Roots blower air 1000 m/hr 480 C 64 kg/ m!

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

7S %

I/ -an 1'# C

$o Sta k

&eat In3.t4

,,

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

11()% 11!+.# $ 1 *)# +%!*

1!! 1#( .1 * )1*)) 1!)%+

1%!( 1!!). 1!)%! $)(

1%)%) 1!(1.) ( 1)$#( **$$

1 1*! 1%+*.) ! 1($$) +)$$

+ (1

$ ()

$$*#

111($

1 +)+

11 (!

11!##

*%!.!* 1%!1% ( * (#%+( +

*!*.%) +*1$ (11!

()*.)# #!(# 1$%

* %.*% 11+%1 #%$+

#1#.+% 1(%+) +#%

%(.+! 1%*$% *! + (#(!1 %

+*+ 1!(! #+*1 * 1! )

%.1) 1.#%

#(*++)

$*+%$+

#% %!$

(+!+#1

#%) )$

*()#!)

( (!*

()1))*

(#*1$$

*)#$%$

$%.(*

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

("86 9 k al / hr #"# $%& #"# $%& 1"(, 9*