Henan Hongke Heavy Machinery Co., Ltd. has delivered a sponge iron (direct reduced iron, DRI) rotary kiln production line to a customer in Algeria. The line is designed for an annual output of 10,000 tons. This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Algeria (industrial zone, northern region)
Industry: Steel / direct reduced iron production
Algeria has a growing steel sector, supported by domestic iron ore resources and increasing demand from construction and infrastructure projects. Sponge iron—produced by direct reduction of iron ore in a rotary kiln—is a key feedstock for electric arc furnace (EAF) steelmaking, particularly where natural gas is available and scrap supply is limited.
Our customer is a steel producer in Algeria. They wanted to establish local sponge iron production using domestic iron ore and locally available reductant, to reduce dependence on imported scrap and stabilize feedstock supply for their downstream operations.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical challenges:
| Problem | Impact |
|---|---|
| Reliance on imported scrap | Volatile prices, uncertain supply, currency exposure |
| Variable iron ore quality | Local ore varied in iron content, gangue, and particle size |
| No established process parameters | Direct reduction behavior of local ore not well documented |
| Metallization target | Needed consistent metallization for EAF feedstock |
| Energy efficiency | Fuel consumption had to be competitive |
| Environmental requirements | Dust and emissions had to meet Algerian regulations |
| Capacity target | 10,000 TPY required a robust, continuous line |
The customer needed a purpose-built direct reduction line—not a modified cement kiln or a repurposed dryer.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Process discussion, not just equipment quotation
Direct reduction in a rotary kiln depends on the interaction of ore properties, reductant ratio, kiln temperature profile, residence time, and atmosphere control. We discussed these parameters in detail during technical exchange—not just dimensions and price.
b) Design based on their actual iron ore
We requested samples of the customer's iron ore and reductant, and reviewed their chemical composition, particle size, and reduction behavior before finalizing the kiln design and process parameters.
c) Complete line responsibility
We supplied the full scope: ore preparation, reductant handling, the rotary kiln, burner system, discharge cooling, dust collection, and PLC controls. The customer did not have to coordinate multiple suppliers.
d) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar kiln projects before signing.
e) Long-term support commitment
The customer wanted a supplier who would remain available for process optimization and spare parts after handover.
4. Equipment Configuration
The line is built around a rotary kiln for direct reduction of iron ore.
| Parameter | Specification |
|---|---|
| Application | Sponge iron (DRI) production |
| Design capacity | 10,000 TPY |
| Raw materials | Local iron ore + carbon reductant (coal or coke) |
| Kiln type | Rotary kiln with refractory lining |
| Operating temperature | Up to 1,100–1,200°C (reduction zone) |
| Drive system | Heavy-duty gear drive with main and auxiliary motors |
| Sealing | Labyrinth seals with air purge |
| Control | PLC-based with temperature, speed, and feed monitoring |
Scope of supply:
| System | Function |
|---|---|
| Ore preparation | Crushing, screening, mixing with reductant |
| Rotary kiln | Reduction of iron ore to sponge iron |
| Burner system | Heat input and temperature control |
| Discharge cooling | Cooling of hot sponge iron for safe handling |
| Dust collection | Cyclone + bag filter for emission compliance |
| Conveying equipment | Material transfer between process stages |
| PLC control system | Process monitoring and data logging |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Raw material testing and process design | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to Algeria | Completed |
| On-site installation | Completed |
| Commissioning and trial production | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Metallization rate | Consistent, meeting target for EAF feedstock |
| Kiln temperature control | Stable across operating zones |
| Throughput | Meets design capacity for 10,000 TPY |
| Product quality | Consistent sponge iron with target iron content |
| Dust emissions | Within regulatory limits |
| Operational stability | Continuous operation achieved |
| Fuel consumption | Within expected range for the process |
7. Customer Feedback
"The kiln has been running steadily since commissioning. It handles our local iron ore without the problems we were concerned about. Metallization is consistent, and the product meets our EAF requirements. The engineering team was responsive during installation and commissioning." — Production Manager, Algerian steel producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| Reduced scrap dependence | Stable feedstock from local ore |
| Consistent metallization | Predictable EAF performance |
| Lower feedstock cost | Local ore + local reductant vs. imported scrap |
| Environmental compliance | Meets Algerian emission requirements |
| Reliable operation | Continuous production |
| Full-scope supplier | Single point of responsibility |
9. Building Long-Term Partnerships
Our commitment to the Algerian customer does not end at handover. We continue to provide:
Technical support on process optimization for different ore sources
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for sponge iron, lime, dolomite, zinc oxide, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines.
Let's Talk About Your Sponge Iron Project
If you are planning a direct reduction line using local iron ore, we can discuss kiln sizing, process configuration, and expected metallization based on your actual material data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built for Reliability, Backed by Service