Sponge Iron
India is the world's largest producer of Sponge Iron, most of which is produced primarily through the coal based method of production. Growth in the sponge iron production can be attributed largely to the popularity of secondary steelmaking route, which has shown a phenomenal growth in India. The proportion of crude steel produced by the secondary steel sector rose from 26 mMT(37%) in 1999-2k to 54 mMT(59%) in 2007-08. This has been mainly due to the lower investment cost of the EAF as compared with the integrated blast furnace--oxygen converter route and also because of its greater flexibility of product mix.

Sponge iron is an iron source relatively uniform in composition, and virtually free from tramp elements. It is used increasingly in Electric Arc and Induction furnaces to dilute the contaminants present in the scrap used in these processes. It has an associated energy value in the form of combined carbon, which has a tendency to increase furnace efficiency. For captive DRI production facilities, there is an added advantage that the delivery of hot DRI to the furnace can reduce energy consumption to 16 - 20%.

Shree Ganesh Metaliks Ltd. & Maa Mangla Ispat Pvt Ltd. Have a combined capacity of producing 200,000 TPA of superior grade Sponge Iron.
Standard Chemical Composition of Sponge Iron produced:
Constituent Sponge Iron Lumps Sponge Iron Fines
Fe (M) 80+/-1% 81+/-1%
Fe (T) 90-92% 90-92%
Metallization 88+/-1% 89+/-1%
P 0.05% max 0.05% max
S 0.03% max 0.03% max
C 0.1% max 0.15% max
(Char & Other Process Contaminants) 1% max 2% max
SiO2+Al2O3+other gangue materials 6% max 6% max
Constituent Sponge Iron Lumps Sponge Iron Fines
Sponge Iron Size (mm) 3-20 mm 3 mm
Bulk Density (gm/cc) 1.8-2.1 MT/m 1.8-2.1 MT/m