a …
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. ... direct reduction shaft furnace. We developed a new mathematical model, with the aim of introducing a more-detailed description of the chemical processes, compared to ...
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Mathematical Modeling of the Melting of Sponge Iron in …
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 …
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Optimization of the Parameters Affecting the …
3.1. Choosing the appropriate fitted model The quadratic model was the model that was fitted after the analysis and showed the best results. As shown in Table 5, the model is completely significant because the values of P and F for the model were less than 0.0001 and 154.81, respectively. On the other hand, all selected variables are also ...
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A review of ironmaking by direct reduction processes: …
DRI (also known as sponge iron) is an important advancement in the ironmaking industry due to its high productivity and strong adaptability to raw materials (Guo et al., 2017). 2. Overview of DR processes Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing gas to produce Direct ...
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Sponge Iron Process for Manned Space Exploration
Sponge Iron Process for Manned Space Exploration Ariadna Contract No. 18461/04/NL/MV Technical officer: Dr. Tiziana Pipoli - Final project report -
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Mathematical Modelling of Sponge Iron …
A non-isothermal and non-isobaric mathematical model which consists of 19 independent equations, was developed for the study of the kinetics of reduction iron ore in an ore/coal composite,...
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Optimal Control of Accretion Growth and Quality of Sponge Iron …
General features of the mathematical models for non-catalytic reactors are described along with models for the phenomena mentioned above. ... Sponge iron is an intermediate product of steel formed ...
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Analytical and numerical solutions for the melting of sponge iron
Conditions are R0=1.0 cm, Tb =1 843 K and h = 27 104 W/m 2 K. from publication: Mathematical Modeling of the Melting of Sponge Iron in a Bath of Non-reactive Molten Slag | In this work a ...
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Optimization of the Parameters Affecting the …
sponge iron. The statistical analysis showed that the furnace bed temperature is the most effective parameter for the quality of the sponge iron in Midrex, and the most significant interaction was …
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Mathematical Modelling of Sponge Iron Production in a …
Development of a comprehensive mathematical model for direct reduction of iron ore by a mixture of coals is presented here.
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Mathematical model of the Reformer Sponge Iron Cycle
Request PDF | On Jan 1, 2003, Simon Fraser and others published Mathematical model of the Reformer Sponge Iron Cycle | Find, read and cite all the research you need on ResearchGate
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Mathematical Modeling of the Melting of Sponge Iron in a …
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 …
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A thermodynamic analysis of the reformer sponge iron cycle
A mathematical model of the reformer sponge iron cycle (RESC) is presented. The model is based on a thermodynamic analysis of the process, simulating the complete hydrogen …
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Heat and Mass Transfer in Reduction Zone of …
tant role in sponge iron reduction zone mathematical model. Unreacted cor e model proposed by Levenspiel [9]i sw i d e l y. used for kinetics model of iron reduction in which the reac-
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Necessary power for melting one ton of iron sponge versus …
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.
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Mathematical Modeling of the Melting of Sponge Iron …
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 modeling of a real process in an industrial scale electric arc furnace. The model was validated by computing the melting
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[PDF] Modeling of rotary kiln for sponge iron processing …
CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package (ANSYS 13.0). …
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Conventional and AI Models for Operational Guidance and Control of
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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Low Emission Sponge Iron Production in RHF: A CFD Study
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 ...
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