GROUP

ROTARY HEARTH

7
FURNACE

Arini Mulia Salsabila

Arum Cahyanurani S.
Irene Angela
Muhammad Adli
 Evolution of Direct Reduction Technologies
The process available for direct reduction can be broadly categorised into
those using non-coking coal and those using natural gas and other
gases. The preference for a particular type of direct reduction technology has
come in waves at different periods of time has summarised in table below.

The genesis of Rotary Hearth Process is to

make the reduction step faster by
increasing area of contact between the
oxide and the reductant
 Principles of Heating in a Rotary Hearth Furnace
Iron ore forms an approx. thin layer on the furnace hearth
in the form of pellets or fines without any agglomeration

Bed moves slowly as CO2 and H2 works as a reductant

RHF promotes no heat transfer except radiation, makes

temperature in this process can reach at least 800C

REDUCTION STAGES IN ROTARY HEARTH FURNACE

THE EFFECT OF THICKNESS/ LAYERS ON THE Pre-heating zone Pre-reduction zone Final Reduction
PROCESS Zone
Materials gets The majority of FeO reduced to
heated to 600C iron oxide is itom
reduced to FeO
Within 15 minutes 20 minutes
Pellets (input) are made of
Very fine iron ore (under 250 micron)
Fine coal
Small quality of lime
Bentonite as binder
 RHF-Blast Furnace Combination

Most of sulfur and slag in coal remain in the output of RHF proces. Thus RHF
needs a smelting process in order to remove them.
 RHF-Smelting Furnace Combination
Cold ore needs approximately
10GJ/t-HM meanwhile hot direct
reducted iron can reduce energy
by approximately 3GJ/t-HM.This
process can reduce not only
energy consumption but also the
smelting furnace size

Direct reduction iron made by rotay heat

furnace is charged to smelting furnace
directly in order to utilize the sensitive
heat of direct reduction iron and then
smelting furnace will produce pig iron
PROCESS FLOW CHART AND
REACTIONS
 PROCESS REACTION

Oxidation of natural gas with presence of heat and

catalyst:

2CH4 + O2 -> 2CO + 4H2

Reaction between gas and iron ore, producing

sponge iron:

Fe2O3 + CO -> 2Fe + CO2 + 2H2O

PRODUCT
SPECIFICATION
Product Specification

RHF process will result in high purity iron

nuggets. Hasil akhir dari proses ini adalah iron nuggets dengan
kemurnian yang tinggi.

Iron nuggets could be utilized as a substitution

to pig iron in the use of EAF method in steel
making.
Iron nuggets sendiri dapat menjadi pengganti yang baik untuk pig iron
dalam proses pembuatan baja dengan EAF.
Product Specification
Common dimension of iron nuggets formed is ranging
from 5-25 mm with a high density of 7.4-7.6 kg/m3.
Iron Nuggets yang terbentuk biasanya memiliki ukuran sebesar 5-25 mm dengan
densitas yang tinggi yaitu sekitar (7,4-7,6 Kg/m3).

Produced nuggets will not experience oxidation, hence

could be straightly put into EAF and used for
steelmaking process.
Dan nuggets dari proses tidak akan mengalami oksidasi kembali sehingga
dapat langsung dimasukkan ke dalam EAF untuk dijadikan baja.
Product Specification
Iron nuggets are composed of:
Komposisi nuggets:
C = 2,5 - 3,0 %
P = 0,01 - 0,02 %
S = 0,05 - 0,07 %
Fe = 96,0 - 97,0 %
Product Specification
RHF process tend to be more
environmental friendly and demanding
less energy requirement.
Proses Rotary Hearth ini lebih ramah lingkungan dan
membutuhkan konsumsi energi yang lebih rendah.
 ADVANTAGES

More efficient to be used in steelmaking industry producing scrap

metal
Lower CO2 emission per ton compared to those in blast furnace use
Lower operational cost

DISADVANTAGES

RHF productivity is limited to the amount of heat transfer

Complex design is required
MIDREX PROCESS
MIDREX direct reduction ironmaking

Utilize natural gas to reduce iron ore.

Produces direct reduced iron (DRI) used as material for EAF and hot
briquette iron (HBI) used for steelmaking and rolling process.
Specification DRI HBI
Fe total (%) 90-94 90-94

Fe metallic (%) 83-89 83-89

Bulk density (t/m3) 1.6-1.9 1.6-1.9

Apparent density (t/m3) 3.4-3.6 5.0-5.5

Discharge temperature (oC) 40 80

MIDREX PROCESS
MIDREX direct reduction ironmaking
MIDREX PROCESS
MIDREX direct reduction ironmaking

GROWTH OF MIDREX CAPACITY FEEDSTOCK OPTIONS

Pellets

Lump
MIDREX PROCESS
MIDREX direct reduction ironmaking

CHARACTERISTICS OF FEED:
MIDREX PROCESS
MIDREX direct reduction ironmaking

-> MIDREX
process flow
sheet
MIDREX PROCESS
MIDREX direct reduction ironmaking
Reaction of iron reduction inside the shaft furnace is described as follows:

Fe2O3 + 3CO -> 2Fe + 3CO2

Fe2O3 + 3H2 -> 2Fe + 3H2O

While the reaction that occurs in the reformer tubes filled with nickel catalysts,
passed through by mixture of tops gas and natural gas, producing reductant gas
is described by the following reaction:

CH4 + CO2 -> 2CO + 2H2

CH4 + H2O -> CO + 3H2
2 CH4 + O2 -> 2CO + 4 H2
CO + H2O -> CO2 + H2
CH -> C + 2H
REFERENCES
RHF GROUP 7

Atsushi Masaaki, Uemura Hiroshi. Midrex Processes. Kobelco Technology

Review No. 29 (2010)
http://www.midrex.com. Monday, 13-3-2017, 15.30 P.M.
http://mmmmconferences.com/01JyunpeiKikuta_29Sept2012.pdf. Saturday, 11-3-
2017, 10.33 A.M.
http://www.tlzchina.com. Sunday, 12-3-2017, 12.32 P.M.