Scholarlink

<p>The direct reduction (DRI) rotary kiln is continuously charged with a calibrated mixture of iron ore, non-coking coal, and dolomite to enhance the reduction kinetics and maintain the desired temperature profile. Thermal energy is supplied through a centrally located burner supported by eight strategically positioned air injection pipes. This configuration facilitates efficient countercurrent heat exchange between the ascending hot gases and the descending solid burden, thereby sustaining optimal reduction conditions within the kiln. The central burner, installed at the kiln outlet end, performs several essential process-control functions. During start-up, it provides controlled preheating of the kiln; during transient operational disturbances, it stabilizes internal temperatures; and under normal steady-state operation, it contributes to continuous combustion air supply and flame stability. This study reports an operational incident in a direct reduction (DRI) rotary kiln system, wherein Kiln experienced a sudden overpressurization caused by a punctured water wall tube in the waste heat recovery boiler (WHRB). The resulting pressure surge dislodged the central burner (CB) pipe at the kiln outlet, leading to displacement of the burner assembly, failure of the expansion hose, and brief flame propagation. The kiln remained overpressurized for approximately 132&#xa0;seconds, creating localized safety hazards and damaging monitoring equipment. Following the incident, the kiln was transitioned to controlled cooling, and stable operating conditions were restored. This event highlights the critical importance of pressure integrity and burner assembly reliability in DRI rotary kiln operations.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Over Pressurization of Rotary Kiln Shell Due to WHRB Tube Leakage

  • 期刊论文

  • 发表日期：

    2026年5月2日

查看全文
  • Durga Madhab Padhy,
  • Shaikh Mohammed Farman,
  • Shruti Kumari,
  • Mukesh Kumar Vishwakarma,
  • Omji Anand,
  • Nikhil Dubey,
  • T. Thirumurugan

摘要

The direct reduction (DRI) rotary kiln is continuously charged with a calibrated mixture of iron ore, non-coking coal, and dolomite to enhance the reduction kinetics and maintain the desired temperature profile. Thermal energy is supplied through a centrally located burner supported by eight strategically positioned air injection pipes. This configuration facilitates efficient countercurrent heat exchange between the ascending hot gases and the descending solid burden, thereby sustaining optimal reduction conditions within the kiln. The central burner, installed at the kiln outlet end, performs several essential process-control functions. During start-up, it provides controlled preheating of the kiln; during transient operational disturbances, it stabilizes internal temperatures; and under normal steady-state operation, it contributes to continuous combustion air supply and flame stability. This study reports an operational incident in a direct reduction (DRI) rotary kiln system, wherein Kiln experienced a sudden overpressurization caused by a punctured water wall tube in the waste heat recovery boiler (WHRB). The resulting pressure surge dislodged the central burner (CB) pipe at the kiln outlet, leading to displacement of the burner assembly, failure of the expansion hose, and brief flame propagation. The kiln remained overpressurized for approximately 132 seconds, creating localized safety hazards and damaging monitoring equipment. Following the incident, the kiln was transitioned to controlled cooling, and stable operating conditions were restored. This event highlights the critical importance of pressure integrity and burner assembly reliability in DRI rotary kiln operations.