The document discusses the inputs and process for manufacturing sponge iron in a rotary kiln. It describes the chemical and physical composition of iron ore, coal, and dolomite that are fed into the kiln. It then outlines the rotary kiln process which involves preheating and combustion zones, use of primary and secondary air, coal injection, and rotary cooling before magnetic separation and screening to produce sponge iron and char as outputs. Waste heat is recovered to generate steam for power generation and gas is cleaned by an electrostatic precipitator before emission.

1. ALBERTUS SEPTYANTOKO
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3. IRON ORE
• Iron = 65-67 %
• SiO2 + Al2O3 = 2-3 %
• CaO + MgO = 0,5-1 %
• Sulphur = 0,02 % max
• Phosphorus = 0,04 % max
Chemical
Composition
• Size = 5-18 mm
• Shatter Index = +95 %
• Tumbler index = +88 %
• Reducibility Index = +94 %
• Thermal Degradation Index = 5
%
Physical
Composition

4. COAL
• Fixed Carbon = 45 %
• Volatile Matter = 25-30 %
• Ash = 20 %
• Moisture = 8 %
Chemical
Composition
• Size = 3-20 mm
Physical
Composition

5. DOLOMITE
• MgO = 20 %
• CaO = 28 % min
• SiO2= 5 % max
Chemical
Composition
• Size = 2-6 mm Physical
Composition

6. PRIMARY AIR
Primary air is used to combustion the injection
coal
Temperature in used below 950 C

7. SECONDARY AIR
Secondary air is introduced axially in the direction of the
gas flow
The air supplied to the length of the kiln is metered for
close control of temperature and gas atmosphere in the
kiln
Heating zone extends from 25% to 40% along length of
the kiln and in the reduction zone

8. INJECTION COAL
Coal Crushing Combustion
Injection to
kiln
Coal Injection over a large range of size 0-20 mm
Temperature combustion below 950 C
Coal injection system makes use of voal volatiles for reduction,
thereby reducing the coal requirement to a minimum
Coal Injection can decrease energy consumption

9. ROTARY KILN

10. ROTARY KILN

11. ROTARY COOLER
The product come to the water cooled
Where its temperature reaches to 80-100 C

12. ROTARY COOLER
The product is conveyed to the product separation
and storage building
The product is Sponge iron and char
Place that spraying a controlled amount of water directly
into hot solids and by spraying additional water outside the
cooler shell

13. SCREENING
+ 10 mm 3-10 mm - 3 mm

14. MAGNETIC SEPARATOR
+ 10 mm 3-10 mm - 3 mm
Mag. pulley
Mag.
separation
Mag.
separation

15. MAGNETIC SEPARATOR
+ 10 mm
3-10 mm
waste
Sponge iron
Lumps +
char
Sponge iron
Lumps +
3-10 mm magnetic + Non magnetic
char
Sponge iron
Lumps + char

16. SPONGE IRON
• Fe (T)= 91,5 % min
• Fe (M) = 85,5 % min
• Sulphur = 0,005 %
• Phosphorus = 0,7 %
Chemical
Composition
• Size = -3 to 10 mm
• Bulk density=1,7-2T/M3
Physical
Composition

17. POST COMBUSTION CHUMBER
To maintain temperature in rotary Kiln
Press particles in flame gas

18. WASTE HEAT RECOVERY BOILER
Cultivate waste heat temperature is produced of
combustion to produce steam to electricty
generation
This steam is channeled to ESP and turbine

19. ELECTRO STATIC PRECIPITATOR
Clean gas from WHRB. Gas is sent to stack
Turbine cultivate steam to electricty generation