Sponge iron making process

ALBERTUS SEPTYANTOKO

2712100014

IRON ORE

• Iron = 65-67 %

• SiO2 + Al2O3 = 2-3 %

• CaO + MgO = 0,5-1 %

• Sulphur = 0,02 % max

• Phosphorus = 0,04 % max

Chemical Composition

• Size = 5-18 mm

• Shatter Index = +95 %

• Tumbler index = +88 %

• Reducibility Index = +94 %

• Thermal Degradation Index = 5 %

Physical Composition

COAL

• Fixed Carbon = 45 %

• Volatile Matter = 25-30 %

• Ash = 20 %

• Moisture = 8 %

Chemical Composition

• Size = 3-20 mmPhysical

Composition

DOLOMITE

• MgO = 20 %

• CaO = 28 % min

• SiO2= 5 % max

Chemical Composition

• Size = 2-6 mmPhysical Composition

PRIMARY AIR

Primary air is used to combustion the injection coal

Temperature in used below 950 C

SECONDARY AIR

Secondary air is introduced axially in the direction of the gas flow

The air supplied to the length of the kiln is metered for close control of temperature and gas atmosphere in the kiln

Heating zone extends from 25% to 40% along length of the kiln and in the reduction zone

INJECTION COALCoal Crushing Combustion

Injection to kiln

Coal Injection over a large range of size 0-20 mm

Temperature combustion below 950 C

Coal injection system makes use of voal volatiles for reduction, thereby reducing the coal requirement to a minimum

Coal Injection can decrease energy consumption

ROTARY KILN

ROTARY KILN

ROTARY COOLER

The product come to the water cooled

Where its temperature reaches to 80-100 C

ROTARY COOLER

The product is conveyed to the product separation and storage building

The product is Sponge iron and char

Place that spraying a controlled amount of water directly into hot solids and by spraying additional water outside the cooler shell

SCREENING

+ 10 mm 3-10 mm - 3 mm

MAGNETIC SEPARATOR

+ 10 mm 3-10 mm - 3 mm

Mag. pulleyMag.

separationMag.

separation

MAGNETIC SEPARATOR

+ 10 mm

3-10 mm

wasteSponge iron

Lumps+

charSponge iron

Lumps+

magnetic Non magnetic+3-10 mm

charSponge iron

Lumps + char

SPONGE IRON

• Fe (T)= 91,5 % min

• Fe (M) = 85,5 % min

• Sulphur = 0,005 %

• Phosphorus = 0,7 %

Chemical Composition

• Size = -3 to 10 mm

• Bulk density=1,7-2T/M3Physical

Composition

POST COMBUSTION CHUMBER

To maintain temperature in rotary Kiln

Press particles in flame gas

WASTE HEAT RECOVERY BOILER

Cultivate waste heat temperature is produced of combustion to produce steam to electricty generation

This steam is channeled to ESP and turbine

ELECTRO STATIC PRECIPITATOR

Clean gas from WHRB. Gas is sent to stack

Turbine cultivate steam to electricty generation