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In this paper, we propose an SCADA Based Automatic Direct Reduction of Iron (DRI) Process Using Allen-Bradley Programmable Logic Controllers. SCADA stands for Supervisory Control and Data Acquisition system. The main objective of the project is to get the high grade (high quality) of Sponge Iron. Main quality of the product depends of the temperature of the different junctions of the rotary KILN .Initially, measures the temperatures of the junctions of KILN and fed as inputs to the PLC which in turn sent to PC through RS-232 for necessary processing. A PLC program is developed based on the signals received from the PLC analog input module, process the signals and send the output signals to the PLC output modules, which is programmed to control the fuel conveyor and shell air fan by using PLC-PID controller functions. Here controller parameters can be determined by PID-tuning methods.PLC program can be implemented by considering Rotary KILN direct reduction of iron process. The SCADA screens are developed on PC regarding process going in rotary KILN using RS-VIEW SCADA software. The Allen Bradley micrologix 1200 PLC have to be linked up with the supporting SCADA RS-VIEW by giving necessary tag names. With the help of SCADA, simulation of the physical equipment is also developed to monitor the quantities to be measured and status of the in the plant from field point.

SCADA Based Automatic Direct Reduction of Iron Process using Allen-Bradley Programmable Logic Controllers