Keshav Sponge & Energy Pvt Ltd (KSEPL)
Keshav Sponge & Energy Pvt Ltd (KSEPL) is one of the leading players in production of sponge iron.
Keshav Sponge & Energy Pvt Ltd (KSEPL) a part of the group, was set up in year 1991 and has its manufacturing unit at Raigarh (Chhattisgarh). It has a capacity of 300 TPD. Manufacturing is done using the latest coal based Direct Reduction Iron method for the production of sponge iron pellets by using non-coking coal along with iron ore as well as some amount of dolomite to produce sponge iron.
An enterprising spirit and ability to discern future trends have been the driving force behind the Company’s remarkable growth. KSEPL consistently tapped new opportunities by improving its productivity by using the best quality raw materials. The Company has already increased the production capacity of sponge iron and further plans to integrate in order to produce finished steel and power.
KSEPL strives to achieve the largest sponge iron capacity earning maximum profits and customer satisfaction in an eco-friendly manner.
KSEPL foresees supplying the best quality finished steel as well as power at a minimum price to its customers.
KSEPL plans to completely integrate the sponge iron plant with an induction furnace and re-rolling mill within the next few years. The company has plans to grow in the parallel sector by setting up a power plant to utilize the waste gases and produce electricity. This would enable it to become self-sufficient in all aspects of this sector and gain carbon credits.
KSEPL has been consistent in supplying high grade spoge iron. The company, being one of the competing producer in the State, has a capacity of 90000 MT per annum across its 3 kilns.
The following is the usual analysis of our sponge iron products:
Fe total : 90-92
Fe Metallic : 81-84
Sulphur : 0.03 max
Phosphorus : 0.05 max
Carbon : 0.10 (approx)
Gangue : 5 (approx)
Lump size : +3mm
Fine size : 0-3mm
Bulk Density : 1.9-2.2 MT/m3
Thus, providing high quality sponge iron enables to produce finer quality steel in further stages.
- Iron ore fines (of varying quality from 55 to 63% Fe)
The quality of raw materials plays a major role in both output quality and the productivity of the plant. Thus, it is important to consider the physical and chemical properties of both coal and iron ore. This is taken care of the in-house laboratory of KSEPL.
Factors which determine the quality of raw materials are:
Chemical analysis: Fixed carbon, volatile matter, ash content, moisture etc.
Physical analysis: Ash fusion and reactivity temperature etc.
KSEPL has a direct supply of D-grade coal from Private and Government organizations, and also has access to regular supply of imported coal – based on company requirements and prices. Thus usage of superior quality coal improves the campaign life of the kiln and quality of the output.
Chemical analysis: Fe content, contamination, washable dust, BHQ, tumbler index etc.
The quality of sponge iron mainly depends on the quality of iron ore fed into the kiln. KSEPL has direct tie-ups with most of the mines in the area for adequate and superior quality supply.
Dolomite acts as a de-sulphurizing agent, thus removing sulphur content from the fed material. Sulphur weakens the quality of the final steel produced, as such its removal is necessary.
Raw Materials Treatment
The primary raw materials to produce sponge iron are non-coking coal and iron ore. These are fed into the rotary kiln along with dolomite to produce the sponge iron. Coal plays a dual role in the process. Firstly, it helps in reduction of iron ore to sponge iron and secondly it helps in maintaining the temperature of the kiln.
Process in brief
Firstly, the iron ore and non-coaking coal (also dolomite) are fed into the feeding yard where iron ore fines (below 5mm) are screened out and by-passed outside. The remaining material is fed into the rotary kilns where iron is obtained by reducing iron ore at a temperature around 1000 degrees C. After leaving the kilns the material is cooled using water and then passed through magnetic separators where sponge iron is separated from other impurities and gets stored in SI bunkers.
Sponge iron is of two categories – Lumps(+3mm) and Fines(-3mm) and both are stored in their respective bunkers. Dispatches are generally done directly from the bunkers in order to avoid re-oxidation of sponge iron and ensuring quicker delivery.
KSEPL produces superior & consistent quality sponge iron for its valued customers. The Company has emerged as one of the leaders among coal-based sponge iron suppliers in Eastern India, while winning compliments from its customers for consistency in supply and product quality. One of the mentors that helped the company secure customers’ confidence in us - is the brand image of SHRICON Group. Moreover, the usage of the best quality raw materials ensures the consistency in the quality of sponge iron produced and thus augmenting the trust of our clients in our group.
Our superior quality sponge iron facilitates induction furnaces and re-rolling mills to produce high quality finished steel.
The plant is situated in Raigarh, Chhattisgarh, holding a production capacity of 300 TPD (90000TPA) spread over a land of more than 30 acres. Coal based DRI process is used to produce sponge iron.