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P.C.Sudhakar
Preamble:
Around
Hot
Non
Continued:
The huge hot air quantity can be used for
air conditioning /ore preheating.
Low pressure steam can be generated for
dust suppression in open low hood furnace.
When uncontrolled firing of non-coking coal
happens in furnace the heat is wasted,
instead make coal char and ore preheating
in kiln retrofitting and use closed furnace
to control smelt reduction.
The temperature is to be controlled and
dust free environment make the fans
consume less power.
H2 O %
( Approximate)
Australia Ore
3.8%
1.2%
2.0%
8.4%
Sandur 26-28
0.4%
Radhika
4.2%
Kiln literature
Kiln Design
3.1m
1.55m
0.333m
A total
7.9m2
A solids
1.6m2
A gases
solid angle
6.272131m2
76.5288 degrees
A solids
1.61607m2
sector A
3.20897m2
Triangle A
1.592897m2
Modes of Operation
22)
Temperature
Size
Slag Volume
Mn Input
Si% lower limit
MnO% in slag
Slag Basicity
Arc voltage
Fume quantity
Coal/coke quality Rank,
type, grade etc.
Total fixed Carbon/ton
Conductivity of coals and
ores
Use of carbonate fraction
Ferro Manganese slag
fraction
Sinter fraction
Coal Size
Coal/Ore Reactivity
Thermal and electrical
losses
Mn/Fe ratio
Mn/P ratio
PYROMET AUTOMATION to
control
Electrode Lengths
23)
24)
25)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
smelting zone
smelting zone
ore nature carbonate/oxide/silicate
low grade ores
customer requirement
TFC/ton of alloy
Unwanted gangue content in ores
Capacity of Manganese furnace and PCD
Temperature
Singareni, South Africa and Australia
0.8
0.85
0.9
1.1
0.95
0.9
1.1
1.5
1.05
1.2
0.9
0.9
1.2
1.1
1.1
0.9
0.9
1.05
0.9
0.9
0.8
0.9
0.9
1.2
1.1
Gas Calculation
= +21%
Conclusions
-The metallurgist point of view is expressed, not
heat transfer problem in general.
-The problem is maze for hard heat transfer
specialist.
-Possible heat transfer is considered, but
efficiencies arent matching
-For which moisture % like around <5 % (i.e,
2.5%) the Optimum matching may occur.
-The fill in the kiln is low (1/3) causing good
heat transfer.
Final
just
THANK YOU.