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| Direct Reduced Iron (DRI) Plant (Sponge Iron) |
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In September 1994, Ispat Industries commissioned the world's largest gas based, single mega-module plant for making sponge iron/direct reduced iron (DRI), in the state of Maharashtra, India. This plant is one of the most efficient Sponge Iron plants in the world and has been certified for ISO 9002 (1994) and ISO 14001 (1996).
The plant's Midrex "Megamod" series 1000 module is the latest and most advanced in the world, engineered by the Midrex Corporation, USA, who are the world leaders in sponge iron direct reduction technology.
The plant has a rated capacity of 1.6 million tonnes per annum, but it has consistently operated over this capacity to achieve a capacity utilisation of 120 per cent. And while it was designed for a capacity of 133 tonnes per hour, it has set the benchmark of 160 tonnes per hour, with an average power consumption of 85 KW/MT as against the prescribed 125 KW/MT.
Armed with the latest in technology, the plant has the flexibility of using indigenous 100 per cent iron ore lumps or any mix of lump ore and pellets. With the best operating equipment and a fully computerised process control, it delivers high quality feed for steel-making. Today, it is the only plant in the world that uses lump ore in excess of 60 per cent in its feed mix, which helps reduce the cost of production.
Moreover, where the prescribed average natural gas consumption is 2.6 Gcal/MT, the sponge iron plant has achieved 2.3 Gcal/MT. Also, as against the prescribed average metallisation of 92 per cent, the plant has already touched 95 per cent.
Several technological enhancements have been responsible for boosting productivity and lowering costs. These include the induction of an automated Lime Coating System for high temperature operation and an Oxygen Injection System to increase the bustle gas temperature. |
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