The vagaries of nature in geographical distribution of Raw Materials required by the conventional integrated steel plants make it impracticable to put up such Steel Plants in many parts of the World. Sponge Iron (DRI) route of Steel making offers a solution to the problem to certain extent. Sponge Iron can be used in Mini Steel Plants, where DRI unit is situated at the site of Steel making plants. Hot Briquetted Iron (HBI), which is a denser form of DRI, is suitable for distant markets and for exports. Compared to scrap, the use of Sponge Iron offers the benefits like consistency in composition, low trace elements, its porous nature and environmental friendliness. Coal based Sponge Iron production by Rotary Kiln is gaining importance in India. The role of refractories in affecting isothermal condition in various zones and heat transfer are presented. A new type of Refractory castable is designed based on Sintered Mullite. The Bulk Density, Thermal Conductivity and total refractory load on the Rotary kiln affects the operational economics to a great extent and a comparison of performance is presented. The chemical affinity of the refractories to the alkali and alkaline-earth environment play a lead role in accretion formation within the kiln and hence the developed refractory which is inert to such attacks has resulted in the substantial reduction of Kiln shutdowns adding to the better performance and profitability to the units.
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