Our Expertise includes

Direct Reduced Iron – Rotary Kiln

This plant consists of raw material preparation section, kiln & cooler area and product house.

Raw Material preparation:

  • Raw materials iron ore, coal and lime stone from the stock yard are fed through conveyer system.
  • After beneficiation, crushing, grinding and screening of materials to the right size, the material is fed in right quantities to the rotary kiln.
  • The quantification of the ingredients depends on respective grade.

Main Reduction Plant:

  • The main plant consists of the kiln, cooler and the waste gas handling area.
  • The kiln is a cylindrical vessel where the length & diameter depends on the capacity of the plant. It is inclined at <2° for the flow of material.
  • The air fans mounted on the top of the kiln supply air to maintain required temperatures.
  • The Coal is also blown from the entrance and discharge end of the kiln to maintain the temperatures. The material is gradually heated to about 1000 C where the iron ore is reduced to sponge iron.
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Cooler:

  • The hot material goes to the cooler which is also a cylindrical vessel. Water is sprayed on the top of the shell to cool the material. The gasses flow in the counter current.
  • The dust in the gasses settle in the dust settling chamber and then any unburned components are burned in the after burner chamber.
  • The gasses are then pass through the waste heat recovery boiler where they are cooled to below 200 C. The cooled are then subjected to electro static precipitation where all the dust is settled.

Captive Power Plants (WHRD +ABC)

The power plant is set up for captive consumption. This system consists of Waste Heat Recovery Boiler, AFBC Boiler, Turbo- Generator and Ash handling System.

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Waste Heat Recovery Boilers:

  • The gases coming out of the kiln are at 1000 C and this heat is recovered for power generation.
  • The gases are made to pass through the furnace chamber where the heat is extracted from the gasses in the water walls.
  • The gasses then pass through the super heater coils and the economizer where the heat is further extracted and the out going gasses are let into the Electrostatic precipitator at 160 C.
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Fluidized bed boiler:

  • The char is the waste/by-product generated from the sponge iron production. It has a moderate calorific value. Fluidized bed boiler is used for firing coal and char.
  • With the utilization of the char in the boiler, coal required for one ton of steam generated will be reduced and hence the specific consumption of coal per Mw of power will be lowered.
  • This steam is connected to the common header and fed to the TG for power generation.

Turbo—Generator:

  • The turbo-generator is a multistage steam turbine. Special provisions are given for taking care of the variation in the utilization of power generated.
  • This power is used for operation of all the plants i.e. Iron ore fines benefaction plant, pellet plant, Sponge Irion Plant, Steel Melting & Rolling Mill section etc.

Ash Handling:

  • The fly ash produced by the combustion of the coal and char will be subjected to the dust collector (ESP) before being let off to the atmosphere.
  • The ash will be collected, dried and used for brick manufacturing to be used in building construction there by avoiding any pollution hazard.
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