2019 Pittsburgh AISTech

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Quality Prediction and Control in Coal-Fired Rotary Kilns at Tata Sponge Iron Ltd. (Room 402)

The conventional models for iron ore reduction assume mass transfer control above approximately 1,000°C. In a rotary kiln, however, the reduction process takes place non-isothermally because the temperatures change from 600 to 1,150°C along the length. A mathematical model taking into account the non-isothermal reaction conditions is developed. The degree of reduction and other kinetic parameters, like the pre-exponential factor, are continuously evaluated and adjusted. Plant data is used to tune the model. The actions needed to control quality are suggested on a dynamic basis. The result is improved quality and its control within a narrow range of 82-85% Fe.