Iron Core

MARUTI ISPAT & ENERGY PVT.LTD, (MIEPL) Produces Superior Quality Sponge Iron under strict process and quality control systems. The Input of raw materials like Iron Ore, Pellets Ore, Metallurgical Coal and Dolomite is monitored and controlled to churn out high-grade Sponge Iron. The efficacy of our processes and the measurement of quality is conducted with a sophisticated Quality Testing Management System.




The manufacture of sponge iron entails the de-oxidization of iron ore through the direct reduction. Direct reduction is a process by which metallic iron is produced by the reduction of iron ore below the melting temperature of iron.

Iron Ore and non-coking coal are the prime raw materials for the production of sponge iron. These are charged into a rotary kiln in requisite proportion along with some dolomite which acts as a desulphurizer.

Typical raw material Specifications:

Iron Core
Fe 62
LOI 2.5
Tumbler 81
Non cooking Coal
FC 52
GCV 600
LOI 41.8
CaO 27.8
MgO 18.6
Pellets Ore
Fe 64
LOI 0.55
Tumbler 94

Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 850-1050 C. The process reduction occurs in solid-state. The crucial factor in this reduction process is the controlled combustion of coal and its conversion to carbon monoxide to remove oxygen from the iron ore.

The basic reduction reactions in a coal based DRI process is as follows:

  • C+ O2 = CO2
  • CO2 +C = 2CO
  • 3 Fe2O3 + CO = 2 Fe3O4 + CO2
  • Fe3O4 + CO = 3 FeO + CO2
  • FeO + CO = Fe + CO2

The overall production process inside the kiln requires a duration of 10-12 hours during which the iron ore is reduced and discharged to a rotary cooler for cooling below 1000C, to prevent reoxidation and effect a better separation of non-magnetic from sponge iron.

By-products from Sponge Iron Kilns are effectively put through a process of recycling meant to lessen any adverse effects on the environment. Flue gases are channeled to produce Steam and Electrical Power from Waste Heat Recovery Boilers and Steam Turbo Generators.

The quality of sponge iron is primarily ascertained by the percentage of metallic content (iron) present in the product. The properties of sponge iron typically produced at MIEPL are shown below

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

Benefits of MIEPL Sponge Iron:

  • Uniform and consistent quality
  • High degree of metallic iron
  • Lower Sulphur & phosphorus content
  • Negligible tramp element
  • High yield in SMS , during melting.
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