FOUNDRY METALLURGY PARK WITH CONTIFUR AS A SOURCE OF

LIQUID IRON

Ram Singh, Mukesh Bhandari

Electrotherm India Ltd.
72, Palodia (Via Thaltej), Ahmedabad - 382 115
Email: ram.singh@electrotherm.com,
Mukesh.bhandari@electrotherm.com

ABSTRACT
The Continuous Induction Furnace (CONTIFUR) technology is an innovative concept developed by
Electrotherm (India) Ltd in association with Mr. Louis J Fourie, StaalTech, S.A. The technology of making
iron/steel in Contifur using DRI fines, iron ore fines, composite pellets and non coking coal fines has been
under development since more than a decade through modeling & laboratory investigations, cold and hot
model studies, experimental trials in pilot/demonstration scale plants. Pig iron with carbon in the range of
2-4% and the steel with carbon in the range of 0.04-2.0% have been produced in different trials. The
stage-wise development of the technology is presented in this paper with study on its commercial
application in foundry industry.
making using DRI fines, iron ore fines and noncoking coal, a steel making campaign was also
carried out with similar inputs in the year 2006.
Electrotherm installed another pilot scale
Contifur in the year 2008 for making pig iron in
its BF shop and carried out few campaigns of
iron making trials.

INTRODUCTION
In India there is shortage of coking coal used for
production of metallurgical coke and high grade
sized iron ore for production of pig iron through
blast furnace route. On the other hand the iron
ore fines and non-coking coals are available in
abundance. Electrotherm (ET) being an
innovative organization for developing new
processes and products thought of developing a
technology for production of iron/steel using iron
ore fines and non-coking coal in the late 90s. In
the year 2001 ET started to work on such a
concept in association with Mr. Louis Fourie
from South Africa.

The work on Govt. funded Contifur project

started in April 2011 and completed successfully
in October 2013. The project included
installation of a 100 TPD pellet plant for
production of composite pellets using iron ore
fines and non-coking coal fines in the ratio of
80:20 and a Pilot Contifur of 550kW inductor for
production
of
iron/steel
using
DRI
fines/composite pellets and non-coking coal.
The technology of making pig iron in Contifur
with use of iron ore fines and non-coking coal
has been established on pilot scale. It now
needs to be demonstrated in a semi commercial
scale plant for wider application in future. For the
mini steel plants planning to charge hot metal to
their IFs or EAFs, Contifur can become a
substitute for MBFs and in foundries it can

The first experimental unit named as

CONTIFUR was setup at Silvassa, India in the
year 2002 for production of steel using DRI
lumps/fines and non-coking coal. Subsequently
a demonstration unit was installed in the year
2004/05 at ET steel Kutch for production of pig
iron. After making a few campaigns for iron

replace Cupolas or IFs for preparing liquid iron

for casting.

PRINCIPLE
OF
WORKING
CONTIFUR TECHNOLOGY

The small foundries cannot install MBFs due to

their high capital cost. In some places away from
merchant coke plants and ports, the coke
transportation could be a problem. Never the
less, pollution is a big issue associated with
production as well as usage of coke. A
Metallurgy Park with Contifur is therefore
thought of like an infrastructure which can be put
up jointly by a few foundries to meet their
requirement of liquid iron in future.

OBJECTIVE
TECHNOLOGY

OF

CONTIFUR

To use iron ore fines(Fe> 61%) and non

coking coal fines for economic production of
Iron/Steel, there by eliminate totally, the use
of metallurgical coking coal/coke and the
graded lump ore/sinter/indurated pellets.
To make composite pellets (without heat
hardening) from iron ore fines and noncoking coal fines as a charge for Contifur.
To develop most environment friendly
technology.

OF

Each particle on charge surface is exposed

to radiation.
Radiation heat transferred to the material
helps in heating and solid state reduction of
iron oxides.
The reducing gas and the volatile matter of
coal emanating from pile are combusted by
hot air.
Material in the toe of the heap is melted by
heat energy supplied by inductor forming
liquid metal and slag (Fig-1).

Fig-1: Principle of working of Contifur

Technology

TRADITIONAL CHANNEL INDUCTION

FURNACES AND EVOLUTION OF
CONTIFUR

ADVANTAGES
PROCESS

The traditional channel induction furnaces

are deep bath, used in foundries for melting
of scrap. The drawbacks are high
temperature in channel and heavy erosion of
lining.
To overcome the drawbacks of channel
induction furnaces, the design of Contifur
with shallow bath and separation of
channels carrying hot and cold metal by
refractory material was developed.
To verify its concept of working the CFD
analysis and water model studies were
carried out.
CONTIFUR is a CONTinuous Induction
FURnace it is a trade name of Electrotherm.

OF

CONTIFUR

Low capital cost/annual ton & low operating

cost.
Low refractory consumption due to no arcing
and no violent stirring.
Ore
fines
can
be
used
without
agglomeration.
Non coking coal fines can be used without
coking.
Hot metal of required quality can be
produced for use in foundries and steel
plants.
Low CO2 emissions Carbon credits can be
earned.
Low pollution control cost.

DEVELOPMENT
TECHNOLOGY

OF

overheating of metal. Next furnace design

was changed with charging from one side.

CONTIFUR

Experimental test Contifur (2.5MW) at

Silvassa

Demonstrated the concept of steel making

using 100% low and high grade DRI with mill
scale during 2002-03. Low grade DRI of
Fe(M) 50-55%was used (Fig-2).
Furnace was operated for one month and
1000T steel was produced of C 0.06-0.10%,
S&P < 0.03.
There was problem in continuous supply of
power and synchronization of DG sets
during power failure.

Fig-3: Contifur (2MW) at ET steel Kutch

Pilot Contifur (550kW) at ET steel

Kutch

Fig-2: Contifur (2.5MW) at Silvassa

Demonstration Contifur (2MW) at

ET steel Kutch

Contifur of bigger size with charging from

two sides length wise was installed during
2005 (Fig-3).
Three campaigns were made for production
of pig iron using 100% DRI fines as well as
mix of DRI fines and iron ore fines to the
extent of 30%.
The C in hot metal was in the range of 2.84.0%, Si 0.4-0.8%, Mn <0.5%, S <0.08% &
P <0.15%.
Another campaign for production of steel
was carried out during 2006. Steel with
carbon content 0.04-1.40% was produced.
There was problem of bridging in the centre
of furnace bath due to charging from two
sides resulting in skull formation and

Single side charging with long charging

m
chute to allow max reduction in solid state
was adopted.
After installing the furnace in 2008, two
campaigns were made with continuous
melting of 100% DRI fines during 2009.
In the charging chute there was problem in
movement of material due to stickiness at
higher temperature. Hence it was removed
before second trial (Fig-4).
About 200T hot metal was produced during
each campaign of 3-4 weeks.
The carbon content in hot metal was 3-3.8%
with S&P< 0.06%.

Fig-4: Contifur (550kW) at ET steel Kutch

Grant from Govt. of India for further

development of Contifur technology

Ministry of Steel and Department of Science

& Technology, Govt. of India granted
financial assistance of INR 13.75 Crores for
further development of Contifur technology
for making iron/steel using DRI fines,
composite pellets and non-coking coal fines.

Development of composite pellets on

lab scale

Table-2
Coal % in
Composite
pellets
20
20
20
20
20
20
20
20

There were problems with respect to

movement of fine materials inside the
Contifur and also in reduction of iron ore
fines in solid state.
It is well known that composite pellets
reduce very fast and can move smoothly on
inclined surface.
Laboratory scale tests were therefore
carried out on development of binders for
producing composite pellets of adequate
strength as well as on their reduction at
higher temperatures.

Binders
(Bentonite
%)
2
2
2
2
2
2
2
2

Reduction
Temp C

Reduction
time min.

1000
1000
1200
1200
1200
1200
1200
1200

30
60
30
60
30
60
30
60

Bed
height
mm
25
25
25
25
50
50
100
100

Degree of
Metallization
%
57.78
75.52
85.54
90.73
81.51
88.36
77.82
86.74

Installation and production trials in

composite pellet plant of 5tph
capacity
Overview of composite pellet plant, dryer with
hot air generator & bag house, ball mill with bag
house, mixer with additives feeding and disc
pelletizer are given in Fig 5 to 9.

Properties of pellets with different binders are

given in Table-1.

Table-1
Binders Used
2% Bentonite
2% Bentonite,
10% Lime
5% Molasses
5% Molasses,
10% Lime
5% Dextrin
5% Dextrin,
5% Lime
4% Dextrose
1% Starch
2% Bentonite,
2% Starch

Green
drop
strength
16
12

Compressive Compressive
strength
strength
N/Pellet (Air N/Pellet (at
0
dried)
150 C)
71
118
58
96

42
34

226
145

165
121

32
23

262
135

396
209

21

78
185
149

251
166
163

Fig-5: Overview of composite pellet plant

Reduction test results: Effect of reduction time,

temp and bed height on metallization are given
in Table-2.

Fig-6: Dryer with hot air generator & bag house

Experimental trials in Pellet plant

Charge mix for making composite pellets

80% iron ore fines & 20% coal fines was
dried in dryer and ground in ball mill. 2%
bentonite & 7-8% water was added in mixer.
1-2% water was also added in disc pelletizer
during balling.
The pellets were air dried (natural curing) to
moisture level below 3%.
About 350T pellets were produced. Out of
which about 300T have been used in
Contifur trials.
Cost of production of composite pellets is
given in Table-3 below.

Fig-7: Ball mill with bag house

Table-3: Cost of production of composite pellets

S.
N.
A
1
2
3

Fig-8: Mixer with additives feeding

D

Particulars

Unit

Rate
Rs/T

Specific
cons., T

Raw material
5200
Iron ore fines
T
0.800
6200
Coal fines
T
0.200
4500
Bentonite
T
0.020
1.020
Total raw
material cost
Direct
expenses
Power
kWh 4.75
50
consumption
Stores &
Consumables
50
Diesel
Liter
0
Repair &
maintenance
Indirect
expenses
Salary/wage/
admin
expenses Rs.
20,000/d
Per MT cost of composite pellets

Cost
Rs./T of
Pellet
4160
1240
90
5490

238

0
100

200

6028

With steam curing to gain higher strength

the cost of composite pellets is expected to
increase to Rs. 6500/T.

Installation and production trials in

550kW Pilot Contifur
Fig-9: Disc pelletizer

Contifur plant facilities

Following facilities are provided;
Raw material, proportioning & feeding
Main Contifur with metal & slag handling

Hot air supply & gas handling system

Power, water & utilities supply system
Process automation & control

Raw materials analysis of Contifur and

pellet plant
Analysis of raw materials used in Contifur and
pellet plant is given from Table 4 to 9.

The Contifur process flow sheet, main Contifur

and hot blast stoves are shown in Fig-10 to12.

Table-4: Sponge iron fines

%
85-88
75-78
2.0-2.5
6.5-8.0
0.15-0.2
0.07-0.09

Fe(T)
Fe(M)
Al2O3
SiO2
C
P

Size
%
+1 mm
52-58
-1+0.3mm
26-30
-0.3+0.15 mm
10-12
-0.15+0.10 mm
2-3
-0.10+0.075 mm
1-2
-0.075 mm
2-3

Table-5: Composite pellets

Fig-10: Contifur process flow sheet

Size

Fe(T)

46-48.5

+10 mm

2-3

SiO2
Al2O3

9.5-11
2.5-3.5

-10+6 mm
-6+3 mm

45-50
40-45

CaO
MgO

0.8-1.2
0.3-0.5

-3 mm

3-5

0.07-0.08

Table-6: Coal fines

Fig-11 Main Contifur

Size

TM

6-9

+6 mm

3-8

IM

1-2.5

-6+3mm

15-22

FC

55-59

-3+1 mm

22-26

VM

25-26

-1+0.3mm

25-30

Ash

13-18

-0.3 mm

12-15

Table-7: Iron ore fines

Fig-12: Hot blast stoves

Size

Fe(T)
SiO2

60-63.5
4-6.5

+6 mm
-6+3 mm

1-5
22-25

Al2O3

1.4-2.5

-3+1 mm

18-22

CaO
MgO
P

0.3-0.8
0.2-0.35
0.05-0.06

-1+0.3 mm
-0.3+0.1 mm
-0.1 mm

8-10
20-25
22-27

Contifur during operation

Table-8: Dolomite fines

CaO
MgO
Al2O3
SiO2
LOI

Size

29-31.5
18-20
0.5-1.0
1.5-3
44-46

+3 mm
-3+2 mm
-2+1 mm
-1 mm

25-30
28-35
14-18
20-25

Priming of Contifur with liquid metal at startup,

metal tapping and slag tapping are shown in
following Fig-13 to 15;

Table-9: Limestone fines

%
CaO
48-51
MgO
1-2
Al2O3 0.8-1.5
SiO2
1.5-3
LOI
40-42

Size
+3 mm
-3+2 mm
-2+1 mm
-1 mm

%
7-10
15-20
12-16
55-60

Fig-13: Priming of Contifur

Important features of trials conducted in

Contifur during 2012
Raw material mixes and duration of trials,

100 % DRI fines with coal fines and fluxes- 8

days.
75% DRI fines and 25% composite pellets
with coal fines and fluxes- 10 days.
50% DRI fines and 50% Composite pellets
with coal fines and fluxes- 14 days.
25% DRI fines and 75% Composite pellets
with coal fines and fluxes- 9 days.
100% Composite pellets with coal fines and
fluxes- 10 days.

Fig-14: Metal tapping

Operating parameters during trials,

Hot air temp: 400 600C.

% carbon in hot metal: 2.5 4%.
Hot gas temp: 900 1200 C.
Slag basicity: 0.6 1.0.
Roof temp: 1050 - 1350C.
Fe % in composite pellets: 46 49.
Diesel oil consumption: 70 90 liters/t.
Fe Met % in sponge fines: 72 78.
Furnace pressure: (-) 5 10 mmwc.
Fig-15: Slag tapping

DRI, 75% DRI + 25% composite pellets and

50% DRI + 50% composite pellets.
Operating parameters and raw materials
were similar to the ones in 2012 trials except
that the slag basicity increased to 1.0 0.1.
Roof
temperatures
were
maintained
between 1200 1350C. The gas was
cooled to below 950C by mist cooling in the
cooling box.
Pet coke burners were used to provide an
additional energy for reduction and melting
needs of the process.
Carbon in hot metal was in the range of 2.3
to 4%.

Handling of gas, metal & slag

Most of sensible heat of hot exhaust gases

is re-circulated back in to furnace through
recuperators (stoves).
On some occasions we transferred liquid hot
metal by ladles to steel melting shop for
charging in to induction furnaces.
Most of the time liquid hot metal was cast in
to mould boxes and cold cakes thus
produced were charged into Induction
furnaces in place of cold pig iron.
Slag was also tapped in mould boxes which
after cooling was dumped and transported to
slag yard.

Observations

Hot metal analysis of 2012 trials

During 51 days trials hot metal with carbon

in the range of 2 to 4% was produced.

Modifications in Contifur to overcome

the problems

Due to change in location of air inlets and

gas outlets, the gas aerodynamics inside the
furnace was improved leading to better
degree of post combustion of CO and coal
volatiles.

The availability of furnace increased due to

reduction in down time caused earlier by
jamming of gas duct and stoves by dust in
hot gases.

Due to combined effect of all modifications,

the productivity of furnace got almost
doubled.

But the problems related to faster movement

of pellets in the charge bed continued. Due
to this reduction was not getting completed
in solid state. Reduction in liquid bath
increases the power consumption and
reduces the productivity.

It was observed that there is scope for

improving
the
following
operating
parameters.

List of modifications is given in Table-10 below,

Table-10: Modifications in Contifur
Sr.
No.
1

Problems faced
Jamming of gas duct
due to sticking of hot
dust.
Re-oxidation
of
metal due to direct
impingement of hot
air on it.
Problem in opening
of tap hole in the
side wall.
Inadequate
post
combustion of gases
inside the furnace.
More erosion in the
front wall due to
nearness of inductor
hot channels.

Modifications
implemented
Mist cooling of gas
to cool it to below
1000C.
Shifting hot air duct
from roof to front
wall at an angle of
35 towards roof.
Tap hole shifted to
front wall.
Inclined roof was
converted
into
convex
roof
to
improve gas mixing.
Inductor was shifted
by 300 mm towards
furnace centre.

Higher blast temp by providing one more

stove.

High temp gas cleaning system (at about

1200C) to avoid jamming of ducts and
stoves.

Higher degree of reduction of composite

pellets in solid state before reaching to
liquid bath.

Iron making trials conducted in 2013

th

Iron making trials were conducted from 10

st
Aug to 1 Sept 2013 (21 days) with 100%

Table-12: Projected cost of hot metal @ 16 tpd

Production cost of hot metal

S.
N.
A
1
2
3
4
5

Actual cost of production of hot metal with

80% DRI fines and 20% composite pellets
(for 11 days average production of 14.22
tpd) is given in Table-11.

Particulars

C
D

Particulars

Rate
Rs/T

Specific
Cons., T

Raw material
6000
Pellets chips
0.240
17302
DRI fines
0.959
6200
SA Coal fines
0.147
1381
Dolomite
0.100
1955
Limestone
0.095
9398
Pet coke
0.100
Total raw material
1.641
cost
Direct expenses
Power (Inductor)
6.5
kWh
625
Power (Aux) kWh
100
Total power kWh
725
Repair &
maintenance
Refractory cost
65 lacs for 1year
for 5190 MT
6500000
Indirect expenses
Salary/wages of
Rs. 504374
504374
Contractor 144010
144010
(Rs.
648384/31=Daily)
20916
Per MT cost of Contifur liquid metal

Cost
Rs/THM
1440
16593
911
138
186
940

C
D

20208

Cost
Rs/THM
13000
1240
156
154
1000
15550

5525
200

2460

1660
25395

4713
200

3X750KW CONTIFUR PROPOSAL

FOR FOUNDRY METALLURGY PARK

1252

Structure of foundry Metallurgy Park

1471
27844

Specific
Cons., T

Raw material
6500
Composite pellets
2.000
6200
Coal fines
0.200
1302
Dolomite
0.120
1920
Limestone
0.080
10000
Pet coke
0.100
Total raw material
2.500
cost
Direct expenses
Power (Inductor)
6.50
kWh
750
Power (Aux) kWh
100
Total power kWh
850
Repair &
maintenance
Refractory cost
For lining life of 6
months
Indirect expenses
Salary/wages/admin
expenses Rs.
25000/d
Per MT cost of Contifur liquid metal

Table-11: Actual cost of hot metal @ 14.22 tpd

S.
N.
A
1
2
3
4
5
6

Rate
Rs/T

Projected cost of hot metal in Contifur with

100% composite pellets for average
production of 16 tpd.

Contifur of 80 tpd hot metal production

capacity.
Composite pellet plant to feed the Contifur
160 tpd capacity.
4 5 cast iron foundries, each of 16 to 20
tpd capacity.

Capital cost of 80 tpd Contifur plant &

160 tpd Composite pellet plant

With
improvements
suggested
under
observations above as well as with improved
strength of pellets by steam curing, the reduction
is expected to be completed in solid state. This
will enable 550kW Contifur to produce on an
average 16T hot metal/day with 100%
composite pellets. The production cost in such a
Contifur will be as given in Table-12,

For hot metal production of 80tpd, a pellet plant

of 160 tpd capacity and a Contifur of 3X750kW
will be installed. This plant will be able to feed 4
to 5 foundries each of 16 to 20 tpd capacity.
About 8 to 10 t metal tapped every time will be
supplied to these foundries, 2 to 2.5 tonne to
each. The capital cost of centrally located

Contifur plant with pellet plant will be as

following,

The cost benefit of Contifur process for supply of

liquid metal to a foundry complex can be
favorable if the cost of liquid metal from Contifur
is lower than the cost of liquid metal produced
by melting of pig iron either in Cupola or in
Induction furnace. The payback period of
investment on Contifur plant will depend on the
production cost of liquid metal from Contifur.

Pellet plant of 160 tpd capacity Rs. 15

Crores.
3X750kW Contifur plant Rs. 25 Crores.
Total cost of project Rs. 40 Crores.

With single inductor (550kW) Contifur producing

16 T/Day, it would be possible to produce 80 T
hot metal/day with three inductors (3X750kW)
Contifur due to reduction in heat losses and
improvement in specific energy consumption.
Composite pellets strength will be increased by
steam curing.

The cost benefit analysis and payback period

presented in Table-14 & 15 below are based on
the current delivered price of foundry grade cold
pig iron to foundries as Rs.33,000 (Basic price +
Tax + Transportation) per tonne and the cost of
Contifur liquid metal as Rs. 21,925 per tonne.

Table-14: Cost benefit analysis of adopting

Contifur in Foundry Metallurgy Park

Projected production cost of hot metal in

Contifur of 80 tpd capacity

S.
N.

Cost
in
Rs./T
Conversion cost of melting pig iron in Cupola
1
Cost of 150 kg coke at the rate of Rs.
2,820
18,800 per tonne
2
Other cost like flux, labour, power, refractory
600
& maintenance
3
2% metal loss @ Rs. 33,000/ tonne
660
4
Total conversion cost in Cupola
4,080
Total liquid metal cost for casting in
37,080
5
Cupola
Conversion cost of melting pig iron in Induction furnace
1
Cost of power of 550 units@ Rs. 6.5 per unit
3,575
2
Other cost like refractories, labour, water &
600
maintenance
3
2% metal loss @ Rs. 33,000 per tonne
660
4
Total conversion cost in Induction furnace
4,835
Total liquid metal cost for casting in
37,835
5
Induction Furnace
Treatment cost of Contifur liquid metal in holding
furnace
1
Cost of 30 kg ferrosilicon@ Rs. 85 per kg to
2,550
increase silicon of liquid metal to 2%
2
Power cost of 80 units @ Rs. 6.5 per unit
520
3
Other cost of holding furnace like water,
200
refractories, labour & maintenance
4
Total treatment cost in holding furnace
3,270
Total liquid metal cost for casting in
25,195
5
Contifur & holding furnace

Table-13: Projected cost of hot metal @ 80 tpd

S.
N.
A
1
2
3
4
5

C
D

Particulars

Rate
Rs/T

Specific
Cons., T

Raw material
6500
Composite pellets
2.000
6200
Coal fines
0.200
1302
Dolomite
0.120
1920
Limestone
0.080
10000
Pet coke
0.100
Total raw material
2.500
cost
Direct expenses
Power (Inductor)
kWh
6.50
600
Power (Aux) kWh
100
Total power kWh
700
Repair &
maintenance
Refractory cost
For lining life of 6
months
Indirect expenses
Salary/wages/admin
expenses Rs.
30000/d
Per MT cost of Contifur liquid metal

Cost
Rs/THM
13000
1240
156
154
1000
15550

4550
200

1250

375
21925

Item Description

The benefit of using Contifur liquid metal in foundries =

Rs. 11,885 over cupola & Rs. 12,640 over IF

Cost benefit analysis of adopting

Contifur technology for supply of liquid
metal to Foundries in Metallurgy Park

10

Table-15: Payback period

Conclusion

Payback period calculation

1 Capital cost of composite
Rs. 40 Crores
pellet plant of 160 TPD and
(Approx)
Contifur of 80 TPD
2 Annual production of Contifur 26,400 tonnes
hot metal (working 330 days
in a year)
3 Annual gross profit (Rs. 11,885 Rs. 38.29 Crores
x 26,400)
4 Interest & Depreciations@ 20
% (considering project funding Rs. 8 Crores
100% by loan capital)
5 Net benefit
Rs. 30.29 Crores
6 Payback period
1.32 years

Sensitivity analysis with variation in

Contifur liquid metal cost
The sensitivity analysis is worked out for
Contifur hot metal cost of Rs. 24000, Rs. 26000
& Rs. 28000 in the Table-16 below,

Table-16 Sensitivity analysis with variation in

Contifur liquid metal cost
S.
N.
1
2

5
6

7
8

Description
Liquid metal cost of
Contifur, Rs/T
Treated metal cost
after holding
furnace, Rs/T
Liquid metal cost
from Cupola
furnace, Rs/T
Difference (Benefit)
in liquid metal cost
between Sr. No.: 2 &
3, Rs/T
Gross annual
benefit, Rs in Crores
Depreciation on debt
capital@ rate of 20
% ,Rs in Crores
Net annual benefit
(Sr. No.: 5-6=7), Rs.
in Crores
Payback period,
years

Variant
1

Variant
2

Variant
3

24,000

26,000

28,000

27,270

29,270

31,270

37,080

37,080

37,080

9,810

7,810

5,810

25.90

20.62

15.34

8.0

8.0

8.0

17.90

12.62

7.34

2.23

3.17

5.45

Electrotherm in last 12 years has

established the Contifur process with one
inductor of different capacities for production
of
cast
iron/steel
using
iron
ore
fines/composite pellets/DRI fines and non
coking coal fines.
As regards the production of liquid iron is
concerned, the process is relevant for
application in cast iron foundries as well as
in steel plants.
Contifur can replace the melting of cold pig
iron/cast iron scrap in Cupola as well as in
Induction furnaces with an economical
advantage in foundry industry.
Two foundry teams from Ahmedabad and
Rajkot area in Gujarat have visited the plant
in operation and showed interest in
considering Contifur to meet the requirement
of pig iron in foundry shops.
In steel plants, the liquid metal produced in
Contifur can be charged in electric arc and
induction furnaces as a partial replacement
of DRI/scrap for reducing the power
consumption and increasing the productivity.
The liquid metal from Contifur can also be
used for production of ductile iron pipes.

For upscaling the technology to a three

inductor
Contifur
incorporating
the
suggested modifications, ET would need
financial support and participation from the
industry/the Govt.

11