Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, 500 TPD)

Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI). Since DRI is produced by removing oxygen from iron ore, its structure is just like sponge with a network of connecting pores. These pores results in a large internal surface area which is about 10,000 times greater than the internal surface area of solid iron. Due to this, DRI is also known as Sponge Iron.

Sponge Iron is gaining more popularity because of the following reasons…

Scrap is getting scarcer by the day

Quality and composition variations are compelling

Tramp elements coupled with Sulphur and Phosphorus hamper the end product quality of sale-able steel

Uniform known composition, size and high bulk density compared to scrap

Low Capex and gestation period compared to Gas based DRI plant

It can be produced with non-coking coal and poor quality of coal that is available in abundance

Capability of forming protective layer of foamy slag in the bath

Potential of sensible heat recovery from waste gases

Maintenance of Sulphur level in steel by its removal during Sponge iron production**

Lower refining requirements of steel produced

It allows steelmaking to dilute metallic residuals in scrap

Main Components of the Rotary Kiln are…

Raw Material Handling & Storage

Rotary Kiln

Rotary Cooler

Magnetic Separators (MS)

Dust Settling Chamber (DSC)

Post Combustion Chamber (PCC)

Product Handling & Storage

Off Gas Handling & Cleaning System

Advantages of ET Design:

ET has the distinction of being the designer, producer and user of Sponge Iron

Equipment and project designed according to international norms for longevity and optimal productivity

Intelligent raw material proportioning system

Versatile design adaptable to use wide range of raw material grades

Facility to substitute natural gas for some portion of coal

Advanced instrumentation & automation to reduce utilities’ consumption

High combustion efficiency through gas monitoring system

Highly engineered plant layout for minimal material handling and smooth material flow

Efficient plant and process design for maximum waste heat recovery

Pollution free plant with state-of-the-art dust suppression and collection system