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Sunday, May 4, 2014



sponge -iron services and consultancy






NEW ROUTE TO PROFITABLE MAKING OF SPONGE IRON

SPONGE IRON MAKING THROUGH COAL BASED (NON-COKING COAL) IS DEVELOPED BY SIIL, ANDHRA PRADESH THROUGH UNDP/UNIDO AID AND M/S.LURGI CHEMIE TECHNIQUE GmbH, WEST GERMAY. ALL THE SPONGE IRON PLANTS OF CAPACITIES OF 50TPD, 100 TPD, 350 TPD AND 500 TPD ARE DEVELOPED ON THIS TECHNOLOGY ONLY.

THE COAL CONSUMPTIONS ARE ONLY AVAILABLE TO CONTROL IN THE PROCESS SINCE 35 TO 40% ENERGY IS GOING  IN WASTE GASES WHICH CAN BE UTILISED EITHER IN POWER GENERATION OR ELSE.  PRESENTLY PER MW INVESTMENT FOR WHRB  IS 5 CR MINIMUM AND IT WILL BE COSTLY TO RECOVER INVESTMENT.

NOW,  WE PROPOSE TO PROVIDE TECHNOLOGY FOR 300 TPD ONLINE PELLET MAKING (MINI)  PLUS  DRI IN CONVENTIONAL KILNS IN COST EFFECTIVE METHODS. THE COST OF SPONGE MAKING IS SO LOW AND NEVER IMAGINED.

INTERESTED PARTIES CAN CONTACT US AT:

M/S.SPONGE IRON SERVICES & CONSULTANCY, HYDERABAD, ANDHRA PRADESH
TEL: 040-23057622
MOBILE: 09885190820
CONTACT PERSON: K V SATYANARAYANA,
 MANAGEMENT  CONSULTANT

TECHNICAL SERVICES

We are pleased to introduce ourselves as a consultant for Iron and steel making. We are in this field for the last 35 years. We undertake Operation and Maintenance  of sponge iron plants. The preheating plant of M/s.Jairaj ispat pvt ltd., Bellary was under our operation for commissioning and run record production with quality for 16 months. The style of organization named as M/s.Sponge Iron services and Consultancy, Hyderabad.

Presently, our consultancy is being offered for the following plants:
  1. M/s.MGM steels ltd., Bhubaneswar (1 x 350 tpd sponge iron plant) since December 2011 to uptil now. Integrated plant works are underway. Commissioning of the plant under our guidance and a production rate of 350 t/day from the day one.

  1. M/s.Gallantt Metals (Units : Gorakhpur and Gujarat as well (both are integrated steel plants) since December 2010 uptil now WHRB power generation maximization system developed and running at 8.5 to 9 MW/hr in 350 tpd sponge iron plant. Associated with their Induction Furnace also. The extra power generated in 100 tpd plant with baghouse dust is 0.5 MW/hr. The design was done by us.

  1. 0 – 6 mm Non-coking coal used in (100%) in 350 tpd M/s.Gallantt Metals, Gorakhpur continuously.

  1. M/s.Amoda steels, Jagayyapet, Andhra Pradesh for the last one year.(1x100,2x50tpd DR plants)Technical advisor for Modular Hydro-jigging plant for Kadapa high BHQ ore plant

  1.  
We would like to offer our services for  operations and maintenance  for  esteemed organizations having any capacity of with or without PRE-HEATING sponge iron plants with the following goals:
1.      Lowest coal consumption in any combination.
2.      Long campaign life and highest production.
3.      Maximum Personal supervision is offered for good operations.

4.     Any sort of Process, Mechanical probles assistance is provided.

We have presented two papers for sponge iron conference held in SVM Minerals college, Garividi, near Vijayanagarm Andhra.Pradesh,India.
1.Effective Coal consumption in preheating kilns
2.Accretion formation in sponge iron kilns and control also.



The list of plants under our consultancy are:

No.
Client name and address
Plant configuration
Type of contract
Period(From to)
1
Steel Rolling Mills, Uganda
1x175tpd
Erection &commissioning
May 2012 to June2012
2
Gallantt Metals,Gorakhpur
1x350
Tech.Advisor
Dec2010-uptildate
3
Gallantt Metals,Gujarat
2x100; 2x175tpd
Tech.Consultant
May 2011-uptildate
4
MGM steels, Bhubaneswar
1x350tpd
Regular Consultant
December2011- uptildate
5
Gagan Ferrotech,Ranigunj,WB
2x175tpd
Regular consultant
Jan-Dec 2010
6
RPA FERRO ALLOYS,Dharwad
1x175
Erection& commissioning
Year 2009
7
Rayon steels, Bellary
1x100
1x175
Plant modification
August-Dec 2009
8
Amoda Steels & sponge,Jagyyapet,AP
2x50
1x100
Sponge Iron and Ore Beneficiation plant at Kaddpa
Jan 2011 to uptildate.
9
Jairaj steels Pvt ltd.,Bellery
2x175
Plant modification & service contract
June 2008 to july 2009
10
Sheetal Metals & Alloys, AP
1 x 175
Plant head
Jan 2007 to May 2008
11
Hadeed, Saudi Arabia, Midrex gas based plant & 150x3 EBT furnaces.
HyL gas based plant
400x2
600x2
1Mx1
Process Evaluation and Development
Jan 1989 to Jan 1997
12
Sunflag Iron & Steel,Maharashtra.
500 tpd
DyProject Manager
July 1988 to Dec 1988
13
M/s. Tata sponge iron, Odisha.
350 tpd
Gen Foreman
June 1986 to June 1988
14
Sponge Iron India Ltd.,FIRST DEMONSTRATION PLANT ,UNDP/UNIDO, AP.
2x100 tpd
.Engineer Metallurgy
May 1975 to May 1986




PELLETISATION PLANT EXCLUSIVELY SUITABLE TO DEDICATED SPONGE IRON PLANTS DESIGN, DEVELOPMENT AND SUPPLY IS OFFERED  @ 300 TPDAY PELLETS, 450 TPD PELLETS. (non-coking coal based) NEED TO PROCURE IRON ORE FINES AND MAKE PELLETS AND MANUFACTURE SPONGE IRON AT CHEAPER PRICE.

WE ARE TECHNICAL ADVISORS FOR:

1.M/S, VINAYAKA SPONGE IRON PLANT,HYDERABAD WITH 300 TPD PELLETISATION UNIT BUILT INDIGENOUSLY AND RUNNING SUCCESSFULLY.

The COST of the pellet making at this level :
1.Cost of the ramaterial per ton of pellet :  Rs.3500 (+60Fegrade)
2.Conversion cost per ton of pellet            :Rs.1500/-
          Total                                                 :Rs.5000/- max (in house making)
Bought out pellets ex-works cost               :Rs.7500/ minimum
i.e, A cost difference of minimum Rs.2500/- min per tone of pellet is being maintained excluding transport cost to site.

The pelletising plants are based on non-coking coal only. No oil is used. Hence, the profitability is guaranteed.

The period of plant construction: maximum 12 months.
The gestation period of the project is only : 12 months. Max.
300 tpd Project cost Rs.17 Cr.
500 tpd Project cost Rs.22 Cr. only

INTERESTED PARTIES CAN CONTACT US AT:

M/S.SPONGE IRON SERVICES & CONSULTANCY, HYDERABAD, ANDHRA PRADESH
TEL: 040-23057622
MOBILE: 09885190820
CONTACT PERSON: K V SATYANARAYANA,
 MANAGEMENT  CONSULTANT

Off : Plot no.338, HMT hills, Opp: JNTU, Kukatpally, Hyderabad – 500 072, A.P.
Mobile: 9885190820