Sponge Iron Production Line

The reduction of Iron Ore can be achieved by using either carbon bearing material, such as non-coking coal or a suitable reducing gas in the form of reformed natural gas. The processes employing coal are known as solid-reluctant of coal-based processes while those employing reducing gases are known as gas-based processes. Sponge Iron produced by gas-based process is normally hot briquette and hence it is also known as Briquetted Iron.

Coal-Based Process

» This process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.
» The reduction is carried out in an inclined horizontal rotary kiln, which rotates at a predetermined speed. A temperature profile ranging from 800-1050 degree centigrade is maintained along the length of the kiln at different zones and as the material flows down due to gravity the ore is reduced.
» The hot reduced sponge iron along with semi-burnt coal, discharged from kiln is cooled in water-cooled cylindrical rotary cooler to a temperature of 100–200 degree centigrade.
» The discharge from cooler consisting of sponge iron, char other contaminations are passed on through magnetic separators so that sponge iron can be separated from other impurities.
» Later the sponge iron is screened into two size fractions i.e. –3 mm & +3 mm. +3 mm fraction directly goes for usage, -3 mm fraction can be either used directly where ever it is possible or is to be briquetted by using molasses and hydrated lime as binders.

The basic reactions in this process is as follows:

Raw Material Requirements
As in case of any process, here also quality of raw materials plays a vital role in obtaining the rated capacity and product quality. The iron ore shall have resistance for physical & thermal decrepitation and good reducibility and the coal should be of reactive nature along with the characteristics of high fusion temperature and less amount of ash.

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