MSVAYU

Sponge Iron

MS VAYU produces superior quality sponge iron under stringent process and quality control systems. The input of raw materials, such as iron ore, pellets, metallurgical coal, and dolomite, is meticulously monitored and controlled to ensure the production of high-grade sponge iron. Our sophisticated Quality Testing Management System ensures the efficacy of our processes and the consistent measurement of quality, resulting in exceptional sponge iron.

Advantages

Stringent Quality Control: Every stage of the production process is monitored to maintain the highest standards of quality.
High-Grade Raw Materials: Utilizes top-quality iron ore, pellets, metallurgical coal, and dolomite to produce premium sponge iron.
Advanced Testing Systems: Employs a sophisticated Quality Testing Management System to guarantee the purity and quality of the final product.
Efficient Processes: Streamlined production processes that ensure high efficiency and consistency in sponge iron production.
Industry Applications: Ideal for use in the manufacturing of steel, providing a crucial raw material for various industrial applications.
Environmental Compliance: Our production methods adhere to strict environmental standards, minimizing the impact on the environment.

MS VAYU'scommitment to excellence ensures that our sponge iron not only meets but exceeds industry standards, making it a preferred choice for customers seeking reliable and high-quality materials.

Typical raw material Specifications:

Iron Core

Fe	62
LOI	2.5
Tumbler	81

Dolomite

LOI	41.8
CaO	27.8
MgO	18.6

Pellets Ore

Fe	64
LOI	0.55
Tumbler	94

Non cooking Coal

FC	52
GCV	600

Sponge Iron Production Process

Coal plays a dual role in the sponge iron production process, acting as both a reductant and a fuel to maintain the required temperature inside the kiln, ranging from 850°C to 1050°C. The reduction process occurs in a solid state, with the controlled combustion of coal being crucial for converting it to carbon monoxide, which then removes oxygen from the iron ore.

Basic Reduction Reactions in a Coal-Based DRI Process:

1. C + O₂ → CO₂

2. CO₂ + C → 2CO

3. 3Fe₂O₃ + CO → 2Fe₃O₄ + CO₂

4. Fe₃O₄ + CO → 3FeO + CO₂

5. FeO + CO → Fe + CO₂

The entire reduction process inside the kiln takes approximately 10-12 hours, during which the iron ore is reduced and then discharged to a rotary cooler. The cooling process, which lowers the temperature below 1000°C, prevents reoxidation and facilitates better separation of non-magnetic materials from the sponge iron.

Environmental Sustainability:

By-products from the sponge iron kilns are effectively recycled to minimize environmental impact. Flue gases are utilized to produce steam and electrical power through Waste Heat Recovery Boilers and Steam Turbo Generators, contributing to a more sustainable production process.

Quality Assurance:

The quality of sponge iron is primarily determined by its metallic content, specifically the percentage of iron present in the product. The properties of sponge iron typically produced at MS VAYU include:

High metallic iron content
Low levels of impurities
Consistent and reliable performance

By adhering to stringent quality control measures and leveraging advanced production techniques, MS VAYU ensures the production of high-grade sponge iron that meets industry standards and exceeds customer expectations.

The Technical Specifications of Sponge Iron:

Constituent

Percentage

A. Physical

Size	Lump	3 mm - 22mm
	Fines	0-3 mm

B. Chemical

Fe, Metallic

82% AVG.

Metallization

92% AVG.

Sulphur

0.03%

Phosphorus

0.065% to 0.080%

Carbon

0.10% to 0.15%

Non Mag content

2.0 % Max

Sponge Iron

Sponge Iron

Advantages

Typical raw material Specifications:

Iron Core

Dolomite

Pellets Ore

Non cooking Coal

Sponge Iron Production Process

Basic Reduction Reactions in a Coal-Based DRI Process:

Environmental Sustainability:

Quality Assurance:

The Technical Specifications of Sponge Iron:

Benefits of MS VAYU Sponge Iron: