Lloyds Metals and Energy Limited. (LMEL) is a unit of Lloyds Group which is in the manufacturing of Sponge Iron had initially set up its first 500 TPD (Tonnes per day) kiln with the rated capacity of 1,50,000 TPA by opting OSIL-Technology in the year 1994-95 at the village-Ghugus, District-Chandrapur (Maharashtra).

Later, the unit was expanded by installing 4 x 100 TPD kilns (with Lurgi technology) in the year 2006 and achieved its production capacity of 2,70,000 TPA (Tonnes per annum). It has now become one of the biggest Sponge Iron manufacturers in Vidarbha region of Maharashtra.

The major raw materials required for production of Sponge Iron by using Rotary Kiln Process are sized iron ore and Non-coking coal. Dolomite / limestone in small quantities is also required as de-sulphurizing agent to control sulphur in the sponge iron. The details of required specification given below:

I- IRON ORE

The Technical Specifications of Iron Ore (Hematite)

A.  Physical

Size5-20 mm
Oversize< 5 % max
Undersize< 5% max
Tumbler Index - + 90
Silica< 3% Contamination - < 5%
B.  Chemical
Fe (Total)65%
Si O2 + Al2O35%
Sulphur0.01%
Phosphorous.0.62
Moisture.0.01

 

II- IRON ORE (PELLETS)

The Technical Specifications of Iron Ore (Pellets)

A.  Physical
Size5- 18 mm

(-5mm and +18mm=5.00%Max each)

B.  Chemical
Fe(T):63.5 Min (+/-0.5%)
SiO2 :4.5%Max,Al2O3: 3% Max,Guage 7.00%max
CCS:220(+/-20) Phos: 0.05 (Max)
TI:93%, MIN
Abrasion Index:6.5%Max
Porosity :25% Min,
Moisture: Dry season 1% Max & Rainy season 2% max

 

III- COAL

The Technical Specifications of Imported Coal (RB2)

A.  Physical
SizeFine0-5 mm
Lump5-50 mm
B.  Chemical
HGI45-70
NCV5200-5500 Kcl/kg
TM ARB9%-14%
IM ARB2-4%
SULPHUR ARB0.8% TO 1%
ASH ARB21%-24%
VM ARB22%

 

The Technical Specifications of Local Coal (WCL)

A.  Physical
SizeFine0-5 mm
Lump5-200 mm
B.  Chemical
GRADE% FC minGCV Kcal/kg
G-10304300
G10-G11294180
G12263700
G10-G11294180
G8G9334780
G8G10324600

 

IV- DOLOMITE

The Technical Specifications of Dolomite

A.  Physical
Size1-8 mm
B.  Chemical
Cao%30 ± 5
Mgo%18 ± 2
%sio23.0 Max
%Moisture0.62

 

The Major equipments installed are

  • Rotary Kilns
  • Rotary Cooler
  • Off gas handling system
  • Raw material handling system
  • Water Distribution system
  • Air distribution system
  • Pollution control equipments
  • Air Distribution system
  • Piping for air and water system

The Technical Specifications of Sponge Iron

Chemical Characteristics

  • Fe (metallic) = 82% avg.
  • Carbon = 0.15% to 0.25% (0.2% avg.)
  • Sulphur = 0.04% to 0.06% ( 0.055% avg.)
  • Phosphorus = 0.035% to 0.050% .
  • Gangue = 5.0 % avg.
  • (Al2O3+SiO2+MgO+CaO)

 

Physical Characteristics

  • + 20mm = 5% max.
  • -18mm to + 3mm = 70 % avg.
  • -3mm = 25% max.
  • Bulk Density: 1.80 T/ Cu.Meter

 

Advantages of DRI Plant 

  • It allows steelmaking to dilute metallic residuals in scrap
  • Since it is manufactured it has a uniform composition
  • It has a uniform size
  • DRI has low Sulphur and Phosphorus content as compared to scrap
  • DRI product has enormous potential and will be in demand subject to scrap deficit and the need to produce ultra-high purity grades.
  • DRI is produced in countries with cheap gas and iron ore raw materials