Major Problems faced by Sponge Iron Manufacturers
Iron Ore with 63% Fe content if available fluctuates highly in terms of cost, irrespective of its production cost.
Availability of Coal from the Government controlled Mines contains high level of ASH or else FC content is low.
Low metallization of DRI is available in the market, resulting from POOR QUALITY of Iron ore, which ends up affecting the yield of liquid steel production.
High Ash content in coal and contamination in Iron ore results in ACCRESION and low CAMPAIGN life of the kiln.
The quantity of FINES generated in the Product during the processing (25% to 45%) affects the profit margins especially in the South.
High volumes of Ash and Coal Char generated everyday is becoming a THREAT to the Environment. And COST of waste disposal remains high.
High degree of FLUCTUATION in the prices of the finished product is also a worry.
How Iron Ore Pellets Compare Better with Iron Ore Lumps
Very High Tumbling Index (about +95).
No Disintegration during handling.
High Crushing Strength.
Low Abrasion Index compared to Lumps.
Uniform in size and Shape (+9mm to 15mm).
High Compressive strength.
Good Porosity resulting High Metallization of Sponge Iron.
Cannot be contaminated during transportation.
Advantages of Using Iron Ore Pellet
There will be no losses in transportation and handling.
The same Rotary Kiln can produce 25% more DRI without any changes in Principle Design.
Specific consumption of coal will come down by 10 to 20%.
Campaign life of Kiln will increase to almost 60%.
The Refractory repairing cost will reduce to 50%.
Metallization will be better compared to Lump Ore as the Porosity of the Pellets are very High.
There will be 5% fines in the finished product instead of 25 to 30% in case of lump ore as the Thermal Cracking(Spalling) is very low in the Pellets, due to the already done thermal treatment during Pelletization.
Raw material handling system can be simplified and cost of electricity and maintenance will be reduced by 25%.
- Finally the environment will get much better to work in.
