01
Integrated Production
Produced and consumed under one roof — the DRI kiln feeds our SMS directly, ensuring consistent feedstock quality for our billet production.
Product 01 · Iron Making
SpongeIron
High-metallization sponge iron produced through solid-state reduction in our 500 TPD DRI rotary kiln. The first link in our integrated chain.
01 Product Overview
Iron Making
Sponge Iron · DRI Output · Sambalpur
The Foundation Of Every Billet We Cast
Sponge iron — also known as Direct Reduced Iron (DRI) — is produced by reducing iron ore in the solid state using coal as a reductant, without melting. The result is a high-metallization, low-impurity iron product that serves as the primary feedstock for induction-furnace-based steelmaking.
Our sponge iron is produced in a single 500 TPD rotary kiln with a design capacity of 1,50,000 TPA. Every batch is spectrometer-tested for chemical composition before it leaves the DRI section — ensuring that the quality of the iron directly controls the quality of the steel downstream.
- 0TPA
- Annual Capacity
- 0TPD
- DRI Kiln
- HighMET
- Metallization Grade
- 0%
- Spectrometer Tested
02 Product Specifications
Technical Specifications
Every parameter below is verified through in-house spectrometer testing on every batch. Full chemical analysis reports available on request.
| Parameter | Value | Test method |
|---|---|---|
| Total Fe (Metallized) | 80 – 88% | Spectrometer |
| Metallic Fe | 70 – 82% | Spectrometer |
| Metallization | 85 – 92% | Calculated |
| Carbon | 0.15 – 0.25% | Spectrometer |
| Sulphur | 0.02 – 0.04% | Spectrometer |
| Phosphorus | 0.03 – 0.06% | Spectrometer |
| Size range | 3 – 20 mm | Screening |
| Size range | 3 – 20 mm | Screening |
| Size range | 3 – 20 mm | Screening |
| Size range | 3 – 20 mm | Screening |
- 0TPA
- Annual Capacity
- 0TPD
- DRI Kiln
- HighMET
- Metallization Grade
- 0%
- Batch Tested
- LowS & P
- Impurity Control
- FullTrace
- Traceability
03 Key Features & Benefits
Why Buyers Source Our Sponge Iron
Six advantages that go beyond price — from integrated sourcing to batch-level traceability.
04 Manufacturing Process
How We Make
From Ore To Reduced Iron
A five-stage solid-state reduction process that converts iron ore into high-metallization sponge iron without melting — preserving purity and controlling composition at every step.
01/ 05
Raw Material Preparation
Iron ore (calibrated lump, 5–20mm) and non-coking coal are sized, screened, and proportioned. The charge mix is calculated per shift to target the desired Fe content and metallization in the output.
Input Stage
- Iron ore + coal + dolomite flux
- Sized to 5–20mm calibrated lump
Solid-State Reduction In DRI Kiln
The charge is fed into our 500 TPD rotary kiln (80m length, 4.5m diameter, tilted at 2–3°). At 1000–1100°C, iron ore is reduced to metallic iron by carbon monoxide generated from the coal — without melting. This solid-state process preserves the physical form of the ore while stripping out oxygen.
Core Process
- 1 × 500 TPD rotary kiln
- Temperature: 1000–1100°C
- Retention time: 8–10 hours
Cooling & Discharge
The reduced material is discharged into a water-jacketed rotary cooler and brought below 100°C in a controlled atmosphere to prevent re-oxidation before separation.
Cooling
- Water-jacketed rotary cooler
- Discharge temp < 100°C
Magnetic Separation & Screening
Product passes through magnetic separators and screens that split metallic sponge iron from non-magnetic char, then size it into lumps and fines for different end-uses.
Separation
- Magnetic separation
- Screened 3–20mm
Testing & Dispatch
Every batch is spectrometer-tested for Total Fe, metallic Fe and metallization before stockpiling. Certified product is loaded for in-house SMS use or external dispatch.
Output Stage
- Spectrometer tested
- Batch-wise certification
04 Manufacturing Process
How We Make
From Ore To Reduced Iron
A five-stage solid-state reduction process that converts iron ore into high-metallization sponge iron without melting — preserving purity and controlling composition at every step.
01/ 05
05 Quality & Safety
Zero Compromise
Tested, Traced, Accountable
Quality control at BR Steel is a system, not a check. Every batch of sponge iron passes through multiple verification stages before it enters our SMS or leaves our facility.
“Every Batch. Every Parameter. Every Dispatch. No Exceptions.”
- 01Spectrometer Chemical Composition TestingPer Batch
- 02Total Fe & Metallic Fe VerificationPer Batch
- 03Sulphur & Phosphorus ControlContinuous
- 04Size Distribution ScreeningPer Shift
- 05Batch-Wise Traceability Documentation100%
06 Applications
Where It Goes
Where Our Sponge Iron Goes
From our DRI kiln to induction furnace steelmakers, integrated plants, and foundries — our sponge iron feeds the steel value chain across India.
01
Steel Melting Shops
High-metallization sponge iron from our 500 TPD DRI rotary kiln, used in-house and supplied to top steel plants.
02
Integrated Steel Plants
Clean iron source for BOF/EAF charge mix — high purity complements scrap-based melting.
03
Foundries & Casting
High-purity iron substitute for premium casting applications requiring controlled trace elements.
03 Send an Enquiry
Built to scale
Whether you're a rolling mill sourcing billets, an EPC evaluating sponge iron supply, or an industrial buyer exploring long-term partnerships — reach out. Our sales team responds within 24 working hours.
Sales
sales@brsppl.com
Careers
hr@brsppl.com
Phone
+91 663 XXX XXXX
Hours
Mon – Sat · 9 AM – 6 PM
Business Enquiry
All fields marked with * are required. We respond within 24 working hours.