In this work a mathematical model was developed to predict the melting kinetics of an isolated sponge iron pellet in a bath of non-reactive liquid slag. The model represents an incipient stage of modeling of a real process in an industrial scale electric arc furnace. The model was validated by computing the melting
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The present paper deals with 2D CFD model of rotary kilns employed in sponge iron process. Using this model the effects of variations of input parameters, such as angle of inclination, number of ...
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A few researchers proposed mathematical expressions to model the temperature profile, ... 2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters. Based on grid independent test for temperature profile optimum mesh size ...
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General features of the mathematical models for non-catalytic reactors are described along with models for the phenomena mentioned above. ... Sponge iron is an intermediate product of steel formed ...
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3.1. Choosing the appropriate fitted model The quadratic model was the model that was fitted after the analysis and showed the best results. As shown in Table 5, the model is completely significant because the values of P and F for the model were less than 0.0001 and 154.81, respectively. On the other hand, all selected variables are also ...
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quality and capacity of sponge iron products through mathematical modeling arrangement and simulation. Simultaneous mass and energy balances along the reactor lead to a set of ordinary ...
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In this work a mathematical model was developed to predict the melting kinetics of an isolated sponge iron pellet in a bath of non-reactive liquid slag. The model represents an incipient stage …
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In this work the melting process of sponge iron particles in iron-bath is mathematically modelled. Based on the fact that the heat conductivity of sponge iron is much smaller than that of dense iron, a simplified analytical solution for the system has been derived. This solution agrees very well with the exact one from numerical calculation. The melting time and melting course of sponge iron ...
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sponge iron, is cooled in the lower part of the furnace, down to approximately 50 °C, prior to being discharged. ... Mathematical Model 2.1. Principle The reduction of hematite ore to iron occurs via two intermediate oxides, namely, magnetite and
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CFD analysis of heat transfer in freeboard of rotary kiln was done with licence version of ANSYS 13.0, authorized by NIT Rourkela. ANSYS 13.0 is an engineering simulation software (Computer-Aided Engineering. Kiln of a typical Sponge Iron producing plant having capacity 500 Tons Per Day was modelled and simulated with CFD package (ANSYS 13.0). …
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The shaft furnace's core function is to convert iron ore into sponge iron. This process involves downward solid flow and upward counter-current gas flow, enabling chemical transformations. ... This research focuses on the development of a multiscale mathematical model for a shaft furnace, aiming to understand how the shape of iron ore pellets ...
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Most shaft furnaces producing sponge iron, however, have been designed empirically up to the present. In order to optimize operations a mathematical model has been developed to be applied to shaft furnace design. The model, whose reduction rate equations are derived from the three-interface model, involves both mass and heat balances.
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Request PDF | On Jan 1, 2003, Simon Fraser and others published Mathematical model of the Reformer Sponge Iron Cycle | Find, read and cite all the research you need on ResearchGate
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Download Table | Summary of mathematical modelling proposes for the melting of particles in a metallic bath. from publication: Mathematical Modeling of the Melting of Sponge Iron in a Bath of Non ...
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Recycling iron-bearing solid wastes generated during iron and steelmaking processes is crucial for optimizing resource utilization and mitigating carbon emissions. The Rotary Hearth Furnace (RHF) has emerged as a promising alternative for sponge iron production from solid waste. This study developed a 3D computational fluid dynamics (CFD) model of a …
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DRI, also known as sponge iron, is the product of reducing iron oxide in the form of iron ore and steel plant wastes into metallic iron, below the melting point of iron and typically in the range of 800–1200°C. ... As a mathematical model, the conceptual 1D pseudo-homogeneous model from [3] is adopted. The model variables are the components ...
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Coal-based sponge iron plants have very high average heat to power ratios, often in the range of 25:1 to 31:1 (Choudhury 2014). This reflects that coal-based sponge iron plants use mostly thermal energy in comparison to electrical energy. So, all these studies are aimed to reduce the coal consumption in these plants which is the only source of ...
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DRI (also known as sponge iron) is an important advancement in the ironmaking industry due to its high productivity and strong adaptability to raw materials (Guo et al., 2017). 2. Overview of DR processes Direct reduction processes reduce iron ore (in the form of lumps, pellets or fines) to the solid state using a reducing gas to produce Direct ...
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Conditions are R0=1.0 cm, Tb =1 843 K and h = 27 104 W/m 2 K. from publication: Mathematical Modeling of the Melting of Sponge Iron in a Bath of Non-reactive Molten Slag | In this work a ...
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Therefore, a material namely iron oxide coated sponge (IOCSp) has been developed by coating iron oxide on polyurethane sponge [17], [18]. Our earlier pilot study found that a 180 g of IOCSp packed in a bucket (200 mm in diameter and 350 mm in height) could reduce arsenic concentration of 480 μg/L in 1500 L contaminated natural water to below ...
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Since the last 30 years, the Indian Sponge Iron (SI) industry has grown by leaps and bounds. Though the sector has undergone rapid growth in recent past, the growth graph is not likely to be sustained due to multiple geo-political and other related factors. Besides, the opening up of the economy has given unprecedented importance to the issues pertaining to …
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Data-1 includes temperatures profiles and air inlet at positions, AT-1 to AT-3 and MF-1 and MF-2, inside the kiln whereas, flow rates of iron ore, feed coal, slinger coal and sponge iron is ...
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(d) Melting of sponge iron in slag. The model was validated with experimental results reported by O'Malley 23) for sponge iron pellets in non-reactive slag, as can be seen in Fig. 5. The thermal histories obtained numerically show good agreement with the experimentally measured thermal history of the sponge iron in the center of the DRI pellets.
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The mathematical model was customized and validated with data from one of the industrial scale rotary kilns at Tata Sponge Iron Limited (TSIL) and was utilized for process analysis and ...
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Yu et al. [46] developed a 3D mathematical model separated into the arc zone and ore zone to study the passing heating procedure of ores in the flooded AC-EAF for ferrochrome melting. ... Casting of sponge iron is done with a conveyor belt. The height of the conveyor belt should be determined so that the sponge iron can easily pass through the ...
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In this work a mathematical model was developed to predict the melting kinetics of an isolated sponge iron pellet in a bath of non-reactive liquid slag. The model represents an incipient stage of...
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A mathematical model of the reformer sponge iron cycle (RESC) is presented. The model is based on a thermodynamic analysis of the process, simulating the complete hydrogen production cycle ...
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Sponge Iron Process for Manned Space Exploration Ariadna Contract No. 18461/04/NL/MV Technical officer: Dr. Tiziana Pipoli - Final project report -
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The product gases from coal-fired sponge iron kilns exit at a high temperature (800-950 o C) and contain some unburnt carbon and carbon monoxide along with nitrogen, carbon dioxide and entrained dust.
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An improved mathematical model that can reproduce the kinetics of melting of a pellet of sponge iron immersed in a slag bath was successfully developed. The model is robust …
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