Sponge Iron (DRI)

India is the world's largest producer of sponge iron most of which is produced primarily through the coal based method of production.

The process of sponge iron manufacturing involves removal of oxygen from iron ore. When that happens, the departing oxygen causes micro pores in the ore body turning it porous. When the eventual product is observed under a microscope it resembles a honeycomb structure which looks spongy in texture. Hence the name sponge iron.

Sponge iron is an iron source relatively uniform in composition and virtually free from tramp elements. It is used increasingly in Electric Arc and Induction furnaces to dilute the contaminants present in the scrap used in these processes. It has an associated energy value in the form of combined carbon, which has a tendency to increase furnace efficiency.

Properties of Sponge Iron
  • High iron content and high degree of metallization
  • Uniform and consistent quality
  • Lower sulphur and phosphorus content
  • Negligible tramp element
  • Minimum dust generation during material handling
  • Good flow ability in bins, pipes and conveyors for continuous and trouble free charging
  • Superior technical support to induction furnace operators
Chemical Composition
SPONGE IRON
We produce Pellet Sponge Iron as per the following specifications.
Parameter Pellet Sponge
FeT 88% Max
FeM 78% Min
FeO 6-8% Max
Carbon 0.1% approx
Sulphur 0.030% Max
Phosphorus 0.080 % Max
M2 0.91
SiO2 7+/-1%
AI2O3 0.02/td>
Size: 4 - 8 MM

IRON ORE BASE SPONGE IRON
Quality of our sponge iron
Total Iron: Pellet Sponge
Metalic Iron 92-94%
Metalic Iron 80-81%
Degree of Metalization 88%
Carboim 0.10%(min)x
Sulphur Less than 0.04%x
Phosphorus less then 0.50%
Gaunge Less then 5%
Non metallic Less than 0.05%
Size 3-20 MM ( Below 3MM 5% Tolerance)/td>

Why Pellet sponge Iron?

Since the higher grade domestic lumpy Ore will be exhausted in the next 10 years. Because of these reasons value addition to the Iron Ore Fines by various processes such as Pelletisation is the need of present scenario which will be economically beneficial for the long run.

The fines are agglomerated by balling them up in the presence of moisture and suitable binders such as betonies, lime etc into 8-20 mm or larger size.

This process of agglomeration of fines is known as pelletisation.

Pellet sponge is having following advantage: