ISPC Saudi Arabia

DRI Produced from
Various Iron Oxide Lumps and Pellets
in
MIDREX modules
of Direct Reduction Iron Co. (DRIC)

Direct Reduction Iron Company
(DRIC)
A Subsidy of
Ittefaq Steel Product Company (ISPC)
by
M. Aslam Khan

ISPC NETWORK AT 2 ND INDUSTRIAL CITY, DAMMAM

ISPC products high tensile Steel Bars
Deformed Reinforcement Bars
According to ASTM A-615 grade-60/40, BS-4449,
Grade-460B and 500B
Diameter Range : 8 to 40 mm
Annual Production Capacity : 2,750,000 Tons
Wire Rods
According to C1008 and C1006 grades
Diameter Range : 5.5mm to14mm (plain)
Annual Production Capacity : 250,000 Tons

• This is one of the largest downstream
industries in the Middle East having the
capacity of 500,000 Tons Per Annum
• Set up to ensure Vertical diversification,
Integration Strategy & Enhance Value
Addition
• The products of FSPC are as follows:
• Straightening & Cutting
• Cut and bend
• Cold rolled
• Weld Mesh
• Spring Wire
• Fusion Bonded Epoxy coating

The kingdom’s First Private Sector Steel
Melt Shop
Strategic Backward Integration for
uninterrupted Billets supply to ISPC
State-of-Art Technology
Steel Producing through EAF-LRF-CCM
route
Basic Engineering by BSE (Germany)
Equipment from VAI (Austria) & Siemens
(Germany)
Set up in a Record time utilizing in-house
expertise

With the existing production facilities,
billets of following grades are produced as
per the market demand:
Low carbon steel
Medium carbon steel
Low alloy steel
Grades Produced
• ASTM A615 Gr.40,Gr.60
• BS4449Gr B500B
• SAE 1008,SAE 1006
• SAE 4140,EN8

◙ Two twin shell
DC EAF of
130 ton
capacity each

◙ One twin station LF & two of 130 ton
capacity each

◙ 2 x 6 strands billet casters

GAS TURBINE POWER STATION - TSML

• TSML HAS ;--
• Special permission to export 100% of its production as EPZ.
• Full ownership rights to foreign investor.
• Full Repatriation of capital and profits.
• No minimum or maximum limit for investment.
• Duty free imports of machinery, equipment and material.
• No sales tax on electricity and gas bills.
• Freedom from national import restrictions
• Foreign Exchange Control Regulations of Pakistan not applicable
• Being EPZ unit, TSML is only required to pay tax @ 1% at the
time of export. No other taxes are applicable on import or export
of any part of the plant, production including utilities.

Two MIDREX DRI modules built to produce 1.5
million tons of low residual metallic iron for the
production of high quality steel in NASCO & ARAB
Steel of ISPC.

Project Achievements
• Project started in Oct 2005 and successfully commissioned
first phase in May 2007 and second phase in Dec 2007 with
capacity enhanced from 0.88 million Ton to 1.5 million Ton.
• Modules were mobilized from Mobile, Alabama U.S.A.
• DRIC has the latest and most technologically advanced process
control System of Yokogawa.

Modules

DRIC PRODUCT – COLD DRI
COLD DRI

DRI IN BAGS FOR SALE

DRI BAGS IN 20 FEET CONTAINER

DRI BAGS LOADED ON TRAILER

Courtsey – Gregory L. Dressel, USA

Parameters Rio Tinto Lump Samarco
Fe (total) 92.09% 92.53%
Fe (metallic) 88.55% 86.60%
Metallization 96.31% 93.59%
FeO 4.56% 7.63%
Carbon 0.96% 1.94%
Sulphur 0.010% 0.004%
SiO2 1.21% 1.61%
Al2O3 0.25% 0.67%
CaO 0.22% 1.01%
MgO 0.10% 0.14%
Conclusion – Very Good Reducibility : But more Fines generation
( Ore TFe – 67.7%)

Chemical Analysis of Basket DRI
Parameters Lump Ore( Yemen) Samarco
Fe (total) 78.18% 92.24%
Fe (metallic) 17.53% 86.31%
Metallization 22.42% 93.57%
Gangue Not Done 4.31%
Carbon 0.62% 1.54%
Sulphur 0.00% 0.006%
Conclusion- No Reducibility observed. ( Ore TFe –68.2% )

Chemical Analysis of Basket DRI
Parameters Iran Pellets GIIC Pellets
Fe (total) 89.49 90.49
Fe (metallic) 83.82 85.84
Metallization 93.67 94.86
Gangue 7.99 5.53
Carbon 0.92 2.64
Conclusion- Poor reducibility: High Fines generation in DRI ; Low
Carbon Potential ( Pellets TFe -66.16% )

Chemical Analysis of Basket DRI
Parameters
CHIGENDIK(BALUCH
ISTAN)
Lump Ore
Samarco Pellets
Fe (total) 85.42 92.53
Fe (metallic) 80.46 86.83
Metallization 94.19 93.84
Gangue 11.39 3.34
Carbon 1.77 2.50
Conclusion- Good Reducibility : High Acid gangue & Low Metallic
Iron (Ore TFe – 61.81% )

Chemical Analysis of Basket DRI
Parameters
NML Pellets
Samarco
Fe (total) 91.21% 92.17%
Fe (metallic) 85.01% 86.29%
Metallization 93.20% 93.63%
Gangue 4.43% 4.20%
Carbon 3.30% 2.37%
Sulphur 0.0060% 0.0054%
Conclusion- Very Good Reducibility : Very Good Carbon Potential
( Tfe- 66.81%)

Chemical Analysis of Basket DRI
Parameters Peru DRI Samarco DRI
Carbon 2.14 2.07
Fe (total) 91.99 92.56
Fe (metallic) 87.50 87.79
Metallization 95.12 94.85
Gangue 4.58 4.01
Conclusion – Very Good Reducibility : Less Fines in DRI
( Tfe-67.40%)

Chemical Analysis of Basket DRI
Parameters Poltava Pellets GIIC Pellets
Fe (total) 88.10% 91.93%
Fe (metallic) 82.47% 88.04%
Metallization 93.61% 95.77%
FeO 7.24% 5.00%
Carbon 1.04% 1.78%
Sulphur 0.0044% 0.0046%
SiO2 6.89% 2.70%
Al2O3 0.70% 0.84%
CaO 0.84% 0.92%
MgO 0.15% 0.18%
Conclusion- Good Reducibility : Low Carbon Potential :High Acid gangue
( Tfe—65.29% )

KUMBA LUMP ( 30;70)
Parameters GIIC KUMBA
%Carbon 2.60 1.90
%Total Fe 89.45 92.23
%Metallic Fe 84.71 88.67
%Metallization 94.75 96.14
%Gangue 5.30 6.40
Conclusion;-- Very Good reducibility; Low carbon potential; High Mfe
( Lump Tfe – 66.3% )

(9) BALUCHISTAN LUMP (1/2)
Parameters GIIC Baluchistan(1/2)
%Carbon 2.16 3.27
%Total Fe 90.14 89.66
%Metallic Fe 85.09 83.49
%Metallization 94.40 93.12
%FeO 6.49 7.93
%Gangue 6.26 5.31
Conclusion;-- Good reducibility;Low gangue; High Carbon
Potential ( Lump Tfe – 66.69% )

(10) BALUCHISTAN LUMP (2/2)
Parameters GIIC Baluchistan(2/2)
%Carbon 2.05 1.96
%Total Fe 90.91 91.23
%Metallic Fe 86.24 86.23
%Metallization 94.86 94.52
%FeO 6.01 6.43
%Gangue 5.70 5.38
Conclusion;-Good Reducibility ; Properties as good as GIIC
pellets ( Ore Tfe -66.90% )

(11) MGL-201(DSO) LUMP (KSA)
Parameters GIIC MGL-201
%Carbon 2.06 2.78
%Total Fe 90.81 89.98
%Metallic Fe 86.07 79.78
%Metallization 94.78 88.66
%FeO 6.10 13.12
%Gangue 5.77 4.32
Conclusion;-- Poor Reducibility with low gangue; Good
Carbon potential ( Ore Tfe – 67.73% )

(12) MGL-193(DSO) LUMP
Parameters GIIC MGL-193
%Carbon 2.44 3.27
%Total Fe 88.17 84.11
%Metallic Fe 82.19 77.43
%Metallization 93.22 92.06
%FeO 7.69 8.59
%Gangue 7.68 10.71
Conclusion; - Good Reducibility and Carbon Potential;
High Gangue and low Metallic Iron ( Ore TFe -64.57% )

(13) SISHEN (SA) LUMP
Parameters GIIC SISHEN
%Carbon 2.93 1.24
%Total Fe 90.91 90.79
%Metallic Fe 85.65 85.77
%Metallization 94.21 94.47
%FeO 6.76 6.45
%Gangue 4.66 6.53
Conclusion;- Good Reducibility and TFe; Carbon
potential slightly lower (Ore Tfe- 66.27% )

(14) ZRP (SA) PELLETS
Parameters GIIC ZRP
%Carbon 1.72 1.45
%Total Fe 90.50 90.85
%Metallic Fe 85.19 85.33
%Metallization 94.14 93.92
%FeO 6.82 7.10
%Gangue 7.99 7.57
Conclusion;-- Good Reducibility and Total Iron ; Gangue lower
though Carbon potential slightly lower ( Pellets Tfe -67.29% )

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