As is typical in any metallurgical process, sponge iron manufacturing is highly sensitive to raw material characteristics that would help obtain the rated capacity and the desired product quality. Hence, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. The basic raw materials for the production of sponge iron are iron ore, non-coking coal and dolomite.
 
Several tests are conducted in the company laboratory to ascertain their suitability in a rotary kiln. A state-of-the-art modern R&D facility has been established along with a chemical laboratory to conduct the monitoring process.

During sponge iron manufacturing, iron ore is reduced in solid state. Unlike the conventional steel melting processes, the gangue content of iron ore cannot be separated as a slag. Hence, it becomes essential to select an ore with high iron content and a low gangue content, to optimize yield during steel making. In order to ensure a better kiln campaign life and output, the iron ore is made to undergo a series of other tests viz. shatter, tumbler & abrasion indices, reducibility etc.
 
By virtue of its location in the Northern part of Orissa, Vikram Private Limited enjoys proximity to good iron ore reserves, effective for sponge iron manufacturing.

Dolomite is an important ingredient and acts as a desulphuriser removing sulphur from the feed mix during the reduction process.

It is mixed in small proportions along with other raw materials before charging into the kiln. Control of sulphur content is an essential pre-requisite for the manufacture of good quality steel.

• The process utilizes non-coking coal as reducing agent along with lumpy rich grade iron ore.
   

• The reduction is carried out in an inclined horizontal rotary kiln, which rotates at a predetermined speed. A temperature profile ranging from 800-1050 degree centigrade is maintained along the length of the kiln at different zones and as the material flows down due to gravity the ore is reduced.
   

• The hot reduced sponge iron along with semi-burnt coal, discharged from kiln is cooled in water-cooled cylindrical rotary cooler to a temperature of 100–200 degree centigrade.
   

• The discharge from cooler consisting of sponge iron, char other contaminations are passed on through magnetic separators so that sponge iron can be separated from other impurities.
   

• Later the sponge iron is screened into two size fractions i.e. –3 mm & +3 mm. +3 mm fraction directly goes for usage, -3 mm fraction can be either used directly where ever it is possible or is to be briquetted by using molasses and hydrated lime as binders.