Tabarestan Steel Foundry (TSF) specializes in the manufacturing of critical components for the Lurgi technology used in iron pelletizing. The pallet car unit is composed of over 60 distinct components, each requiring specific materials and manufacturing processes. TSF's primary advantage is its integrated approach: all these components (except bearings) are produced in-house within the TSF group. This complete control over the entire production and assembly process, supervised by TSF's engineering and quality control units, ensures the delivery of complete assemblies that fully meet all required standard specifications.

History, Experience, and Proven Success

In 2009, Tabarestan Steel Foundry (TSF) began producing a complete pallet car unit that was experimentally installed and successfully tested in the production line of Golgohar's pelletizing plant. After this initial success, TSF signed a contract in 2010 resulting in the production and delivery of 22 complete pallet car sets that have been in operation since 2011. Furthermore, due to the product's quality, ten pallet cars manufactured by TSF have been utilized in Golgohar's pelletizing line 2 since its start-up in 2016, operating alongside units supplied by Outotec. The satisfactory performance of TSF's products led to a major contract with Mobarakeh Steel Company, securing an order for 50 center parts in 2012 and 50 complete pallet car sets in 2013. These parts have been successfully operating in Mobarakeh Steel's pelletizing line for over ten years and are recognized as the highest quality pallet cars used in that complex. TSF's extensive customer base in the pelletizing sector also includes Sirjan Iranian Steel Company, Opal Parsian Sangan Company, Sangan Steel Mining Industries Company, and Khorasan Steel.

Detailed Manufacturing Summary of Main Pallet Car Components

1. Center Part

• Function: The main structural chassis, supporting the entire pellet load. It must resist distortion and thermal fatigue from repeated heating and cooling cycles.
• Material: Cast from creep-resistant alloy steel conforming to ASTM A 217 grades WC6 and WC11. Weight ranges from 2,000 to 5,100 kg.
• Key Processes:
• Vital Heat Treatment: Performed in calibrated furnaces with real-time monitoring to achieve required mechanical properties (high creep resistance and adequate strength).
• Quality Control: Passes chemical analysis, mechanical property tests, ultrasonic testing (UT), and liquid penetrant or magnetic particle inspection.
• Machining: Conducted at the subsidiary, Rueen Sath Tabarestan, located next to the foundry.

2. End Casting

• Process: Production is similar to the Center Part, involving casting and heat treatment, followed by machining. It is bolted onto the Center Part using high-strength bolts.

3. Grate Bars

• Requirement: Requires high dimensional and surface quality.
• Material: Made from heat-resistant steel according to ASTM A 297 HH(1.4837) or HK grade (1.4848).
• Process: Produced using the specialized Replicast (ceramic shell) method in TSF foundry No. 2.

4. Side Walls (Upper & Lower)

• Lower Side Walls: Cast from low-alloy, creep-resistant steel; they are not exposed to direct flame but are adjacent to fired pellets. They are machined and bolted onto the End Casting.
• Upper Side Walls:
• Material: Cast from heat-resistant steel (high Chromium and Nickel content).
• Advanced Manufacturing: Produced in TSF foundry No. 2 using the Replicast (ceramic shell) method to ensure superior corrosion resistance and surface quality.

5. Wheel & Roller Shaft Assembly

• Assembly Detail: Consists of 18 different part types made from steel, cast iron, and rubber.
• Main Wheel: Manufactured from forged Mo40 steel (offering higher mechanical strength than cast steel). It undergoes machining and case hardening (up to 50 HRC in 3mm).
• Bearings: Sourced from reliable bearing manufacturers like FAG or HKT.

6. Spring Seal Assembly

• Components: Made up of eleven different high-strength steel components.
• Function: Provides a relative seal beneath the End Casting between the inside and outside of the furnace.
• Manufacturing: Involves bending, spring coiling, welding, and machining.

7. Protective Wear Plates

• Function: Assembled on the lateral and top surfaces of the End Casting to protect it from hot pellet dust.

We are confident that our fully integrated production chain and quality control measures will significantly reduce your operational risks and extend the service life of your pelletizing line equipment.

To see how Tabarestan Steel Foundry can meet your specific needs and deliver the highest quality components, we encourage you to contact our sales team today to receive a detailed, competitive quote for replacement parts or complete pallet car sets.

Ready to Optimize Your Pelletizing Operations? Get the reliability of 10+ years of operational success. 

Contact TSF today for a competitive quote on complete Pallet Car assemblies or high-wear replacement parts.