Optimization of sponge iron production in direct reduction plants with the KIPEX method

Due to internationally agreed commitments to reduce production and CO2 emissions in various industries, including steel and sponge iron production through various direct reduction processes such as Midrex, these processes are now being used and developed worldwide more than ever. However, the technological complexity in this area, resulting from a multitude of control parameters and the intricate cause-and-effect relationships between these parameters, means that different plants around the world produce under slightly different quantitative and qualitative conditions.This article aims to educate stakeholders that it is possible to produce sponge iron with improved quantity and quality by highlighting the successful results of leading direct reduction plants in this context. It then explains how this goal can be achieved by relying on indigenous and certified technical knowledge such as KIPEX, which is able to implement automation levels 1 and 2. The introduction of KIPEX technology in sponge iron production has led to significant improvements. The production rate increased from 115 to 125 tons per hour, with metallization increasing from 92.088% to 93.77%. The carbon content fell from 1.3% to 1.28%, and the process gas throughput was reduced from 109,500 Nm3/hour to 107,000 Nm3/hour. These improvements mean higher productivity, quality, and efficiency in the production of sponge iron.