DRI PLANT.pptx

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1. Presentation on DRI Plant Shashank Gautam Rahul Mandal Himanshu Ranjan Konkala Navyasri Reddy Arpon Samui Harsh Chauhan Anoop Tiwari Gaurav Jain Ruchi Kushwaha Sevi Dewarwar Aakanksha GROUP MEMBERS

2. CONTENT Overview Purpose of Sponge Iron Raw material Flow Chart Process Rotary Kiln Ellingham Diagram and Chemical Reactions Rotary Cooler PSB ESP Problem Statement

3. Direct reduced iron (DRI) also known as Sponge Iron. It is the product which is produced by the direct reduction of iron ore or other iron bearing materials in the solid state by using non-coking coal. Overview of DRI(Direct reduced Iron )

4. It is a superior substitute of steel scrap for EAF(electric arc furnace) and Induced furnace. Sponge iron has low Sulphur content. Sponge iron is a pivotal material used for the production of various steel items like best quality TMT bars, Ductile Iron (DI) pipes. Purpose of Sponge iron

5. Coal Fines(0-5mm in size) – Injection coal from kiln outlet Iron ore(5 -25mm in size)- Raw material (pellet) which is feed from inlet Dolomite(1- 6 mm in size)- for removing coal Sulphur Coal(3-20mm in size) – Feed from inlet Coal Lumps(5-25mm in size)- feed from inlet Raw materials used in DRI

6. Pellet Coal dolomite Rotary Kiln Coal Coarse Coal Rotary Cooler fuel Air WHRB ESP A B C Turbine Flowchart Fine coal PS B DRI Lumps + Fines Dolochar Transfer Chute

7. PROCESS Raw material(Coal, Pellets, Dolomite) is taken from the RMHS and stored in Bunkers. 4 bins : 2 for feed Coal , 1 for pellets , 1 for Dolomite. Mixture of these 3 goes to Kiln by using Conveyor. In the Kiln we use injector for injecting fine and coarse coal. Then heated Sponge iron goes to cooler and gets cooled up to 100C. Cooled Material goes to PSB building for Screening and Separation of material . PROCESS

8. Kiln is the major equipment in DRI Plant, which is also known as Rotary Furnace. The transport rate of materials through the kiln can be controlled by varying its slope and speed of rotation(0.3 RPM) Length of Kiln=76m Diameter of Kiln=4.3m ROTARY KILN

9. Ellingham Diagram T=710⁰ 2 + C + Co 3 o + C o + Co C   C + + C 2CO   Chemical Reactions :

10. Used for decreasing the temperature of the Sponge Iron upto 100C . Ac motor & motor drive used. RTD used for Temperature measurement. Dimensions : Diameter = 3m , L = 30m. Water tray is used for cooling. ROTARY COOLER

11. Product Separation Building(PSB) Sponge iron(Magnetic) and char(Non-Magnetic) are separated with the help of Magnetic Separator. Magnetic material further screened by vibrating screen and separated into lumps and fines. Magnetic Separator

12. Sponge Iron + Dolochar Vibrating Screen Fines Lumps Magnetic Separator Magnetic Separator DRI Fines DRI Lumps Char Product Separation Building

13. ESP Used for remove ash , dust and smoke from flue gas. Principle based on Corona effect. Efficiency = 99%. High Voltage is required. Components : Smoke stack , electrodes , collecting plates , hopper , rapper etc

14. PROBLEM STATEMENT Backlash error in Girth Gear .

15. . Grinding should be done on the gear teeths . Oiling should be done. Solution

16. . Leakages from rotary cooler cause corrosion . Harmful effect of corrosion:- It cause crack on the surface of metal it reduce the quality and strength of metal surface. PROBLEM STATEMENT

17. SOLUTION GALVANISING -: Apply protective layer of zinc on surface of metal. Oiling or Greasing BLUEING-: This process creates a layer of magnetite over the metal to prevent the rust.

18. PROBLEM STATEMENT Problem: Accretion formation

19. Solution 1 . Using good quality of raw materials: A. Iron ore : Low gangue content High tumbler index Low abrasion index 2 . By increasing the fusion temperature of the complex compound which sticks to refractory wall By using Dolomite the fusion temperature can be increased. 3. By performing the procedure and maintaining the temperatures inside the Kiln. . B. Non-coking coal: Low ash content High reactivity High ash fusion temperature Low swelling and caking index