SEMINAR ON INTERNSHIP
PRESENTED BY:
ROHAN KUMAR JOSHI
REGD. NO-2202090133
DEPARTMENT:MECHANICAL
ENGINEERING
VEER SURENDRA SAI UNIVERSITY OF TECHNOLOGY,
BURLA
NARBHERAM POWER &
STEEL PRIVATE LIMITED
DRI PROCESS
ELECTROSTATIC PRECIPITATOR
PRESENTED BY:
ROHAN KUMAR JOSHI
CONTENT
[Link]
[Link] Profile
3. Raw Material Handling
4. DRI Process
5. Rotary Kiln
[Link] precipitator (ESP)
[Link]
INTRODUCTION
•Internship at Narbheram Power And Steel
Pvt. Ltd., Dhenkanal
•Duration: 10 May - 10 June
•Supervisor: Mr. Ananta Kumar Mishra (Sr.
General Manager, Works)
•Objective: To gain hands-on industrial
experience in Direct Reduced Iron (DRI)
production process.
COMPANY PROFILE
• Established in 1999, located in
Dhenkanal, Odisha
•Production capacity: 1,00,000 tons
sponge iron/year
• 60,000 tons billets/year
• Focused on sustainability, innovation,
and environmental compliance
RAW MATERIALS FOR DRI
PRODUCTION
1. Iron Ore
Main source of iron (oxide form).
Usually used in the form of:
Sized Lump Ore (5–18 mm, hematite is preferred).
Pellets (made from iron ore fines).
Sometimes fines (with pelletizing or special processes).
Types of iron ore
Hematite
Magnetite
Georite
Pyrite
Limorite
Generally Hematite is used Because it contain 50% to 90%
iron
DRI PROCESS
(Direct reduced iron)
Rotary kiln
A rotary kiln in a Direct Reduced
Iron (DRI) plant is a critical
component used for the reduction of
iron ore to produce direct reduced
iron (DRI). The rotary kiln is a
cylindrical vessel that rotates
around its axis and operates at a
slight incline
PROCESS DESCRIPTION
[Link] Material:
Iron ore (in the form of pellets or lump ore), non-coking coal, and dolomite
are fed into the rotary kiln. The iron ore is the primary material, while coal
acts as a reducing agent, dolomite serves as a flux to remove impurities
like Sulphur.
Coal Also feed from end of the Kiln through Backflow chute to continue
the reduction process.
[Link] and Reduction Zone:
As the kiln rotates, the materials are heated by the combustion of coal.
The temperatures inside the kiln can reach up to 1000-1100°C. The heat
causes the reduction reaction, where iron ore (Fe2O3) is reduced to
metallic iron (Fe) by carbon monoxide (CO) produced from the burning
coal.
[Link] Reactions:
The primary reduction reaction in the kiln is:
Fe2O3+3CO→2Fe+3CO2
Additional reactions involving carbon and carbon monoxide also take place to
ensure the complete reduction of iron ore.
[Link] Zone:
After the reduction, the hot DRI is cooled before being discharged from the kiln.
Cooling is achieved in a separate cooling vessel. In some designs, water spray
cooling is used.
ELECTROSTATIC PRECIPITATOR
An Electrostatic Precipitator (ESP) is
an advanced air pollution control
device used to remove fine particles
(dust, smoke, soot, fly ash, and mist)
from flue gases before releasing
them into the atmosphere.
It works on the principle of
electrostatic attraction, where
particles are charged electrically
and then collected on oppositely
charged plates.
WORKING PRINCIPLE
1. Flue Gas Entry
Smoke containing tiny dust particles (from boilers, kilns,
furnaces, etc.) enters the ESP.
This gas looks dirty because it has suspended solid particles in
it.
2. Charging the Particles
Inside the ESP, there are discharge electrodes (thin wires) that
are connected to a high-voltage power supply (30–100 kV).
When current passes, these wires create a corona discharge (like
an invisible electric field).
This electric field releases free electrons, which attach to the
dust particles, giving them a negative charge.
(Think of it like rubbing a balloon on your hair – the dust particles
get electrically charged in a similar way.)
3. Attraction to Collecting Plates
On the sides of the ESP, there are large metal plates which are
kept positively charged (grounded).
The negatively charged dust particles are attracted to these
positive plates (like how a magnet pulls iron filings).
Slowly, the particles move sideways and stick to the plates,
leaving the gas cleaner.
WORKING PRINCIPLE
4. Collection of Dust
The dust forms a layer on the plates.
Periodically, a rapping mechanism (like a
hammer or vibrator) shakes the plates so
the dust falls down.
The fallen dust collects in a hopper at the
bottom.
5. Clean Gas Outlet
After the dust is removed, the clean gas
(almost free from dust) exits the ESP
through the chimney.
This prevents air pollution and keeps the
environment safe.
CONCLUSION
My internship at Narbheram Power & Steel Pvt. Ltd., Dhenkanal
provided me with valuable exposure to the working of the
Rotary Kiln and Electrostatic Precipitator (ESP). The rotary kiln
ensures efficient sponge iron production, while the ESP plays a
crucial role in controlling emissions and maintaining clean
operations. Together, they enhance both production efficiency
and environmental sustainability. This experience has
strengthened my technical knowledge and given me practical
insights into real industrial processes.
THANK YOU