Process Engg > Tools > Sponge Iron Rotary Kiln Simulator
Sponge Iron Rotary Kiln Simulator

About the simulator

Sponge Iron Rotary Kiln Simulator is a tool based on a fundamental mathematical model for direct reduction of iron ore by coal in a rotary kiln. The model uses ore and coal properties such as particle size distribution and chemical analysis along with kiln geometry and air profile as inputs. Heat and mass balances, reactions between different phases are included in the model for predicting the gas and solid temperature and composition profiles along the length of the kiln, degree of metallization and waste gas analysis. A user friendly GUI makes it easier to use the simulator and helps train operators and equips them to derive greater productivity in kiln operations.

The measurement of kiln internal temperature profile becomes inaccurate with time due to accretion. Our simulator can act as a soft sensor to predict the inside temperatures along kiln length and help the plant operators take appropriate decisions to run the plant in an optimized manner.


With the help of the Sponge Iron Rotary Kiln Simulator, you can enhance the productivity of your manufacturing process through model-based optimization. Facilitating process control, this solution brings the following benefits:

  • Increased kiln productivity

  • Enhanced kiln campaign life

  • Improved energy efficiency by optimized coal consumption

  • Reduced raw material consumption

  • Tool for training operators


Model Validation with the operating rotary kiln temperatures