Computational fluid dynamics analysis of sponge iron rotary kiln

Abstract

2D CFD model of rotary kiln of sponge iron process is developed to study the effects of angle of inclination, number of rotation and mass flow rate of iron ore on output parameters. Based on grid independent test for temperature profile optimum mesh size is selected. The result shows that optimum angle of inclination, number of rotation and flow rate of iron ore are found as 2.7 degree, 4.8 rpm and 10 kg/s, respectively. At these optimum conditions the % metallization is predicted as 89.5%, which is 3.24% less in comparison to the existing system. The temperature profiles of gas and bed are also found within acceptable temperature limits. The results are compared well with the published work as well as industrial data. © 2016 Elsevier B.V. All rights reserved.