Flow Chart of Sponge Iron Rotary Kiln Production Plant

Equipment List

Equipment TypeOption (Example)Function
Storage & FeedingHopper + Belt Feeder / Weigh FeederStable feeding and batching
Raw Material PreparationScreen / Crusher (Optional)Size control and preparation
Rotary Kiln (DRI Kiln)Sentai CustomizedMain reduction unit
Burner / Heat SystemFuel-configurable (by project)Heat supply based on local conditions
Cooling SystemRotary Cooler / Controlled CoolingCooling for safe handling
Dust CollectionCyclone + Pulse Bag FilterDust capture and emission control
Induced Draft Fan & DuctingSentai CustomizedAirflow and negative pressure control
Screening & ConveyingScreen + Belt ConveyorProduct sizing and transfer
Control SystemPLC Control CabinetCentral monitoring and operation

Description

Sponge Iron Rotary Kiln Production Plant
Sentai Machinery provides a complete Sponge Iron Rotary Kiln Production Line (DRI plant solution) for converting iron ore or iron-bearing materials into sponge iron through a controlled direct-reduction process. For sponge iron projects, customers typically care most about: (1) stable metallization and product consistency, (2) reliable kiln operation under high temperature and abrasive conditions, (3) safe handling of hot material and gases, and (4) dust/emission control based on local regulations. Our solution focuses on an integrated system design: raw material preparation and batching, rotary kiln reduction, discharge and cooling, gas/dust handling, and finished product screening/handling. Key process parameters—such as feed ratio, residence time, and temperature profile—are defined in the technical proposal according to your raw material and target sponge iron specification. As a solution provider, we can support process design, equipment selection, layout guidance, installation/commissioning, and operator training. Manufacturing documentation and compliance requirements (ISO/CE-oriented) can be aligned with contract scope.

Features

1.Process Stability for Metallization Control

System design supports stable feed ratio, residence time, and temperature control—critical for consistent sponge iron quality.

2.Heavy-Duty Kiln Design for Abrasive Service

Optimized kiln shell, refractory lining options, and drive system for continuous high-temperature operation.

3. Safety-Focused Material & Gas Handling

Sealed feeding and controlled cooling reduce operational risk; safety interlocks can be configured per project.

4. Dust/Emission Management by Project Standard

Dust collection and airflow control are designed according to local requirements and customer compliance targets.

Process Workflow

Solution for crushing and sand production

Process Flow Diagram
1
Raw Material Preparation & Batching

Iron ore (lumps/pellets/fines briquettes where applicable) and reductant are prepared and batched according to process requirements.

2
Metered Feeding & Sealing

A controlled feeding system maintains stable kiln load and helps reduce air leakage for safer operation.

3
Rotary Kiln Direct Reduction

Materials travel through the rotating kiln under a controlled temperature profile to achieve direct reduction and required metallization.

4
Discharge & Cooling

Hot sponge iron is discharged and cooled in a controlled way to improve safety and downstream handling.

5
Screening & Product Handling

Sizing/screening removes fines where needed, and the product is conveyed to storage or packing.

6
Off-Gas & Dust Collection

Process gas and dust are treated through dust collection (e.g., cyclone + bag filter) and related systems based on project standards.

Note: Stcrushers can customize a set of Sponge Iron Rotary Kiln Production Plant according to customer's needs.

FAQ

A: The applicable feed depends on your ore type, size condition, and process route. Share your ore analysis and size distribution, and we will propose a suitable configuration.
A: Yes. Fuel configuration depends on local availability, cost, and compliance requirements. We confirm the burner/heat system in the technical proposal.
A: A typical configuration includes cyclone + pulse bag filter and controlled airflow/negative pressure. Additional measures can be integrated as required.
A: Please provide ore analysis, target product specification, desired capacity, available fuel options, and site constraints (area, elevation, utilities).

Customize large scale mining equipment with affordable cost

STCrushers provides high quality and reliable mining equipment customize manufacturing service for global customers, we design the production line according to the needs of the customer's processed materials and output, and realize fully automatic production from feed to discharge.

20 years of experience


We have more than 20 years of experience in the production of large mining equipment.


Professional production and R&D team

We have an experienced production line design team to meet the processing needs of different materials.

Advanced production facilities

We have two large workshops, a variety of processing equipment and machine tools.


Competitive prices


The company strives to provide customers with preferential prices and payment methods to meet customer needs.

Send an Inquiry

If you are looking for mining equipment such as stone crushers, ball mills, rotary dryer, rotary kiln and other equipment, feel free to contact us and our team will reply within 48 hours.

Do You Have Any Questions!

Gongyi City, Henan Province, China

WhatsApp Email +86 15538010601