Tata Sponge Iron Ltd
Annual Report
Your Opinion
Business with Us
Social Endeavours

DRI Advantage

» More Volumetric Weight :
Considerably higher (10-100%) than other types of scraps.

» Consistent Chemical Analysis :
Avoids product quality deviations, residual element free.

» Continuous Charging :
Eliminates scrap recharging; consistant power loading during melting.

» Reduced Flicker & Noise Level :
Significant reduction in noise and flicker than that of scrap.


Reduced Nitrogen content :
Lower nitrogen level (~20 ppm) for 100% DRI.

Better Bath Stirring :
Highly effective bath stirring due to CO boiling.

Foamy Slag :
Easy Generation of foamy slag.

  Home › Products & Services › Sponge Iron

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.

The process of sponge iron manufacturing involves removal of oxygen from iron ore. When that happens, the departing oxygen causes micro pores in the ore body, turning it porous. When the eventual product is observed under a microscope, it resembles a honeycomb structure, which looks spongy in texture. Hence the name sponge iron.

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%.

Tata Sponge produces high-grade sponge iron that is consistent in quality. The Company has an annual manufacturing capacity of 390,000 tonnes of sponge iron from its 3 kilns. The production process followed at Tata Sponge makes it unique and superior than its competitors.

Various properties of sponge iron typically produced at Tata Sponge: 

Constituent Percentage

A.  Chemical

Fe, Total 90-92
Fe, Metallic 81-84
Metallisation 88-90
Sulphur 0.03 max.
Phosphorus 0.05 max.
Carbon 0.10 (approx.)
 Gangue content 5 (approx.)
B.  Physical
Size  Lump +3 mm
Fines 0-3 mm
Bulk density 1.9-2.2 MT / m3


Optimised for Google Chrome with 1024 x 768 screen resolution | Disclaimer |  Tata Sponge 2011