High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

Upgrade your sponge iron production with our high-efficiency DRI rotary kiln. We are a leading factory with advanced technology and expert solutions.
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  • Overview
  • Product Description

Basic Info.

Model NO.
3 Years
Multi Color
After-sales Service
1300 T/Day
Production Line
We Design for You
Hongke Wet Rotary Kiln
Incline of Body
Main Motor(Kw)
Kiln with Plateau Suspension Preheater
Factory Visit
Engineers′ Guide
Worker Training
After-Sales Service Provided
Engineers Available to Service Machinery Overseas
Transport Package
Standard Export Package, Suitable for Sea Shipping
Designed on parameters
Zhengzhou, Henan, China
HS Code
Production Capacity
5 Set/Sets Per Month

Product Description

Product Description

High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln 

1.What's the DRI?


Direct reduced iron (DRI) is a type of alternative iron made by heating iron ore, mill scale pellet or concentrated iron powder so that the oxygen and carbon burns off while the temperature is kept below iron's melting point. Direct-reduced iron is also known as sponge iron and is sold as briquettes, lumps, or pellets. It is typically used in smaller scale steel mills to enhance the condition of the steel that is manufactured.


During the reduction process in the production of direct reduced iron, either coal or a special gas - commonly containing a combination of carbon monoxide and hydrogen - is used. This mixture functions as a reducing agent and facilitates the decrease in the iron's oxygen and carbon content. The result is a type of iron that is 90-97% pure, containing only minuscule amounts of carbon and other impurities.

In the modern era, direct reduced iron is considered an alternative method of making iron. The process of crafting iron via the direct-reduction route has a distinct advantage over the more traditional, blast furnace mode of production. Not only is the resulting iron more plentiful in total iron content, but it entails a much cheaper production process than the operation of a large blast furnace.
High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

2.The raw material

The raw material to produce DRI is Iron ore, mill scale, or concentrated iron powder which in Fine pellet or Lumps shape.

High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron KilnHigh Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln 

3.The chemical reactions of DRI production

The chemical reactions involved in the direct reduction of iron are the following:

With H2 (Gas Based)

3Fe2O3 + H2 → 2Fe3O4 + H2O
Fe3O4 + H2 → 3 FeO + H2O
FeO + H2 → Fe + H2O

With CO (Coal Based)

3Fe2O3 + CO →2Fe3O4 + CO
Fe3O4 + CO → 3 FeO + CO2
FeO + CO → Fe + CO2

With Solid Carbon in reaction

CO2 + C → 2CO
High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

4.Direct reduction processes

There are several processes for direct reduction of iron ore:

-- gas-based rotary kiln furnace processes 

-- coal based rotary kiln furnaces 

Generic illustrations of the types of process are shown in the graphics below.


(1) For your required concentrated iron powder process flow:

Generally speaking, the Fe content of your sample > 65%, firstly, the concentrated iron powder will be made to small pellet by pelletizer (iron powder will be mixed with Coal powder by certain ratio, please note, the coal powder function as reduction agent), and then after making pellet, and after screen, it will be conveyed into the Chain grate, which function is preheating the pellet and making the pellet more strength.

Then after preheating, the pellet will be calcined in the rotary kiln during temperature 950ºC-1100ºC, and the reduction chemical reaction will be occurred, as the above introduction, during this process, the inside of pellet will shape many small hole, which called DRI.


1. One ton raw material (Mill scale or Concentrated iron powder) should be mixed with reduction agent coal 500-600kg;

2. Heating source consumption: Coal: 220kg/t, or Gas: 140m3/t

3. Reduction coal technical require: Volatile (Vad) >30%, Ash(Ad) < 20%, C >50%, S<1%,  Moisture <10%-15%, TS+6mr >70%;

4. Lime consumption: about 120kg for desulfidation and dephophorization

5. Electricity: whole plant total power * 0.75/ day  (500tpd plant total power 1312KW), s to produce one ton DRI need about 47.23KWH electricity.

6. Final Product: TFe≥92%, MFe≥89%, M≥94% ,S≤0.02% ,P≤0.05%, C≥0.04%
High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron KilnHigh Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

Hongke DRI Plant Flow:

Concentrated Iron Powder or Mill Scale Coal based DRI production
High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

Coal based iron ore DRI plant flow as below:
High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln Product Description
Rotary kiln, also known as rotary calcination kiln, can be divided into metallurgical and chemical kilns, cement rotary kilns, lime rotary kilns, etc. according to the different processing materials.
Rotary kilns are key equipment in industries such as cement, lime, and magnesium. Based on the project's production capacity, we can help you choose different sizes of rotary kilns.

The rotary kiln is composed of a cylinder, a supporting device, a block wheel supporting device, a transmission device, a kiln head, a kiln sealing device, a coal injection burner, and other components.
In the cement industry, rotary kilns are important equipment for calcining cement clinker. In the chemical industry, rotary kilns can be used to produce soda, calcine phosphate fertilizer, barium sulfide, etc. In the non-ferrous and ferrous metal metallurgical industries, metals such as iron, aluminum, copper, zinc, tin, nickel, tungsten, chromium, etc. are smelted using rotary kilns as smelting equipment for sintering and roasting ores, concentrates, intermediates, etc.

Sponge iron rotary kiln has been widely used in the production of heating and calcination of small and medium-sized aluminum powder, metal magnesium, scouring sand, bauxite, white lime, alumina, aluminum hydroxide, cement, and various materials. Compared with previous vertical kilns and ground egg kilns, sponge iron rotary kilns have the characteristics of environmental protection, energy conservation, small labor volume, high output, and fast returns. Users can achieve production goals in a short period of time and recover investment costs. Users can also choose different specifications of sponge iron rotary kilns in terms of length, diameter, and size based on the required temperature and output of the burned materials
Sponge iron rotary kiln is mainly suitable for heating and calcining various mineral materials such as metallurgy, building materials, and ores. Heating and calcination of mineral particles and powdery materials such as sponge iron, scouring sand, bauxite, limestone, cement, white material, glass stone, metallic magnesium, alumina, aluminum hydroxide, fly ash, high alumina products, refractory materials, etc.

High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln
Features and Application

The Rotary kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its axis. The material to be processed is fed into the upper end of the cylinder. As the kiln rotates, material gradually moves down towards the lower end, and may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-current), but usually in the opposite direction (counter-current). The hot gases may be generated in an external furnace, or may be generated by a flame inside the kiln. Such a flame is projected from a burner-pipe (or "firing pipe") which acts like a large bunsen burner. The fuel for this may be gas, oil, pulverized petroleum coke or pulverized coal.

The rotary kiln has simple structure, convenient and reliable control during the production process, a few wearing parts, high operation ratio. The rotary kiln produced by our factory has rugged structure, smooth operation, high quality outlet products. Besides, we provide our customers with advanced, efficient vertical heating device, and cyclone heating device.

Efficient: Continuous production, high productivity, high fuel utilization, can effectively reduce production costs.
Energy saving: Rotary kilns can fully utilize waste gas and heat, recover energy through heat exchange and other methods, and reduce fuel consumption.
Strong adaptability: The rotary kiln can adapt to different materials, control the redox performance of the sintering process, and achieve different product quality.
Easy to operate: The rotary kiln has a simple structure, convenient operation, easy maintenance, and stable and reliable operation.
Sponge iron rotary kilns are widely used in various industries such as metallurgy, chemical industry, building refractory materials, and environmental protection. The rotary kiln consists of a cylinder, supporting device, thrust roller supporting device, transmission device, movable kiln head, kiln tail sealing device, coal dust pipe device, and the kiln body is inclined at a certain angle with the horizontal plane. The entire kiln body is supported by a roller support device, which is also equipped with a thrust roller device to control the up and down movement of the kiln body.

High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln
Working Principle

The rotary kiln is composed of barrel,  supporting device, catch wheel supporting device, transmission device,  movable kiln head,  kiln tail sealing device, and coal injection pipe device.The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about its axis. The material will be calcined in the shell after feeding at the head of the kiln. The fuel will be spurted from the kiln tail and start burning. The hot air from the end blow into the kiln directly impacting the raw materials. And then will be turned over along the direction of circle and mixing from the high-end to low-end along the axial because of the shell's slope and low speed rotation. The material will be calcined into the clinker after discomposition, calcination and cooling process. So they will discharge from the low-end.
Sponge iron ore fine material enters the inner layer of the multi-layer drum through the feeding device, achieving downstream drying. The material is continuously picked up and scattered under the cutting plate of the inner layer of the rotary kiln in a spiral motion to achieve heat exchange. The material is moved to the other end of the inner layer and enters the middle layer of the rotary kiln for countercurrent drying. The material is continuously lifted in the middle layer, using two-step and one-step walking modes. This material fully absorbs the heat emitted by the inner drum in the middle layer, as well as the heat from the middle drum of the rotary kiln, prolonging the drying time and achieving a better drying state of the material. The material travels to the other end of the intermediate layer and falls into the outer layer. The material travels in a rectangular multi loop manner inside the outer cylinder of the rotary kiln.
The material that achieves the drying effect moves quickly under the action of hot air and is discharged from the drum. Wet materials that have not reached a drying effect cannot move quickly due to their own weight. The material is fully dried in this rectangular board to achieve a drying effect and complete the drying process.

High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln High Efficiency Sponge Iron Rotary Kiln Plant Dri Direct Reduced Iron Kiln

Technical parameters of wet rotary kiln:
Specification Capacity(t/d) Incline of body(°) Speed(r/min) Main motor(kw) Remarks
Φ2.5*60 168 3.5 0.516-1.549 75 Alumyte-alumina forge kiln
Φ3*48 700 3.5 0.726-3.63 110 Kiln with 5-stage cyclone precalciner
Φ3*60 650 3.5 0.492-1.476 75 Alumyte-alumina forge kiln
Φ3*100.94 450 4 0.3-1.503 90 Multiple-drum cooling
Φ3.2*46 1000 3.5 0.36-3.57 160 kiln with preheater precalcine
Φ3.2*52 1200 3.5 0.343-0.34 125 kiln with preheater
Φ3.3*50 1300 3.5 0.676-3.38 160 kiln with plateau suspension preheater
Φ3.3*52 1300 3.5 0.266-2.66 125 kiln with preheater precalcine
Φ3.5*54 1500 3.5 0.55-3.4 220 kiln with preheater precalcine
Φ3.6*70 1800 3.5 0.25-1.25 125 Generating kiln for using ofterheat
Φ4*60 2500 3.5 0.396-3.96 315 kiln with preheater precalcine
Φ4.15*58 1050 5 0.35-0.7 110 Zinc leaching(calcine rotary kiln)
Φ4.2*60 3000 4 0.4-3.98 375 kiln with preheater precalcine
Φ4.3*60 3500 3.5 0.396-3.96 375 kiln with preheater precalcine
Φ4.5*66 4000 3.5 0.41-4.1 560 kiln with preheater precalcine
Φ4.8*74 5000 4 0.396-3.96 630 kiln with preheater precalcine
Φ5.0*74 6000 4 0.35-4 710 kiln with preheater precalcine
Φ5.6*87 8000 4 Max4.23 800 kiln with preheater precalcine
Φ6.0*95 10000 4 Max5 950*2 kiln with preheater precalcine
1. What is the raw material do you want to grind?
2. What is the capacity per hour do you need?
3. What is the raw material input size?
4. What is the output size of your product?
 1.Are you a manufacturer or a trading company?
A: We are a professional manufacturer of rotary kiln equipment and related machinery
(Rotary kiln, granulator, crusher, grinder, dryer, cooler, feeder, conveyor belt), etc.
2.What should I do if I encounter some trouble while using it?
A: We will provide English manuals and videos to show you how to solve the problem, and if necessary, we will dispatch our engineers to your factory.
3. Do you provide installation services after ordering the machine?
A: For single machines, we provide guidance and operation videos for users.
For the production line, we provide professional construction drawings and arrange engineers to guide users in installing machines. Assist users in training skilled workers.
4.Can we visit your factory and see your equipment?
A: We really warmly welcome every customer to visit our factory, and we can take them to visit the machinery factory
1. We have comprehensive technical and business consulting services;
2. Propose the most suitable solution and equipment for our customers;
3. Free CAD design: If you can provide materials, target capabilities, and factory information, we can provide you with free CAD design.
After sales service:
1. Safe and fast payment methods;
2. Assist clients in equipment foundation construction;
3. Dispatch engineers to install and debug the equipment;
4. Provide training for frontline operators on site;
5. Regularly visit customers, solve production problems, and provide lifelong service

Our engineers will suggest you the most suitable one for you according to your information. 
We will give you factory price with full specification, so pls leave us an inquiry to know more details about price, packaging shipping and discount.
Now, please click the following contact to send us email for best offer and more details !
Henan Hongke Heavy Machinery Co.,ltd


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