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g Stea m #"# $%& *&R + Iron Ore feed 6"# $%& Coal feed -l.e gas ,, $%& 6iln ( 10#0 $%& C 1 al Central b.rner air 4000 m/hr (0 C Coal In2e tor air d.st *ater 6 m/hr /olomit e 0"# $%& rotar5 ooler *ater 1'# (0 ,6#0 m/hr C Coal In2e tion ,"# $%& (0 C 10 1 al m/hr C Shell air fan 1'000 m/hr (0 C )ir (,00 )+C m/hr 0#0 C -l.e gas
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1 al *aste heat O.t3.t4 1 al Radiation 8 9is " loss : #; Rea tion 7nerg54 1 al $heoreti al Rea tion 7nerg54 1 al Ratio of ) t.al to $h" 7nerg5 ons.m3tion
4"0 1"1 16 4"(# ("' )sh 1"1 $%& S3onge Iron 4"# $%& < 1,0 C Char 1"# $%& < 1,0 C
Tables below gives month wise data collected from site for DRI section. The average ratios at the plant are in line with industry benchmarks. The average Coal consumption is 1. ! kg"kg DRI and is satisfactory. The ore consumption is 1.# kg"kg and is also satisfactory. The overall power consumption is $% k&h"Ton and is in line with similar si'ed industries.
May13 1)*!% 1 1$. ! 1+) 111(* Ratio/Ton DR! 1. !
Particulars Fee" #oal #onsu$ption %!n&ection #oal #onsu$ption Dolo$ite #onsu$ption !ron Ore Sponge !ron Pro"uction #'ar (eneration Po)er #onsu$ption
Jan-13
Feb-13
Mar-13
Apr-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Avg
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Table below gives an overview of the energy and material balance across a DRI kiln. The overall average energy consumption is around (. , cal " ton DRI. -owever. at normal production rates the unit also achieves .$ , cal " ton DRI. The same is satisfactory and close to similar si'ed industry standards. Table /. DRI 0iln 1nergy 2 3aterial 4alance
Sr" no " %resent da5 o3eration basis 100 $%/ 100 $%/
%arti .lars /esign a3a it5 of 1 /RI 6iln %rod. tion a hie=ed Rated - grade oal s3e ifi ons.m3tion ratio >ormal rates 7 8 - grade oal ons.med Char generated at 6iln )=g" &eating =al.e of oal fired 7ffe ti=e &eat =al.e of Coal fines ass.med &eat =al.e of Char &eat in3.t to 6iln &eat in3.t to 6iln 3er $on of /RI
1"' kg/kg 1"(# kg/kg 1(# $%/ (6 $%/ 4000 k al/kg (,00 k al/kg 1'#0 k al/kg #40 9 k al/kg #"40 9 k al
&eat a=ailable in kiln waste fl.e gases &eat a=ailable in kiln waste fl.e gases &eat a=ailable in kiln waste fl.e gases 9inim.m -l.e gas inlet tem3erat.re to &RS1 9a?" -l.e gas o.tlet tem3erat.re from &RS1 S3e ifi heat of fl.e gases onsidered -l.e gas @.antit5 estimated4 kg/hr &eat re o=er5 3otential from fl.e gas in *&R+ 7@.i=alent steam generation at *&R+ $otal steam generation 3otential from ea h kiln %ower generation 3otential from 6iln *&R+
,1; 1"1( 9 k al /ton /RI 4"',# 9 k al / hr 000 C 100 C 0",4 k al/kgC ,,6,0 kg/hr