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„Current information of the company.

„Overview and Profile of the industry.
„Challenges faced by the company.
Current information of the company
„ Principal activity is to manufacture and market
Sponge iron and Crush Iron ore Lumps.
„ Sponge iron/Direct reduced iron is used to
produce Billets and Ingots which is further
processed and used in construction and
infrastructure development.
„ Major raw materials are Iron ore, Coal and
Dolomite, all of which are available in and
around the locality.
 rocess Flow Chart for Sponge Iron Unit
uaw material feeding at
ground hopper (Coal, Ore)

Coal Iron ore Lumps

Crushing Crushing
Over size Over size
Screening Screening

Coal Bin Iron ore Bin Dolomite Bin

Setting up of production of mixed raw

materials for kiln feed

Processed in rotary kiln at 1000 ȚC

 uaw Materials
¦
 

 





 rocess Flow Chart for Sponge Iron Unit
uaw material feeding at
ground hopper (Coal, Ore)

Coal Iron ore Lumps

Crushing Crushing
Over size Over size
Screening Screening

Coal Bin Iron ore Bin Dolomite Bin

Setting up of production of mixed raw

materials for kiln feed

Processed in rotary kiln at 1000 ȚC

uotary Kiln
"


Indirect cooling in rotary cooler with water

spray

Screening of mixed end product

(Sponge iron & unburnt coal )

S.I Lumps + Dolochar S.I Fines + Dolochar

Drum type magnetic separator Drum type magnetic separator

S.I Lumps Dolochar S.I Fines Dolochar

(5mm ʹ 18mm) (5mm ʹ 18mm) (below 5mm) (below 5mm)
uotary Cooler
"


Indirect cooling in rotary cooler with water

spray

Screening of mixed end product

(Sponge iron & unburnt coal )

S.I Lumps + Dolochar S.I Fines + Dolochar

Drum type magnetic separator Drum type magnetic separator

S.I Lumps Dolochar S.I Fines Dolochar

(5mm ʹ 18mm) (5mm ʹ 18mm) (below 5mm) (below 5mm)
roduct Separation System
 Sponge Iron

½
 
Iron ore Crusher
 Iron Ore

½



 Õhe composition of uI
"

 
Õotal Fe 94 ʹ 95
Metallic Fe 88 ʹ 90
Degree of Metallization 93 ʹ 95 ± 1.2
Carbon 1.0 - 1.5 ± 0.3

Sulphur 0.0005 ʹ 0.015

Phosphorous 0.02 ʹ 0.09
Silica 1.0 ʹ 2.0

„ For maximum yield, the metallic iron content should be

at the highest possible level with sulphur and
phosphorous as low as possible.
Overview and rofile of the
Industry
Ê 
  
„ cccording to one survey by joint plant committee
in 2005-06, the growth of Indian sponge iron
industry has been spectacular i.e. from a
production of only 10,000 tonnes in 1980, it
reached a level of 1.25 million tonnes in 1991-92
& 5.44 million tonnes in 2000-01 making it the 3rd
largest producer in the world that year.
"


„ Sponge iron is the raw material for units producing

long products, which indicates a greater demand for
Sponge iron by these units. It is also a substitute of
Steel scrap.
„ Õhe domestic average growth has been 21% in the last
three years while the growth rate stands at 10%.
„ India is at this point the largest producer of Sponge
iron and makes more than 111 lakh tonnes p.a.
"



 
„ Sponge iron industry plays a key role in development of
the steel sector as per national steel policy.
„ Sponge iron is substitute for steel melting scrap. Scrap
availability is getting difficult. Õherefore, steel industry
has to depend heavily on sponge industry for the
supply of metallic's in future.
Sponge Iron lants ranted
Consent
to
stablish (OC) as on
14.12.2008 in Orissa
 Challenges faced by the company
„ cvailability of high quality uaw materials.
„ High input costs.
„ High cost of Capital.
„ Slowdown of economy, resulting in Demand
recession.
„ Heavy competition by different players in the
market.
 muman uesource evelopments
¦  

„ Maintenance of peaceful relations with the workers in
order to avoid loss of any man days.


„ mphasis on safety & security of the work force in all
areas.
„ nlighten the workers on the importance of safety to
avoid accidents & develop a safe working practice
environment.
Õ