IS 11285: Various Tests on Raw Materials to be Used for Coal Based Rotary Kiln Direct Reduction

10 Pages·2002·1.1 MB·English

by  Bureau of Indian Standards

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IS 11285 (2002): Various Tests on Raw Materials to be Used
for Coal Based Rotary Kiln Direct Reduction [MTD 30: Sponge
Iron and Smelting Reduction]
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Satyanarayan Gangaram Pitroda
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IS 11285:2002

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Indian Standard
I
VARIOUS TESTS ON RAW MATERIAL TO
!
BE USED FOR COAL BASED ROTARY KILN
I
DIRECT REDUCTION
I (First Revision)
ICS 73.040; 77.080.10

0 BIS2002
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARC
NEW DELHI 110002

Fcdvwyy 2002 Price Group 2
Sponge Iron and Smelting Reduction Sectional Committee, MTD 30
FOREWORD
This Indian Standard (First Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Sponge Iron and Smelting Reduction Sectional Committee had been approved by the Metallurgical
Engineering Division Council.
This standard was earlier published in 1985. In this revision, various tests on dolomite/limestone have been
incorporated. Apart from this other parameters like size distribution and caking index for reductant coal have
also been included.
The testing of raw materials for coal based direct reduction in rotary kiln process assumes great importance
owing to the sensitivity of the manufacturing process to the raw material characteristics. In addition to the
testing for rate of reduction, disintegration and sticking behaviour for the oxide feed stock, reactivity and ash
softening characteristics ofthe reductant, the testing of acombination of ore and coal isof significance.
The Composition of the Committee responsible for formulation ofthis standard isgiven inAnnex A.
Forthe purpose of deciding whether aparticular requirement ofthis standard iscomplied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS2:1960 ‘Rules forrounding offnumerical values(revised)’. Thenumber ofsignificant placesretained inthe
rounded off value should be the same asthat ofthe specified value inthis standard.
IS 11285:2002
Indian Standard
VARIOUS TESTS ON RAW MATERIAL TO
BE USED FOR COAL BASED ROTARY KILN
DIRECT REDUCTION
(First Revision)
1SCOPE IsNo. Title
8167:1989 Method for determination of
TIIisstandard coversthetestsofrawmaterials for coal reducibility indexofironoreoxides,
based direct reduction processes in rotary kilns, to
lump ore, sinter and pellets @rst
produce sponge iron for use in steelmaking furnaces
revision)
and in foundaries.
8624:1995 Method for determination of
2 REFERENCES swelling index of iron ore pellets
&t revision)
The following standards contain provisions which
9963:1981 Determination of shatter index of
through reference in this text, constituteprovisionsof
iron ore, lumps sinter and pellets
this standard. At the time of publication, the editions
10823:1994 Methodfordetermination ofthermal
indicatedwerevalid.Allstandardsaresubjecttorevision,
degradation index (TDI) and
and parties to agreements based on this standard are
reduction degradation index (RDI)
encouragedto investigatethepossibilityofapplyingthe
of iron oxides; lump ore sinter and
mostrecent editionsofthestandardsindicatedbelow:
pellets (f2rstrevision)
[s No, Title 11283:1985 Determination of softening point of
[350 Methodsoftestforcoalandcoke(in ironoxides(inpowder form) :lump,
various parts) ore, sinter and pellets
(Part 2) :1970 Determination of calorific value 11284:1985 Rotary tube test for iron bearing
(firsretvision) materials for the manufacture of
1353: 1993 Methods of tests for coal carboni- sponge ironfdirect reduced iron
zation-caking index, swelling (DRI)
number and (LT) gray-king assay 11795:1996 Guidelines forash softening studies
(firsretvision) on solid reductants for direct

1354: 1992 Methodsoftest for coke-specialtest reduction ~rst revision)

(second revision) 12381:1994 Methods of determination of coal
1493: 1959 Methods of chemical analysis of
(char) reactivity fordirect reduction
iron ores
processes (first revision)
1493 Methods of chemical analysis of
(Partl) : [981 iron ores: Part 1 Determination of 3 TEST METHODS
common constituents
3.1 For Oxide Feed Stock (Iron Oxides: Lump Ore,
1607: 1977 Methods for test sieving (first
Pellets, Mill Scale, Etc)
revision)
1760 Methodsofchemicalanalysisoflime- 3.1.1 Size Distribution
stone,dolomiteandalliedmaterials:
3.1.1.1 The sizeofthe oxide feed inthe form of lump
(Part 1):1991 Determination of loss on ignition
ore should be fixed for this particular test.
~irs[ revision)
(Part 2) : 1991 Determination of silica (first 3.1.1.2Thesizedistributionofthesampleofironoxide
revisiot7) when de~ermined in accordance with the methods
(Part 3) : 1992 Determination of iron oxide, given in IS 1607shall be asfollows:
aIumina, calcium oxide and
magnesia (firstrevision) –20+15mm 16-18percent
5842: 1986 Method for measuring bulk density –15+10mm 28-30 percent
of ironoxides lumpores, sinterand –10+ 8mm 35-40 percent
pellets (firstrevision) –8+ 5mm 12-15percent
6495: 1984 Method of tumbler test for iron
oxides, lump ores sinter and pe llets For other sizes, the exact figures shall be noted and
(f7rslrevision) reported in the results.
1
IS 11285:2002
3.1.2 Chemical Analysis determined in accordance with the methods given in
1S1607shall be asfollows:
The chemical analysis oftheoxide feed stockshallbe
determined for moisture, total iron, Fe20~, FeO, –20+15mm : 10-15percent
sulphur, phosphorus, SiOz,A120~,CaO,MgOandloss –15+10mm : 35-40 percent
on ignition.
–10+ 5mm : 35-40 percent
The chemical analysis ofthe oxide feed stock forthe –5mm : 10-15percent
above constituents shallbedetermined bythemethods
3.2.2 Chemical Analysis
specified in IS 1493 and 1S1493 (Part 1)or by any
other established instrumental methods (for example, The proximate analysis of the coal for the deter-
instrumental methods employing X-ray fluorescence minationofmoisture,volatilematter,ash,fixedcarbon
technique). and the ultimate analysis for the determination of
carbon, hydrogen, nitrogen, oxygen and suIphur and
3.1.3 Physical Testing
the chemical analysis of ash for the determination of
The physical testing of the oxide feed stock is done SiOz,AIZOJ,Fe20J,CaO,MgO,N~O, KZOarecarried
forthebulk density, angle ofrepose, sizedistribution,
out.
shatter index, tumbler index and swelling index.
The chemical analysis of the coal samples shall be
3.1.3.1 The bulk density of samples shall be
carried out according to the procedures given in
determined according to 1S5842.
various parts of IS 1350 (for example, instrumental
3.1.3.2 The angle of repose of samples shall be method employing X-ray fluorescence technique).
determined according tothe method mutually agreed.
3.2.3 Physical Testing
3.1.3.3 The shatter index of the samples shall be
3.2.3.1 C’alor@ value
determined according to IS9963.
The gross caloritic value and the net calorific value
3.1.3.4 The tumbler index of the samples shall be
are determined for the coal samples according to the
determined according to IS6495
procedure prescribed in IS 1350(Part 2).
3.1.3.5 The swelling index of the samples shall be
3.2.3.2 Bulk Densip
determined according to IS 8624.
The bulk density ofcoal samples shall be determined
3.1.4 Other Tests
by the procedure laiddown in IS 1354.
3.1.4.1 Thermal degradation, reducibility and
3.2.3.3 Angle of Repose
decrepitation tests under static conditions and rotary

tube tests are conducted on the oxide feed stock to The angle of repose of the coal samples shall be

assessthesuitabilityfordirectreduct ioninrotarykilns. determined as per the method mutually agreed (for
example, instrumental method employing X-ray
3.1.4.2 The thermal degradation test for the
fluorescence technique).
determination ofthethermal degradation index(TDI)
and reduction degradation index (RDI) shall be 3.2.3.4 Caking index, swelling shall be determined
determined as per IS 10823.
by the procedure laiddown in IS 1353.
3.1.4.3 The reducibility and the decrepitation tests
3.2.4 Other Tests
under static conditions are carried out as per the
procedure outlined in IS 8167. 3.2.4.1 Melting characteristics of reductant ash
3.1.4.4 Rotary tube tests are conducted for assessing The sotlening point, the melting point and the flow
the suitability ofcombination ofoxide feedstockand pointoftheashincoalunderreducing conditions play
the reductant to determine the reducibility index and important role in the temperature profile for the
the decrepitation behaviour. The rotary tube tests are reduction in the kiln. These characteristics shall be
conducted as per procedure outlined in IS 11284. determinedaspertheprocedure laiddowninIS11795.
3.1.4.5 Softening pointof ironoxideforlumporewill 3.2.4.2 Reactivi~ of reductant
bedetermined bythisprocedure laiddowninIS11283.
The reactivity of the reductant coal is defined as the
3.2 For Reductant Coal generation ofcarbon monoxide per unitweight ofthe
reductant per unit time at the given experimental
3.2.1 Size Distribution
conditions. The reactivity of the coal shall be
The size distribution of the sample of coal wh en determined asper the methods given in IS 12381.
2
IS 11285:2002
3.3 For Dolomite/Limestone shall be carried out as per the procedure outlined in
IS 1760(Part 1).
3.3.1 Size Anaiysis
3.3.2.2 Silicashallbedetermined aspertheprocedure
The size distribution of the dolomite/lime stone shall
outlined in IS 1760(Part 2).
be asfollows:
3.3.2.3 CaO, MgO, FezOqand A120~shall be carried
+6mm = 5.0 percent, J4ax
out asper theprocedure outlined in IS 1760 (Part 3).
– 6 + 1mm = 90 percent
. 1mm = 5.0 percent, Max 3.3.2.4 Size distribution of sample coal when
determined maybe asfollows:
3.3.2 Chemical analysis of dolomite shall be
+15–20mm = 10 percent
determined for loss on ignition, CaO, MgO, FezOJ,
–15+10mm = 30-40 percent
Si02, A1201.
+ 5–10mm = 30-40 percent
3.3.2.1 Loss on ignition of dolomite and lime stone
– 5+10mm = less than 10percent
IS 11285:2002
ANNEX A
(Foreword)
COMMITTEE COMPOSITION
Sponge Iron and Smelting Reduction Sectional Committee, MTD 30
0rgd)7ixrli0n Representative(s)
Tata Iron& Steel Co Ltd, .iamshedpoI DRAMTICHATTERWE(Chairman)
Mu!iond Ltd. Thane SHRIC.H.SHARMA
SmuA.CHATTEFUE(AElternate)
M.N.Ekular& Co (P) Ltd, Kolkata SHRIADHWSENGUPTA
MsAm’n TARAFOAR(Alternate)
Notional Meta[lOrgiGt]Laboratory, Jamsbedpur DRSWATANrRAPRAKASH
Kodermakh iron Ore Co Ltd, Chiiimaglor SHRIT.R.RAO
Sponge iron India Ltd. Khammam (AP) SHIUM.AMARESHWARRAO
SAII.. R&D Ccntre. Ranchi SHIUG.I.S.CHAUHAN
DRK.K. PRASAD(Alrerrrafe)
Central FLICIRescarcb Institute. Dhaobad REPRESWA~
MECON (India) Ltd, Ranchi SHRIP.BHAITACHARYA
SHRIA.K.AGRAWAL(Alternate)
Orissa Sponge iron Ltd. Distt Keonjhor SsrroN.K.PATNAIK
SHRIS.C.JENA(Alternate)
Sonflag India ltd. Bhandam SHRID.K.GAUR
SHRIS.P.DASH(Ahernate) ‘
GtIsAot!mrity ol’lndia. New Delhi SHRIR.G. RAJAN
SHRIP.S.SAREEN(Alternate)
Essar Steels, hlomhai SHRIK.JYoma
National Mineral Development Corporation Ltd, Hyderabad F@PREsWA~E
I’ATA Sponge hon. Distt IGxmjhor SHRIB.M. SARANGI
Vikram [spat, Mumbai DRS.K.S.YADAV
Jindal Steel &Power Ltd. Raigarh SHRIK.C, THATOI
SHRI[J.BHAmAUOUEE(Alternate)
Ministry ofStccl. New Delhi SHRtD.KASHIVA
SHRIS.K.BHATNAGA(ARlternate)

Steel Fornaw Association oflndia, New Delhi SNRIM.S.UNNINAIR
GSA1, Ltd, I[yclerahad SrrRIK.P.PATNAIK
SHRIK.S.N.MURTHY(Alternate)
HIX ltd. Dorg SHRIS.N.MISHRA
Nova Ircro&Steel Co Ltd, t3ilaspor SHRIA.R.AIASEXARAN
SfmoB.GOPICHAND(Alferrrate)
l~rakas]]Industries. New Delhi REPRESENTATIVE
RaipOrAlto>s. Raipur SHRIN.RATH
[sp~t Indostrics 1.td(Nippo Denro), Raigad SHRIV.V. JAMNSS
SHRIA.K.SAXENA(Ahernafe)
Monnet Ispa( ltd. Raipur SHIUB,L.VERMA
(Jsha (India) ltd. New Delhi .%CWB.K.ROY
Sponge Iron Manotactorers’ Association, New Delhi SHRIS.S.BHATNAGAR
FJISDirectorate General SHRtN.MITRA,Director &Head (MTD)
[Representing Director General (.Ex-o~~cio)]
Member-Secretary
SmrrRAMAWADHRAM
Depoty Director(MTD), BIS

4
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This Indian Standard has been developed from Doc :No. MTD 30(4254).
Amendments Issued Since Publication
Amend No. DateofIssue TextAffected
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