WHAT WE DELIVER

Engineering & Construction for DRI Sponge Iron Plants

Rs ASSOCIATES delivers engineering, heavy equipment manufacturing, and structural steel erection for Direct Reduced Iron (DRI / Sponge Iron) rotary kiln plants. From rotary kiln shell fabrication and cooler bodies to heavy discharge housings, waste heat recovery boilers (WHRB) ducting, and raw material handling circuits, our engineering capability covers all critical DRI plant subsystems.

We fabricate heavy-duty kiln drive supports, raw material feed towers, and high-efficiency baghouse dust collectors built to withstand 24/7 continuous thermal operation.

Key Service Deliverables & Scope

✓

Rotary Kiln Shell Fabrication & Tyre Alignment Support

✓

Rotary Cooler Bodies & Water Spray Shells

✓

WHRB Waste Heat Boiler Heavy Flue Gas Ducting

✓

Raw Material Circuit (Iron Ore, Coal & Dolomite Feeding)

✓

Intermediate Bunkers & Product Storage Silos

✓

Heavy Kiln Building Structural Steelwork

✓

Baghouse Dust Collectors & Exhaust Stacks

✓

On-Site Equipment Erection & Mechanical Commissioning

Heavy Machinery & Structural Standards

Rotary kiln shells fabricated with ultrasonic tested IS 2062 E350 steel plates, double-bevel SAW welded and shop stress-relieved.

IS 2062 E350AWS D1.1ASME IXISO 9001

🔥

Rotary Kiln Shells

Precision rolled heavy cylinder shells with internal refractory anchors.

❄️

Rotary Cooler Assembly

Water jacketed cooler bodies designed for efficient DRI quenching.

📦

Feed & Batching Systems

Weigh feeders & conveyors for precise coal, iron ore & dolomite batching.

🌪️

WHRB & Flue Gas Ducting

Heavy insulated ductwork directing hot flue gases to waste heat boilers.

🏗️

Kiln Building Framework

Heavy multi-tier structural steel towers and drive platforms.

🌿

Environmental Dust Control

Reverse pulse jet baghouses maintaining low stack emissions.

DRI TECHNICAL SPECS

Coal-Based Direct Reduction Kiln Parameters

100-500 TPD

Rotary Kiln Capacity

Dia 3.0-4.5m

Kiln Shell Diameter

>80% Met

Sponge Iron Metallization

1,050°C

Operating Temp Rating

Heavy kiln shell plate rolling, tyre & girth gear precision alignment to 0.5mm
Multi-point air injection shell fans with automated variable frequency control
High-efficiency rotary cooler and pneumatic discharge magnetic separation line

Discuss DRI Kiln Sizing & Engineering Scope

METHODOLOGY & EXECUTION

How We Deliver DRI Plants (Direct Reduced Iron)

Structured 5-stage engineering and execution methodology ensuring precision and performance.

Designing & Detail

Rotary kiln reduction calculations, thermal expansion profile, 3D plant GA & detailed mechanical shell drawings.

Plant Layout & Sizing

Kiln L/D ratio selection, load distribution & master plant GA design.

Kiln & Shell Fabrication

Heavy plate rolling, seam SAW welding & shop pre-assembly.

Site Structural Erection

Heavy crane lifting of kiln sections, structural framework & silos.

Alignment & Commissioning

Laser kiln alignment, drive mechanical trials & hot trial runs.

DRI Plants (Direct Reduced Iron)