Sponge pellet Sponge Iron Pellets Pellets are small, spherical agglomerates of iron ore fines, typically ranging between 8–18 mm in diameter, used as a key feedstock in blast furnaces, direct reduction plants (DRI), and steelmaking units. These iron ore pellets are produced by agglomerating and indurating fine iron ore concentrate under controlled temperature, forming high-density iron pellets with excellent metallurgical properties. The HSN code for iron ore pellets is 2601, classified under “iron ores and concentrates, including roasted iron pyrites”. Note: Sponge pellet prices are listed per metric tonne (1 MT = 1,000 kg). To estimate the per-kg rate, simply divide the quoted MT price by 1,000 for an easy comparison. What is a Pellet? In metallurgy, a pellet refers to a compacted, spherical mass of iron ore used for efficient furnace feeding. The pellet plant process involves grinding, filtering, mixing, balling, and indurating to achieve high strength and uniform chemical composition. Compared to lump ore, iron pellets offer better permeability, higher reducibility, and consistent performance during reduction — essential for producing sponge iron and liquid steel.
Sponge Pellet (Sponge Iron Pellet)
Grades & Specifications
Grades & Specifications
Iron ore pellets are classified by Fe content, basicity, and end-use application:
| Grade | Fe % | Application |
|---|---|---|
| Blast Furnace Grade | 62–65% | For integrated steel plants using coke-based reduction |
| DRI / Sponge Iron Grade | 65–68% | Used in rotary kilns and gas-based DRI units |
| BF–DR Dual Use | 63–67% | Compatible for both furnace types |
Other parameters:
- Size range: 8–18 mm (uniform spherical form)
- Tumbler index: 90% minimum
- Cold crushing strength (CCS): 250–300 kg/pellet
- Porosity: 20–25%
Pellet Manufacturing in India
India hosts several advanced pellet manufacturing units equipped with rotary kilns and straight-grate technology. Prominent pellets manufacturer in India include:
- Rungta Steel Plant (Chaibasa, Jharkhand) – large-scale iron ore pellets and sponge iron production integrated with captive mines.
- Jindal Steel Barbil Pellet Plant (Odisha) – one of India’s leading pellet plants, producing high-grade DRI pellets for domestic and export use.
- Tata Steel, JSW, AM/NS India, and Godawari Power & Ispat – established players with pellet and sponge iron pellet manufacturing capacities exceeding several million tons annually.
Raw material sourcing hubs like Barbil, Keonjhar, Raipur, Durg, and Chaibasa play a crucial role in India’s pellet supply chain, supported by nearby iron ore mines in Odisha, Chhattisgarh, and Jharkhand.
Applications & Uses of Sponge Pellet
Pellets uses span across various iron and steelmaking processes:
- Sponge Iron Production: Used in gas- or coal-based DRI plants for metallic iron yield.
- Blast Furnace Feed: Replaces sinter or lump ore to improve furnace productivity.
- Electric Arc Furnace (EAF): Ensures consistent melting and cleaner steel output
- Export Market: India is among the top exporters of iron ore pellets to China, Korea, and the Middle East.
These steel pellets help achieve better control on chemical composition, lower slag volume, and higher metallic recovery , all contributing to energy efficiency and quality in steelmaking.
Iron Ore Pellets vs Sponge Iron Pellets
| Parameter | Iron Ore Pellets | Sponge Iron Pellets |
|---|---|---|
| Raw Material | Iron ore fines | Iron ore pellets reduced in DRI kilns |
| Fe Content | 62–68% | 80–90% metallic Fe |
| Process | Induration at 1250–1350°C | Direct reduction at 900–1100°C |
| Appearance | Hard, dense, spherical | Porous, gray, spongy texture |
| Application | Feed for DRI, BF, EAF | Raw material for steelmaking |
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