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Sponge Iron - Made From Iron Ore.

Three DRI kilns. 300 TPD. 85-92% metallisation. Consistent chemistry, every batch.

What is Sponge Iron?

Sponge iron – also known as Direct Reduced Iron (DRI) – is a metallic product produced through the direct reduction of iron ore (in the form of lumps, pellets or fines) in the solid state. The reduction process removes oxygen from the ore without melting it, producing a porous, sponge-like solid – which is where the name comes from.

Sponge iron is one of the most important raw materials in modern steel production. It is used by induction furnaces and electric arc furnaces to produce billets, which are then rolled into TMT bars, wire rods, and structural products. At Apple Industries Limited, We sell sponge iron pellets in the market as well to produce MS billets, which in turn feed our rolling mill.

Technical Specifications

ParameterSpecification
Total Fe Content80% to 95%
Degree of Metallisation85% to 92%
Controlled ImpuritiesCarbon, Silicon Dioxide, Sulphur and Phosphorus – all within specification
Physical FormLumps and pellets
Size Range5 mm to 25 mm
Bulk Density1.60 to 2.0 t/m3 (approximate)
Gangue Content (Impurities)Below 8% (high-quality grade)
Daily Capacity300 TPD (Tonnes Per Day) across 3 DRI kilns
Monthly Capacity9,000 to 9,500 MT per month
Our DRI Process

Apple Industries Limited produces sponge iron through the coal-based direct reduction route – a process that uses controlled high-temperature reduction inside rotary kilns to strip oxygen from iron ore in the solid state. The output is a uniform, porous, high-iron-content metallic product.

Our three DRI kilns operate continuously, fed by verified-quality raw materials:

  • Iron Ore - sourced from low-sulphur SA coal
  • Coal - low-sulphur South African origin metallurgical coal
  • Dolomite and other reductants in controlled proportions

Every kiln output batch is tested in-house for Fe content, metallisation, carbon level, sulphur and phosphorus before it enters our induction furnace line.

Why Our Sponge Iron Performs ?

  • Consistent Fe content batch to batch
  • Uniform chemical composition – controlled impurities
  • Cost-effective – because we use only verified high-quality raw materials and operate in-house
  • Reliable monthly output – 9,000 to 9,500 MT every month, without supply disruption
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Applications

Sponge iron is primarily used as a charge material in:

  • Induction furnaces – the most common application, used to produce MS billets and other semi-finished steel products
  • Electric arc furnaces – for higher-grade steel production

At Apple Industries Limited, our sponge iron is currently captive-consumed in our own induction furnace line to produce MS billets for our rolling mill. We are open to discussing external supply to verified industrial buyers – get in touch with our sales team for details.

FREQUENTLY ASKED QUESTIONS

What is the difference between sponge iron and pig iron?

Sponge iron is produced by reducing iron ore in the solid state without melting it – which is why it retains a porous, sponge-like structure. Pig iron, by contrast, is produced by melting iron ore in a blast furnace at very high temperature. Sponge iron has a higher iron content by weight than pig iron, lower impurities, and is the preferred charge material for induction furnaces.

Metallisation rate is the percentage of iron in the sponge iron that exists in a free metallic state – rather than being bound to oxygen as iron oxide. A higher metallisation rate means more usable iron per tonne charged into the furnace, which translates directly into better yield and lower production cost downstream. Apple Industries sponge iron typically operates between 85% and 92% metallisation.

Apple Industries Limited sponge iron is produced in both lump and pellet form, in sizes ranging from 5 mm to 25 mm. Bulk density is approximately 1.60 to 2.0 tonnes per cubic metre. Specific dimensions and form can be discussed for industrial buyers – please contact our sales team.

Apple Industries sponge iron is currently consumed in-house to produce our MS billets. We are open to discussing supply arrangements with verified industrial buyers – typically induction furnace operators and secondary steel mills. Contact sales@appleindustriesltd.in for specifications and availability.

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Looking to source sponge iron for your operation?

    FREQUENTLY ASKED QUESTIONS

    What is the difference between sponge iron and pig iron?

    Sponge iron is produced by reducing iron ore in the solid state without melting it – which is why it retains a porous, sponge-like structure. Pig iron, by contrast, is produced by melting iron ore in a blast furnace at very high temperature. Sponge iron has a higher iron content by weight than pig iron, lower impurities, and is the preferred charge material for induction furnaces.

    Metallisation rate is the percentage of iron in the sponge iron that exists in a free metallic state – rather than being bound to oxygen as iron oxide. A higher metallisation rate means more usable iron per tonne charged into the furnace, which translates directly into better yield and lower production cost downstream. Apple Industries sponge iron typically operates between 85% and 92% metallisation.

    Apple Industries Limited sponge iron is produced in both lump and pellet form, in sizes ranging from 5 mm to 25 mm. Bulk density is approximately 1.60 to 2.0 tonnes per cubic metre. Specific dimensions and form can be discussed for industrial buyers – please contact our sales team.

    Apple Industries Limited sponge iron is currently consumed in-house to produce our MS billets. We are open to discussing supply arrangements with verified industrial buyers – typically induction furnace operators and secondary steel mills. Contact sales@appleindustriesltd.in for specifications and availability.

    Integrated steel manufacturer in South India. Sponge iron, MS billets and German-Thermex TMT bars from our 82.96-acre Anantapur plant since 2010.

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