Rotary Kiln

High-quality sponge iron rotary kiln manufacturer

Sponge iron rotary kiln is a large cylindrical high-temperature equipment used to produce sponge iron. The rotary kiln manufactured by Tongli is an advanced equipment designed for efficient direct reduction of iron ore. The equipment can operate stably within the temperature range of 900°C to 1100°C to ensure that the iron ore fully reacts with the reducing gas (such as natural gas or hydrogen). Through continuous rotation and optimized slope design, the materials in the kiln are evenly heated, and the conversion rate is as high as 95% or more, which is suitable for large-scale production of sponge iron. The equipment has a sturdy structure, easy operation, and low energy consumption. It is widely used in the steel industry to help manufacture high-quality steel.

tongli heavy machinery sponge iron rotary kiln main picture

TONGLI Sponge Iron Rotary Kiln

A MACHINE YOU CAN DEPEND ON!

The sponge iron rotary kiln produced by Tongli combines advanced heat exchange technology and efficient cooling system to ensure excellent production performance and equipment durability. It is also equipped with precise gas control devices to ensure efficient and environmentally friendly production process. In addition, it uses high-strength alloy materials, which are suitable for long-term high-temperature operation.

Rapid Cooling Device

The automatic cooling system equipped at the end of the kiln can quickly reduce the roasted sponge iron raw materials from 1100°C to room temperature within 30 minutes, greatly reducing the loss of raw materials caused by long-term high temperature, and improving the recovery rate and production efficiency of raw materials.



Precision Gas Control Device

This rotary kiln is equipped with a high-precision gas control device, which can monitor and adjust the flow and composition of the reduction gas in real time. The equipment can accurately control the ratio of hydrogen and carbon monoxide to ensure the stability of the gas reduction reaction, improve the purity of sponge iron, and reduce the impurity content by about 25%.

High-Efficiency Heat Exchange System

The advanced heat exchange system equipped with the rotary kiln has a heat recovery efficiency of 90%, which can effectively recover the heat energy generated during the roasting process. The system optimizes the heat distribution of the kiln body and maximizes the utilization of heat energy, thereby reducing energy consumption and reducing production costs.

xxxxxxxCapacity (t/h)Motor Model:Gearbox ModelInput Moisture (%)Fuel Coal Calorific Value (kcal)Output Moisture (%)
φ1.2x102.5-3M160M-6 → 7.5ZQ350Ⅱ-2525±5≥5500≤13
φ1.5x147-9Y180L-6 → 15ZQ400Ⅱ-31.525±5≥5500≤13
φ1.5x189.5-12Y180L-6 → 15ZQ400Ⅱ-31.527±5≥5500≤13
φ1.8x1412-15Y200L-6 → 18.5ZQ400Ⅱ-31.525±5≥5500≤13
φ1.8x1814-18Y200L1-6 → 18.5ZQ400Ⅱ-31.527±5≥5500≤13
φ2.0x1818-22Y200L2-6 → 22ZQ50Ⅱ-31.525±5≥5500≤13
φ2.0x2018-23Y200L2-6 → 22ZQ50Ⅱ-31.530±5≥5500≤13
φ2.2x1821-25Y200L2-6 → 22ZQ65Ⅱ-31.527±5≥5500≤13
φ2.2x2022-25Y225M-6 → 30ZQ65Ⅱ-31.530±5≥5500≤13
φ2.4x2025-29Y225M-6 → 30ZQ75Ⅱ-31.527±5≥5500≤13
φ2.4x2226-30Y225M-6 → 30ZQ75Ⅱ-31.530±5≥5500≤13
φ2.6x2028-33Y250M-6 → 37ZQ85Ⅱ-31.525±5≥5500≤13
φ2.6x2429-35Y250M-6 → 37ZQ85Ⅱ-31.530±5≥5500≤13
φ3.0x2045-50Y280S-6 → 45ZQ100Ⅱ-31.525±5≥5500≤13

FAQ

1. What is the main use of sponge iron?

Sponge iron is one of the key raw materials in steel production and is mainly used to improve the quality and performance of steel. During the steelmaking process, sponge iron can effectively reduce impurities in molten steel, such as sulfur and phosphorus, thereby improving the strength and toughness of steel. According to data, using sponge iron as an additive can significantly improve the strength and toughness of steel. For example, adding 10% sponge iron can increase the tensile strength of steel by about 20% and significantly reduce the brittleness of steel.

In steel production, sponge iron’s high iron content (≥90%) makes it ideal for improving steel quality. Its high purity increases the iron content in the steel, thereby reducing the impact of other impurities. In addition, sponge iron is widely used to produce high-strength steel and special alloy steel, which have important applications in industries such as construction, automotive and machine manufacturing.

By using sponge iron, steel producers are able to create higher quality, more competitive products that meet rising industry standards.

2.How to control the gas composition in sponge iron rotary kiln?

The sponge iron rotary kiln uses an advanced gas control system to accurately manage the components of the reduction gas to ensure efficient reduction reaction and the production of high-quality sponge iron. The rotary kiln is equipped with a real-time gas analyzer that can control the oxygen content in the reducing gas within an accuracy range of ±0.5%. For example, the Φ4.0×60 meter rotary kiln accurately controls the oxygen content between 0.5% and 1.0% through a gas monitoring system to optimize the reduction reaction, prevent oxidation, and ensure the quality of sponge iron.

Rotary kilns are equipped with automated feedback adjustment devices that automatically adjust gas flow and composition based on real-time data. For example, a large rotary kiln with a diameter of 6.0×95 meters optimizes the reduction process and improves output and quality by adjusting the proportion of hydrogen and carbon monoxide in the reduction gas. The efficient gas control system not only improves production efficiency, but also reduces exhaust emissions and energy consumption, complying with environmental protection standards

3. How often does a sponge iron rotary kiln need to be maintained?

The sponge iron rotary kiln will experience a certain degree of wear and fatigue due to high temperature and high load operation during the production process. Therefore, regular maintenance is essential to ensure the long-term stable operation of the equipment. It is usually recommended to conduct a comprehensive inspection and maintenance every 6 months to ensure the normal working condition of the equipment.

Maintenance work includes the following key aspects: Inspection and replacement of refractory materials: The refractory materials of the rotary kiln will gradually wear and deteriorate in high temperature environments. The condition of the refractory materials needs to be checked every 6 months and replaced as necessary. Damage to refractory bricks and linings can affect thermal efficiency and safety. For example, when the thickness of refractory bricks decreases by more than 25mm, they need to be replaced in time.

Mechanical component overhaul: including inspection and maintenance of the kiln's drive system, gears, bearings and sealing devices. Regularly check the lubrication of the gears to ensure the quality and quantity of lubricating oil to prevent excessive wear and failure of mechanical components.
Cleaning and calibration: Clean the inside of the rotary kiln from dust and scale, especially the gas exhaust system and heat exchanger. Calibrate temperature sensors and pressure sensors regularly to ensure the accuracy of temperature and pressure control systems.

Exhaust gas treatment system maintenance: Check the exhaust gas treatment system, including dust collectors and desulfurization devices, to ensure their normal operation. Clean filters and inspect pipes regularly to avoid production problems caused by blockages.

4. How to test the quality of sponge iron?

The quality testing of sponge iron is mainly carried out through the following aspects:
Chemical composition analysis: The main component of sponge iron is iron, and the content should be ≥90%. Through spectral analysis and chemical titration methods, iron content and impurities such as sulfur (≤0.1%) and phosphorus (≤0.1%) are detected to ensure compliance with standards
Physical property testing: including density, strength and porosity. The density of sponge iron is usually 4.0-5.0 g/cm³, the crushing strength should be greater than 50 MPa, and the porosity should be in the range of 30%-40% to optimize reduction efficiency.

Reduction rate test: To measure the reducing performance of sponge iron, its reduction rate is generally about 90%. Its reduction efficiency is evaluated through laboratory testing to ensure effectiveness.

Antioxidant capacity test: Test the oxidation rate of sponge iron in oxygen. The oxidation loss of high-quality sponge iron should be controlled within 1% to avoid excessive oxidation during the production process.

Standardized testing: Test according to standards such as ISO 10930 or ASTM E14 to ensure the accuracy and reliability of test results.

5. What are the main raw materials of sponge iron rotary kiln?


Sponge iron rotary kiln mainly uses iron ore as raw material to perform reduction reaction to generate sponge iron. There are many types of iron ore, but the most commonly used are hematite and magnetite. The main component of hematite is iron oxide (Fe2O3), and its iron content is generally between 60% and 70%. Magnetite contains a higher proportion of iron, usually between 70% and 75%, and is suitable for sponge iron production.

In the operation of rotary kiln, the particle size of iron ore is one of the key factors. Usually, the particle size of the ore ranges from 50mm to 210mm to ensure the full progress of the reduction reaction. Taking the Φ4.0×60 meter rotary kiln as an example, it can process about 2,500 tons of raw materials, including iron ore of various specifications.

By precisely controlling the particle size of the ore, the rotary kiln can effectively improve the output and quality of sponge iron. Different specifications of raw materials can adapt to the processing requirements of the rotary kiln, while ensuring the stable quality of each batch of sponge iron

6. How to improve the reduction efficiency of sponge iron?

Improving the reduction efficiency of sponge iron can be achieved by optimizing the operating parameters and raw material selection of the rotary kiln. First of all, precise control of the temperature in the rotary kiln is key, and the optimal reduction temperature is usually between 900°C and 1100°C. Within this temperature range, iron ore reacts with reducing gases such as hydrogen or carbon monoxide to produce high-quality sponge iron.

Secondly, it is also crucial to control the composition and flow rate of reducing gas. For example, an increase in hydrogen concentration helps to speed up the reduction reaction, thereby improving the reduction efficiency. It can also control the oxygen content to prevent the re-oxidation of the ore and ensure the smooth progress of the reduction reaction. In addition, selecting the appropriate iron ore type and particle size is also a key factor in improving reduction efficiency. Using hematite or magnetite with high iron content can effectively improve the yield and quality of sponge iron.

Finally, regular maintenance of the operating equipment of the rotary kiln to ensure its stability and thermal efficiency will also help improve reduction efficiency.

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APPLICATION

Iron Ore Pellets

Iron Ore Pellets

Efficient reduction of iron ore pellets to produce sponge iron.

Coke

Coke

Used as a reducing agent in the rotary kiln for producing sponge iron.

Limestone

Limestone

Serves as a fluxing agent, aiding in the removal of impurities from iron ore.

Charcoal

Charcoal

An alternative fuel source for sponge iron production, reducing carbon footprint.

Bauxite

Bauxite

Can be processed in a rotary kiln to extract aluminum from its ore.

Coal

Coal

A key fuel source for the high-temperature process of sponge iron production.

Zinc Ore

Zinc Ore

Zinc extraction in rotary kilns, commonly used in metallurgy processes.

Phosphate Rock

Phosphate Rock

Applied in rotary kilns for producing phosphoric acid or fertilizer products.

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