AFRZEN’s advanced tunnel kiln technology is arguably the most efficient and effective method for sponge iron production, enabling economically feasible plant setups.

The tunnel kiln system allows a continuous process: as some materials begin heating at one end, others are firing in the middle, while more are cooling down at the far end — resulting in seamless production flow.

AFRZEN tunnel kilns ensure:

• High production rates
• Preheating of materials
• Efficient and economical cooling
• Low energy and coal consumption

Tunnel Kiln Technology Process for Sponge Iron

• Crushing and screening of raw materials
• Mixing iron ore, coal, and limestone
• Charging the mixed materials in specific ratios into storage bins
• Automatic charging of the raw mix into SiC crucibles
• Transportation of crucibles via wagons to the tunnel kiln
• Preheating, reduction, and cooling within the kiln
• Production of sponge iron
• Crushing of the final product
• Output: Iron powder or sponge iron cold briquettes

Main Machineries in Sponge Iron Production via Tunnel Kiln Technology

• Material handling systems
• Storage equipment
• Magnetic separators
• Screening machines
• Tunnel kilns
• Burners
• Wagons
• SiC crucibles
• Charging and discharging systems
• Crushing and milling machines
• Briquetting machines
• Iron powder reduction furnace

Design Features & Operational Benefits

• Consistent, high-volume production
• High-level process control ensuring top product quality
• Low energy usage and reduced production costs
• Simple and reliable operation via computer control
• Minimal maintenance and downtime
• Streamlined storage and handling systems
• Flexibility for varied product types
• Improved firing environment due to reduced internal air movement
• Modular construction allows pre-shipment assembly
• Space-saving multi-level installation designs
• Robotic or manual car movement adaptable to plant layout
• Cost savings via reduced energy consumption
• Enhanced workforce skills
• Reduction in effluent discharge
• Lower greenhouse gas (GHG) emissions
• Overall emissions reduction