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Design Innovation

Design Modifications for Energy Conservation of Sponge Iron Plants

[+] Author and Article Information
A. K. Prasad

Department of Mechanical Engineering, National Institute of Technology, Jamshedpur 831001, Jharkhand, Indiaanilnitj@yahoo.co.in

R. K. Prasad

Department of Mechanical Engineering, National Institute of Technology, Jamshedpur 831001, Jharkhand, Indiarkpappnit@gmail.com

S. Khanam1

Department of Chemical Engineering, National Institute of Technology, Rourkela 769008, Orissa, Indiashabinahai@gmail.com; skhanam@nitrkl.ac.in

1

Corresponding author.

J. Thermal Sci. Eng. Appl 3(1), 015001 (Mar 10, 2011) (11 pages) doi:10.1115/1.4003506 History: Received March 16, 2010; Revised January 19, 2011; Published March 10, 2011; Online March 10, 2011

During the operation in the coal based sponge iron plant, a tremendous amount of heat is generated and significant part of this heat, associated with the waste gas, remains unutilized. It appears worth interesting to modify the process that facilitates the integration of heat available with the waste gas. In the present paper, for the utilization of heat of waste gas, two modifications, namely, case-1 and case-2, are proposed based on preheating of inlet streams. In case-1, preheating of feed material is considered, whereas in case-2, preheating of feed material as well as air is accounted. These cases are then compared with the existing waste heat recovery system of the plant based on coal consumption, operating and capital costs, profit, and payback period. It is found that both cases are better than the existing heat recovery system of the plant. However, case-2 is selected as the best heat recovery option. In comparison to the existing system, case-2 reduces coal and water consumption by 30.5% and 72.6%, respectively. Further, case-2 releases minimum waste gas to the atmosphere that makes the process environment friendly.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Longitudinal section of sponge iron plant

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Figure 2

Normal injection of air into the kiln

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Figure 3

Principle of counterkiln operation

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Figure 4

Kiln with waste gas processing equipments and its flow direction

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Figure 5

Schematic diagram of the conventional process

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Figure 6

Schematic diagram of modified process for case-1

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Figure 7

Schematic diagram of modified process for case-2

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