Detail about sponge iron making process rotary kiln

The sponge iron making process involves heating iron ore in the presence of a reductant, typically coal, until the metal becomes spongy and porous. The sponge is then removed from the kiln and cooled before being used in steelmaking or other applications.

While sponge iron can be made using different methods, the most common method is through rotary kiln production. In this method, iron ore is fed into a rotary kiln along with coal and air. The kiln is slowly rotated as it heats up, allowing the reductant to penetrate the pores of the iron ore and reduce it to sponge iron.

The process of making sponge iron

The process of making sponge iron is a process in which iron ore is reduced to metallic iron in the presence of oxygen. The process is carried out in a rotary kiln, which is lined with refractory bricks.

The iron ore is fed into the rotary kiln through a feed chute at the base of the kiln. The ore is then heated to a high temperature by the combustion of fuel in the kiln. The products of combustion react with the iron ore to form metallic iron.

The metallic iron produced in the process is known as sponge iron. Sponge iron can be used as a raw material for the production of steel and other metals.

How to use sponge iron

Sponge iron is a processed form of iron ore that contains a high percentage of carbon. The high carbon content makes it ideal for steelmaking. Sponge iron can be produced using either a direct reduction or an indirect reduction process.

The direct reduction process involves reducing iron ore in a rotary kiln at temperatures below the melting point of the metal. This process reduces the volume of the ore and drives off impurities, leaving a porous, spongy mass of metal that is called sponge iron.

The indirect reduction process starts with a pre-heated charge of iron ore and non-coking coal being fed into a rotary kiln. In this case, the reducing gases are formed by injecting hot gas from an external source into the rotary kiln. These gases react with the iron oxide in the feed to produce sponge iron.

What is rotary kiln?

A rotary kiln is a type of furnace that is used for the calcination of minerals, in order to remove impurities. The rotary kiln is rotated on its axis, while being heated by an external source, such as a natural gas burner or a coke-fired heater. As the kiln rotates, the material inside is brought up to high temperatures, which causes the impurities to be released from the minerals.

The Different Types of Rotary Kilns

There are three main types of rotary kilns: direct fired, indirect fired, and co-current. Direct fired rotary kilns use a direct flame to heat the material, while indirect fired rotary kilns use heat radiating from the shell of the kiln to heat the material. Co-current rotary kilns have both a direct and an indirect heating source.

Direct Fired Rotary Kiln:

A direct fired rotary kiln is comprised of a rotating shell that is lined with a refractory material. The shell is rotated while fuel is fed into the Kiln. The fuel ignites and starts to burn; the burning fuel heats up the lining of the Kiln, which in turn heats up the charge material.

Indirect Fired Rotary Kiln:

An indirect fired rotary kiln is very similar to a direct fired rotary kiln, except that the heat for drying and calcining is generated by hot gases flowing over the outside surface of the rotating Kiln shell. The hot gases can be generated by burning fossil fuels or wastes, by using waste heat from another process, or by using a combustion catalyst.

Co-Current Rotary Kilns:

A Co-Current rotary Kiln has both an Indirect and Direct component to its design. In this type of Kiln, Material is fed into one end of a rotating drum; as it moves through the drum it is heated indirectly by hot gases flowing over the outside of the drum. As it nears the other end of the drum, it is heated directly by flames from a burner. This type of Kiln is often used when two different temperature zones are required within the same rotary Kiln.

Pros and Cons of Sponge Iron Production

The process of sponge iron production involves reducing iron ore to obtain sponge iron. The main advantages of this process are that it is less energy intensive than other methods of iron production and produces a high quality product. However, there are also some disadvantages to consider, such as the potential for environmental pollution and the fact that it requires a lot of water.

Rotary Kiln Sponge Iron Production

A rotary kiln is a type of furnace that is used to reduce the size of a material by subjecting it to high temperatures. Rotary kilns are commonly used in the production of sponge iron, which is a type of iron that contains a high concentration of pores.

Sponge iron is made by direct reduction, which involves reducing iron ore into iron metal without going through the intermediate step of making pig iron. In order to do this, sponge iron must be heated to a temperature between 700 and 1,200 degrees Celsius in a reducing atmosphere. This can be accomplished in a rotary kiln, which is lined with refractory material to protect it from the high temperatures.

The reductant used in the production of sponge iron can be either gaseous or solid. When using a solid reductant, such as coke or anthracite coal, the reduction process takes place on the surface of the reductant particles. This type of reduction is known as surface reduction. When using a gaseous reductant, such as natural gas or hydrogen, the reduction process takes place within the gas phase. This type of reduction is known as gas-phase reduction.

The choice of reductant generally depends on factors such as cost and availability. Sponge iron produced with solid reductants tends to have a higher quality than sponge iron produced with gaseous reductants because surface reduction results in less impurities being introduced into the sponge iron.

The production of sponge iron in a rotary kiln generally consists of three steps: preheating, reduction, and cooling.

Preheating

The first step in the production of sponge iron is preheating. Preheating is necessary in order to drive off any moisture that may be present in the iron ore and to increase the temperature of the ore to the point where reduction can take place.

Reduction

The second step in the production of sponge iron is reduction. Reduction is accomplished by subjecting the iron ore to a reducing atmosphere in order to cause the oxygen in the iron ore to be removed. The reductant used will react with the oxygen in the iron ore, causing it to be removed from the ore.

Cooling

The third and final step in the production of sponge iron is cooling. Cooling is necessary in order to stop the reduction process and solidify the sponge iron.

Conclusion

sponge iron making process in a rotary kiln is a very efficient way to produce high quality sponge iron. The process is also relatively simple and can be easily scaled up or down to meet the needs of your operation. If you are considering starting a sponge iron making operation, we hope that this article has given you some useful information to get started.