Sponge Iron is reduced iron ore in solid state. Here, the ore is reduced using coal gas, natural gas or coal which act as reductants. As such, it is also known as Direct Reduced Iron (DRI).
The process of DRI production began in ancient times. But, because of the technical complexity, the process was not carried out at large scale. Later in 50's, sponge iron manufacturing process started with Electric Arch Furnaces (EAFs). However, the production process faced problems of the availability of quality scrap of desired quantity.
DRI process than became popular since 1957, when the first sponge iron plant was set up in Mexico. In India, the sponge iron industry entered in 1980, when the coal based DRI plant was commissioned in Andhra Pradesh.
CASE Group in India has set up India's first DRI unit using Tunnel Kiln. The Kiln measures about 194m in length and is longest in India. It was successfully fired at MTPL, Wardha.
Recently in January 2015, CASE has commissioned a gasifier for 100 TPD DRI kiln for its client Mangal Sponge & Steel Pvt Ltd at Bilaspur, Chattisgarh.
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