<p>The grate bars in induration furnace for transfer the pellet inside the furnace. The grate bars were found to fail frequently with poor air cooling. Failure of these grate bars results in process interruption, production loss, and low pellet strength. A detailed failure analysis of grate bars was carried out to investigate the mechanism and reasons for such failure and suggested for preventive measures. The grate bars were collected at the affected and unaffected regions and were analyzed using visual examination, optical microscopy, fractography, scanning electron microscope equipped with energy-dispersive spectroscopy (EDS) and hardness testing. The visual examination revealed that corrosive depositions on the grate bar, the microstructure of the unaffected grate samples revealed a austenite (A) and delta ferrite structure, whereas at the affected region the microstructure showed dendritic grains with micropores, fractography shows the oxides layer found, and the EDS analysis shows predominantly oxides of Cr–Mn–Si and oxides of Fe in the scanned defect region. This change in microstructure indicated that failure of grate bar resulted due to internal oxidation and intergranular corrosion due to corrosive environment. The composition of alloy elements in lower range and corrosive environment inside the furnace cause by high electrical conductivity (EC) and high chloride content has led to the exposure of the grate bar and resulted in the premature failure of the grate bar.</p>