Sponge Iron
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Sponge Iron
BS Group has considerable expertise in the production of sponge iron.
sponge iron has excellent quality characteristics of excellent metal content, perfect consistency in chemical and physical properties, and low sulfur and phosphorus content.
The manufacturing process also ensures that the sponge is free of dust generated during material handling..
The main sources of sponge iron are iron ore and non-coking coal.
These are put into a rotary kiln in the required ratio along with some dolomite used for desulfurization.
The coal plays a dual role in the process, acting as a reductant and as a fuel that provides heat to maintain the required temperature in the kiln between 850-1100°C.
The process reduction is done in the solid state.
The key to this reduction process is the controlled combustion of coal, converting it to carbon monoxide to remove oxygen from the iron ore.
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The entire manufacturing process in the furnace takes 10-12 hours for the iron ore to be reduced, discharged to the rotary cooler, and cooled to below 1000°C.
The manufacturing process of sponge iron is intended to remove oxygen from the iron ore.
When the same thing happens, the escaping oxygen creates micropores in the ore body, making it porous.
When viewed under a microscope, the final product resembles a honeycomb structure and appears “spongy” in texture, hence the name sponge iron.
Because the metallurgical process involves solid-state reduction, sponge iron is also called direct reduced iron (DRI).
Characteristics of sponge irons typically produced at TSLP are shown next to raw materials.
The manufacture of Sponge Iron is very sensitive to the properties of the raw materials.
It is therefore essential to examine the chemical and physical properties of raw materials, either individually or in combination.
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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 Properties :
| Elements | Sponge Iron Lumps | Sponge Iron Fines |
|---|---|---|
|
Fe (M) |
80 ± 2% |
80 ± 2% |
|
Fe (T) |
90 ± 2% |
90 ± 2% |
|
Mtz % |
88 ± 2% |
88 ± 2% |
|
P |
0.06% |
0.06% |
|
S |
0.03% |
0.04% |
|
C |
0.10-0.25% |
0.25-0.35% |
|
Non-magnetic (Char & Other Process Contaminants) |
0.8% (max.) |
1% (max.) |
|
Sio2 + Al2O3 |
6% (max.) |
6% (max.) |
|
Sio2 + Al2O3 |
6% (max.) |
6% (max.) |
|
Cao + Mgo |
1% (max.) |
1% (max.) |
|
Size(mm) |
3 to 2 |
0 – 4 mm |
