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