design calculation of kiln in iron

design calculation of kiln in iron

Modelling and optimization of a rotary kiln direct ...

In the case of a generic iron-ore reduction kiln, Table I provides an overview of the parameters (and ranges) that are considered. Table I. Model inputs used in the evaluation of kiln performance Design parameters Values Kiln internal diameter 4.34 m Kiln length 80 m Kiln

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Modelling and optimization of a rotary kiln direct ...

of iron ore reduction in a generic rotary kiln. Rotary kiln model Kiln modelling consists of two steps. Firstly, an Excel®-based calculation is used to determine the kiln bed profile and residence time based on specific operating conditions and the kiln configuration. This is followed by a calculation of the kiln operating character-

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Formulas kiln - SlideShare

Jul 22, 2010  Degree Of Kiln filling Kiln Cross Sectional loading: % of Filling or Area of this segment (A1) = Kilns Degree Area of cross section of Kiln (A) Theta Centric Angle Theta % of Kiln (Degree) filling 110 15.65 105 13.75 100 12.1 Segment 95 10.7 r = radius inside lining 90 9.09 85 7.75 r^2 A1 = O – Sin O 80 6.52 2 75 5.42 70 4.5 A = II r^2

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Calculation of Kiln Aerodynamics with two RANS Turbulence ...

Feb 28, 2015  The combustion air flow patterns have a significant effect on the mixing and hence the combustion efficiency, motivating a systematic study of the kiln aerodynamics. The objective of this work is to compare turbulence models when modeling the kiln aerodynamics of an iron ore pelletizing rotary kiln.

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1. Kiln Capacity b. Chamber Dimensions Height Width

The kiln shown in Figure 3 was designed for a sawmill that only processed nominal 12 ft long sawlogs (actual length about 12-ft 6-in). The lumber produced was trimmed to 12 ft - 3 in . in length. The dry kiln chamber was designed with an inside dimension of 12 ft – 6 in. The extra three inches allow for ease of placement of the units in the kiln.

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(PDF) Industrial Applications of Rotary Kiln in Various ...

To conclude the kiln modeling, the design of a 50-MWth rotary receiver for a solar tower plant that operates in continuous mode was optimized, achieving an efficiency greater than 83%.

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Cement Kilns: Design features of rotary kilns

Design features of rotary cement kilns. The shell of the kiln is made of mild steel plate. Mild steel is the only viable material for the purpose, but presents the problem that the maximum temperature of the feed inside the kiln is over 1400°C, while the gas temperatures reach 1900°C.

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Calculating Kiln Volume by Marc Ward - Clay Times Magazine

Calculating Kiln Volume By Marc Ward. From the November/December 1996 issue of Clay Times. To determine the amount of heat (BTUs) required for your kiln to reach a desired temperature in a certain time frame, you need to know your kiln's volume. To calculate the volume, measure and record its height, width and depth.

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Rotary kiln - Wikipedia

A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process.Materials produced using rotary kilns include: Cement; Lime; Refractories; Metakaolin; Titanium dioxide; Alumina; Vermiculite; Iron ore pellets; They are also used for roasting a wide variety of sulfide ores prior to metal extraction.

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Calculation of Kiln Aerodynamics with two RANS Turbulence ...

Rotary kilns are large, cylindrical, rotating ovens with a burner in one end that are used in various industrial processes to heat up materials to high temperatures. The kiln burners are characterized by long diffusion flames where the combustion process is largely controlled by the turbulent diffusion mixing between the burner fuel jet and the surrounding combustion air.

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A Thesis Submitted for Partial Fulfillment of the Degree ...

3 sponge iron processing 10 4 rotary kiln design operation 23 5 computational fluid dynamics (cfd) its application 31 6 model development 37 7 result discussion 43 8 conclusion 54 9 reference 56 . list of figures figure no. figure caption page no. 1.1 image of a sponge iron granule 2 ...

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production calculation in rotary kiln

Formulas kiln - SlideShare. 22/07/2010 Rotary Kiln power input calculation : W x bd x td x N x F x 0.0000092 1 H.P = rd W = Total vertical load on all roller shaft bearing,lb bd = roller shaft bearing diameter, inches Note : This is Frictional rd = roller diameter, inches 1 Horse Power td = tire or riding rind diameter, inches N = rpm of Kiln shell P = Coefficient or friction of roller ...

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(PDF) Industrial Applications of Rotary Kiln in Various ...

To conclude the kiln modeling, the design of a 50-MWth rotary receiver for a solar tower plant that operates in continuous mode was optimized, achieving an efficiency greater than 83%.

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE

The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln. Further, the waste gas at reduced temperature is used to cool hot sponge iron which is previously carried out by water.

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Rotary Kiln Maintenance Procedures

A kiln should be aligned when it is in operation for four very important reasons: 1. A straight cold kiln has a measurable misalignment at operating temperatures. This is because the shell axis elevation increases by one half of the thermal expansion of the shell diameter. This expansion is the function of the shell temperature and, as such, it

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Design and Analysis of an Axial Fan used in Kiln Shell Cooling

Design and Analysis of an Axial Fan used in Kiln Shell Cooling 43. B. Procedure and calculations . The fan design is an iterative process. For starting the calculations with efficiency assumed to 89% as an initial guess. With blading design in process, efficiency is calculated and checked for convergence.

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Chemicl parameters defining clinker composition

NB: This calculation (0.7 x SO 3) is based on the ratio of the molar masses of calcum oxide and sulfur trioxide, ie: 56/80 = 7/10. It therefore assumes that all the sulfate in the clinker is present as anhydrite; it does not account for sulfate present as clinker sulfate in the form of potassium and sodium sulfates, or for water in gypsum, and ...

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Sponge iron making process - SlideShare

Nov 09, 2014  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 7.

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Energy Audit Methodology of Sponge Iron Manufacturing ...

Jul 14, 2014  Raw material mix-iron ore, dolomite and coal are fed to one end of rotary Kiln and product sponge iron along with char is taken out from the other end. Apart from this, primary and secondary airs are supplied to the Kiln to initiate the combustion and reaction processes. The reaction takes place at high temp (1050 to 1065˚C ˚C).

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KOBELCO Pelletizing Process

Grate-Kiln-Cooler process allows independent operation adjustment of grate, kiln and cooler, which enables the operators ; a) to, easily and without any risk, decrease and increase the rate of pellet production. b) to overcome radical changes in the characteristics of iron ore materials fed to the

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Everything You Need to Know on Rotary Kiln Refractory

Refractory is a critical component in the design of a direct-fired rotary kiln, helping to protect the kiln shell from the harsh processing environment within. A customizable part of kiln design, refractory can be engineered to suit the unique needs of an application, with factors such as material and multiple layers coming into play.

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Calculating Kiln Volume by Marc Ward - Clay Times Magazine

Calculating Kiln Volume By Marc Ward. From the November/December 1996 issue of Clay Times. To determine the amount of heat (BTUs) required for your kiln to reach a desired temperature in a certain time frame, you need to know your kiln's volume. To calculate the volume, measure and record its height, width and depth.

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Rotary kiln - Wikipedia

A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process.Materials produced using rotary kilns include: Cement; Lime; Refractories; Metakaolin; Titanium dioxide; Alumina; Vermiculite; Iron ore pellets; They are also used for roasting a wide variety of sulfide ores prior to metal extraction.

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Calculation of Kiln Aerodynamics with two RANS Turbulence ...

Rotary kilns are large, cylindrical, rotating ovens with a burner in one end that are used in various industrial processes to heat up materials to high temperatures. The kiln burners are characterized by long diffusion flames where the combustion process is largely controlled by the turbulent diffusion mixing between the burner fuel jet and the surrounding combustion air.

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A Thesis Submitted for Partial Fulfillment of the Degree ...

3 sponge iron processing 10 4 rotary kiln design operation 23 5 computational fluid dynamics (cfd) its application 31 6 model development 37 7 result discussion 43 8 conclusion 54 9 reference 56 . list of figures figure no. figure caption page no. 1.1 image of a sponge iron granule 2 ...

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Rotary Kiln Maintenance Procedures

A kiln should be aligned when it is in operation for four very important reasons: 1. A straight cold kiln has a measurable misalignment at operating temperatures. This is because the shell axis elevation increases by one half of the thermal expansion of the shell diameter. This expansion is the function of the shell temperature and, as such, it

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Design and Analysis of an Axial Fan used in Kiln Shell Cooling

Design and Analysis of an Axial Fan used in Kiln Shell Cooling 43. B. Procedure and calculations . The fan design is an iterative process. For starting the calculations with efficiency assumed to 89% as an initial guess. With blading design in process, efficiency is calculated and checked for convergence.

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SOFTWARE TOOL OPTIMIZES FURNACE DESIGN AND

treaters, process engineers, and plant operators can use the design and analysis software to determine the best setup for any furnace/part combination. Sintering furnace case study To help illustrate the benefits of design software, an analysis of a furnace was performed first using manual calculations and then using FurnXpert software.

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Modeling of Rotary Kiln in Cement Industry

The modern design of the plant, a cyclone preheater to increase the temperature of the solid input materials are used to shorten the length of the kiln. Raw materials to the kiln consist of calcium carbonate (CaCO 3), silica (SiO 2), shale (Al 2 O 3) and iron oxide (Fe 2 O 3) feeds. These compounds are very fine powder and mixed with cement to ...

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Phillips Kiln Services Blog - International Cement Review

The basic design concept is to reduce ovality (the amount of shell flexing) during rotation of the kiln. Shell flexing aka ovality is typically ¼ that of a migrating tire design. The primary motive for this is that it enhances the mechanical stability of the brick lining. At the same time there still is

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Chemicl parameters defining clinker composition

NB: This calculation (0.7 x SO 3) is based on the ratio of the molar masses of calcum oxide and sulfur trioxide, ie: 56/80 = 7/10. It therefore assumes that all the sulfate in the clinker is present as anhydrite; it does not account for sulfate present as clinker sulfate in the form of potassium and sodium sulfates, or for water in gypsum, and ...

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Sponge iron making process - SlideShare

Nov 09, 2014  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 7.

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Bogue calculation - Understanding Cement

The standard Bogue calculation refers to cement clinker, rather than cement, but it can be adjusted for use with cement. Although the result is only approximate, the calculation is an extremely useful and widely-used calculation in the cement industry. The calculation assumes that the four main clinker minerals are pure minerals with compositions:

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CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN

The ASL Sponge Iron unit at present consists of one rotary kiln of 500 TPD and the flue gas generated from the kiln is about 120,000 Nm3/hr at 950-10000C. Flue gas with high heat content is generated in the Rotary kiln in the Sponge iron plant during conversion of Iron Ore into Sponge Iron. The entire

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Chapter 8 - Metal kilns

Some kiln manufacturers use thinner gauge metal sheets than that recommended in the TPI design. To ensure the maximum working life of a kiln, especially when operated carelessly, the thickness and type of metal used in the kiln's construction is of prime importance.

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