New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System

Sponge iron rotary kiln is professional equipment for smelting sponge iron. Due to its high degree of mechanization and low labor intensity, many sponge iron plants around the world use the rotary kiln process to produce sponge iron. This time we introduce a new design sponge iron rotary kiln energy comprehensive utilization system, no matter from the sponge iron kiln design, or the improvement of production links, make the sponge iron manufacturing process energy utilization rate has been improved.

Sponge iron rotary kiln

Sponge Iron Uses In Many Fields

Sponge iron is also known as direct reduced iron. Using high-quality ore, using the principle of an oxidation-reduction reaction, in a rotary kiln, shaft kiln, or other reactors, the iron ore undergoes a reduction reaction and becomes porous sponge iron. Sponge iron has a low content of harmful impurities such as sulfur and phosphorus and non-ferrous metals. It is mainly used as a raw material for electric furnace steelmaking, especially as a raw material for high-quality steel and clean steel.

Structural of New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System

Structural of New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System

1- Sponge iron rotary kiln 2- Central burner system 3- Cooling rotary kiln 4- Crushing magnetic separation system 5- Warehouse 6- Metering pneumatic conveying device 7- Mingled storehouse 8- Air supply equipment 9- Air nozzle 10- Coarse coal pipe 11- Fine coal pipe 12- Dust settling chamber 13- Scraper machine 14- Waste heat boiler 15- Turbine generator 16- Oxygen tube

Sponge Iron Manufacturing Process of New Design Sponge Iron Rotary Kiln Energy Comprehensive Utilization System

  1. The iron concentrate, dolomite, and coal from the stockyard enter into three groups of metering pneumatic conveying devices of the feeding system for metering. The measured iron concentrate, dolomite, and 50% of coal all enter the mixing bin for full mixing.
  2. The mixed material after being fully mixed in the mixing bin enters the hopper at the end of the sponge iron rotary kiln, and the remaining 50% of the coal is also added through the kiln head of the sponge iron rotary kiln. The coarse coal passes through the coarse coal pipe at the kiln head and enters 30% of the kiln body of the sponge iron rotary kiln for combustion and heating, and the fine coal passes through the fine coal pipe for combustion and heating at the kiln head. The ignition pipeline of the central burner system at the kiln head only uses gas and air for ignition at the beginning of the operation.
  3. The mixture first enters the preheating zone of the sponge iron rotary kiln and is heated to the reaction temperature. The water in the mixture, the carbon dioxide in the dolomite, and the volatile components in the coal enter the upper space of the sponge iron rotary kiln, forming reducing gas. Then the mixture enters the reduction zone of sponge iron rotary kiln, and the iron concentrate is reduced by carbon monoxide to form iron elements. During the sponge iron manufacturing process, hot air enters through the air tube and air nozzle of the sponge iron kiln, providing heat for the reaction.
  4. The mixture first enters the preheating zone of the sponge iron rotary kiln and is heated to the reaction temperature. The water in the mixture, the carbon dioxide in the dolomite, and the volatile components in the coal enter the upper space of the sponge iron rotary kiln, forming reducing gas. Then the mixture enters the reduction zone of sponge iron rotary kiln, and the iron concentrate is reduced by carbon monoxide to form iron elements. During the sponge iron manufacturing process, hot air enters through the air tube and air nozzle of the sponge iron kiln, providing heat for the reaction.
  5. The waste gas produced by the rotary kiln first enters the dust settling chamber, and the settled dust is finally discharged by the scraper.
  6. The treated exhaust gas can enter the waste heat boiler for secondary combustion. The cooling water from the cooling rotary kiln is used to provide the water needed by the waste heat boiler, and the steam generated by the waste heat boiler enters the turbine generator for power generation.

Sponge Iron Rotary Kiln for Sale

Production Specifications(m)KilnBody Size

Motor Power (kW)Gross Weight(t)Remarks
Diamete(m)


Length(m)Inclination(%)Yoeld(t/d)Rotation(r/min)
Φ2.5×402.5403.51800.44-2.4455149.61
Φ2.5×502.55032000.62-1.8655187.37
Φ2.5×542.5543.52800.48-1.4555196.29External Rotary Kiln
Φ2.7×422.7423.53200.10-1.5255198.5
Φ2.8×442.8443.544500.437-2.1855201.58External Rotary Kiln

Design and Process Advantages

In the newly designed sponge iron rotary kiln system, a coarse coal branch pipe and fine coal branch pipe are added at the kiln head. The original way of adding 100% coal at the kiln head is changed to 50-70% coal is added together with fine iron ore and dolomite through the mixing mode at the kiln tail, and the remaining 30-50% coal is added by the kiln head. The coarse coal in this part of coal passes through the coarse coal branch into the 30%-60% of the sponge iron rotary kiln body for combustion and heating, and the fine coal passes through the fine coal branch for combustion and heating at the kiln head.

Design and process advantages of new designed sponge iron rotary kiln system

The air nozzle and the air pipe are used together to improve the control of the combustion rhythm. The air pipe is used as a combustion air supplement device and is evenly arranged along the kiln body to achieve the control of the combustion in the sponge iron rotary kiln. At the same time, each air pipe is equipped with a separate air supply device, which flows in parallel with the gas in the rotary kiln to form a vortex.

By changing the energy input port of the sponge iron rotary kiln, the problem of uneven temperature distribution in the kiln and loop formation is solved, and the temperature in the entire kiln can be controlled at multiple points and distributed evenly. In order to improve energy efficiency and reduce energy consumption, a new waste heat recovery system was added to save energy and protect the environment.