Production Unit Micro-Machinery

Rotary Reduction Kiln

Raw Material Silos

Raw and Additive Material Charging Systems

Fuel Supply Systems for the Rotary Kiln

Air Supply Systems for the Rotary Kiln

Rotary Cooling Kiln

Magnetic Product Separating Devices

Electrical and Instrumentation Systems

Product Transfer Systems to Warehouse and for Loading

Hydraulic Systems

Compressed Air Systems

Cooling Water Supply Systems

Control and Command Rooms

Internal Power Transformers

Sponge iron is a high-grade source for making iron and steel. It is obtained by recycling natural or processed iron ore without reaching the melting point. In this method, iron ore pellets with an iron content of 67% are reduced, and the result is sponge iron (porous pellets) with an iron metallization of about 92%. The product from the reduction unit, without passing through the cooling section in the furnace and at a temperature of about 600°C, is transferred by a special material handling system to the steelmaking section for direct charging into the furnace.

After melting and reduction in steelmaking, sponge iron is formed into the required products in the casting process and is used in three forms: slab, billet, and rebar. Today, about 5% of the world’s steel is produced from sponge iron (DRI), and this trend is increasing.

Applications of Sponge Iron

The use of sponge iron in induction furnaces is one of its most important applications. It can be said that the use of sponge iron in induction furnaces can replace nearly 50% of scrap metal. However, its use in an induction furnace requires technical knowledge and experience. Furthermore, the use of sponge iron is a great revolution in the continuous casting of the steel industry.

It is possible to use it in almost all steel production methods. Many small and large steel production units in the country use this method. Iran has accessible natural resources for direct reduction. Sponge iron is a suitable alternative to iron scrap. Therefore, we can supply a high percentage of the raw materials needed for the melt in steelmaking units through sponge iron instead of using scrap.

Direct reduction of iron ore is done through gas or coal resources. The choice of the direct reduction method for iron ore depends on the location of the production plant and the available resources. For example, in Iran, with its rich gas resources, choosing gas is a more reasonable option, and gas is used as the reducing agent. As you know, the use of coal resources for reduction also leads to air pollution problems, and access to its mines is not easy. However, currently, the world’s largest producer of sponge iron is India, which uses coal resources.

Types of Briquettes:

Hot Briquetted Iron (HBI)

Sponge Iron Fines Briquette

Cold Briquetted Iron (CBI)

Hot Briquetted Iron (HBI) is a product manufactured in the briquetting process from hot DRI at a temperature of over 650°C. This type of briquette is considered the most well-known product for easy and safe transport globally.

However, in the cold briquetting process, the input materials enter the briquetting machine at ambient temperature. In this process, depending on the type of material entering the machine, two types of products are known: sponge iron fines briquette and cold briquetted iron.

Sponge Iron Production Process

Two methods using gas and coal resources:

Gas Resources:

Midrex Method

HYL

Coal Resources:

SL/RN

Jindal

DRC

Sponge Iron Production by the Midrex Method

This method is one of the most widely used production methods in Iran and the world. In this method, natural gas enters a gas reforming unit, then, under heat and with special catalysts, it is converted into hydrogen and carbon.

This hydrogen and carbon then enter a furnace called the reduction kiln, where we have heated the iron ore pellets. It combines with the oxygen in the iron ore pellets, causing the iron ore to be reduced. This method is known as the least-consuming and most-visited method in Iran and the world. About 80% of Iran’s sponge iron is produced by this method. After that is the HYL method, but its high electricity consumption and capacity issues are a problem. Therefore, the HYL method and methods based on coal are not used in Iran.

Sponge Iron Sales

The sale of this product in the country is carried out by various reputable companies.