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    10 Pellet-Grate-Kiln Tech

    Uploaded by

    Amit Kumar Uke
    The document describes an iron ore pelletizing process using a grate kiln system. Key components include a traveling grate for drying, preheating and oxidizing green balls, a rotary kiln for firing the pellets, and an annular cooler. Hot air from the kiln and cooler is recirculated to provide heat to the various zones of the grate. Temperature and pressure are carefully controlled to optimize pellet properties during induration in the kiln.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    10 Pellet-Grate-Kiln Tech

    Uploaded by

    Amit Kumar Uke
    90 views14 pages
    The document describes an iron ore pelletizing process using a grate kiln system. Key components include a traveling grate for drying, preheating and oxidizing green balls, a rotary kiln for firing the pellets, and an annular cooler. Hot air from the kiln and cooler is recirculated to provide heat to the various zones of the grate. Temperature and pressure are carefully controlled to optimize pellet properties during induration in the kiln.

    Original Title

    10 Pellet-Grate-Kiln tech(2)

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    The document describes an iron ore pelletizing process using a grate kiln system. Key components include a traveling grate for drying, preheating and oxidizing green balls, a rotary kiln for firing the pellets, and an annular cooler. Hot air from the kiln and cooler is recirculated to provide heat to the various zones of the grate. Temperature and pressure are carefully controlled to optimize pellet properties during induration in the kiln.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    90 views14 pages

    10 Pellet-Grate-Kiln Tech

    Uploaded by

    Amit Kumar Uke
    The document describes an iron ore pelletizing process using a grate kiln system. Key components include a traveling grate for drying, preheating and oxidizing green balls, a rotary kiln for firing the pellets, and an annular cooler. Hot air from the kiln and cooler is recirculated to provide heat to the various zones of the grate. Temperature and pressure are carefully controlled to optimize pellet properties during induration in the kiln.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 14

    Iron

    To Tailing Thickener
    Fines Closed ckt
    Bin grinding
    Hydro clone
    Wet
    Screen

    Primary Ball Secondary Ball


    Mill Mill

    Primary Sump
    Secondary Sump

    Concentrated Thickener
    Flush Water
    Tank Holding Tank

    Pressure Filter

    Filtrate
    Tank
    Ball
    Ball MillMill
    Circuit
    Filter Cake Conveyor to Stock Pile
    Circuit –
    FEEDING & GREEN BALL FORMATION CIRCUIT
    1 2 3 4 5 6 7 8 9 10

    WF WF WF WF WF WF WF WF WF WF

    Belt Conveyor:

    Mixer
    1 2 3 Bel
    t Con Belt
    vey Con
    or: veyo
    r:
    VF VF VF

    1 2 3

    o O/S ize Ro ll e r Screen)


    Belt Conveyor: (T
    MATERIAL FLOW FROM O/SIZE SCREEN TO GRATE TO KILN TO COOLER TO PRODUCT STOCKYARD

    O/Si
    ze R
    Scre oller
    en
    -16mm Green Balls

    yor
    Be l t Conve
    Wide

    een
    o l l er Scr
    R
    d er Size 8-16mm Green Balls
    Un

    DD-1 DD-2 PH-1 PH-2


    KILN
    TO B.C.- ALONG WITH BELT & SCRAPPER CONVEYORS
    O/SIZE RETURN.

    Product C
    Product t onveyor
    o Screen
    Stockyard

    Annular Cooler Blowers

    Product Fines:
    (+3mm) FINES (-3MM)
    (-3mm)
    Process Gas Flow Diagram –Grate Kiln

    Furnace Oil
    & Coal
    P.H.-2 P.H.-1 D.D.-2 D.D.-2

    KILN

    C.B. Blower
    E.S.P.

    HAF-1 ID Fan
    Gas Temp
    Profile:
    P.H.-2 I/L- Mat. Temp
    Cooler blowers 1000 C,
    0 HAF-2
    Profile:
    D.D.-1 I/L-
    Sedimentation Chamber/Dedusting Unit P.H.-1 I/L- 7000C, 30 C,
    0

    DD-2 DD-2 O/L- 2500C,


    I/L- 450 C,
    0 P.H.-1 O/L-
    4500C, P.H.-2
    O/L- 9000C.
    Grate Kiln Process
     The grate-kiln process has three units for meeting radically
    different thermal conditions.
     Drying, pre-heating and oxidation are carried out in a
    traveling grate while pellets are fired in a rotary kiln. Hot
    pellets are cooled in a rotary cooler.
     Hot air from the rotary kiln is used in the grate for drying and
    preheating. The hot air from the cooler is recirculated in the
    rotary kiln, and Traveling Grate.
     Heat supply for various reactors can be regulated very easily
    because of three units being separate.
     Pellets Produced have more uniform properties because
    Induration takes place in the Rotary kiln exposing each pellet
    to uniform heat.
    TEMPERATURE AND PRESSURE GUIDELINES

    Pelletizing Process - This is an oxidation process with high temperature and


    negative pressure .The source of heat is coal , fuel oil and flue gases coming from
    cooler. Here three fans ( hot air fan-1, fan-2 & ID fan ) are sucking flue gases and are
    controlled to maintain temperature and pressure at various zones.

    TRAVELLING GRATE

    900°c 500°c 300°c 150°c


    COAL BURNER FLAME
    1000°C to 1350°C To To To To
    1100°c 700°c 500°c 300°c
    3
    1
    2 PH -2 PH -1 DD -2 DD -1

    Annular cooler
    Cooler -1 zone- 1000 – 1100°C
    2 zone- 300 – 500°C
    Fuel
    3 zone- 90 – 105°C
    Oil
    TRAVELLING GRATE FLUE GAS FLOW

    ID FAN

    HAF-1

    DUCT FROM
    D.D-1 D.D-2 PH-1 PH-2 COOLER-II
    ZONE

    HOT GAS FLOW

    HAF-2
    Grate-Kiln

    Grate :-

    The travelling grate consists of three main parts :

    The movable Grate, the stationary wind boxes below and the stationary hood
    above. The Grate consists of an endless chain of grate plates which are
    connected with the wind boxes in a gas-tight manner. The process gases are
    passed through adequately dimensioned fans.

    12
    Rotary Kiln :-

    In the Rotary kiln, the pellets are brought from their relative position of rest on
    the travelling grate into a rolling movement. They roll spirally in a very thin layer
    towards the discharge end. The pellets are uniformly heated by radiation heat of
    the hot kiln wall and hot gases thus leaving the kiln as indurate pellets.

    13
    PROCESS FLOW-CHART

    14

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