AFRZEN – Manufacturer of Advanced Rotary Kilns for Sponge Iron Production

AFRZEN is a leading manufacturer and supplier of advanced and custom-designed rotary kilns, engineered to heat solids at high temperatures with exceptional durability, efficiency, and longevity.

We provide tailored solutions for low-maintenance rotary kiln operations, ensuring high-quality sponge iron production through our deep technical expertise and industry experience.

What is Sponge Iron?

Sponge iron, also known as Direct-Reduced Iron (DRI), is produced by the direct reduction of iron ore using reducing gases derived from coal. The reducing gas, composed of hydrogen and carbon monoxide, acts as the reducing agent in the process.

Rotary Kiln Process

In the rotary kiln process:

• The material is fed into one end of the rotating kiln.
• As the kiln rotates, the material moves gradually through the tube, undergoing mixing and stirring.
• Hot gases pass through the kiln — either generated internally or from an external furnace — facilitating the reduction and heating of materials.

Advantages

• Length-to-Diameter Ratio: 14 to 16
• Specific Heat Consumption (for Clinker): 695 to 750 Kcal/Kg
• Main Drive: Variable speed drive
• Designed to operate with alternative fuels
• Advanced automation and instrumentation for optimum process control

Key Features

• Enhanced inlet and outlet sealing
• Hydraulic thruster for controlled axial movement
• Three support roller stations for stability
• Optimized for operational safety
• Adjustable throat provision
• Parallel or counter-current flow capabilities
• Optimized refractory lining for durability and efficiency
• Engineered kiln shell to prevent distortion and misalignment

Main Components

• Multiple seal options
• Machined bases
• Screw conveyor feeder
• Automatic gear lubrication system
• Exhaust gas handling equipment
• Ductwork
• Burner configurations
• Efficiency-enhancing internals: flights, dams, bed disturbers, etc.

Additional Components

• Discharge breeching
• Riding ring/tire
• Refractory lining
• Gear/sprocket guard
• Counter-current exhaust system
• Inlet chute
• Inlet breeching
• Leaf seal
• Drive base
• Drive chain
• Pinion/drive sprocket
• Pillow block bearings
• Gear reducer
• Girth sprocket
• Drive motor
• Trunnion base
• Drum shell riding ring
• Graphite block lubrication assembly
• Trunnion wheel
• Trunnion guard
• Thrust roller assembly
• Discharge chute
• Burner