Tunnel kiln: firing sponge iron

In a significant stride toward sustainable and efficient metallurgy, our company proudly announces the full-scale deployment and commercialization of our advanced Tunnel Kiln technology for Direct Reduced Iron (DRI), commonly known as sponge iron production. This innovative solution marks a pivotal shift in the industry, offering a cleaner, more economical, and highly reliable alternative to traditional reduction methods.

Our proprietary Tunnel Kiln system is engineered to transform iron ore pellets or high-grade fines into high-quality sponge iron through a precisely controlled, continuous thermal process. Utilizing solid reductants like non-coking coal or biomass, the tunnel kiln facilitates a uniform reduction reaction in a stable, batch-consistent environment as the material moves through its temperature zones. This method eliminates the need for costly natural gas and bypasses the high emissions associated with conventional blast furnaces.

Key Advantages of Our Tunnel Kiln Sponge Iron Plant:

Enhanced Efficiency & Lower OPEX: The continuous operation and superior heat recovery design ensure optimal fuel utilization, dramatically reducing specific energy consumption per ton of DRI produced, leading to significantly lower operational costs.

Unmatched Product Consistency: The stable, controlled atmosphere within the long kiln ensures uniform metallization and consistent carbon content in every batch of sponge iron, providing steelmakers with a predictable and high-quality feedstock for Electric Arc Furnaces (EAFs).

Exceptional Economic Viability: With lower capital investment (CAPEX) compared to gas-based DRI plants and the use of widely available solid fuels, our technology offers a rapid return on investment and makes high-quality iron production accessible in regions without natural gas infrastructure.

Inherently Eco-Friendly Profile: The process is designed for lower carbon emissions and can be seamlessly integrated with biochar or renewable carbon sources, supporting the global steel industry's decarbonization goals and helping clients meet stringent environmental regulations.

The technology is now available for deployment, with scalable plant designs to meet various production targets.