Sponge Iron Manufacturer in India

India is the largest producer of sponge iron in the world with a host of coal-based units located in the mineral-rich states of the country. Sponge iron is produced primarily through the coal-based method of production. Sponge iron is also known as Direct Reduced Iron (DRI) and is widely used in the steel industry as a primary raw material in induction and electric arc furnaces. Over the years sponge iron, a significant raw material for producing high-quality steel.

Sponge iron or DRI is produced from the direct reduction of iron ore to metallic iron in the form of lumps, pellets or fines. Sponge iron is a metallic product with consistent chemical and physical characteristics. Iron ore pellet is used for reduction and after reduction, the product resembles a sponge for the pores left behind after removal of oxygen. That’s why it is called sponge iron. The process of manufacturing sponge iron aims to remove the oxygen from iron ore. At Shakambhari, we use both iron ore (4-25mm) and pellet (round balls shaped of 5-18mm) as feed material for producing high-quality sponge iron. We have an integrated steel plant where sponge pellets are mostly produced for captive consumption at our Steel Melting Division. We produce high graded sponge pellets with low Sulphur content that are mainly used for manufacturing high-quality QST bars and Wire rods.

  • Application Areas
  • USP

TMT Bar Application Areas

Different projects call for different types of TMT bars depending on the compositional strength, dimensions and features. Available in multiple variations, Elegant QST bars are used by reputed construction and developer firms across residential, commercial, industrial as well as infrastructure sectors. Given their ability to provide optimum strength, safety and durability to the structure, TMT bars are used for critical civil construction purposes such as power plants, dams, long-span bridges & flyovers, roads & highways, underground structures & underwater or marine structures, oil refineries and so on which are produced by TMT bar manufacturers in Kolkata. Apart from these, QST bars are also used in high-rise buildings, malls, schools, airports, hospitals and other large structures.

QST bars are extremely important and often used in earthquake-prone areas since their high bendability/elongation property can protect the structure from being uprooted. Elegant TMT bars are the perfect choice for corrosion-prone areas as the tough outer layer prevents rust, which is often responsible for causing cracks in the structure. Be it a residential building, hospital or any other construction – no structure can skip the risk of being exposed to fire. Being fire-resistant with high heat-withstanding capacity with Reinforcement Steel, Elegant QST bars can be used for all types of construction purposes.

Sponge Iron USP

  • High Fe content & high degree of metallization, consistent chemical composition, negligible tramp element, good flowability in bins and conveyors for continuous and trouble-free charging – all these factors contribute to the excellent quality of steelmaking at Shakambhari.
  • We maintain stringent quality checks to produce quality iron pellets. Standard chemical composition maintained throughout the process lowers the consumption of raw materials and eventually leads to reduced production costs.
  • We use raw materials such as iron ore pellets, iron ore along with coal, which acts as a reducing agent and dolomite, which is used to remove the sulphur content from Iron. Low sulphur substance enhances the toughness and ductility of steel. Hence, the optimum quality of the raw material is maintained.
  • The sponge pellets produced in our DRI unit are mainly used for captive consumption to produce high-quality crude steel which is converted to construction steel QST bars & Wire Rods.
  • Shakambhari group has an annual manufacturing capacity of 800,000 tonnes of sponge iron from its 16 DRI kilns. The production process and quality checks we follow make our products unique and superior to our competitors.

Manufacturing Process

QST or TMT stands for Quenched and Self-Tempered steel rebars fabricated by a quick cooling process called quenching and self-reheating of hot-rolled steel bars. The manufacturing process of Elegant QST bars usually involves 3 essential steps –

  • Quenching
  • Self-tempering
  • Atmospheric cooling

The Process

  1. The raw materials such as iron ore, coal, dolomite etc. are piled, recovered and mixed in required proportion and converted into metallic iron.
  2. The primary construction steel making process begins with the conversion of metallic iron to crude steel through electric heating and refining and after refined steel is brought to the continuous casting machine to solidify into rectangular cuboid called billets/blooms.
  3. Hot billets are rolled through thermomechanical treatment in fully automatic rolling mill, processed through quenching and self-tempering system and finally, rested for atmospheric cooling to produce the world class quality QST bars.
  4. The stringent quality checks are carried out through in line production and final products are tested for chemical, mechanical and physical properties. Batch identification is attached to each lot.

From procurement of the raw material to the manufacturing of TMT bars and dispatch of the final product, the entire process takes place in our integrated steel plant, which allows us to produce the best quality TMT bars.

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