Traveling grate pelletizing

SMS group's traveling grate pelletizing technology stands as the global benchmark for the design and deliery of iron ore pellet plants, powering two-thirds of the world’s installed pelletizing capacity. Being market and technology leader since the inception of this technology, with over 60 years of experience and continuous R&D, this technology supports plant capacities from 1.2 up to 9.25 million t/year and is designed for both blast furnace and direct reduction pellets. The process comprises four main steps: raw material preparation and mixing, green pelletizing, pellet hardening (indurating), and product handling. Advanced mixing systems and proprietary pelletizing discs and roller screens ensure optimal green pellet quality and size distribution, which are crucial for gas permeability, energy efficiency and process stability in the induration. The induration furnace, equipped with a robust traveling grate, features innovative burner systems that allow precise control of temperature profiles and enable the use of alternative fuels, including hydrogen, supporting the transition to carbon-neutral steelmaking. Multiple heat recovery systems and state-of-the-art gas cleaning technologies minimize energy consumption and emissions, meeting stringent environmental standards. Digital solutions such as the Optimus™ process advisor and VisioPellet system provide real-time process optimization, enhancing productivity and product quality. The modular plant design allows for scalability and customization, making it suitable for both large-scale and compact pellet plants. Lifecycle services, including inspections, audits and studies, training, shut-down support, and modernization, ensure long-term reliability and optimal return on investment. Continuous innovation has led to numerous process improvements, new equipment products, and process automation, cementing SMS’s position as leaders in sustainable, efficient, and flexible pelletizing technology.

SMS group’s compact-sized pellet plant brings industry-leading pelletizing technology to smaller capacities, enabling mining companies and steelmakers to expand their value chain and support decentralized steel production concepts like mini mills. Building on decades of expertise and more than 100 global installations, SMS’s traveling grate technology is now available in a 3-meter-wide indurating machine, offering the same high performance and premium product quality as larger plants. The standardized design ensures cost efficiency, optimized delivery times, and flexibility to meet customer specifications.
The pelletizing process includes raw material preparation, green pelletizing, pellet hardening (indurating), and product screening. Advanced control over pellet size and optimized energy consumption are achieved through precise process adjustments and innovative drying sequences, resulting in high-quality pellets with excellent physical and metallurgical properties. The compact plant’s modular layout minimizes CAPEX and OPEX, with delivery times ranging from 16 to 24 months depending on the chosen package.
SMS group offers a full value chain, including base and add-on packages for customization, digital solutions, and proprietary equipment such as pelletizing discs, conveyors, roller screens, indurating machines, pallet cars, and burners. Digital solutions like Optimus™ and VisioPellet™ enhance productivity, energy efficiency, and product consistency, while condition monitoring and virtual training ensure optimal operation and maintenance. Expert services cover inspections, spare parts, upgrades, and digitalization, supporting customers in achieving reliable, efficient, and sustainable pellet production.

The SMS group Ferroflame™ low NOx burner is an advanced solution for travelling grate pelletizing plants, designed to meet the future demands of the industry. Engineered using the latest techniques and validated with both natural gas and hydrogen, this burner achieves up to 80% reduction in NOx emissions compared to conventional designs. Its innovative approach allows lower NOx targets, making it a cost-effective choice for new installations and upgrades.
The LowNOx burner enhances product quality by ensuring temperature uniformity within the furnace, resulting in more homogeneous pellets and increased refractory lifetime. It is compatible with a wide range of gaseous and liquid fuels, offering robust performance and reliable cold start-up characteristics. Trials with Hydrogen have demonstrated excellent burner performance, supporting decarbonization efforts with hydrogen as a carbon-free fuel.
SMS group’s solution is customizable for specific plant needs and can be retrofitted into existing facilities. It is available with integrated Burner Management Systems and fuel handling systems to meet the latest safety standards. Its flexible design allows easy conversion from natural gas to hydrogen operation, supporting future fuel transitions.
Comprehensive services are available, including combustion audits, process evaluation, CFD and physical modeling, flame safety, burner ancillaries, fuel system design, SNCR systems, site surveys, training, and spare parts. The SMS group Ferroflame™ LowNOx burner is a reliable, future-proof solution for minimizing CO₂ and NOx emissions, optimizing operational costs, and enhancing pellet quality in pelletizing plants.

SMS group is a global leader in advanced equipment for iron ore pelletizing, offering decades of process and equipmet expertise and innovation in the industry. Our roller screens are engineered to deliver the highest plant efficiency and pellet quality, ensuring consistent production of pellets with excellent physical and metallurgical properties for high-quality steel production. With a holistic approach to process engineering, equipment design, and project implementation, SMS group solutions are optimized to increase capacity, maximize energy efficiency, and minimize environmental impact.
Our proprietary roller screens are designed to control green pellet size and quality, which are critical for gas permeability in the furnace and, consequently, for product quality, energy consumption, and process stability. For plants with capacities below 4 Mtpy, a Double Deck Roller Feeder (DDRF) is installed to screen out over- and undersize pellets, while larger plants utilize Single Deck Roller Screens (SDRS) for optimal sizing and handling. The bi-layer feeder further enhances pellet bed properties by segregating pellets into two layers, improving heat treatment and overall pellet quality.
SMS group’s roller screens and feeders are robust, reliable, and easy to maintain, with features such as high screening efficiency, variable roller speed, and inbuilt gap flexibility. It can be combined with our VisioPellet system, which is using advanced camera technology to measure and control pellet size in real time, optimizing the entire process. Retrofit options and original spare parts ensure long-term performance and swift maintenance. Partner with SMS group for the best total cost of ownership, optimized energy consumption, and superior pellet quality throughout your plant’s lifecycle.

SMS group’s digital solutions for iron ore pelletizing plants are designed to maximize plant performance by integrating decades of process and operational expertise with advanced digital technologies. These solutions form the foundation for state-of-the-art plants, ensuring optimal operation and maintenance throughout the entire lifecycle. As the original inventor of the pelletizing process, SMS group offers a comprehensive suite of tools that enhance process performance, increase production capacity, and improve product quality, while simultaneously reducing energy consumption, environmental impact, and operational costs.

The model based Optimus Advanced Process Control and Optimizazion systems combines real-time plant measurements with SMS’s process know-how, automatically detecting and correcting process deviations and optimization potentials to maintain stability, efficiency, and consistent product quality. These systems optimize key process inputs, such as temperature and gas flow, and can be tailored to specific plant needs.

The VisioPellet system uses camera technology to measure green pellet size in real time, enabling dynamic adjustments to disc/drum speed and feed rate. This improves pellet size distribution, enhances furnace performance, and reduces energy consumption.

The advanced operator training simulator  provides risk-free, realistic training in a virtual plant environment. Operators can practice standard procedures, emergency scenarios, and adapt to changing process conditions, ensuring high competence and safety.

And the The Pallet Car Condition Monitoring System uses contactless sensors and identification technologies to track equipment health, enabling predictive maintenance and minimizing downtime.

All systems are modular, easy to upgrade, and integrate seamlessly with plant control systems, ensuring a fast return on investment and sustainable operational gains.

Efficient handling of the green pellets is critical for the induration of the pellets and thus for the performance, productivity and energy efficiency of traveling grate pellet plants. SMS group delivers a comprehensive range of special conveyors designed to meet the specific requirements of different plant sizes and arrangements.
Our shuttling spreader conveyor is ideal for compact-size pelletizing plants with smaller capacities and a straight arrangement of green pelletizing and induration areas. It ensures uniform distribution of green pellets onto the downstream wide belt conveyor through precise shuttling movements. Equipped with advanced PLC controls, hydraulic actuation, and variable frequency drives, it offers seamless integration with plant automation systems and guarantees consistent performance even under demanding conditions.
For larger plants with a 90° layout between the green pelletizing area and the induration furnace, the collecting belt conveyor with reciprocating head provides efficient transfer and even charging of pellets, reducing mechanical stress and improving gas prmeability of the pellet bed and process stability.
Our wide belt conveyor ensures gentle handling of green pellets, minimizing breakage and maintaining pellet quality throughout the process. Its robust design withstands harsh environments, while maintenance-friendly features reduce downtime and operational costs.
To complete the system, SMS offers special conveyors for under- and oversize pellets at screening and feeding zones, ensuring smooth material flow and preventing bottlenecks. All solutions are engineered for reliability, safety, and compliance with international standards, delivering maximum uptime and productivity for pelletizing operations worldwide.