Method And A Rotary Kiln For The Manufacture Of Sponge Iron

Annotation About the Book: Now that India is virtually the only player in this field, an elaboration is needed with respect to more fundamental understanding as well as future prospects and needs, which this edition has tried to fulfill. It can now fulfill the need of a reference textbook in alternate iron making area for undergraduate and post graduate students in Metallurgical, Production, Manufacturing, Chemical, Materials and to a minor extent Mechanical Engineering disciplines. The aim of fulfilling the needs of entrepreneurs and plant operators has not only been retained; it has been elaborated. Further, the basic aspects have been presented in a way that is lucid and simple to understand and should serve as an incentive to the operators and entrepreneurs to develop a deeper understanding of the process. The project engineering section now gives guidelines sufficient to make a project report. Opportunities available to this process and the competition it faces has also been highlighted. A chapter on reaction kinetics has been included as also a section on iron ore and pellets. Other sections included are on Aerodynamics, Auto Ignition, Coal Throwing, etc. Rest of the text has been updated to the extent possible. Some advanced features have been introduced such as Mathematical Modeling, Computational Fluid Dynamics, Reduction Mechanism, etc. to give researchers in the area of food for thought. Contents: IntroductionRotary Kiln Process of Making Sponge IronThermodynamic Considerations: Feasibility of ReactionAerodynamics inside a Sponge Iron Rotary KilnMathematical Modelling in Rotary Kiln Sponge Iron MakingPhysical Movement of Solids inside a Rotary Kiln: Charge Movement and Coal Throwing/SlingingRequirement, Generation and Transfer of Heat in a Sponge Iron Rotary KilnReaction KineticsRaw Materials for Sponge Iron MakingAccretion or Ring Formation inside a Rotary KilnSponge Iron Properties: Re-oxidation and Auto-Ignition of Sponge IronUses of Sponge IronProcess Design, Engineering & Operational Aspects of an RK-DR PlantOther Uses of Rotary Kiln for Reduction PurposesEnvironmental Aspects of Sponge Iron Making in Rotary Kiln and Future Prospect.

Comprehensively deals with the production of sponge iron in the rotary kiln. It is divided into 17 chapters. The initial chapters give a brief on the fundamental theories and basic principles of sponge iron production, commercially used DR (direct reduction) processes and physico-chemical principles of sponge iron production. The book then goes on elucidating the testing procedures of raw materials needed for the direct reduction processes.

This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is ‘directly reduced’ in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces (sometimes even in basic oxygen furnaces) to produce liquid steel. Such a process combination enables steel to be produced without using coking coal, which is an expensive input in the normal blast furnace—basic oxygen furnace route of steelmaking adopted in integrated steel plants. The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production. The concluding part of this seminal book summarises the present and future scenario of direct reduction, including the use of gas generated from coal in direct reduction processes. The book is primarily intended for the undergraduate and postgraduate students of metallurgical engineering. It is also a must-read for researchers, technologists and process metallurgists engaged in the rapidly developing field of direct reduction of iron oxides, which is of critical importance for India and other developing nations that are beginning to play a major role in global steelmaking.