Review of DRI factory (Iran)

Review of DRI factory (Iran)

Review and audit of a DRI plant using SL / RN technology

At the invitation of the customer, the specialists of SPA RAKURS LLC together with Ukrasa Energy LLC and Nikoprogresstroy LLC performed a review and audit of the DRI production plant using SL/RN technology on December 6-7, 2019. The factory is located in Iran.

The structure of the plant includes:

  1. Complex for the production of DRI;
  2. Smelting complex.
+Complex for the production of DRI
Complex for the production of DRI
+Smelting complex
Smelting complex

The DRI production complex includes:

1.   Warehouse of raw iron ore;

2.   Warehouse of coal;

3.   The site of crushing and sorting of iron ore;

4.   The site of crushing and sorting of coal;

5.   The site of charge preparation;


6.   Firing area (tube furnace);

7.   DRI sorting section;

8.   Magnetic separation section;

9.   Shipment of finished products.

+Warehouse of raw iron ore
1 - Warehouse of raw iron ore
+Warehouse of coal
2 - Warehouse of coal
+The site of crushing and sorting of coal
4 - The site of crushing and sorting of coal
+The site of charge preparation
5 - The site of charge preparation
+Firing area (tube furnace)
6 - Firing area (tube furnace)
+The site of sorting and magnetic separation DRI
7,8 - The site of sorting and magnetic separation DRI


According to the design documentation, the feedstock is:

  • Oxidized iron ore pellet with Fetotal>62%;
  • Steam coal;
  • Limestone.

At the moment, the plant uses oxidized iron ore Fetotal=56-59% (with a gross rock basicity of 0.7-0.9), steam coal and limestone.

Actual data on the operation of the complex to obtain DRI

During the familiarization work and communication with the technical staff of the factory, our specialists determined the following:

  • The DRI production complex operates on raw materials that are significantly different (for the worse) in terms of characteristics from the design;
  • Oxidized iron ore is used with a content of Fetotal=56-59% with a gross rock basicity of 0.7-0.9 (up to 0.5 permissible), which leads to high crust formation in the furnace;
  • The furnace loading with iron ore raw materials is 50% of the design (13 t/h), which leads to a significant increase in costs to maintain the required temperature regime of the furnace;
  • The furnace burner operates on ground coal;
  • Specific heat consumption through the shell of the tube furnace and with flue gases increased in comparison with the design 1.5-2 times;
  • The presence of small things of -5 + 0 mm in the finished product reduces the specific productivity of the tube furnace for a suitable product;
  • The use of hematite ore with an iron content of less than 55.0% as an iron ore raw material is not economically feasible due to the high slag yield at the metallurgical conversion in an induction furnace;

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"SPA "RAKURS" LLC was established in 2015 by the chief project engineers and department heads of "SRDI "Mekhanobrchormet" PJSC