Agarwal Group of Industries
Agarwal Sponge & Energy Pvt. Ltd.,
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Manufacturing Details

Raw Materials
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 in the in-house laboratory of ASEPL.

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.

ASEPL has a direct supply of D-grade coal from Singareni Coal Collieries limited, a government organization, and also has access to regular supply of imported South African as well as Indonesian coal – based on company requirements and prices. Thus usage of such superior quality coal improves the campaign life of the kiln and quality of the output.

Iron Ore
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. ASEPL has direct tie-ups with most of the mines in Bellary and Hospet 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, thus its removal is necessary.
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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. 

Brief Process
Firstly iron ore and non-coaking coal(also dolomite) is 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 separated from other impurities and gets stored in SI bunkers.

Sponge iron are 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.
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ASEPL produces superior & consistent quality sponge iron for its all valued customers. The Company has emerged as one of the leaders among coal-based sponge iron suppliers in Southern India, while winning customer compliments for consistency in supply and product quality. One of the maintors that helped the company secure customers’ confidence in us - is the brand image of Agarwal Group. Moreover, the usage of the best quality raw materials (I.E. South African coal along with high grade iron ore) ensures the consistency in the quality of sponge iron produced and thus augmenting the trust of our clients for our group.

Our superior quality sponge iron facilitates induction furnaces and re-rolling mills to produce high quality finished steel. Thus, building up the confidence for our group in our customers.

The plant is situated in Bellary, Karnataka holding a production capacity of 350 TPD (90000TPA) spread over a land of more than 40 acres. Coal based DRI process is used to produce sponge iron.

Detailed facilities at works comprise:

Administration Block

Core facilities
2 * 100 TPD kiln
1 * 150 TPD Kiln

Pollution control equipments (supporting entire 350 TPD)
FD Cooler
Wet Scrubbers
Intermediate Bins
Storage yards for raw-materials and sponge iron

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