Innovation for the production of value added products from sponge iron fines (waste) by simulation of rotary kiln-submerged arc furnace route

A large number of sponge iron plants is producing sponge iron lumps associated with sponge iron fines (waste material) which may be present up to 40%
(~4mm) of the main product. These fines are not properly utilized and are always considered as waste. These fines can be utilized directly or agglomerated in to briquettes or packed in small packs or uplifted the process in submerged arc furnace. But our goal is to utilize this sponge iron fines (waste) directly in bench scale 50kVA submerged arc furnace (SAF). The objective of the present investigation is to utilize sponge iron fines
for the production of basic grade iron and foundry grade iron. A methodology has been
designed to smelt sponge iron waste (fines) discharged from rotary kiln sponge iron
plants in suitable reducing agent as petroleum coke, flux as limestone and additive as
quartzite in a précised furnace. The rotary kiln can be coupled with submerged arc
furnace in order to produce basic grade iron and foundry grade iron more economically
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making use of sponge iron fines in hot condition(at about 600 C). The proposed
technology can be implemented on commercial scale. This will be alternative route for
the production of basic grade iron suitable for steel making and foundry grade iron
suitable for spheroidal graphite iron (S.G. Iron) making.