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the idea of the process of how to make sponge iron from iron ore is basically to add coal to remove oxygen from iron by adding non coking coal and to remove sulfur by adding lime stone , the iron ore and coal are crushed in crushers and screened to the recommended sizes (5mm- mm) , then mixed and heated to degrees centigrade s , the mixture is treated in rotary kiln process with air control and the rotary kiln process is7-8 hours the chemicals reaction are as follows
Fe2O3+ Co2-----2Fe+3Co2
C+O2--------CO2
C+CO2-------2CO
Fe2O3+3Co------2Fe+3Co2
3Fe2O3(hematite)------2Fe2O4(magnetite)----6Feo---6Fe(iron)
now for sulfur removal Fe O+H2s-----Fe S+ H
Fe s+ ca o+co----Fe + ca s+co2
iron ore must satisfy physical, chemical and metallurgical requirements
