Lloyds Metals and Energy Limited. (LMEL) is a unit of Lloyds Group which is in the manufacturing of Sponge Iron had initially set up its first 500 TPD (Tonnes per day) kiln with the rated capacity of 1,50,000 TPA by opting OSIL-Technology in the year 1994-95 at the village-Ghugus, District-Chandrapur (Maharashtra).

Later, the unit was expanded by installing 4 x 100 TPD kilns (with Lurgi technology) in the year 2006 and achieved its production capacity of 2,70,000 TPA (Tonnes per annum). It has now become one of the biggest Sponge Iron manufacturers in Vidarbha region of Maharashtra.

The major raw materials required for production of Sponge Iron by using Rotary Kiln Process are sized iron ore and Non-coking coal. Dolomite / limestone in small quantities is also required as de-sulphurizing agent to control sulphur in the sponge iron. The details of required specification given below:

I- IRON ORE

The Technical Specifications of Iron Ore (Hematite)

A.  Physical

Size 5-20 mm
Oversize < 5 % max
Undersize < 5% max
Tumbler Index  - + 90
Silica < 3% Contamination - < 5%
B.  Chemical
Fe (Total) 65%
Si O2 + Al2O3 5%
Sulphur 0.01%
Phosphorous. 0.62
Moisture. 0.01

 

II- IRON ORE (PELLETS)

The Technical Specifications of Iron Ore (Pellets)

A.  Physical
Size 5- 18 mm

(-5mm and +18mm=5.00%Max each)

B.  Chemical
Fe(T): 63.5 Min (+/-0.5%)
SiO2 : 4.5%Max,Al2O3: 3% Max,Guage 7.00%max
CCS: 220(+/-20) Phos: 0.05 (Max)
TI: 93%, MIN
Abrasion Index :6.5%Max
Porosity : 25% Min,
Moisture : Dry season 1% Max & Rainy season 2% max

 

III- COAL

The Technical Specifications of Imported Coal (RB2)

A.  Physical
Size Fine 0-5 mm
Lump 5-50 mm
B.  Chemical
HGI 45-70
NCV 5200-5500 Kcl/kg
TM ARB 9%-14%
IM ARB 2-4%
SULPHUR ARB 0.8% TO 1%
ASH ARB 21%-24%
VM ARB 22%

The Technical Specifications of Local Coal (WCL)

A.  Physical
Size Fine 0-5 mm
Lump 5-200 mm
B.  Chemical
GRADE % FC min GCV Kcal/kg
G-10 30 4300
G10-G11 29 4180
G12 26 3700
G10-G11 29 4180
G8G9 33 4780
G8G10 32 4600

 

IV- DOLOMITE

The Technical Specifications of Dolomite

A.  Physical
Size 1-8 mm
B.  Chemical
Cao% 30 ± 5
Mgo% 18 ± 2
%sio2 3.0 Max
%Moisture 0.62

 

The Major equipments installed are

  • Rotary Kilns
  • Rotary Cooler
  • Off gas handling system
  • Raw material handling system
  • Water Distribution system
  • Air distribution system
  • Pollution control equipments
  • Air Distribution system
  • Piping for air and water system