World is Blessed With. Large Reserves Of Iron Ore And Non-Coking Coal. Direct Reduction Through Coal-Route Has Now Been Stabilized. It Is Natural That Coal Route Direct Reduction Process Can Make A Great Stride In The Near Future. Focus Is Now On Optimization Of Operation And Production Of Quality Sponge Iron By Using High Ash Coal And Poor Quality Iron Ore That Is Available In Plenty. It Is Reported That In Rotary Kiln Process The Quality Of Raw Material Plays Vital Role To Operate And Produce Consistently Quality Sponge Iron. The Challenge Is To Produce Sponge Iron At Minimum Cost Without Affecting Quality. For This Either We Have To Operate The Plant As Per Designed Input Material Or To Adjust Process/Operations With The Available Raw Materials. Since It Became Apparent That We Could Not Get The Specified Raw Material, The Only Option Left For Us Was To Modify Our Process Or Operations. Set Up With Indigenously Developed 'O.P Jindal Technology' Jindal Steel & Power Limited-India (A Flagship Company Of O.P Jindal Organization) is The Wonderful Example Of How To Convert Adversity Into Opportunity. At Jindal Steel & Power Ltd, India, An Attempt Was Made To Utilize High Ash Coal And Poor Quality Iron-Ore To Make Sponge Iron Of Prime Quality By Modifying Operating Parameters, Some Changes In Facility And Design Of The System, This Attempt Of Us Met With Considerable Success And As A Result We Have Been Able To Produce Quality Sponge Iron At Lowest Level Of C/Fe Ratio Lowest Net Specific Energy Consumption And Lowest Cost Of Production As Well. This Paper Highlights The Secrets Of Success Behind The Achievements And The Initiatives Taken To Modify Operations To Get More Than 99% Kiln Availability, 97% Quality Product. In A Short Span Of 10-12 Years, Jindal Steel & Power Ltd, World's Largest Coal Based Sponge Iron Plant Has Emerged As One Of The Most Profitable Integrated Steel House Based On Its Size Of Operation.
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