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Technology
Capacity MPTA 0.85
No. of battery Nos. 2
Nos.
Oven length mm 13500Oven Width mm 490 / 510
Oven height mm 4300
Oven temperature 1250 1300
Type of coal charging
MT 2332
Useful volume M3 26.68 41.6
Day
Cycle time Hrs. 18 22.5
Coke cooling
Combustion technology Underjet firing system
Oven pressure
MT 1.4
Stamp charging 2
Pusher car Nos. 2
Guide car Nos. 2
Quenching car Nos. 2Quenching time Sec 90
Coke cutter MT/hr 280 300
Coal silo Nos. 16 x 500
Coal bunker Nos. 4 x 400
Coal tower MT 2754
Coke conveyor MT / hr 250 300
NM3 480
3.2 mBtu/3.36 GJ
By-products like benzene, toluene, xylene, napthalene, coal tar, creosote oil, pitch, ammonium sulphate and benzol pro
By product12500 gallon/day
By product recoverytype / Non recovery/heat recovery type
No. of Oven in each
0C
Stamp charging/ topcharging
Qty. of coal charged peroven
Oven availability per
Wet (water) / Dry (Inertn2 gas)
Coal consumption (Neton dry basis)per ton of Coke
Coke oven gas / MT of
Input energyreconciliation (Coal)
68% as coke, 12% cokeoven gas, 8% oil, 4%chemical, 8% waste
heatEnergy consumption perton of Coke
Light oil(Benzene,toluene,Xylene)
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Heavy oil (Napthalene)
Coal tar 29000 gallon /day
Pitch
Amonium sulphate 12 t/day
Benzol
Coke specification
Mean Min Max
Average Coke Size (mm) mm 52 25 60
Plus 4" (% by weight) % 1 4
Minus 1"(% by weight) % 8 11
Stability Minute 60 58
Minute 65 61 68
CRI 22 27
M 10 7 10
M 40 75 80
Physical: (% by weight)
Ash % 8 12
Moisture % 2.5 7
Fixed carbon % 86
Sulfur % 0.65 0.82
Volatile Matter % 0.5 1.5
% 0.25 0.4
Phosphorus % 0.02 0.33
Raw material specification (Coking coal) Coking coal Bitu
Ash % 9.7
Volatile Matter % 18 38
Total moisture % 10
Moisture (IM) % 1
Phosphorus % 0.04
Sulfur % 0.58MMR % 1.15 1.3
Fluidity ddpm 400 1600
Fixed carbon
LAMC Low ash metallurgical coke
Coke Size
Foundry coke mm >75
Physical: (measured at theblast furnace)
Coke strength after reactionwith CO2 (CSR)
Alkali (K2O+Na
2O)
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BF grade coke mm 25-75
Nut coke mm 15-25
Pearl coke mm Jun-15
Coke breeze mm 0-6
Input
Coal
Output
Coke
CO gas
Heavy oil (Napthalene)
Coal tar
Pitch
Amonium sulphateBenzol
Light oil(Benzene,toluene,Xylene)
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ucts are also recovered from the coke ovens gas.
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inus Lignite
25 4
25 51
10 17
0.6 0.3
50 45
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Technology Grate Kiln technology
Capacity
Grate area Sqm 768
Thermal energy /ton GJ 0.63 0.96
Electrical energy / ton KWh 78 84
InputIron ore less than 325 mesh (45 micron)
Limestone,dolomite
Bentonite
Output
Iron ore pellet
Iron ore pellet specification
Grade % Tolerance
Fe 65 Minimum
FeO 0.3 Maximum
5 Maximum
CaO 0.03 ± 0.01
MgO 0.06 ± 0.01
Basicity 65 Maximum
Phosphorus 0.05 Maximum
Physical Properties Value Tolerance
Bulk Density 2.2 T/m3 ± 0.2
Tumbler Index 93% Minimum
Abrasion Index 3% Min ± 0.5 %
Cold Crushing Strength (Avg) 250 Kg/P Minimum
Size Analysis
8 - 16 mm 94% Minimum
-5 mm 2 % Maximum
+16 mm 4 % Maximum
Metallurgical Properties
Porosity 18% Minimum
Reducibility 62% Minimum
Particular Chemical (ON DRYBASIS)
SiO2 + Al2O3
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Capacity MTPA 0.15 6.5
Travelling Grate area Sqm 36 600
Machine width Mtr 2 5
Availability Day/year 330 345
45
MJ 1250 1400
KWh 28 32
Thermal energy /tpn GJ 0.06
M3 0.03 0.05
Nos. 16 20
CO2 generation /ton Kg 5
Bed height mm 500 730
Suction m bar 130 190
Return fine rate % 18 25
% 75 80
RDI (-3 mm) max % 28 32
FeO (max) % 5 8
Basicity CaO/SiO2 1.2 2.9
Input
Iron ore fine kg 850 100 mesh-10mmCoke breeze kg 70 0~6mm
Limestone kg 120 0~3 mm
Dunite / pyroxenite (mkg 40
Lime fine kg 30
Solid waste kg 80
Sinter
0.15 mm <10%+10 mm 70%
- 5 mm 6%
Fe
CaO
MgO
Advantage of Sinter
Specific production MT/m2/24
Solid and gaseous
fuel per ton of sinterElectrical energy / ton
Process water per tonof sinter
Manpower ( 4 shiftbasis) pera day
ISO strength (+6.3
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Technology
Capacity TPD
Combustion system
Fuel consumption
Thermal energy /ton GJ 3.47Electrical energy / ton KWh 30 40
Input
Output
Loading / chargingsystem
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Technology Cryogenic /Non cryogenic
Capacity TPD
Purity of oxygen
Product Nitrogen, oxygen, argon
Start up time Hr 72 96
Air filter
Multi stage cenrifugal air compressor
Chilling and air washing unit
Air purifier
Cold box
Air expansion unit
Liquid oxygen extraction syatem
Liquid oxygen storage tank
Gas oxygen compressorGas oxygen storage tank
Cooling tower
Circulating water pump house
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Technology Gas based (Midrex , HYL) ; Coal base (SL/RN, ACCAR)
Capacity TPD
Kiln size
0C 900 1100
0CWaste heat recovary
GJ 20 27 2.6Gcal/mt
KWh 60 70
Metalization % 92
Feed Iron ore lump (60%), pellet
Properties of sponge iron
Size mm 5 20
Fe metallic % 82 84
Fe total % 91 92
Metalization % 89 93
Density gm/cc
Crushing strength
Weather resistanceCarbon content % 0.06 0.2
Sulphur % 0.02 0.04
Phosphorus % 0.05 0.08
Non metallic % 1 2
Input requirement
Pellet / lump Mt 1.43 1.45
Coal (Fixed carbon) Kg 380 400
Electricity KWh 80 100
Water m3 2.5 3.5
Manpower Man-H 0.35 0.6
Plant availability % 90 92
Iron ore spec for DRI
Fe total % 67.4
Sio2 % 1.5
Al203 % 1
CaO % 0.05
Operating temp(reduction zone)
Operating temp (pre
heating zone)
Energy consumption(Thermal) / Ton of sponge of
Energy consumption(electrical) / Ton of sponge of
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Mgo % 0.05
Tio2 % 0.01
P % 0.03
Size mm 5-15
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Useful volume m3 35 5775
Capacity MTPA 0.08 4
Productivity MT/m3/day 1.7 2.54
Coke rate Kg/ THM 500 756
Charge
Blast temperature 0C
Top pressure Kgf/cm2 2.5
Tap hole Nos.Hearth dia mtr 13.8
Slag granulation
Top feeding arrangement
Coal injection rate Kg/ THM 160 200
KWh 106 214
GJ 33
BF gas / ton of hot metal MT / m3 2.5 3.5
Specific energy consumption in europe 17.1 GJ/Ton of crude steel
Energy consumption / ton of DRI 10.8 GJ
Input
Iron ore lump (Iron bearing material)
Sinter
Iron ore pellet
Coke (Fuel & reductant)
Lime stone (Flux) mm 25-60
Output
Hot metal
Slag basicity 0.9~1.0 with MgO content 8~11%
BF gas
Top gas pr. recovery
Energy consumption(electrical)
Energy consumption(thermal)/TCS
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Technology
Capacity
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Technology
Heat size MT 340
No. of heat per day
LD gas /TCS Nm3 100
Input
Energy consumption(Electrical) / TCS
Energy consumption(Thermal) / TCS
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Technology
Capacity
Heat size MT 180
No. of heat /day Nos. 16
Tap to tap time Min
Nm3
Carbon injection
Door lance
EBT lance
Continuous DRI charging
Electrode consumption / ton
Cooling water / ton
KWh 650 800
Input
Hot metal
Scrap
DRI
Lime
Dolomite
Coal
Pulvarized coal
Oxygen
Nitrogen/argon
Out put
Crude steel
Rmoval of
Phosporus
Sulphur
silicon
ManganeseAluminium
Carbon
Nitrogen
Hydrogen
OX consumption / heat
(100%hot metal)
Energy consumption(Electrical) / Ton of steel
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KWh 550 800
GJ 2
KWh 300
Energy consumption(Electrical) / Ton of steel
Energy consumption(Thermal) / Ton of steel
Theoritical Energyconsumption(Electrical) / Ton of scrap
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KWh 3000 4000
GJ 16
Electrical energy / Ton of ferroalloy
Thermal energy / Ton of steel
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Capacity MPTA 1.2
No. of strand Nos. 1 2
Thickness mm 230 350
Width mm 800 2600
Length Mtr
ladle size MT 60 300
Machine length Mtr 19Machine radius Mtr 8
No. of segment 10 19
Mould oscillator
Tundish capacity
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Capacity MPTA 2 5
Width mm 1850
Thickness 1.2 25
Descaling
Rougher Nos
Finishing stand
Coil boxLaminar cooling
Down coiler Nos
Thermal energy /ton GJ 1.3
Electrical energy / toKWh
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Capacity
Thickness
Width mm 1500 4900
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KWh 260
GJ 3
Energy consumption(Electrical) / Ton of steel
Energy consumption(Thermal) / Ton of steel
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Reheating furnace
roughing stand
Intermediate stand
finishing stand
Hot shear
Progressive cooling
Finishing and packaging
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McNally Bharat Engineering company Limited
Unit Technology partner Country
Sinter plant Tyazhpromexport (TPE) Russia
Sinter plant China Metallurgical Group Corporation (MCChina
Coke oven by product DMT Germany
Continuous caster Simens VAI Germany
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EAF steel making cost -2010
Factor Unit Unit cost Fixed Variable Total
1.13 t 315 356.58 356.58 74.35
1.13 t 5 5.66 5.66 1.18
0 t 395 0 0 0.00
0 t 40 0 0 0.00
Oxygen 14 m 3 0.08 1.12 1.12 0.23
0.01 t 1400 19.6 19.6 4.09
Fluxes 0.04 t 30 1.29 1.29 0.27
0 t 8900 13.35 13.35 2.78
0.01 t 600 3 3 0.63
1.33 GJ 12.5 16.63 16.63 3.47
Electricity 0.34 MWhr 90 4.59 26.01 30.6 6.38
Labour 0.35 Man hr 35 3.07 9.21 12.29 2.56
1 8 8 1.67
Interest 1 11.5 11.5 2.40
Total 27.16 452.45 479.61 100.00
Blast furnace route steel making cost
Factor Unit Unit cost Fixed Variable Total
Iron ore 1.44 t 62 88.97 88.97
1.44 t 20 28.7 28.7
0.52 t 128.5 66.69 66.69
0.52 t 19.5 10.12 10.12
0.16 t 325 52.65 52.65
0.16 t 5 0.81 0.81
Oxygen 80 m 3 0.08 6.4 6.4
Item$/unitSteelscrapScrapdeliveryPig iron /
DRIPig iron /DRIdelivery
Ferroalloys
ElectrodesRefractoriesThermalenergy
Depreciation
Item$/unit
Iron oretransport
Cokingcoal
Cokingcoal
transport
Steelscrap
Scrapdelivery
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0.01 t 1400 19.6 19.6
Fluxes 0.52 t 30 15.63 15.63
0.01 t 600 6.6 6.6
1 13 3.25 9.75 13
-20 -20
-2.68 GJ 12.5 -33.5 -33.5
0.12 MWh 150 2.75 15.56 18.3
Labour 0.64 Man hr 35 5.6 16.8 22.4
40 40
Interest 44 44
Total 95.6 284.78 380.37
Therm Coal Iron Ore Electric
$/tonne $/ton C/dmtu $/000m3 C/KwH
2008 M1 98.3
106.1
140.6 369.7 385-400 6.39
2008 M2 141.4 140.6 369.7 390-405 6.38
2008 M3 126.7 140.6 369.7 490-510 6.54
2008 M4 131.8
113.9
140.6 428.4 510-530 6.64
2008 M5 142.7 140.6 428.4 570-580 6.8
2008 M6 171.2 140.6 428.4 635-660 7.4
2008 M7 192.9
122
140.6 517 630-640 7.78
2008 M8 169.7 140.6 517 385-390 7.63
2008 M9 160.7 140.6 517 240-245 7.35
2008 M10 115.7
129.1
140.6 576.7 220-225 7.23
2008 M11 98.8 140.6 576.7 205-210 7.04
2008 M12 84.3 140.6 576.7 230-235 6.88
2009 M1 85.7
137.1
101 576.7 270-275 6.9
2009 M2 80.8 101 520.9 200-205 6.98
2009 M3 65.4 101 412.9 195-200 6.84
2009 M4 68.1
143.4
101 309.6 220-230 6.78
2009 M5 69.1 101 309.6 220-225 6.89
2009 M6 76.5 101 309.6 230-235 7.18
2009 M7 79.1
151
101 244.4 245-250 7.11
2009 M8 77.7 101 222.5 320-325 7.17
2009 M9 72.5 101 222.5 285-290 6.99
2009 M10 76.1 101 232.2 260-265 6.67
Ferroalloys
Refractories
Othercosts
By-productcredits
Thermalenergy,net
Electricity
Depreciation
Year/Month
CokingCoal
NaturalGas
SteelScrap$/tonne
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2009 M11 84.4
142.2
101 232.2 290-300 6.44
2009 M12 89 101 232.2 340-350 6.52
2010 M1 103.9
n/a
101 273.2 335-345 6.54
2010 M2 100.9 101 273.2 325-335 6.55
2010 M3 101.1 101 273.2 435-440 6.5
2010 M4 107.3 n/a 167 300.6 415-420 n/a
2010 M5 107.3 n/a 167 283.3 n/a n/a
Hot metal cost
Raw material 86%
Saleble steel
raw material cost 57.70%
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Iron ore lump
Iron ore fines
Iron ore concentrate
Non coking coal
Coking coal
Natural gas
LPG
LDOHFO
Lime
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Capacity MTPA 0.01 0.36
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Capacity MPTA
Coil width mm
Coil ID mm
Coil wt MT
Line speed mpm
Thickness mm
Coil car
Decoiler
Entry support device
Width adjustor device
Straightening machineGauge table
Shearing machine
Run off table
Pneumatic discharge and stacker device
Unloading table
Pueumatic system
Electrical system with computer PLC program control
Hydraulic system
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Uncoiler
Double cut shear
Bridle roll
Side trimmerFine masher
Entry loop tower
Deflector roll
Vulcan annealing furnace
Water cooling
Galvanizing equipment
Steering
X ray thickness measuring
Skin pass mill
Tension levellerChromate tank
Dryer
Marking machine
Exit loop tower
Flaw detector
Exit shear
EPC unit
Recoiler
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Uncoiler
Press joining machine
Entry loop tower
Degreasing unit
Scotch bite unit
Grain refining unit
Drier
Back coater 1&2
Oven1Prime coater 1&2
Oven2
Drier 3
Top coater 1&2
Printer 172
Oven3
Drier4
Exit loop tower
Tension roll
Guard film laminatorShear
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Pay off real
Scale breakingEntry shear
Welder
Bridle roller
Entry looper car
Hot water dip tank
Acid pickling
Cascade rinse
Drier
Exit looper
Side trimmerBridle roll
Drier
Exit shear
Mill housing
Coiler
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Welder
Hot alkali dip cleaningElectrolytic cleaning
Hot water tank drier
Bridle roll
Shear
Skin pass mill
Pinch roll
Flattner
Shear
Slitter
Looping deviceBatch annealing furnace
Rewind
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India World
Per capita consumption of steel in (2009) kg 47 190
Steel industry (directly and indirectly) CO2 emission 6%
Jan-07
1857
Steel industry was delicensed in 1991 1991
Steel industry was decontrolled in 1992 1992
India's Tata Steel made a successful$11.3 billion offer to buy European steelmaker Corus Group PLC.
Bulk production of steel began afterdevelopment of Bessemer converter byHenry Bessemer's in 1857.
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1. Next to Aluminum, Iron is the most widely distributed and abundant metal, consist
2. The essential iron minerals which are commercially exploited are MAGNETITE (F
3. In addition certain important iron ores are composed to some extent of Hydrous ir
4. Even though the iron content (Fe) of the mineral is a important factor, an equally i
5. Specific energy consumption/ TCS -6.5Gcal
The averag
Among the elements composing the crust of the earth, iron
Continuous casting accounts for 95% of steel production in t
Continuous casting technology started in late 1950s
During mining of iron ores run of mine (ROM) is crushed an
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ing about 4.6% of the Earth’s crust.
e3O4) containing 72.4% Fe, HAEMATITE (Fe2O3) containing 70% Fe, Goethite [FeO(OH)] containing 68.5% Fe, LIMONITE a
on silicates, such as Chamosite, Thuringite, Greenalite and Glauconite.
mportant issue is type and proportion of gangue material present in the said mineral which may influence the metallurgical ope
Fe) exists in the largest quantity next to oxygen (O), silicon (Si), and aluminium (Al).
he world
screened for sizing, producing both iron ore fines (IOF, size minus 10 mm) as well as cali
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nd the carbonates namely SIDERITE, CHALYBITE or SPATHIC IRON ORE, containing 48.3% Fe. Less important ores are th
rations because of process of fluxing involved in separation of Iron metal from the gangue in the furnaces.
rated lump ore (CLO, size 10-30 mm).
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e Sulphides, Pyrite, (FeS2), Pyrrhotite (Fe1-nS) and the complex oxide like Franklinite (FeZnMn) (FeMn)2O4.
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Process unit Function
Pickling line
Skin Pass Mill
Temper Mill
CR Slitter
To inspect the coil aginst any defect.
Sl.No.
To remove the oxides and mill scalefrom strip surface to enable furtherreduction of thickness to desired levelin cold rolling mill.
Cold RollingMill
To reduce the thickness of the pickledhot rolled coil to desired level.
ElectrolyticCleaning line
To remove the oil from the surface of the cold rolled coil to produce brightand corrossion free steel
BatchAnnealingFurnace
To obtain desired properties in thefinished cold rolled coil.
ContinuousannealingLine
To obtain desired properties in thefinished cold rolled coil.
To obtain desired surface finish andimprove flatness and suppresses theyield point elongation
To enhance the physical propertiesthrough cold forming of the steelproduct in the bite of the work roll
To cut the CR coil length wise and toremove side trims to obtain uniformwidth throughout the coil as perrequirement.
Cut ToLength
To cut the slitted coil to desired lengthas per requirement
CoilInspectionLine
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Galvalume
Plate Mill
Hot Strip Mill
Skelp Mill
Section mill
Hot DipGalvanizingLine
To provide protective zinc coating tothe cold rolled coil.
To provide protective zinc andaluminium coating to the cold rolledcoil.
ColourCoating Line
To provide protective colour coating tothe cold rolled coil.
Electrolytictin &Chromiumplating Line
To provide protective tin or chromiumcoating to the cold rolled coil.
To produce plate of varying thicknessby hot rolling of slab.
To produce strip of varying thickness inthe form of coil by hot rolling of slab.
To produce strip of varying thicknessand narrow width in the form of coil by
hot rolling of billet.Merchantmill
To produce plain or TMT rebar for billetby hot rolling
To produce joist,channel,angle frombloom by hot rolling
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SMS-II 2 mt
SMS-III 4 mt