Pig Iron Division (PID) started operating in 1992. It was the first to introduce low phosphorous foundry-grade pig iron in India. The PID has two blast furnaces with a working volume of 173 m3 along with the newly commissioned third blast furnace of 450 m3 capacity, making SESA’s PID the largest producer of low phosphorous pig iron in India with an installed capacity of 625000 Tones/Year. The Company also commissioned an 800,000 tones’ sintering facility that would enable the PID to partially meet its iron ore requirement with sintered iron ore fines, resulting in significant cost savings and increasing efficiencies.
Pig iron is produced from the blast furnace. The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions. Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance.
Pig iron is an intermediate product and first product of Iron making reduced from Iron ore. Pig iron has a very high carbon content, typically 3.5–4.5%, along with silica, Manganese, Sulphur, Phosphorus, Titanium and other trace elements.
Pig Iron comprises three main types: BASIC PIG IRON, used mainly in electric arc steelmaking, FOUNDRY PIG IRON used in mainly in the manufacture of grey iron castings in cupola furnaces, and NODULAR PIG IRON (SG GRADE) used in the manufacture of ductile iron castings. Pig iron is used for steel making, Foundries, Alloy making, in automotive castings and other iron based castings.
Our Pig Iron Plant is strategically located at Amona, on the banks of Mandovi River, at an optimum distance of 40 kilometres from Marmagao port which gives us the dual advantage of transporting Pig Iron by road in trucks & containers as well as by riverine barges in bulk. We have two Blast Furnaces having a working volume of 173m3 each. Our third Blast Furnace of 450m3 capacity was successfully commissioned on 17th August 2012. The annual capacity of total Plant is 0.832 MTPA.
We produce compositions within fairly narrow ranges of specifications with the objective of optimizing customer's costs due to non-addition of additives, standardization of process parameters and minimization of rejects. We are long-term suppliers to some of the global brands & OEMs from automobile industry and some of the most reputed steel mills and foundries.
Given below are the indicative specifications of our various pig iron grades which we supply to our valued Customers primarily in India and also in Middle-East, Far-East, South–East Asia:
|Basic Grade||3.5% - 4.6%||1.25% max||0.4% - 1.2%||0.07% max||0.14% max|
|Nodular/SG Grade||3.5% - 4.6%||1.25% max||0.3% max||0.015% max||0.08% max|
|3.5% - 4.6%||1.25% - 2.25%||0.3% max||0.015% max||0.08% max|
|Foundry Grade||3.5% - 4.3%||1.75% - 2.00%||1.00% max||0.07% max||0.14% max|
|3.5% - 4.3%||2.00% - 2.50%||1.00% max||0.06% max||0.14% max|
|Semi Foundry Grade||3.5% - 4.6%||1.25% - 1.75%||0.4% - 0.8%||0.07% max||0.10% max|
Note: Above specifications are indicative and can be modified to suit customer requirements. Each pig iron unit has single notch, has an approximate size of 140mm x 140mm x 70mm, and weighs approximately 5-8 kg.