Advances in Rotary Kiln Sponge Iron Plant.

Cover -- Preface to the First Edition -- Acknowledgement -- Glossary -- List of Figures -- List of Tables -- Contents -- Chapter 1. Introduction -- 1.1 What is Spongs Iron and What is DRI? -- 1.2 History of Modern Sponge Iron Making -- 1.3 Iron Ore Reduction at a Glance -- 1.4 Multiple Role of a Rotary Kiln -- Chapter 2. Rotary Kiln Process of Making Sponge Iron -- 2.1 Historical Background -- 2.2 Important Features -- 2.3 Sponge iron Pilot of RDCIS SAIL -- 2.4 Features of a Rotary Kiln Sponge Iron Plant -- 2.5 The Indian Scene -- 2.6 Why Should we Select a Rotary Kiln? -- 2.6.1 Process Strengths -- 2.6.2 Product Strengths -- 2.6.3 Weaknesses of the Process -- 2.6.4 Weaknesses of the Product -- Chapter 3. Thermodynamic Considerations:Feasibility of Reaction -- Chapter 4. Aerodynamics Inside a Sponge Iron Rotary Kiln -- 4.1 Thumb Rules Used in Production of Sponge Iron -- 4.2 Sources of Gas -- 4.3 Effects of Air Injection -- 4.4 Limits to Gas Velocity -- 4.5 Gas Flow Pattern -- 4.6 CFD Analysis -- Chapter 5. Mathematical Modellingin Rotary Kiln Sponge Iron Making -- 5.1 What is a Model? -- 5.2 What is a Mathematical Model? -- 5.3 How Can we Make a Useful Mathematical Model? -- 5.4 Example of a Small Mathematical Model -- 5.5 Roal of Coal in Rotary Kiln Sponge Iron Making Process -- 5.6 Quantity of Protective Char -- 5.7 Reduction of Iron Oxide -- 5.8 Coal for Combustion -- 5.9 Waste Gas Temperature -- 5.10 Programming Based on Model -- 5.12 Sigment-wise Modelling -- 5.13 Prodection from the Model -- 5.14 Summary of the Modelling Process -- Chapter 6. Physical Movement of Solids Inside a Rotary Kiln:Charge Movement and Coal Throwing/Slinging -- 6.1 Importance of Residence Time -- 6.2 Estimation Gross Residence Time from Input and Output of Solids -- 6.3 Charge Movement: Cascading Flow of Granular Material.

6.4 Mathematical Treatment of Charge Movement -- 6.5 Importance of Filling Degree -- 6.6 Techniques of Measuring Residence Time -- 6.7 Importance of Throwing Coal From Discharge End -- 6.8 Caol Throwing Philosophy -- Chapter 7. Requirement, Generation and Transfer of Heat ina Sponge Iron Rotary Kiln -- 7.1 Material and Energy Balance in a Conventional Rotary Kiln Sponge Iron Making Process -- 7.2 Generation and Transfer of Heat -- 7.3 Mathematical Treatment of Heat Transfer -- 7.4 Segment-wise Air Requirement -- Chapter 8. Reaction Kinetics -- 8.1 Factors Affecting Reaction Rates -- 8.2 Rate Law and Order of Reaction -- 8.3 Birth of the Rate Law or Law of Mass Action -- 8.4 Unimolecular Reaction and First Order Reaction -- 8.5 Decomposition of an Oxide -- 8.6 Temperature Dependence of Velocity Constant: The Arrhenius Equation -- 8.7 Experimental Determination of Activation Energy -- 8.8 Variation of Reaction Rate with Temperature -- 8.9 Role of Diffusion -- 8.10 How Sponge Iron Making is a First Order Reaction? -- Chapter 9. Raw Materials for Sponge Iron Making -- 9.1 Iron Oxide Feed -- 9.2 Iron Ore Lumps -- 9.3 Magnetic and Hematitic Ores -- 9.4 Magnetic Ore Minerals -- 9.5 Laboratory Test on (Method of Determining ) Iron Ore Reducibility -- 9.6 Coal for Sponge Iron Making -- 9.7 Peat -- 9.8 Conversion of Peat Into Higher Ranks -- 9.9 Indian Coal Deposits -- 9.10 Size of Coal for Sponge Iron Making -- 9.11 Role of Coal in a Sponge Iron Rotary Kiln -- 9.12 Measurement of Reactivity of Coal Char -- 9.13 Gas Analysis of Reactivity Measurement -- 9.13.1 Principle -- 9.13.2 Test Conditions -- 9.13.3 Test Apparatus -- 9.13.4 Test Procedure -- 9.14 Indicators to Reactivity -- 9.15 Other Criteria for Coal Selection -- Chapter 10. Accretion or Ring Formation Inside a Rotary Kiln -- 10.1 Can Ring Formation be Avoided?.

10.2 Deposit Formation Through Solid State Sintering -- 10.3 Reasons for Catastrophic Growth of Deposits -- 10.4 Precautions Required -- 10.5 Accretion Removal During Operation -- Chapter 11. Sponge Iron Properties: Re-oxidation and Autoignition of Sponge Iron -- 11.1 Reasons for Re-Oxidation Tendency -- 11.2 History of Auto-Ignition -- 11.3 First Reported Incidence -- 11.4 Eye Witness Report -- 11.5 Investigations releated to Auto-Ignition -- 11.6 Other Significant Results -- 11.7 Clancey's Hypothesis -- 11.8 Hypothesis of Neil Birks -- 11.9 Ignition Temperature of Spong Iron: Crossing Point -- 11.10 How Valid is this Hypothesis? -- 11.11 Precautions Needed in Sponge Iron Storage -- 11.12 Conclusions -- Chapter 12. Uses of Sponge Iron -- 12.1 Uses of Sponge Iron in Electrical Steel Making -- 12.2 Use of Sponge iron in Submerged Arc Furnace -- 12.3 Uses of Spong Iron in Iron Making -- 12.4 Uses of Sponge Iron in Cupola -- 12.5 Uses of Sponge Iron in Oxygen Steel Making -- 12.6 Sponge Iron and Hot Metal: Partners in Progress -- Chapter 13. Process Design, Engineering and Operational Aspects of an RK-DR Plant -- 13.1 Process Design and Engineering -- 13.1.1 Raw Material Testing -- 13.1.2 Upscaling -- 13.1.3 Sizing of Key Equipment -- 13.1.4 Process and Material Flow Diagrams -- 13.1.5 Preparation of List of MajorEquipment -- 13.1.6 Preparation of Layout -- 13.2 Project Engineering -- 13.3 Installation, Commissioning and Project Cost -- 13.4 Process Enhancing Equipment and Concepts -- 13.4.1 Gas Sealing System -- 13.4.2 Underbed Hydrocarbon Injection System-The Ported Kiln Concept -- 13.4.3 Coarse Coal Throwing or SlingingSystem -- 13.4.4 Waste Heat Recovery System-Generation of Electrical Power -- 13.4.5 Use of Waste Gas Energy forPreheating -- 13.4.6 An Optimised Rotary Kiln SpongeIron Making Process -- 13.4.7 Pros and Cons of the OptimisedConcept.

13.5 Kiln Refractories -- Chapter 14. Other Uses of Rotary Kiln for Reduction Purposes -- 14.1 Magnetising Roasting of Lean Iron Ores -- 14.2 Pre-Reduction of Chromite Ore -- 14.4 Pre-Reduction of Titaniferous Ore -- 14.3 Pre-Reduction of Manganese Ore -- 14.5 Pre-Reduction of Nickeli-Ferrous Overburden -- 14.6 Use of Rotary Kiln for Gasification of Coal -- Chapter 15. Environmental Aspects of Sponge Iron Making in Rotary Kiln and Future Prospects -- 15.1 Carbon Dioxide Emissions from the Sponge Iron Industry -- 15.2 Other Pollutants and Arisings in Sponge Iron and Steel Industries -- 15.3 Sponge Iron in India -- 15.4 Projections of Steel Consumption -- 15.5 Projections for India -- 15.6 Possible Sources of Additional Iron -- 15.7 Role of Sponge Iron and Newer Processes -- 15.8 Rotary Kiln Sponge Iron Making: Status and Prospects -- 15.9 Use of Sponge Iron in Blast Furnaces -- 15.10 Smelting Reduction in India -- 15.11 Modern Trends in Iron Making -- 15.12 A Peep Into the iron and Steel Making Practice of Twenty Second Century -- 15.13 What Makes Rotary Kiln Sponge Iron Making Click in India? -- 15.14 Another Opportunity for Rotary Kiln Sponge Iron Making? -- Bibliography -- Index.

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Electronic reproduction. Ann Arbor, Michigan : ProQuest Ebook Central, 2024. Available via World Wide Web. Access may be limited to ProQuest Ebook Central affiliated libraries.