Sponge Iron

Sponge iron is also known as Direct Reduced Iron (DRI). Direct reduction, is an alternative route of iron making has been developed to overcome some of the difficulties of conventional blast furnaces. DRI is successfully manufactured through either gas or coal-based technology. Iron ore is reduced in solid state at 800-1050 c either by reducing gas (H2+CO) or coal. The direct reduction process uses palletized iron or natural "lump' ore. Process Sponge iron making is a process in which iron ore lumps (typically 5mm-18mm size) are tumbled with a "select' grade of iron-coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished product bunkers prior to dispatch. The process entails a direct reduction of the iron ore (i.e. removal of oxygen from the bre) in solid state to metalize the ore at a 'critical' temperature to make this possible..