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At & P.O:At & P.O:At & P.O:At & P.O: Hijalgora, P.S:Hijalgora, P.S:Hijalgora, P.S:Hijalgora, P.S: JamuriaJamuriaJamuriaJamuria, , , , DistDistDistDistrict: Paschim Bardhaman, West Bengal.rict: Paschim Bardhaman, West Bengal.rict: Paschim Bardhaman, West Bengal.rict: Paschim Bardhaman, West Bengal.

DPR of expansion project: M/s M/s M/s M/s M B SPONGE & POWER LIMITEDM B SPONGE & POWER LIMITEDM B SPONGE & POWER LIMITEDM B SPONGE & POWER LIMITED.

At: Hijalgora, P.S: Jamuria, District: Paschim Bardhaman, West Bengal 2

IIIIndexndexndexndex

ChChChCh. NO.. NO.. NO.. NO. TITLETITLETITLETITLE PAGE NO.PAGE NO.PAGE NO.PAGE NO.

CH-1 PROJECT AT GLANCE 3

CH-2 INTRODUCTION PROFILE 7

CH-3 PROJECT PROFILE 12

CH-4 SITE ANALYSIS 95

CH-5 PLANING BRIEF 105

CH-6 PROPOSED STRUCTURE 107

CH-7 REHABITATION & RESETTLEMENT 116

CH-8 PROJECT SCHEDULE 117

CH-9 ANALYSIS PROPOSAL 122



CHAPTER –I PROJECT AT A GLANCEPROJECT AT A GLANCEPROJECT AT A GLANCEPROJECT AT A GLANCE

1.1.1.1.1111 EXECUTIVE SUMMARYEXECUTIVE SUMMARYEXECUTIVE SUMMARYEXECUTIVE SUMMARY::::

1 Name of the Company. M B SPONGE & M B SPONGE & M B SPONGE & M B SPONGE & POWERPOWERPOWERPOWER LTD.LTD.LTD.LTD.

2

Registered Office.

M B SPONGE & POWER LIMITED

21, Hemanta Basu Sarani, 4 th Floor, Room No:

428, Kolkata - 700001, W.B.

Phone: 033-39509775 / 30223548

email: [email protected]

Factory.

Village: Hijalgora, Post Office: Hijalgora. P.S: Jamuria, District: West Bardhaman. State : West Bengal.

3 Name of the Directors.

Sri Shankar Lal Agarwal Sri Pawan Agarwal Sri Ritesh Agarwal Sri Raj Agarwal

4 Present Business. Steel Manufacturing.

5 Area of plant. 8.31 Acres

6 Topo Sheet No. 73 M/2

7 Latitude. 23041’ 52.9” N

8 Longitude. 870 06’ 52.9” E

Production CapacityProduction CapacityProduction CapacityProduction Capacity:::: 9 Existing Capacity. DRI : 2 x 100 TPD

10 Proposed Expansion.

DRI : 1 x 350 TPD SMS : 3 x 15 Ton (With 6/11 radius 2 strand Concast.) Rolling Mill : 400 TPD Power : 22 MW (WHRB : 11 MW & AFBC : 11 MW )

11 Cost of Project (Expansion). Proposed Proposed Proposed Proposed –––– 22227474747482.00 82.00 82.00 82.00 LacLacLacLac



12 Manpower requirement.

Existing : 125 Nos. Proposed : 211 Nos.

Total : 3Total : 3Total : 3Total : 333336666 NosNosNosNos

13 Power requirement. Existing : 1.5 MW Expansion : 17.0 MW Total : Total : Total : Total : 18.5 MW18.5 MW18.5 MW18.5 MW

14 Water Consumption. Existing : 190 KLD Expansion : 1067 KLD Total : Total : Total : Total : 1111222257 KLD57 KLD57 KLD57 KLD

14 DG sets. 2 x 250 KVA 1 x 750 KVA

COST OF PRCOST OF PRCOST OF PRCOST OF PROJECTOJECTOJECTOJECT ----:::: SL SL SL SL NoNoNoNo

DetailsDetailsDetailsDetails Rs. In LacksRs. In LacksRs. In LacksRs. In Lacks PROPOSEDPROPOSEDPROPOSEDPROPOSED

1 Land & Site development incl. Boundary Nil

2 Office Building 327.00

3 Structural Building 2250.00

4 Plant, Machinery & Equipment 15620.00

5 Erection & Installation 1050.00

6 West Gas Cleaning System 650.00

7 Miscellaneous & Fixed Asset 810.00

8 Contingencies 500.00

9 Engineering & Consultancy Charges 275.00

10 Working Capital 6000.00

TOTALTOTALTOTALTOTAL 22227474747482828282.00.00.00.00

The company proposes for expansion to set up a 1x350 TPD DRI, 3x15 Ton SMS with Concast Machine & 400 TPD Rolling Mill with 22 MW Captive Power Plant with capacity 120000 Ton per annum of Rolled Product through the existing & Proposed Sponge Iron & proposed Captive Power Plant –proposed Induction Furnace – CCM & Rolling mill route.



After reviewing the various probable options including economical viability, power balancing, implementation schedule, it was concluded that the above set up would be best suited for the project. 1.21.21.21.2 SELECTION OF PROCESS ROUTESELECTION OF PROCESS ROUTESELECTION OF PROCESS ROUTESELECTION OF PROCESS ROUTE:::: Over the last few years, there has been a great change in the Indian Economic scenario which has concomitant impact on industries. Under spell of liberalization, the Indian Steel Industry has witnessed a rapid growth. Sponge Iron being a substitute for scrap, the demand for Sponge Iron is on the rise mainly for two reasons i.e. Firstly, with an improvement in the Steel scenario, there has been a growth in the use of Induction Furnace method of producing steel which requires the use of good quality iron input, and secondly due to the shortfall in the availability of good quality scrap. Sponge Iron or Directly Reduced Iron (DRI) is becoming increasingly important around the world as a raw material for high quality steel; India being no exception and after giving due consideration to the raw materials; the Coal based direct reduction process through rotary kilns is considered for the plant as the process route for sponge iron. The waste heat from the kilns will be utilized in WHRB for steam generation. Similarly dolochar generated as solid by-product of sponge iron will be used as mixed fuel along with coal/coal fines in AFBC for steam generation and steam driven TG will be used for power generation.

1.31.31.31.3 The Proposed Expansion The Proposed Expansion The Proposed Expansion The Proposed Expansion will be set up with the following combination:will be set up with the following combination:will be set up with the following combination:will be set up with the following combination: 2222 x 100 TPD Sponge Iron x 100 TPD Sponge Iron x 100 TPD Sponge Iron x 100 TPD Sponge Iron PlantPlantPlantPlant ( Existing )( Existing )( Existing )( Existing ) 1 x 350 TPD Sponge Iron Plant ( Proposed )1 x 350 TPD Sponge Iron Plant ( Proposed )1 x 350 TPD Sponge Iron Plant ( Proposed )1 x 350 TPD Sponge Iron Plant ( Proposed ) 22222222 MW Power Plant usingMW Power Plant usingMW Power Plant usingMW Power Plant using WHRB and AFBC boiler ( ProposedWHRB and AFBC boiler ( ProposedWHRB and AFBC boiler ( ProposedWHRB and AFBC boiler ( Proposed ))))

3333 x 1x 1x 1x 15555 TTTTonononon = = = = 450450450450 TPDTPDTPDTPD Induction Furnace with CCMInduction Furnace with CCMInduction Furnace with CCMInduction Furnace with CCM ( Proposed )( Proposed )( Proposed )( Proposed ) 400400400400 TPD Rolling MillTPD Rolling MillTPD Rolling MillTPD Rolling Mill (Proposed(Proposed(Proposed(Proposed ))))

TheTheTheThe proposal proposal proposal proposal has been made has been made has been made has been made with with with with the following assumptions:the following assumptions:the following assumptions:the following assumptions: • Total number of working days for Sponge Iron Plants is 300 days at 80% efficiency

in the first year of operation and 90% efficiency in the 2nd year of operations henceforth.



• There will be Captive Power Plants which will generate 22 MW. 11 MW from Waste Heat Recovery and balance 11 MW by using the dolochar and coal fines generated in Sponge Iron Production.

Licensing/ RegistrationLicensing/ RegistrationLicensing/ RegistrationLicensing/ Registration:::: Company has already initiated the various processes of Licensing/ Registration. Government approvals required and status

Approval/ ConsentApproval/ ConsentApproval/ ConsentApproval/ Consent AgencyAgencyAgencyAgency StatusStatusStatusStatus

Land Possession Private parties Existing - 8.31 Acres

Environmental Clearance

Ministry of Environment & Forests

The project has been incorporated before 14 th Sept, 2006 Hence EC is NA for existing Unit.

Consent to Establish

West Bengal State Pollution control Board

For Existing _ Consent to Establish Obtained 06 / 01 / 2006

Consent to Operate West Bengal State Pollution control Board

For Existing _ Consent to Operate Obtained Vide _ Letter No. 1973/WPBA/Red (Bwn)Cont (517)/16 Dated:30/11/207

Power Requirement India Power Ltd. Existing power connection



CHAPTER –II INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION PROFILE OF INDUSTRYPROFILE OF INDUSTRYPROFILE OF INDUSTRYPROFILE OF INDUSTRY

2.12.12.12.1 Company and Directors’ ProfileCompany and Directors’ ProfileCompany and Directors’ ProfileCompany and Directors’ Profile:::: M/s. M/s. M/s. M/s. M B M B M B M B SPONGE & POWERSPONGE & POWERSPONGE & POWERSPONGE & POWER LTD. LTD. LTD. LTD. is a limited company carrying out business in production of sponge iron. The company has been promoted by a group of experienced businessmen who are presently engaged in manufacturing and trading business of various products. They are:

SL NoSL NoSL NoSL No Name & DesignationName & DesignationName & DesignationName & Designation AgeAgeAgeAge QualificationQualificationQualificationQualification ExperExperExperExperienceienceienceience

1 Sri Shankar Lal Agarwal 63 B.Com (Hons) Business for last 33 years

2 Sri Pawan Agarwal 56 B.Com (Hons) Business for last 30 years

3 Sri Ritesh Agarwal 47 B Tech. Business for last 16 years

4 Sri Raj Agarwal 40 B.Com (Hons) Business for last 10 years

2.22.22.22.2.... Cost EstimateCost EstimateCost EstimateCost Estimate & Capacity & Capacity & Capacity & Capacity for the Proposed Project:for the Proposed Project:for the Proposed Project:for the Proposed Project:

Sponge Iron, SMS with CCM, Rolling Mill & Captive Power Plant are under proposed plant. Cost of project has been arrived at taking cost of land, cost of ESP after WHRB and AFBC in cost of power plant, SMS & Rolling Mill is as follows.

SL NoSL NoSL NoSL No DetailsDetailsDetailsDetails Rs. In LacksRs. In LacksRs. In LacksRs. In Lacks

1 Land & Site development incl. Boundary Nil

2 Office Building 327.00

3 Structural Building 2250.00

4 Plant, Machinery & Equipment 15620.00

5 Erection & Installation 1050.00

6 West Gas Cleaning System 650.00

7 Miscellaneous & Fixed Asset 810.00

8 Contingencies 500.00

9 Engineering & Consultancy Charges 275.00

10 Working Capital 6000.00




2.32.32.32.3.... Location and Land Use BreakupLocation and Land Use BreakupLocation and Land Use BreakupLocation and Land Use Breakup The area is having a very good infrastructural facility in terms of road connectivity as NH 19 connecting Kolkata – Delhi at a distance of 5.6 Km & NH 14 connecting Bankura and Suri at a distance of 3.4 Km. Site is located at Vill – Hijalgora, P.O. – Hijalgora, District – Paschim Bardhaman, West Bengal. Total Land Area – 8.31 acres. Proposed approximate use of Land:

SL SL SL SL TYPE OF USETYPE OF USETYPE OF USETYPE OF USE AREAAREAAREAAREA (Acres)(Acres)(Acres)(Acres)

1 Manufacturing Plant & Storage 2.20

2 Administrative offices, canteen, security, maintenance 0.20

3 Entrance, Roads and Paved Area 0.80

4 Green Belt 2.75

5 Rolling & SMS 1.10

6 Captive Power 0.86

6 Vacant land 0.40

TOTAL LAND ACQUIREDTOTAL LAND ACQUIREDTOTAL LAND ACQUIREDTOTAL LAND ACQUIRED 8.31 Acres8.31 Acres8.31 Acres8.31 Acres

2.42.42.42.4.... Implementation ScheduleImplementation ScheduleImplementation ScheduleImplementation Schedule of proposed Expansionof proposed Expansionof proposed Expansionof proposed Expansion Based on the consideration that pre-project activities are accomplished prior to the award of the main machinery order, an implementation period of 18 months from the date of signing / effectiveness of the contract 2.52.52.52.5. . . . Usage of Sponge IronUsage of Sponge IronUsage of Sponge IronUsage of Sponge Iron:::: It is used as a replacement of scrap. Hence it can be used as a very cheap raw materials for steel making via EAF (Electric Arc Furnace) or IF (Induction Furnace) route. Hence, sponge iron has assumed prime importance in today’s steel scenario, where cost effectiveness is the buzz word.



RAW MATERIAL REQUIREMENT:RAW MATERIAL REQUIREMENT:RAW MATERIAL REQUIREMENT:RAW MATERIAL REQUIREMENT: For For For For ExistinExistinExistinExisting g g g SPONGE IRONSPONGE IRONSPONGE IRONSPONGE IRON 2222 xxxx 100TPD100TPD100TPD100TPD::::

Sl Sl Sl Sl NoNoNoNo

ITEMITEMITEMITEM PER MT OF PER MT OF PER MT OF PER MT OF PRODUCTPRODUCTPRODUCTPRODUCT

REQUIREMENTREQUIREMENTREQUIREMENTREQUIREMENT MT PER DAYMT PER DAYMT PER DAYMT PER DAY

REQUIREMENT REQUIREMENT REQUIREMENT REQUIREMENT MT PER YEARMT PER YEARMT PER YEARMT PER YEAR

a. IRON ORE 1.60 320.00 96000.00

b. NON COKING COAL 1.30 260.00 78000.00

c. DOLOMITE/ LIMESTONE 0.03 6.00 1800.00

TOTALTOTALTOTALTOTAL 2.932.932.932.93 586.00586.00586.00586.00 175800.00175800.00175800.00175800.00

For PFor PFor PFor Proposed roposed roposed roposed SPONGE IRON 1SPONGE IRON 1SPONGE IRON 1SPONGE IRON 1 xxxx 350TPD:350TPD:350TPD:350TPD:





a. IRON ORE 1.60 560.00 168000.00

b. NON COKING COAL 1.30 455.00 136500.00


TOTALTOTALTOTALTOTAL 2.932.932.932.93 1025.501025.501025.501025.50 307650307650307650307650....00000000

RAW MATERIAL REQUIREMENT FORRAW MATERIAL REQUIREMENT FORRAW MATERIAL REQUIREMENT FORRAW MATERIAL REQUIREMENT FOR POWER POWER POWER POWER GENERATIONGENERATIONGENERATIONGENERATION::::

A WHRBWHRBWHRBWHRB

HOT FLUE GASES 2 x 26000 Nm3/hr from ABC of Existing DRI kilns 1 x 91000 Nm3/hr from ABC of Proposed DRI kilns

B AFBCAFBCAFBCAFBC

ITEMITEMITEMITEM COMPOSITION /COMPOSITION /COMPOSITION /COMPOSITION /

UNITUNITUNITUNIT REQUIREMENTREQUIREMENTREQUIREMENTREQUIREMENT

TPDTPDTPDTPD REQUIREMENTREQUIREMENTREQUIREMENTREQUIREMENT TPATPATPATPA (300 Days)(300 Days)(300 Days)(300 Days)

b. DOLOCHAR (CV – 1300 Kcal/Kg)

0.40 165.00 49500.00

c. COAL FINES (CV – 2100 Kcal/Kg)

0.20 82.50 24750.00

d. COAL (CV – 3200 Kcal/Kg)

0.40 165.00 49500.00

TOTAL TOTAL TOTAL TOTAL (Avg.CV– 2300 Kcal/Kg)

1.001.001.001.00 412412412412....55550000 123750.00123750.00123750.00123750.00



RAW MATERIAL REQUIREMENT FOR RAW MATERIAL REQUIREMENT FOR RAW MATERIAL REQUIREMENT FOR RAW MATERIAL REQUIREMENT FOR BIBIBIBILLET UnitLLET UnitLLET UnitLLET Unit:::: ---- 450 TPD:450 TPD:450 TPD:450 TPD:

Raw materialRaw materialRaw materialRaw material SpSpSpSpecificecificecificecific

ConsConsConsConsumumumumptptptptionionionion.... Per DayPer DayPer DayPer Day PerPerPerPer AnnumAnnumAnnumAnnum SourceSourceSourceSource

Sponge Iron 0.816 367.20 110160.00 In House

production

Scrap 0.343 154.35 46306.00 Out source/

Local

Ferro Alloys 0.006 2.70 810.00 Local

TotalTotalTotalTotal 1.165 524.25 157275.00157275.00157275.00157275.00

RRRRaw Material aw Material aw Material aw Material for for for for Rolling Mill Rolling Mill Rolling Mill Rolling Mill 400 TPD400 TPD400 TPD400 TPD: : : :

Raw materialRaw materialRaw materialRaw material Sp.ConsSp.ConsSp.ConsSp.Consumumumumptptptptionionionion.... Per DayPer DayPer DayPer Day Per AnnumPer AnnumPer AnnumPer Annum SourceSourceSourceSource

Billets 1.03 412 T 123600 T In House production

2.72.72.72.7. . . . ManpowerManpowerManpowerManpower:::: Total requirement of manpower in the proposed production and power plant comes to approximately 336336336336 numbers for 3 shift work and general shift administration.

UnitUnitUnitUnit ExistingExistingExistingExisting PPPProposedroposedroposedroposed TotalTotalTotalTotal

DRI / Sponge Iron 120 30 150

SMS & CCM - 45 45

Rolling - 55 55

CPP/Auxiliary - 71 71

Administrative Staff 5 10 15

TOTAL 125125125125 NosNosNosNos 211211211211 NosNosNosNos 336336336336 NosNosNosNos



2.82.82.82.8. . . . PowerPowerPowerPower:::: Power will sourced initially from India Power for construction/erection and preliminary work. Initially 1.5 MW load will be sanctioned. Later on power will be sourced through the CPP as it will be commissioned simultaneously with the sponge iron plant.

UnitUnitUnitUnit Existing (MW)Existing (MW)Existing (MW)Existing (MW) PPPProposed (MW)roposed (MW)roposed (MW)roposed (MW) Total (MW)Total (MW)Total (MW)Total (MW)

DRI SPONGE 1.5 1.5 3

SMS & CCM - 12.0 12.0

ROLLING - 2.0 2.0

CPP/AUXILLARY - 1.5 1.5

TOTAL 1.51.51.51.5 17.017.017.017.0 11118888.5.5.5.5

2.92.92.92.9. . . . WaterWaterWaterWater:::: Water is one of the most important resources of any manufacturing unit. For this unit water will be drawn from both surface and ground water sources. Make up water requirement is estimated as:

UnitUnitUnitUnit ExistingExistingExistingExisting mmmm3333/day/day/day/day

ProposedProposedProposedProposed mmmm3333/day/day/day/day

Total MakeTotal MakeTotal MakeTotal Make----upupupup mmmm3333/day/day/day/day

DRI SPONGE 172 200 372

POWER PLANT 645 645

SMS 110 110

ROLLING MILL 90 90

WATER SPRINKLING & GREEN BELT 10 10 20

DOMESTIC USE 8 12 20

TOTALTOTALTOTALTOTAL 111190909090 1010101067676767 1111222257575757

2.102.102.102.10. . . . ConnectivityConnectivityConnectivityConnectivity:::: RoadRoadRoadRoad:::: The project site is located at 5.6 Km from NH - 19 which connects Kolkata and Delhi via Asansol, Dhanbad. The location is also just 12 Km away from Asansol. RailRailRailRail:::: The Railway siding is Ikhra at a distance of 0.3 Km & Asansol at a distance of 15 kms away at Asansol Goods Shed is connected by the above highway.



CHAPTER –III

BRIEF DESCRIPTION OF PROJECTBRIEF DESCRIPTION OF PROJECTBRIEF DESCRIPTION OF PROJECTBRIEF DESCRIPTION OF PROJECT::::

3.1 IntroductionIntroductionIntroductionIntroduction:::: Steel is crucial to the material development of any modern economy. It is a product of a large technologically complex industry having strong forward and backward linkages in terms of material flow and income generation. All major economies are not only characterized by existence of a strong steel industry, the growths of many of these economies have been largely shaped by the strength of their steel industries during their early stages of development. Some of the rapidly expanding newly industrialized countries like South Korea, China, and Brazil amongst others have built up substantial capacities not only to support their rapidly growing domestic economies, but also to export significantly to mark their presence in international markets. India has seen nearly a century of steel making as it stands on the threshold of a new era. The face of Indian Iron and Steel Industry is changing at such a fast pace that it is difficult to focus it now in the historical perspective. Steel is a core industry and thus its demand is strongly linked to overall level of economic activity in the country. Given the inherent long-term potential of the Indian Economy and its cyclical nature, the long-term prospects of the steel industry are fairly comfortable. Liberalization and opening up of economy has given a new vitality to this sector. Demand and production have been growing at a healthy rate for past two years and forecast for next ten years is very bright. As the process of economic development takes off growth rate in industrial and infrastructure sectors such as capital goods, power, transport, telecommunication and hydrocarbons also increases leading to increased steel consumption. The Indian Iron and Steel Industry today display variety in size, ownership, technology and output. The industry was traditionally divided in to main producers and so called secondary sector. This division is getting blurred by latest developments fueled by liberalization and opening up of economy, such as:

• Larger EAF based units going on stream producing sophisticated finished products as compared to small EAF/ IF units producing pencil ingots.

• Mini BF based plants being planned in the private sector. • Growth in induction furnace units with sizeable production.



• High growth in iron making sector with large gas based DRI units, based sponge iron units and mini blast furnaces producing merchant grade pig iron.

The electric steel industry, which initially started as a result of general steel shortage and dual pricing policy in the country in the past, has grown significantly in the recent years. The older units have been modernizing while new units have been set up with latest technology enabling reduction in cost of production. The major factors contributing to the existence and growth of the industry are as follows:

• Lower investment cost and shorter gestation period as compared to BF-BOF route of steel making.

• Ability for wider dispersal. • Less strain on transport and other infrastructural facilities. • Fewer unit operations. • Non-dependence on metallurgical coke and coking coal. • Less manpower per ton of steel produced. • Short conversion time from raw material to finished products. • Lesser environmental and pollution problem. • Flexibility in production of different qualities of steel and alloy steel.

Besides this above factors the Induction Furnace/Electric Arc Furnace method of manufacturing iron & steel, allows flexibility in the charge mix, amounts to reduced electricity consumption and decreased refractory electrode consumption which has resulted in the manufacture of international quality steel. Since India has rich reserves of coal, and the technology for manufacturing sponge iron is no more new, sponge iron production seems to have a bright future. Sponge Iron or Direct Reduced Iron, DRI as it is popularly known, is a high ferrous content charge material and is used as a substitute for steel scrap as the primary raw material in the Electric Arc Furnace or Induction Furnace, during the process of manufacture of steel. It can be produced both in the lump and pellet form and in a compact and briquetted form known as hot briquette iron. Sponge Iron is becoming increasingly important around the world as a raw material source for high quality steel; India being no exception. In the mid- seventies, the Department of Steel had identified that sponge iron would play a major role in the growth of the secondary steel sector. Apart from making the secondary steel sector less vulnerable to fluctuations in the international scrap prices by reducing dependence on



imports, increased domestic production of sponge iron and the consequent reduction of scrap imports have led to substantial savings in foreign exchange.

3.23.23.23.2 Existing Existing Existing Existing Unit _Unit _Unit _Unit _ DRI DRI DRI DRI ---- Sponge Sponge Sponge Sponge Iron:Iron:Iron:Iron: Sponge iron or DRI (direct reduced iron) is the product obtained from direct reduction of iron ore with an iron content varying from 83 to 92 %. Reduction causes elimination of oxygen leaving behind a honeycomb like porous structure which is “SpongySpongySpongySpongy” in nature. Hence the name Sponge IronSponge IronSponge IronSponge Iron. Usage of Sponge Iron: Usage of Sponge Iron: Usage of Sponge Iron: Usage of Sponge Iron: It is used as a replacement of scrap. Hence it can be used as a very cheap raw materials for steel making via EAF (Electric Arc Furnace) or IF (Induction Furnace) route. Hence, sponge iron has assumed prime importance in today’s steel scenario, where cost effectiveness is the buzz word.

Typical composition shredded scrap and DRI (per cent)Typical composition shredded scrap and DRI (per cent)Typical composition shredded scrap and DRI (per cent)Typical composition shredded scrap and DRI (per cent)

ItemItemItemItem Shredded ScrapShredded ScrapShredded ScrapShredded Scrap DRIDRIDRIDRI

CarbonCarbonCarbonCarbon 0.25 1-1.15

CopperCopperCopperCopper 0.22 0-0.01

ChromiumChromiumChromiumChromium 0.18 0.001-0.01

NickelNickelNickelNickel 0.11 0.001-0.01

MolybdenumMolybdenumMolybdenumMolybdenum 0.02 0.001-0.002

TinTinTinTin 0.02 0.001-0.002

ManganeseManganeseManganeseManganese 0.40 0.002-0.02

SuSuSuSulphurlphurlphurlphur 0.04 0.002-0.02

PhosphorousPhosphorousPhosphorousPhosphorous 0.025 0.02-0.10

Quality and ProductivityQuality and ProductivityQuality and ProductivityQuality and Productivity:::: In terms of quality and productivity, use of sponge iron as cold charge is more advantageous. The demerits of using pig iron and scrap as cold charge are as follows:



Pig ironPig ironPig ironPig iron:::: • It increases the heat time. • Affects the final composition of steel due to insufficient decarburization.

ScrapScrapScrapScrap::::

• It is relatively better but it suffers from following demerits: • Its chemical composition is unknown. • It is uneconomical vis a vis other alternatives.

Another advantage of DRI use is its homogeneity of composition compared to scrap. However Sponge Iron gives a lower yield compared to scrap. It contains some amount of oxide also, i.e. its metallization is low compared to scrap which is reflected in the lower price of DRI. The usage of DRI in EAF varies in the range of 83 % to 89 % (from HBI alone the yield can be as high as 94%) while the yield from scrap is around 93-94 % for most Arc Furnaces. Hence, overall, sponge iron scores over these alternatives by it stable chemical composition, balanced carbon content, low sulphur and moreover assurance of uninterrupted supply at a cheap rate. With stable composition, the sponge iron is alluring all the steel makers of the world to go for sponge iron in pursuit of higher quality and reliability. 3.2.13.2.13.2.13.2.1 PROCESS PROCESS PROCESS PROCESS SELECTION:SELECTION:SELECTION:SELECTION: Selection of a suitable production process and the capacity of the production units form the nucleus around which the basic concept of a plant is developed. While the selection of a process takes into account factors like type of products, availability and amenability of local raw materials, process status, specific energy consumption, level of energy required, and environmental pollution etc., the capacity selection of major units would depend on the volume of production, available unit sizes, economies of scale etc. The process of production of iron by reduction of ore in the solid state is at least more than one hundred years old. In fact the first patent stands in the name of Henry Bessemer, the pioneer of modern steel making. But, there was a growth of serious interest in this field only after the end of the Second World War. However, the technical, economic and social parameters, which decide the viability of a project on a commercial scale changed significantly over the



years. The twin problems of fast depleting reserves of coking coal (both quantitatively and qualitatively) and fluctuating ferrous scrap market can be solved to large extent by the Direct Reduction Process which provides a viable alternative of processing high grade iron ore into steel without utilizing coking coal. The process of manufacture of sponge iron is very simple. The percentage of oxygen associated with iron as oxide is removed from the ore particle and the process is often referred to as "Percentage Reduction" whereas the percentage of iron forming a part of the whole iron, and which exists in the metallic form, is called the degree of metallization in sponge iron making technology. There are two well-established processes for the manufacture of sponge iron, namely: (a) The reformed natural gas process i.e. By the gaseous reduction of the iron ore. (b) Coal based Rotary Kiln process- Solid reduction. 3.2.23.2.23.2.23.2.2 REFORMED NATURAL GAS DIRECT REDUCTION PROCESS:REFORMED NATURAL GAS DIRECT REDUCTION PROCESS:REFORMED NATURAL GAS DIRECT REDUCTION PROCESS:REFORMED NATURAL GAS DIRECT REDUCTION PROCESS: The reformed natural gas process is based on the equation given below, where the natural gas feed stock, primarily Methane, is reformed in the catalyst filled reformer tubes producing the reformed natural gas (Carbon Monoxide & Hydrogen). CH4 + CO2 = 2CO + 2H2 Carbon Monoxide & Hydrogen thus produced; act as the principal reductants of Iron Oxide. i) Fe2O3 + 3C = 2Fe + 3CO ii) Fe2O3 + 3H2 = 2Fe + 3H2O iii) Fe2O3 + 3CO = 2Fe + 3CO2

The CO reacting with Fe2O3 produces Fe and CO2. The CO2 gas thus produced is reduced again to react with natural gas. CH4 + CO2 = 2CO + 2H2 The reformed natural gas reduction process has been developed and made commercially viable by two companies, viz., Nitrox Corporation - KOBE Steel Company and, the HYCL (Hojalatory Y.A. Lamina C.H.) of Mexico. In gas based DRI process, the reduction gas is produced outside vertical reactor orbit is a capital-intensive unit. The plant should be located near gas basin, otherwise laying pipeline would be tedious work and also gas based plants requires mainly iron ore pellets



as main feed stock. Production of pellets involves additional investment and are relatively costlier compared to lump ore. It is not proposed to consider the above reformed natural gas process because of the following factors: a. The availability of natural gas is problematic, being restricted to the Bombay High

area. b. The raw material charge has to be partly in the form of iron ore pellets, which are

expensive. c. The landed price of natural gas is quite high. EQUIPMENTS INVOLVEDEQUIPMENTS INVOLVEDEQUIPMENTS INVOLVEDEQUIPMENTS INVOLVED::::

Reformer, Heat Recovery Units, Turbo Generators, CO2 Removal System, Process Gas Heater, Recycle Gas Compressor, Reactor, Conveyors, Stacker Reclaimer and Distributed Control System (DCS).

33333333........22222222........33333333 CCCCCCCCOOOOOOOOAAAAAAAALLLLLLLL BBBBBBBBAAAAAAAASSSSSSSSEEEEEEEEDDDDDDDD DDDDDDDDIIIIIIIIRRRRRRRREEEEEEEECCCCCCCCTTTTTTTT RRRRRRRREEEEEEEEDDDDDDDDUUUUUUUUCCCCCCCCTTTTTTTTIIIIIIIIOOOOOOOONNNNNNNN PPPPPPPPRRRRRRRROOOOOOOOCCCCCCCCEEEEEEEESSSSSSSSSSSSSSSS:::::::: The coal based method of producing sponge iron involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. The reduction process is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850oC – 1050oC). The inclination and the rotary motion of the kiln ensures that the raw materials move from feed end to the discharge end of the kiln and it is during this movement that the actual reduction of iron ore to iron takes place. The material discharged from the kiln is taken to a rotary cooler for cooling and the cooled product, after being discharged from the cooler moves on to the next step in the production process viz. product separation and handling system. At this stage the product is a mixture of sponge iron and non-magnetic matter such as char and with the aid of magnetic separators, the final product, sponge iron is separated and stored in bins meant for the purpose. The basic reactions for the process are as follows: 3Fe2O3 + CO > 2Fe3O4 + CO2 Fe3O4 + CO > 3FeO + CO2 FeO + CO > Fe + CO2 The CO is generated for above reaction according to:



Co2 + C > 2CO Following are few advantages of coal based sponge iron unit: c. Lump iron ore is used as the feed stock. d. Abundant availability of non-coking coal, which is used as the reductant. e. Could be established with relatively lower capacity and high ash content coal also

could be used. f. Power generation could be achieved by using waste heat from rotary kiln.

EQUIPMENTS INVOLVEDEQUIPMENTS INVOLVEDEQUIPMENTS INVOLVEDEQUIPMENTS INVOLVED:::: Rotary Kiln, Rotary Cooler, Magnetic Separator, Product Storage Bins, Electro-Static Precipitator (ESP), Dust Settling Chamber (DSC), Gas Conditioning Tower (GCT), After Burning Chamber (ABC), D.G. Set, Compressor, Electronic Weighbridge, De-dusting System, Cooling Towers, Belt Conveyor System, Iron Ore Crusher, Coal Crusher, Raw Material Storage Bins, EOT Crane, Plant Communication System, A.C. Ventilation System, Ground Hopper, Pug Mill, Screw Conveyor, Vibrating Screens, etc.

CONSTITUENTCONSTITUENTCONSTITUENTCONSTITUENT COAL BASED DRICOAL BASED DRICOAL BASED DRICOAL BASED DRI GAS BASED HBIGAS BASED HBIGAS BASED HBIGAS BASED HBI

Chemical CompositionChemical CompositionChemical CompositionChemical Composition

Fe (Total) 90 – 92% 93.0%

Fe (Metallic) 81-84% 86.5%

Metallisation 90 (+/- 2) 93.0%

Carbon 0.2 - 0.3 % 1.5 – 3.0 %

Sulphur 0.025 - 0.030 % max 0.015 max

Phosphorus 0.05 – 0.06 % max 0.04% max

Gangue 5.0 – 8.0 % max 3.7%

Physical CompositionPhysical CompositionPhysical CompositionPhysical Composition

Size 3 – 30 mm +6 – 200 mm

Bulk Density 1.6 – 2.0 mt/m3 2.5 – 2.7 mt/m3

Inherent Density 3.5 mt/ m3 5.1 – 5.5 gms/cm3

Nominal Weight -- 0.5 kg per briwuette

Nominal Size -- 110 x 50 x 30 mm



3.3.3.3.2222.4.4.4.4 The brief outline of the Existing The brief outline of the Existing The brief outline of the Existing The brief outline of the Existing DRI projectDRI projectDRI projectDRI project is as given below:is as given below:is as given below:is as given below: The basic raw materials required for the production of the sponge iron are the ore, coal and lime stone. The plant consists of iron and coal crushing plant for lime stone is envisaged. The iron ore is crushed to the required size and fed to the day bins. The coal will also be sized and screened. The different size fractions are fed to separate coal bins. The finer size is used for blowing from the discharge end of the kiln and the coarser sized coal is fed along with the iron ore, coal and lime stone. The sized materials are stored in day bins, from which the raw materials are fed to the rotary kiln through the volumetric feeders at a predetermined rate. The iron ore is pre-heated and reduced in the rotary kiln and passes to the rotary cooler where it gets cooled. The cooled material then passes to the belt conveyor system to the product separation system. A junction house is provided to take care of the any eventualities occurring due to the breakdown of the product separation system. The hot gasses will be cooled in the wet scrubber and cleaned before being let off through the chimney. Emergency stack provided for the escape of gasses when there is break down of the waste gas treatment system. Control room has the PLC operation from which the complete control and operation of the plant is carried out. 3.2.53.2.53.2.53.2.5 SOME GENERAL INPUT SOME GENERAL INPUT SOME GENERAL INPUT SOME GENERAL INPUT –––– OUTPUT SPECIFICATIONS:OUTPUT SPECIFICATIONS:OUTPUT SPECIFICATIONS:OUTPUT SPECIFICATIONS: Specifications of Sponge IronSpecifications of Sponge IronSpecifications of Sponge IronSpecifications of Sponge Iron:::: In light of the above comparative study between the two processes, one could obviously select coal based one and the decision could be justified. Hence, for the proposed sponge iron project, process selection is limited to sponge iron production by Direct Reduction processes using non-coking coal as reluctant. The technology for the present project is the same as that used by OSIL, Tata Sponge, etc. The entire outcome coincides with the ISI specifications and is the same as above groups' products. Quality wise, its performance is comparable with that of OSIL.

33333333........22222222........66666666 MMMMMMMMAAAAAAAANNNNNNNNUUUUUUUUFFFFFFFFAAAAAAAACCCCCCCCTTTTTTTTUUUUUUUURRRRRRRRIIIIIIIINNNNNNNNGGGGGGGG PPPPPPPPRRRRRRRROOOOOOOOCCCCCCCCEEEEEEEESSSSSSSSSSSSSSSS--------DDDDDDDDRRRRRRRRIIIIIIII:::::::: Direct reduction is basically a chemical process occurring at high temperature in which oxygen is removed from the iron ore converting the ore, practically entirely to metallic iron. The Direct reduction process consists of reducing iron ore with solid carbonaceous material such as coal in a rotary kiln heated to a temperature of about 1000oC. After



reduction the products are cooled to room temperature in the rotary cooler with indirect water cooling system. The products are then screened and magnetically separated into Sponge Iron, Char, Ash, etc. High degrees of reduction and thermal efficiency can be obtained by controlling process parameters such as reduction temperature, rate of feed, size of feed, grade of feed, etc. In the process for the production of sponge iron, the raw materials viz., iron ore, Coal and dolomite are charged into the Rotary Kiln from the inlet end by means of a feed tube in a pre-determined ratio by electronic weighing equipment. The rotary kiln is of 3 mts. In diameter and 42 mts. long is inclined at an angel of approximately 1.43°. It is internally lined with refractory of 230 mm thickness. An AC variable speed motor at a step-less variable speed ranging from 0.2 to 1.0 RPM rotates it. Due to the inclination and the rotary motion of the kiln the material moves from the feed end of the kiln to the discharge end in approximately 10 to 12 hrs. The fine coal is blown from the discharge end of the kiln to maintain the required temperature and the carbon concentration in the bed. The kiln has five shell air fans mounted on the top which blow air in the respective zones to maintain the required temperature profile. The material and the hot gasses move in the counter current direction; as a result of which the iron ore gets pre-heated and gradually reduced by the time it reaches the discharge end.

The kiln can be divided process-wise into two zones namely pre-heating zone and reduction zone. The pre-heating zone is approximately 3.3% of the total length of the kiln and the rest is taken as the reduction zone. The material gets heated to the reduction temperature in the pre-heating zone. Upto 200OC, the iron ore, coal and limestone gets dried and all the moisture is vaporized. Upto 800OC the iron ore gests roasted and any carbonates in it get calcinated. In the coal the volatile matter starts getting released. The limestone

also gets calcinated and becomes active. The iron ore, which is in the form of hematite, get reduced to magnetite. After this the materials enter to the reduction zone where the magnetite is reduced to wustite and then to the metallic iron. The various stage wise reduction of iron ore is as shows below :-



3Fe2O3 + CO � 2Fe3O4 + CO2 Fe3O4 + CO � 3FeO + CO2 FeO + CO � Fe + CO2

Thus the iron in the ore gets reduced to its metallic from. The sum total of the above reactions is endothermic. So to carry out these reactions to completion additional source of heat is required. This additional heat is obtained by burning the coal in the gas phase, which transfers the heat to the bed material. Coal contains sulphur in it. During the decomposition of the coal the sulphur is released in the form of Iron sulphide. During the reduction process of iron ore the sponge iron picks up sulphur by the following reaction: FeO + H2S � FeS + H2O The iron sulphide (FeS) has deleterious effect in the steel making and is to be removed. So lime stone is used to prevent the sulphur pick up by the sponge iron. The reaction occurring is FeS + CaO + CO � Fe + CaS + CO2 All the above reactions are possible only in the presence of CO. The generation of the CO is most important reaction, which is called the Boudard reaction. The Boudard reaction is as given below : CO + CO2 � 2CO The reaction is highly endothermic which is also reversible. The conditions favourable for the forward reaction i.e. the generation of CO are: 1. The higher temperature favours the production of CO. 2. The concentration of the reactants has to be high so that the forward reaction

occurs. 3. Low pressure favours the CO generation. All the above reactions occur in the bed phase. In the gas phase the following reactions occur: CH4 + 2O2 � CO2 + 2H2O 2CO + O � 2CO2 C + O2 � CO2



All these reactions are exothermic. They supply the heat required for the reactions in the bed phase to occur. The oxygen required for the burning of these combustibles is supplied from the air tubes placed along the length of the kiln. By controlled combustion, the temperature in the various zones is maintained so that the reduction is proper and to sufficient degree. The product quality is defined by the degree of metallization. The degree of metal list iron is defined as the ratio of the metallic iron to the total iron present.

Fe (metallic) Degree of Metallization --------------------------- x 100

Fe (total) The reduction of iron ore is topo-chemical i.e. the reduction proceeds from the surface in the core. The iron ore on partial reduction has all the different stages of the reduction. The hot material, after the reduction is complete, is transferred to the total cooler via the transfer chute. The cooler is 2.3 mtrs. in diameter and 22 mts. long and made up of Mild Steel sheet. It is also inclined at 1.43O approximately and rotates at 1.4 rmp. It is driven by an AC motor. The water is sprayed on the top of the shell which cools the material inside the cooler indirectly. The heat from the material is extracted by the shell. In order to increase the surface area for the heat extraction, fins are welded inside. Complete shell is covered by thin layer of water. The heat is transferred from the shell to the water by convection. By this the material gets cooled to 80OC. and is discharged on the belt conveyor by the double pendulum valve. The double pendulum valve acts as the seal for the prevention of the atmospheric air into the kiln cooler system. The total kiln cooler system is kept under positive pressure of about 0.3–0.5 mbar. This prevents the atmospheric air from getting into the system. The kiln has to be always operated on ositive pressure as any leakage into the system will cause the re-oxidation of the sponge iron thereby causing the drop in the quality of the product. The material after the discharge from the cooler is dropped on to the cooler discharge conveyor. A diversion chute is provided at the head end of this conveyor for diversion of the material in case of break down in the production separation. The material is then sent to the product separation system. In product separation system, consisting of double deck screen, the material is screened to 0-3 mm and 3-20 mm size fractions. The oversize i.e. + 20mm obtained is small in quantity so it is taken on the floor or diverted to the sponge iron



bin. The 0-3 mm sized fraction is called the fines and is fed to a drum type magnetic separator where the magnetic sponge iron fines and the non-magnetic dolochar get separated and are fed to the respective bins through the chutes and conveyor. The coarser fraction is similarly separated by another magnetic separator and fed to respective bins. This magnetic fraction is called the sponge iron lumps and the non-magnetic as char, which is the unburned coal. This char can be recycled depending on the quality obtained after processing. The gasses, which flow in the counter current direction of the material, go to the dust-settling chamber where the heavier particles settle down. These particles are continuously removed by the wet scrapper system. The gases then pass to the after burner chamber where the residual carbon or CO are burned by the excess air available. The gases are at high temperature and have lot of heat energy, which can be utilized for the power generation through the waste heat recovery boiler. The hot gasses after the heat recovery boiler get cooled at 2000C. The gases are then scrubbed and let of to the atmosphere at 800C through the chimney. Alternatively the hot gases are quenched and scrubbed to clean all the dust in it. And then are let off to the atmosphere through the stack. RAW MATERIALS FOR EXISTING UNIT:RAW MATERIALS FOR EXISTING UNIT:RAW MATERIALS FOR EXISTING UNIT:RAW MATERIALS FOR EXISTING UNIT:





a. IRON ORE 1.60 320.00 96000.00

b. NON COKING COAL 1.30 260.00 78000.00



Make up water requirement is estimated as:Make up water requirement is estimated as:Make up water requirement is estimated as:Make up water requirement is estimated as:

UNITUNITUNITUNIT EXISTING (MEXISTING (MEXISTING (MEXISTING (M3333/DAY)/DAY)/DAY)/DAY)

DRI SPONGE 172

WATER SPRINKLING & GREEN BELT 10

DOMESTIC USE 8

TOTALTOTALTOTALTOTAL 111190909090



MANUFACTURING MANUFACTURING MANUFACTURING MANUFACTURING FLOWFLOWFLOWFLOW CHART:CHART:CHART:CHART:

Sponge Iron Fines + Dolo

Coal

Raw Material Feeding at Ground

Hopper

Iron Ore

Crushing Crushing

Screening

Iron Ore Bin

Screening

Coal Bin

Over Size Over Size

Lime Stone Bin

Sponge Iron Lumps +Char

Setting up of proportion of

mixed Raw Materials for Kiln

Processed in rotary kiln at 1075

deg. centi. With air control

S.I. Lumps Bin

Belt Type magnetic

Indirect cooling in rotary cooler

with Water Spray

Dolo Char Bin

Belt type magnetic

Char Bin Fines Bin

Screening of mixed product

(Sponge Iron and unburnt Coal)



3.2.7 3.2.7 3.2.7 3.2.7 EXPANSION PROJECT :EXPANSION PROJECT :EXPANSION PROJECT :EXPANSION PROJECT : The company proposes for expansion to set up a 1x350 TPD DRI, 3x15 Ton SMS with Concast Machine & 400 TPD Rolling Mill with 22 MW Captive Power Plant with capacity 120000 Ton per annum of Rolled Product through the existing & Proposed Sponge Iron & proposed Captive Power Plant –proposed Induction Furnace – CCM & Rolling mill route.

3.2.3.2.3.2.3.2.8888 RAW MATERAW MATERAW MATERAW MATERIALSRIALSRIALSRIALS –––– PROPOSED PROPOSED PROPOSED PROPOSED DRIDRIDRIDRI 1 x 350 TPD1 x 350 TPD1 x 350 TPD1 x 350 TPD:::: Sl Sl Sl Sl NoNoNoNo



REQREQREQREQUIREMENT UIREMENT UIREMENT UIREMENT MT PER YEARMT PER YEARMT PER YEARMT PER YEAR

a. IRON ORE 1.60 560.00 168000.00

b. NON COKING COAL 1.30 455.00 136500.00



RAW MATERIAL SPECIFICATION: The main raw materials required for the proposed Sponge Iron Plant are lump Iron Ore, Coal and dolomite. Iron OreIron OreIron OreIron Ore::::

Fe (T) : 64 % SiO2 : 0.85 % Max. Al2O3 : 1.80 % Max. S : 0.01 % Max. P : 0.05 % Max.

PhysicalPhysicalPhysicalPhysical:

Compression Strength : > 2000 N/p Tumbling Index : 90% Abrasion Index : 4.0% Swelling Index : 5% Size : 8 to 20 mm



Coal:Coal:Coal:Coal: Non-Coking Coal would be used as reductant in the process for production of sponge iron. The desirable quality of Coal to be used in the proposed Sponge Iron Plant is as follows:

A. Chemical CompositionChemical CompositionChemical CompositionChemical Composition.... Value.Value.Value.Value.

Ash. 20.0 – 24.0 %

Volatile matter. 30.0% maximum

Fixed Carbon. 40.0% minimum

Sulphur. 1.0% maximum

B. Moisture. 8.0% maximum

C. Size Range. 0 – 20 mm

D. Reactivity. 2.2 cm3 of CO/gm of Carbon oC.min.

E. Calorific Value. 5200 Kcal/Kg. Min.

F. Ash Softening Temperature. 1200o C

It is proposed to procure Coal form Central Coalfield Ltd., which is at a distance of about 200 to 250 kms. from the proposed site. The annual requirement of coal would be transported by means of trucks to the plant site.

Dolomite/LimestoneDolomite/LimestoneDolomite/LimestoneDolomite/Limestone :::: Dolomite is required as a de-sulphurising agent. The desirable quality of Dolomite to be used in the proposed Sponge Iron Plant is as follows:

MgO 20% Minimum

CaO 28% Minimum.

SiO2 5% Maximum.

Phosphorus 0.04% Max.

Alkalies 0.10% Max.

L.O.I. Remaining.



3.2.3.2.3.2.3.2.9999 Equipments in DRI PlantEquipments in DRI PlantEquipments in DRI PlantEquipments in DRI Plant :::: 1. IRON ORE handling circuit. 2. Coal Handling circuit. 3. Product separation and storage. 4. KILN , COOLER and assembly. 5. Hydraulic System. 6. Pneumatic System. 7. Refractories. 8. Electrical and Instrumentation. 9. Pollution Control System.

1. BAG FILTERS. 2. ESP. 3. ASH HANDLING.

3.3.3.3.3333 CAPTIVE POWER PLANTCAPTIVE POWER PLANTCAPTIVE POWER PLANTCAPTIVE POWER PLANT :::: 3.3.1 3.3.1 3.3.1 3.3.1 General General General General :::: In India, of late, some coal based Sponge iron plants, realizing the need, have set up waste heat power generation facilities. In view of strong government initiative or incentive for private captive power generation and availability of cheap power, new coal based DRI plants are now being planned with captive power generation from the beginning of the project itself. The efficiency of the process can be increased substantially from around 25 - 30% through utilisation of above mentioned wastes. Through power generation, not only the internal demand of power from Sponge iron production can be met, but also there exists a substantial exportable surplus, which can be either used in down stream steel making units or be sold off. Production of sponge iron in DR kilns generates huge quantities of hot flue gas carrying considerable sensible heat. The char produced by DR Kilns also contains reasonable heat value. The energy content of these gases and solid fuels can effectively be used to generate electric power as well as steam for various needs. These fuels if not used properly would have been simply wasted leading to inefficient use of energy as well as cause disposal problems and to some extent pollution hazard in the plant premises. The quantities and heat content of the waste fuels are enough to produce about 11 MW power



and also generate steam required for process and Steam Turbine. Thus the Power Plant would not only make the plant independent of external source of electric power but would also result in energy conservation and environment protection. It is therefore proposed to install a Power Plant 22 MW capacity. The Power and Blowing Station will be self-reliant in meeting its in house power requirement, other power requirement of the plant, turbo blower steam requirement and process steam requirement.

3.3.3.3.3333.2 .2 .2 .2 Fuel SystemFuel SystemFuel SystemFuel System :::: The fuels available for power and steam generation are as follows: Flue gas from DRI kilns after the After Burning Chamber (ABC) Char produced in the process of making sponge iron in DRI Kilns. Coal fines from coal crusher and purchased coal. The quantities and particulars of the above mentioned fuels are given below: FUEL REQUIREMENFUEL REQUIREMENFUEL REQUIREMENFUEL REQUIREMENT AND ITS SOURES.T AND ITS SOURES.T AND ITS SOURES.T AND ITS SOURES. Two types of fuel will be used in boilers for steam generation. Fuel gases from existing sponge iron kilns. Coal, coal fines, char. Fuel gas based Waste Heat Recovery Boiler (WHRB) In WHRB steam is generated from waste flue gases of kilns. Heat contained in fuel gases is utilized for steam generation. No additional fuel is required. AFBC boiler is being designed to burn Coal E & F Grade and char ultimate & proximate analysis as furnished below:

UTIMATE ANALYSIS: % BY FUELUTIMATE ANALYSIS: % BY FUELUTIMATE ANALYSIS: % BY FUELUTIMATE ANALYSIS: % BY FUEL

S.NoS.NoS.NoS.No ParticularParticularParticularParticular COAL (%)COAL (%)COAL (%)COAL (%) Coal Fines (%)Coal Fines (%)Coal Fines (%)Coal Fines (%) Char (%)Char (%)Char (%)Char (%)

1. Carbon 32.60 43.10 15.44

2. Hydrogen 02.74 03.11 00.25

3. Oxygen 10.36 10.62 04.78

4. Sulphur 00.50 00.69 00.56

5. Nitrogen 00.94 01.20 00.25

6. Moisture 07.90 08.11 03.32

7. Ash 44.96 33.17 75.40

TOTALTOTALTOTALTOTAL 100.00 100.00 100.00



Gross Calorific Value kcal/kg

2800 ~ 3000 3000 1500

Average GCV 2850 3000 1500

PROXIMATE ANALYSIS: % BY WEIGHTPROXIMATE ANALYSIS: % BY WEIGHTPROXIMATE ANALYSIS: % BY WEIGHTPROXIMATE ANALYSIS: % BY WEIGHT

S.NoS.NoS.NoS.No ParticularParticularParticularParticular COAL(%)COAL(%)COAL(%)COAL(%) Coal Fines (%)Coal Fines (%)Coal Fines (%)Coal Fines (%) Char (%)Char (%)Char (%)Char (%)

1. ASH 46.48 35.17 75.50

2. VOLATILE MATTER 23.00 21.92 01.20

3. FIXED CARBON 22.62 36.81 19.98

4. MOISTURE 07.90 06.10 03.32

TOTALTOTALTOTALTOTAL 100.00 100.00 100.00

3.3.3.3.3333.3.3.3.3 Flue gas from DR kilns Flue gas from DR kilns Flue gas from DR kilns Flue gas from DR kilns –––– Each Phase (2 x 100 TPD Kiln)Each Phase (2 x 100 TPD Kiln)Each Phase (2 x 100 TPD Kiln)Each Phase (2 x 100 TPD Kiln) :::: SL NOSL NOSL NOSL NO DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION UNITUNITUNITUNIT QUANTITYQUANTITYQUANTITYQUANTITY

1 Flue gas from DR Kiln of 2x100 TPD. Flue gas from DR Kiln of 1x350 TPD.

Nm3/h 52000 (Avg.) 91000 (Max)

2 Temperature of gas at ABC outlet. 0C 950-1000

3 Dust Loading. gm/Nm3 30 (Avg.)

3.3.3.3.3333.4 .4 .4 .4 Char Char Char Char –––– Each Phase (2 x 100 TPD Each Phase (2 x 100 TPD Each Phase (2 x 100 TPD Each Phase (2 x 100 TPD & 1 x 350 TPD DRI & 1 x 350 TPD DRI & 1 x 350 TPD DRI & 1 x 350 TPD DRI Kiln)Kiln)Kiln)Kiln) ::::

SL NOSL NOSL NOSL NO DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION UNITUNITUNITUNIT QUANTITYQUANTITYQUANTITYQUANTITY

1

Quantity of DOLO CHAR available for Power Generation from DR plant of 2 x 100 TPD 1 x 350 TPD

T/day 60 105

TOLAL T/Day 165

2 GCV Kcal/kg 1800

3.3.3.3.3333.5 .5 .5 .5 Purchased Coal/Coal Purchased Coal/Coal Purchased Coal/Coal Purchased Coal/Coal fines:fines:fines:fines:

SL NOSL NOSL NOSL NO DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION UNITUNITUNITUNIT QUANTITYQUANTITYQUANTITYQUANTITY

1 Calorific Value. Kcal/Kg 3300



Typically, 2 x 100 TPD & 1 x 350 TPD capacity of sponge iron plant can produced around 99 TPH of steam and 11 MW of power from waste gases and another 11 MW from solid wastes (char+ coal fines). Thus power generation of 22 MW is possible, only 3.0 MW is consumed by Sponge iron, 12 MW is consumed by SMS & 2 MW in Rolling mill, 1.5 MW in CPP / Auxiliary, TOTAL 18.5 MW. Sponge Iron Plant of capacity 2 x 100 TPD & 1 x 350 TPD will be producing more than 1,43,000 Normal Cubic Meters of waste gas per hour at a temperature of over 900-1000°C. In a normal case, this waste gas is cooled to a temperature of 200°C by high pressure water spray/Air before it is cleared in an electrostatic precipitator and let off in to the atmosphere. Of late, technology has been developed to recover the heat from waste gases, utilize them for steam/power generation. Almost every Sponge Iron Plant in the country are going set up waste heat recovery Power Plant and these plants are proved to be operating successfully without hindering the processes of Sponge Iron manufacture besides an uninterrupted power at very cheap rate but also expected to generate an appreciable revenue which would improve the overall profitability of the company Power Generation from Coal Based Sponge Iron Technology. Power is generated through Waste Recovery Boiler (WHRB) & Fluidized Bed Combustion Boiler (FBC).

S. NO.S. NO.S. NO.S. NO. PARTICULARSPARTICULARSPARTICULARSPARTICULARS CAPACITY CAPACITY CAPACITY CAPACITY

1. Capacity DRI KILN : Existing

Proposed 2 x 100 TPD 1 x 350 TPD

2. With WHRB 11 MW

3. With AFBC 11 MW

TOTAL POWER GENERATION (EACH PHASE) 22 MW

3.3.3.3.3333.6.6.6.6 Brief descriptions of the major facilities:Brief descriptions of the major facilities:Brief descriptions of the major facilities:Brief descriptions of the major facilities: � The Existing DRI plant shall be configured with 2 nos of Waste Heat Recovery Boilers (WHRB) of capacity of 10 TPH each Boiler operating at 67 kg/cm2 and 485±5˚C. � The Proposed DRI plant shall be configured with 1 nos of Waste Heat Recovery Boilers (WHRB) of capacity of 35 TPH each Boiler operating at 67 kg/cm2 and 485±5˚C.



� The balance steam for generating the rated power will be generated by one no of Fluidized Bed Combustion Boiler (FBC) using Coal and Char of capacity 55 TPH. � The proposed 22 MW Steam Turbine shall have one uncontrolled extraction connected to one constant pressure de-aerator normally working at 125˚C feed water temperature. � The steam generated in the boilers would be sufficient to generate 22 MW of power. � The installed feed water system of Boilers will be sized to support the capacity of boilers to enable 22 MW power generations. � Induced draft RCC counter flow Cooling Tower with three cells of adequate capacity to meet the design operating point of the proposed CPP is envisaged. � Rated flow capacity single stream fully manual operated outdoor type DM plant is envisaged for the proposed CPP. � All electrical equipment will conform to relevant IS/IEC standards and recommendations of IEEE standards. � One centralized Control System is envisaged for the operation of major equipment (Boiler, STG, CW System) in the plant and other auxiliary systems (Compressors and DM plant) shall be operated from their relay based local control panels/stations. � The steam at required parameter to STG would be provided through a main steam header. All Boilers will be connected to this main steam header. The variation in the steam generation of WHRB will vary in line with the variation in the hot gas parameters and its flow.

3.3.3.3.3333.7.7.7.7 SectionsSectionsSectionsSections //// Equipments in Power Equipments in Power Equipments in Power Equipments in Power Plant:Plant:Plant:Plant: 1. Coal Handling. 2. Water Treatment and handling. 3. Boilers and accessories. 4. Turbine and Generator. 5. Air Condensers. 6. Electrical & Instrumentation. 7. Power Transmission System. 8. Pollution Control System.

1. BAG FILTERS.



2. ESP. 3. ASH HANDLING.

1. The Power Plant has a generating capacity of 22 MW. On an average 11 MW is generated from WHRB (I, II & III) steam & balance 11 MW from AFBC boiler. As specific steam consumption of 4.5 MT per MW, 99 TPH of steam is required. Considering one kiln / WHRB under shutdown, AFBC & WHRB has been sized for 99 TPH steam generation. This ensures availability of sufficient steam for generation of 22 MW even kiln is under shutdown.

2. There is 3 nos Waste Heat Recovery Boiler having 10 TPH + 10 TPH + 35 TPH capacity & 1 X 55 TPH AFBC Boiler. AFBC Boiler of higher capacity is installed to ensure continuous availability of sufficient steam to operate turbine at full capacity. Steam generation from WHRB fluctuates due to variation in flue gases quantity & quality.

3. AFBC Boiler is designed for burning mixed fuel consisting of E & F Grade coal, char, coal fines, having average GCV of 3000 kcal/kg.

4. Fuel requirement/unit = 1.30 kg approx. a. The daily Fuel requirement is 343.2 Mt at 85% PLF. b. Yearly Fuel requirement including losses of 20% is 123552.00 MT for 300 days

a year. 5. The plant will operate at a PLF of 85% & above from 2nd year onward. 6. The 22 MW Turbine generator set is of latest design bleed cum condensing type. Bleed

steam is utilized to reheat condensate to ensure minimum feed water temperature of 126oC.

7. Considering present / future scarcity of water, Air cooled condenser is installed for exhaust condensing.

3.3.3.3.3333.8.8.8.8 WATER WATER WATER WATER REQUIREMENTREQUIREMENTREQUIREMENTREQUIREMENT_CPP_CPP_CPP_CPP:::: Water is required for:-

a. Boiler water loss make up. b. Make up for auxiliary cooling tower evaporation loss + Blow Down loss.

Normal circulating water flow will be 750 m3/hr. Service water for various cleaning purpose.



THE ESTIMTHE ESTIMTHE ESTIMTHE ESTIMATED ATED ATED ATED QUANTITYQUANTITYQUANTITYQUANTITY (Make Up Water)(Make Up Water)(Make Up Water)(Make Up Water):::: a. Boiler water make up is limited to maximum 10% of steam flow i.e.

110 × 0.1 = 11 m3 /hr = 264264264264 mmmm3333/day,/day,/day,/day, b. Cooling Tower make up & blow down (occasional) is limited to 2% i.e. 750m3 × 0.02 = 15 m3/hr = 360360360360 mmmm3333/day./day./day./day. c. Service water considered is 22220 m0 m0 m0 m3333 / day./ day./ day./ day.

d. Total water required = 264 + 360 + 20 = 644 say 645264 + 360 + 20 = 644 say 645264 + 360 + 20 = 644 say 645264 + 360 + 20 = 644 say 645 mmmm3333 /day./day./day./day.

Water requirement is 645 m3 / day. Water storage capacity has been constructed is 8000m3. In normal case it meet requirement of 8000/645 = 12.5 days, which is O.K. considering make up water met from sufficient existing / new bore wells. Borwell yield is proven. The generated power will be utilized for captive consumption in SID, SMS, RMP, CCM etc. Net Power generation (Annual) is 1346.40 lakh units at 85% PLF and 300 days working excluding 10%. Auxiliary consumption.

1. Average generation cost is Rs. 3.031 / including interest & depreciation. The generation cost per unit from WHRB & AFBC is Rs. 0.844 & Rs. 3.246 respectively.

2. The Selling price of electricity by Jharkhand State Electricity Board (JSEB) is Rs. 4.30 /Unit approx to the industries, which will increases each year by 5%.

3. The Plant will be installed with all new & modern equipment. All measures will be taken to make the Plant POLLUTION FREE.

4. The Chimney height for AFBC Boiler shall be 56.0 M which meets the requirement of PCB (Pollution Control Board).

5. Ash generated in Economizer, Air Pre-heater & ESP hoppers of AFBC Boiler will be pneumatically transported (through Dense Phase System) to Ash Silo. From Silo, Ash will be collected in Dumpers for disposal. Ash generated from WHRB will also be collected in Ash Silo. From Silo, Ash will be disposed through Dumpers.

6. Utilization of Ash: Ash will be utilized for selling to Cement plant, for Brick Marking, To Farmers for Soil Conditioner / fertilizer and for filling of low area land.

The boiler is being designed considering GCV of 2500 kcal/kg. The mixed fuel requirement/unit shall be 1.30 kg from AFBC boiler.



3.3.9 3.3.9 3.3.9 3.3.9 FUEL REQUIREMENTFUEL REQUIREMENTFUEL REQUIREMENTFUEL REQUIREMENT:::: The Plant Heat Rate is considered as 3400 kcal/unit. Calculation of mixed fuel requirement:

WHRBWHRBWHRBWHRB

HOT FLUE GASES 2 x 26000 Nm3/hr from ABC of DRI kilns

AFBCAFBCAFBCAFBC

ITEM COMPOSITION PER

UNITOF FUEL REQUIREMENT TON PER DAY

REQUIREMENT TON PER YEAR

b. DOLOCHAR (CV – 1300 Kcal/Kg)

0.40 165.00 49500.00

c. COAL FINES (CV – 2100 Kcal/Kg)

0.20 82.50 24750.00

d. COAL (CV – 3200 Kcal/Kg)

0.40 165.00 49500.00

TOTAL TOTAL TOTAL TOTAL (Avg. CV – 2300 Kcal/Kg)

1.001.001.001.00 412412412412....55550000 123712371237123750.0050.0050.0050.00

This is to be enhanced to include: a) PLF being more than 85%. b) Excess Coal Consumption during partial load operation. c) Shale, Stone etc. present in Coal. d) Loss due to surface moisture present in Coal. e) Ground & windage loss. The above (a) to (e) will be about 20%. Gross Annual Fuel Requirement: a) Coal (E&F Grade) – 49500 T b) Coal Fines – 24750 T c) Dolo Char – 49500 T TOTAL TOTAL TOTAL TOTAL –––– 123712371237123755550000 T (Approx).T (Approx).T (Approx).T (Approx).



ASH PRODUCTION & ITS DISPOSAL:ASH PRODUCTION & ITS DISPOSAL:ASH PRODUCTION & ITS DISPOSAL:ASH PRODUCTION & ITS DISPOSAL: WHRB (Ash Generation) The dust content in fuel gas is 30 grams/NM3. Ash generated/ day /10 TPH Boiler = 18 T. Ash generated/ day /35 TPH Boiler = 67 T. Total ASH generation = 103 TPD

3.3.3.3.3333.10 .10 .10 .10 AAAAFBC (Ash Generation)FBC (Ash Generation)FBC (Ash Generation)FBC (Ash Generation) :::: Mixed fuel burnt in Boiler per hour is 17.16 MT and per year requirement is 123552 T approx) having average 50% Ash Content. The Ash generation will be 61776 T/year. The Ash collection will be as following: Bottom ash – 80%. Eco & APH Hopper – 5% each. Balance 15% Ash will be collected in ESP Hoppers. The Fly generation will be 30.8 TPD/ 9266.4 TPA.

3.3.3.3.3333.11 .11 .11 .11 POWER GENERATIPOWER GENERATIPOWER GENERATIPOWER GENERATION & ITS UTILIZATION:ON & ITS UTILIZATION:ON & ITS UTILIZATION:ON & ITS UTILIZATION: POWER GENERATION:POWER GENERATION:POWER GENERATION:POWER GENERATION:

No of Boiler in operation

Avg. Steam Generation

Avg. Steam Consumption

Avg. Power Generation

Unit (TPH) (T/MW) (MW)

WHRB I 10.00 4.25 2.0

WHRB II 10.00 4.25 2.0

WHRB III 35.00 4.25 7.0

AFBC 55.00 4.25 11.0

A N N U A L G E N E R A T I O N @ 100%PLF



3.3.3.3.3333.12 .12 .12 .12 POWER UTILIZTIONPOWER UTILIZTIONPOWER UTILIZTIONPOWER UTILIZTION after Expansion after Expansion after Expansion after Expansion :::: The power will be generated at 11KV which will be utilized for captive consumption within the premises and excess will be exported to grid.

S.No.S.No.S.No.S.No. UnitUnitUnitUnit Power in MWPower in MWPower in MWPower in MW

1. Power Plant Auxiliary Consumption 1.5

2. S.M.S. - C.C.M & Rolling Mill 12+2= 14

3. DRI, Misc use lighting etc 3

TTTTOOOOTALTALTALTAL 18.518.518.518.5

The proposed power plant will generate power at 11 KV. The generator shall be directly connected to the 11 kV switchgear. The power plant auxiliaries will be fed through 11/415 V Aux transformer. The boilers will discharge the fuel gas to the atmosphere through the high efficiency electrostatic precipitator and the tall stack. The discharge will meet the stipulations of the pollution control authorities. The effluents and water will be treated inside the inside the plant and reused in the system. The noise level will be maintained within the stipulation of the PCB’s with suitable noise abatement measures. In addition to Boilers following Plant & equipment has been installed.

1. A TG set of 22 MW will be installed, operating at 65 kg/cm2, 490±5oC, generating power at 11KV voltage with all auxiliaries like – Air Cooled Condenser, oil system ejector, electrical, control & Instrumentation packages etc.

2. Electro-static Precipitator – One no for AFBC boiler designed to restrict emission to 50mg/NM3.

3. RCC chimney of 56.0 Meters height as per pollution control board (PCB) norm. 4. Water system consisting of DM Plant, Aux. Cooling Tower, Water Storage Tank,

Pumps, piping etc. as per system requirement to meet generation of 08 MW power. 5. Ash handing system including Ash silos as per requirement. 6. Fuel handing system to meet requirement. 7. Electrical package consisting – Transformers, PCC, MCC, 11KV Panel, HT, LT

cables etc. 8. Control & Instrumentation equipment consisting of DCS System.



3.3.3.3.3333.13 .13 .13 .13 STATION STATION STATION STATION ELECTRICALS:ELECTRICALS:ELECTRICALS:ELECTRICALS: The power plant will operate in parallel with WBSEDCL – 33 KV grid Power shall be utilized for startup of power plant & its various units. ENVIROENVIROENVIROENVIRONMENTAL POLLUTION CONTROL:NMENTAL POLLUTION CONTROL:NMENTAL POLLUTION CONTROL:NMENTAL POLLUTION CONTROL: Suitable Pollution Control equipments will be installed to restrict emission as per PCB norms. The noise level will be as per PCB’s with suitable noise control equipment.

3.3.143.3.143.3.143.3.14 SSSSIZING OF PLANT AND MACHINERYIZING OF PLANT AND MACHINERYIZING OF PLANT AND MACHINERYIZING OF PLANT AND MACHINERY :::: As already stated, the power plant will mainly consist of one number steam turbine generator set of 22 MW generating capacity. Steam requirement for the Turbine generator set will be through 2 × 10 TPH & 1 x 35 TPH WHRB (MCR) and 1 × 55 TPH AFBC (MCR). The plant apart from T.G. and boiler units, consists auxiliary plants and system like water Treatment Plant, Fuel handing system, Air Cooled Condenser, Compressed air system, firefighting equipment, Ash handing systems, Switch gear and Switch yard etc. Based on power generation capacity of 22000 KW various equipment will be sized in accordance with the standard engineering practices. The power rating of the generator is 22000 KW at the generator terminals with 10% overload capacity. The speed of the generator is 1500 rpm and the generator is designed to generate electrical power at 11 KV, 50Hz, 0.8 Power factor. The generating voltage at generator terminals will be 11 KV. According all other electrical equipments like power transformer, switchyard etc. shall be sized. The proposed 22 MW power plant will be synchronized with grid. The Power Plant will use start-up auxiliary power from the 33 KV grid supply. One number Diesel generator set of 750 KVA is considered to meet emergency power supply to start BFP, AOP & Barring Gear motors lighting load etc.



3.3.3.3.3333.15 PLANT.15 PLANT.15 PLANT.15 PLANT TECHNICAL FEATURESTECHNICAL FEATURESTECHNICAL FEATURESTECHNICAL FEATURES :::: GENERAL DESCRIPTION The proposed 22 MW Power Plant will have 2 × 10 TPH & 1 x 35 TPH WHRB (MCR) and 1 × 55 TPH AFBC (MCR) and 1 × 22 MW STG with auxiliaries. The condenser shall be Air cooled. Power generated at 11 KV will be utilized for captive consumption after drawl of the PP’s auxiliary power requirements. Besides the plant will have Ash handing system, Fuel handing System, Air Cooled condenser, pumps, Water treatment plant, Fire protection system, Air compressors, Air conditioning and Ventilation system and Electrical system.

3.3.16.3.3.16.3.3.16.3.3.16. WASWASWASWASTE HEAT RECOVERY BOILER (WHRB)TE HEAT RECOVERY BOILER (WHRB)TE HEAT RECOVERY BOILER (WHRB)TE HEAT RECOVERY BOILER (WHRB) :::: Boiler will have a vertical, 3 pass, natural circulation, fully drainable, gas tight membrane casing, water tube boiler for continuous operation and out-door installation. The boiler will have following modes of heat transfer.

Radiative Heat TransferRadiative Heat TransferRadiative Heat TransferRadiative Heat Transfer:::: To avoid abrasion, 1st pass will be large radiative one with-out any surfaces/tube bundles. This is vertical, fully gas tight wall (tube-flat-tube) in membrane construction for cooling of the gases to below critical temperature, to avoid abrasion of convective surface located in 2nd pass. Heat from the flue gases is transferred to water walls by non-luminous radiation. This tall, vertical 1st pass allows dust, loose built-up / accretions to fall down and collected in the Ash Hoppers, located at the bottom of the 1st pass.

Convective heat Convective heat Convective heat Convective heat Transfer:Transfer:Transfer:Transfer: 2nd and 3rd pass will have convective heat transfer through Super heater, Evaporator and Economizer.

Screens:Screens:Screens:Screens: In order to limit the temperature of flue gas entering Super heater section below abrasive temp (< 8500C), tubular screens are provided between 1st and 2nd passes. Screens will spread the flue gas uniformly to the entire cross-section of 2nd pass, which helps effective heat transfer.



Super Super Super Super Heater:Heater:Heater:Heater: Since the flue gas temperature is still high (8500C), a water cooled, membrane construction is selected to act as fully gas tight casting for Super heater and Evaporator and also to cool the gases. In order to maintain the final steam temperature constant over the complete range of low and high / fluctuating loads, a 2-stage Super heater with inter stage De-super heater will be provided. This arrangement will facilitate steam temperature control in low as well as high loads. For effective heat transfer, SH Banks are arranged in cross-counter flow. Arrangement of SH Banks permits on-line cleaning of tube surfaces with retractable soot blowers. Tube Banks will be firmly supported (fixed) on the header end, freely supported on skit in the rear, thus permitting free expansion without additional stresses.

Evaporator 1 and Evaporator 1 and Evaporator 1 and Evaporator 1 and 2:2:2:2: Following the SH Banks, Evaporator tubes are provided to complete the generation of saturated steam. Evaporator Banks will be flag (V) type with 50 slope, to ensure the tubes are always flooded with water. Arrangement of Evaporator banks will permit on-line cleaning of tube surfaces with rotary soot blowers.

Economiser/3rd Economiser/3rd Economiser/3rd Economiser/3rd pass:pass:pass:pass: Following the Evaporator Banks, Economizer is provided to complete the heat recovery from the flue gases. Economizer construction will be tubular coil type. For effective heat transfer, Economizer coils are arranged in cross – counter flow. Arrangement of Economizer coils permit on-line cleaning of tube surfaces with Rotary soot blowers. The dust will freely fall to the Ash Hopper arranged at the bottom of the casing/3rd pass.

Steam Steam Steam Steam Drum:Drum:Drum:Drum: The steam drum acts as a collecting and separating device for the steam generated in the evaporator coils. The steam water mixture from outlet of the evaporators flows into the steam drum through external risers. Demister pad will be provided inside the drum to separate steam from water.



In addition to demister pad, the steam drum will also be provided with perforated distribution pipes for feed water and chemical feed as well as a perforated collection pipe for continuous blow down. Thermal sleeves will be provided for drum connections. All connections are either socket or butt welded except for safety valves, which will be flanged. Vortex breakers will be provided in the down comer connection. The drum is designed with sufficient water volume to provide a stable water level, in case of sudden changes in heat absorption in the boiler.

DeDeDeDe----Superheater:Superheater:Superheater:Superheater: Spray type De-super-heater is located between SH stages. Feed water will be tapped off upstream of the feed water control valve for this purpose. The purpose of this De-super-heater is to maintain constant temperature of steam leaving the final Super-heater. This De-super-heater is wide range mechanical atomizing type. A pneumatically operated injection water control valve, with isolation valves and bypass valve provide the spray water to the De-super-heater. Expansion Joint at Boiler InletExpansion Joint at Boiler InletExpansion Joint at Boiler InletExpansion Joint at Boiler Inlet:::: To ensure free boiler thermal expansion, suitable compensator shall be provided at the boiler inlet to absorb the differential expansions and to avoid undue thermal stresses in the boiler system.

ChimneyChimneyChimneyChimney:::: Flue gas outlet from boiler will be let out to atmosphere through a Chimney. Emission from chimney shall be limited to 50mg/NM3 at 1400C. The emitted gases will be invisible. 3.3.173.3.173.3.173.3.17 AAAASH HANDLING SYSTEMSH HANDLING SYSTEMSH HANDLING SYSTEMSH HANDLING SYSTEM The Ash handling system is provided for the ash collected from the following region: Radiation Zone Hopper Convection Zone hopper Economizer hopper FBC ECO Hoppers Air heater hopper ESP hoppers Fly ash from the boiler will be transported to the ash silo through dense phase pneumatic conveying system.



Fly ash from the Economizer and Electrostatic Precipitator Hoppers will be dry and powdery in nature. The temperature of the ash will be around 150 – 1800C maximum. Fly ash will be carried pneumatically to the fly ash silo. 3.3.183.3.183.3.183.3.18 AAAAFBC BOILERFBC BOILERFBC BOILERFBC BOILER:::: AFBC boiler will be top supported, single drum, balanced draft, natural circulation unit, with under bed firing system for Indian coal. The boiler will be designed for outdoor installation. The boiler will have sub system like pressure parts, feeding system, draft system, feed water system, ESP and chimney.

Pressure partsPressure partsPressure partsPressure parts:::: The boiler pressure part consists of a water cooled furnace, bed evaporator coils, boiler bank, steam and water drums, primary and secondary super heaters, economizer, risers and down comers Furnace Furnace Furnace Furnace –––– Water wall Water wall Water wall Water wall System:System:System:System: The furnace which is fully water cooled is formed by carbon steel seamless tubes of membrane wall construction connecting the respective top and bottom headers. The bottom headers for all the walls are fed with water from mud drum through down comers and bed evaporator headers. The heated water rises along furnace tubes to the top heaters which in turn are connected to the steam drum by rises pipes. Necessary provision will be made in the furnace for admitting the required quantity of over fire air at various levels. Adequate number of inlet and outlet headers, with the necessary stubs, commensurate with the arrangement of the furnace will be provided. The down comers, supply pipes and relief sizing will be based on the circulation calculations. Bed coil Bed coil Bed coil Bed coil assembly:assembly:assembly:assembly: The bed coil assembly will be at the bottom most part of the furnace in the convection zone. It will be the integral part of the furnace and it is immersed within the fluidized bed. The temperature in the bed zone will be around 900 – 9500 C. The bed coil will absorb the heat from the bed and maintain the bed temperature bellow the ash fusion temperature. The bed coil will be properly designed that there would not be any steam accumulation inside the bed coils. The bed coils are connected with inlet/outlet headers are connected



with supply pipe and risers. The supply pipes and the risers shall be designed that the bed coil should not be starved for water at any operation conditions. The bed coil material shall be selected to withstand the high temperature and should be of seamless tube. The inclination of bed coil should not be more than 100.

Boiler Boiler Boiler Boiler Drums:Drums:Drums:Drums: The boiler will be provided with one steam and one water drum and drums will be of fusion welded type. Both the drums will be provided with Torispherical / Semi-Ellipsoidal dished ends fitted with 320 × 420 MW elliptical man ways at either end. The man way doors will be arranged to open inwards. The drum shell, dished ends and the man way doors will conform to SA 515 Gr. 70 or equivalent material specification. The steam drum will be liberally sized to assure low steam space loading, with adequate space to accommodate the internals. The drum design pressure will have a minimum margin of 6% over drum operating pressure. The steam drum will be provided with internals of design, shall be bolted type, and of size that will enable removal through the man ways. The system of internals consisting of the primary and secondary separators will ensure steam of highest purity with dissolved silica carry over limited to a maximum of 0.02 ppm, at all loads of the boiler. All the components of the internals, except the dryer, shall be carbon steel and the dryer shall be of 304 stainless steel.

SuperSuperSuperSuper heater heater heater heater System:System:System:System: The super heater (SH) system will be of Two (2) stage design with inter stage de-super heating to achieve the rated steam temperature over 60 to 100% load range. The super heater will be of convection or a combination of convection and type arranged to give the minimum metal temperature. The super heater pressure drop, the inlet and outlet header sizing, arrangement and sizing of their respective inlet and take off connections will be so as to give minimum unbalance and the tube element material selection will be based on the actual metal temperature calculations. Attemperator Attemperator Attemperator Attemperator System:System:System:System: The Attemperator system to control the temperature of the final super heater outlet steam temperature within the specified value will be provided in between the two stages of the



super heaters. The inter stage Attemperator will be of non contact types preferably of drum coil type with single 3 way control valve. Economizer:Economizer:Economizer:Economizer: The Economizer will be located immediately downstream of the boiler bank. The design will be of bare tube construction with inline, counter flow, and drainable arrangement. The economizer will be designed for an inlet feed water temperature of 1260C. The coil arrangement will take care of proper calculated end gaps to avert gas bypassing and the consequent erosion of the element tubes. Tubes will be of seamless type. Air Air Air Air Heater:Heater:Heater:Heater: The Air heater will be arranged as the last heat recovery section down steam of the economizer. The Air heater will be recuperative type with flue gas flowing inside the tubes and the combustion air flowing over the tubes. The air heater will be arranged with the tubes in the vertical direction. The tubes except those required for staying purpose will be expanded into the tube sheets on both ends. The low temperature bank of the Air pre heater will be designed to prevent corrosion and the cold end material of the air heater tubes will be Carbon Steel. 3.3.193.3.193.3.193.3.19 DDDDraft Systemraft Systemraft Systemraft System :::: The boiler draft system consist of 2 × 100% ID fan, 2 × 100% PA fan and 2 × 100% FD fan. The boiler will be designed for balanced draft. A control system will be implemented to keep the furnace pressure negative always. The FD fan will be varied according to the fuel flow by a combustion control system. The ID fans will maintain the draft. 3.3.203.3.203.3.203.3.20 FFFFUEL HANDLING AND FEEDING SYSTEM FOR FBC BOILERUEL HANDLING AND FEEDING SYSTEM FOR FBC BOILERUEL HANDLING AND FEEDING SYSTEM FOR FBC BOILERUEL HANDLING AND FEEDING SYSTEM FOR FBC BOILER :::: The fuel from the crusher house will be delivered to the fuel bunker in the Boiler house. The bunker will have a minimum of sixteen hours storage of the MCR requirement of boiler. The bunker will have suitable lining, isolation gates, manholes, vibrators etc., The boiler will be provided with bottom hopper feeding system. Fuel is extracted from the bunker by drag chain feeders and fed into the bed by mixing nozzles and fuel nozzles. The



fuel is transported pneumatically to the bed through the fuel pipes by hot air from Primary Air Fan. Drag chain feeders will be provided with variable frequency drives. Isolation gates will be provided at Bunker outlets. Surge hoppers will be provided in between the Bunker chute outlet and drag chain feeders inlet. Fuel feeding system will be designed in such a way that there are no bends on the feed lines keeping minimum horizontal distance between mixing nozzle and cross, minimum vertical distance between the cross and the fuel nozzle. This avoids chokage of fuel in the line and improves the flow ability. 3.3.213.3.213.3.213.3.21 FIFIFIFIRING SYSTEMRING SYSTEMRING SYSTEMRING SYSTEM :::: The firing system will consist of fluidized bed at the bottom of the furnace with in-bed heat exchangers. The furnace will be compartmentalized with ash drain points in each compartment. The boiler will be designed suitable for compartment turn down/part operation. The Air Heater will be located directly beneath the furnace. Separate header will be provided to admit or cut off the air supply to the individual compartments. Necessary pneumatic dampers will be provided for the same. Combustion air from fan flows to the bed through the air nozzles. The header will be of Stainless steel construction. Air nozzles will be screwed whereas fuel nozzles will be bolted. This help in easy removal and replacement of air nozzles. Air nozzles are of Stainless Steel construction and coal nozzles of alloy cast iron construction. Secondary over fire air will be provided from FD fan to ensure complete combustion resulting in minimum unburnt carbon and improving boiler efficiency. The temperature of the fluidized bed will be lower than the ash initial deformation temperature and shall be higher than the ignition temperature of the fuel. The optimum bed temperature selected will be around 850 – 9080C. The bed height will be shallow (less than 1 m) as the fuel used is Indian coal with Sulphur content. The bed particle size will be 1.5 to 2.5 mm with fluidization velocity of 2 to 2.5 m/s. Care will be taken so that the fluidization velocity selected will not increase the erosion rate of in-bed heat exchangers.



3.3.3.3.3.3.3.3.22222222 TurboTurboTurboTurbo----generator generator generator generator System:System:System:System: Steam Steam Steam Steam Turbine:Turbine:Turbine:Turbine: The proposed power Plant will have one no. 22 MW turbo-generator. The turbine will be a bleed cum condensing type and run at a high speed. The generator speed will be 1500 rpm. Hence, the turbine will be coupled with the generator through a reduction gear unit. Steam is admitted into the turbine through an emergency stop valve actuated by hydraulic cylinders. The turbine speed is controlled by an electronic governing system. The bleed pressure is arrived at based on the regenerative feed water requirements. Accordingly, bleed will be provided at 2.5 kg/cm2 (a) for Deaerator. All the bleeds will be uncontrolled. The turbine exhaust pressure will be 0.18 kg/cm2 (a) (max). The turbine will be single cylinder, single exhaust, single bleed, condensing type. All casing will be horizontally split and the design will be such as to permit examination of the blading without disturbing shaft alignment or causing damage to the blades. The design of the casing and the support will be such as to permit free thermal expansion in all directions. The glands will of labyrinth type and sealed with steam. A vacuum system required by the design will be provided. All piping and components of shaft seal and vacuum system will be sized for 300 percent of the calculated leakage. Steam leaving the glands will be condensed in Gland steam condenser.

BearingsBearingsBearingsBearings :::: The Turbine will be provided with liberally rated hydrodynamic radical and thrust bearings. The radial bearings will be split for ease of assembly, and of the sleeve or pad type, with steel shell backed babbitted replaceable pads. These bearing will be equipped with anti-rotation pins and will be positively secured in the axial direction. The thrust bearings will be of the steel backed babbitted multiple segment type, designed for equal thrust capacity in both directions. A liberal flow of lube oil under pressure will be supplied to all the bearings for lubrication and cooling.

Lubrication and Control Oil Lubrication and Control Oil Lubrication and Control Oil Lubrication and Control Oil System:System:System:System: A pressure lubrication and control oil system will be furnished for the turbo generator unit to supply oil at the required pressure to the steam turbine, gearbox, generator and



governing system. Oil in the reservoir will be maintained at an appropriate temperature when the TG set is idle by providing suitable electric and temperature controls. The oil system will include the Main oil pump, Auxiliary oil pump, Emergency oil pump, Control oil pump, Oil storage and settling tank, Centrifugal type oil purifier, Oil cooler and oil filter.

Steam Turbine Governing Steam Turbine Governing Steam Turbine Governing Steam Turbine Governing System:System:System:System: The turbine governing system will be electro-hydraulic or electronic for high accuracy, speedy and sensitive response. The electrical/electronic and hydraulic component of the control system will be selected on the basis of reliability over a wide range of operating conditions. All components used will be well proven to ensure overall system reliability for easy and quick replacement when necessary. The governor will ensure controlled acceleration of the turbo generator and will prevent over speed without tripping the unit under any operating conditions including the event of maximum load rejection.

Condenser:Condenser:Condenser:Condenser: The turbine exhausts steam into Water Cooled Condenser. The pressure of turbine exhaust will be 0.18 ata. The correspondence temperature will be around 550C and above. The design will be based on turbine back pressure of 0.18 ata and design ambient of 420C and relative humidity of 60%. The steam will be condensed by the Air circulated over the tubes. The evacuation system consists of a starting ejector and holding ejector. The ejector creates the required vacuum in the condensing system, using the steam as the fluid. The steam sucked along with the air will be condensed in the ejector condenser by the incoming condensate. The condenser will be provided with a hot well, where the condensate will be collected. The hot well will be equipped with level control devices, to ensure positive flow to the condensate extraction pumps.

3.3.3.3.3333.23 .23 .23 .23 Water Treatment Water Treatment Water Treatment Water Treatment Plant:Plant:Plant:Plant: To cater the make –up water requirements of the boiler, it is proposed to install a DM plant having capacity of 30 Cu.mt/hr. The DM plant shall have a regeneration time of 4 / 6 hours/day. The scheme for the DM plant will be RO-MB system based on the raw water



analysis. The DM plant will consist of activated carbon filters, anion and cation exchangers, degassers, and mixed bed exchangers. The de-mineralized water quality at the outlet of the DM plant shall be as follows: ● Hardness (ppm) : Nil ● pH @ 25 0C : 8.8 – 9.2 ● Chlorides : Nil ● Conductivity @ 25 0C (microsiemen/cm) : 0.5 ● Oxygen (max) (ppm) : 0.007 ● Total iron (max) (ppm) : Nil ● Total silica (max) (ppm) : 0.02

Plant Water SystemPlant Water SystemPlant Water SystemPlant Water System:::: Water will be required in Auxiliary Cooling Tower as make up. Raw water requirement for Auxiliary Cooling Tower, DM plant, Ash conditioning system, auxiliaries cooling system, area cleaning system etc will be 645 m3/day which will be met from Bore wells ADDA water supply. A water tank of 8000 m3 will be constructed.

3.3.243.3.243.3.243.3.24 CCCCranesranesranesranes :::: One no. 15 MT E.O.T. Cranes will be installed to facilitate erection and maintenance of T.G. set.

3.3.253.3.253.3.253.3.25 CCCCompressed Air Systompressed Air Systompressed Air Systompressed Air System em em em :::: Instrument air is required for various pneumatically operated valves in the boiler and TG systems. Air is required to be supplied at a pressure of 6 to 7 kg/cm2 (g) at the various consumption points. Instrument air from the air compressors is be dried by refrigerant type air dryer. Service air is required for cleaning of various areas of the plant. Accordingly, service air connections are proposed to be provided in the boiler area, TG building, workshop, DM plant etc. Two (2) air compressors will be installed along with the drier (for instrument air) and other auxiliaries for supplying the instrument and service air requirements. Out of the two compressors one will be working and the other will be standby.



3.3.263.3.263.3.263.3.26 AAAAir Conditioning and Ventilation systemir Conditioning and Ventilation systemir Conditioning and Ventilation systemir Conditioning and Ventilation system :::: The main control room, DCS rooms will be air conditioned using window/spilt type air conditioners. The capacity of the air conditioning units will be decided based on the area of the room and heat load dissipated in the room. The following mechanical ventilation systems are to be provided for various building/rooms in the power plants. a) Axial type power roof ventilators of adequate capacity for the TG building, b) Centrifugal type supply air fans of adequate capacity for the switch gear room, battery room etc, c) Suitable number of propeller type exhaust fans in the water pump house, DM Plant, filtration plant, workshop, stores and toilets.

3.3.273.3.273.3.273.3.27 FFFFire Protection system ire Protection system ire Protection system ire Protection system :::: Following systems of fire protection is to be provided in the power plant.

- CO2 flooding system - Portable fire extinguishers.

Steam turbine generator area will be provided with CO2 flooding system. Adequate number of portable fire extinguishers will be provided at various locations throughout the power house.

3.3.283.3.283.3.283.3.28 PPPPlant Electrical systemlant Electrical systemlant Electrical systemlant Electrical system :::: The turbine generator will generate 22000 KW at the alternator terminals at 11 KV of this auxiliary requirement of power Plant will be stepped down to 433 V through a station auxiliary transformer. The remaining power will be fed for Captive usage and surplus power will be exported to grid. Thus the system will be designed to operate in parallel with the India Power grid at 33 KV level through 11/33 KV Generator transformer. Power will be from the grid for Power Plant start-up and also during Power Plant outage for feeding the plant. System Design: ● Power Supply Voltage The following Power Supply standard voltage levels will be adopted for the various system.



Power Evacuation. a) 11 KV, 3 Phase, 3 Wire, 50Hz, resistance earthed system. b) 11KV, 3 Phase, 3 Wire, 50Hz, solidly earthed system.

Station Auxiliary System. 11 KV, 3 Phase, 3 Wire, 50Hz, resistance earthed system. & 415V, 3Phase 4 wire, 50 Hz, solidly earthed system.

A.C. Drive Motors. 415 V, 3 Phase, 3 wire, 50Hz

Instrumentation and control including Protection inter locking system (DCS)

110V, 1 Phase, 2 wire, 50 Hz AC stabilized through UPS System.

Control & protection Of HT and LT Switchgear and D.C. Drives.

110V, 2 Wire unearthed D.C.

Panel Lighting and Space Heaters. 240V, 1Phase, 2 Wire, 50Hz, A.C. with one point Earthed.

Welding socket Outlets. 415 V, 3 Phase 50 Hz, A.C.

● Permissible Variations The System / Unit / Plant / Equipment have envisaged to be designed suitable for following Variation in voltage and frequency:

VOLTAGEVOLTAGEVOLTAGEVOLTAGE FREQUENCYFREQUENCYFREQUENCYFREQUENCY

Permissible variation with rated performance and + 10% to – 10% + 5% to – 5% Permissible variation for control and regulation Equipment with rated performance and control quality maintained

± 10% ± 5%

Permissible voltage dip at Switchgear bus during starting of Motor

(-) 15%

● Basic Insulation Levels The basic insulation levels considered for different Equipments are:



RATED VOLTAGE (KV)RATED VOLTAGE (KV)RATED VOLTAGE (KV)RATED VOLTAGE (KV) POWER FREQUENCY H.V.WITHSTAND (KV)POWER FREQUENCY H.V.WITHSTAND (KV)POWER FREQUENCY H.V.WITHSTAND (KV)POWER FREQUENCY H.V.WITHSTAND (KV) BIL (KVp)BIL (KVp)BIL (KVp)BIL (KVp)

33 70 170

11 28 75

0.415 2 ---

● Symmetrical Short Circuit Rating. ● System Earthing. All system will be earthed at the point of eye connected winding of the relevant transformer as stated in the foregoing. Earth Fault current limit of 11 KV shall be 100A through employment of neutral resistance. Separate Underground Ground Mat has been envisaged for TG Building, ESP, Boiler, etc. Other facilities shall have Earth Pits ISS 3043. Separate segregated Earth Pits shall be provided for Electric system earthing, Electronic Earthing, Lightning protection of buildings, stack, etc. As per prudent utility practice estimated 32 mm dia MS roads have been envisaged for making the underground Earth Mat at excavation level with 32dia. Earth spikes down under up to minimum water table. From the mat risers also by 32mm MS rods shall be brought up to the level of 300mm above finished floor level. Earthing grids shall be formed by 50 × 6mm GI strips in different areas and floor elevations connected to the earthing risers of 32MM dia Rod. All Equipment and devices will be connected to the earth grids at least with two connections as per Indian Electricity rules. Electronic Earth Pit shall be preferably done with Copper perforated pipe. Separate Electronic Earth Pits will be done for DCS & PLC system earthing. 3.3.293.3.293.3.293.3.29 POLLUTION CONTROL ASPECTSPOLLUTION CONTROL ASPECTSPOLLUTION CONTROL ASPECTSPOLLUTION CONTROL ASPECTS :::: IntroIntroIntroIntroduction :duction :duction :duction : The Project is an expansion of the exiting Steel plant by installing 2 × 10 TPH & 1 x 35 TPH Waste Heat Recovery Boiler (WHRB) based on Waste gases emanating from kiln and 1 × 55 TPH AFBC (Air Fluidized Bed Boiler) to generate of steam to produce 22 MW power. Important Consideration for Pollution Important Consideration for Pollution Important Consideration for Pollution Important Consideration for Pollution Control:Control:Control:Control: a) Reduction in the generation of pollutants by selecting the best pollution control

process.



b) Reduction of emission of air pollutants generated from the process to level well below well the prescribed minimum standards.

c) Adhering strictly safety rules of the Central and Governments. d) Adopting controls for regulation and monitoring of waste effluents such as air

emissions, solid waste management etc. in the most proven manner. e) Selection of requisite stack heights to keep group level concentration of pollutants

well below the ambient air quality norms. For Sponge Iron Production, Iron Ore in the from of oxides (FeO, Fe2O3 etc.) are reduced to Fe with the help of carbon present in Coal at high temperature. During the process waste gases are produced which have lot of sensible heat. This heat is utilized in WHRB to produce steam. Therefore, it may be stated that the installation of WHRB /power helps to eliminate pollutants and to utilize sensible heat present in waste gases. Boiler itself is not generating or adding any pollution. In fact it is eliminating them when gases pass through Boiler and ESP. Hence, these equipments prevent pollution and are therefore environment friendly and so deserve encouragement.

Air pollutionsAir pollutionsAir pollutionsAir pollutions :::: ParticulateParticulateParticulateParticulate matter i.e. Duct Particles in Gmatter i.e. Duct Particles in Gmatter i.e. Duct Particles in Gmatter i.e. Duct Particles in Gasesasesasesases :::: The waste gases emanating from kiln and entering to WHRB contain fine duct particles of iron, coal etc. When passes through various sections of Boiler, bigger size of particles are entrapped and fall into the hoppers suitably designed to collect them. From hoppers they are conveyed to silo by dense Phase Ash Conveying System for disposal. Therefore, there will not be dust nuisance in the Plant. The remaining fine dust particles are collected in there field ESP having efficiency of 99.9%. From E.S.P. hoppers dust are transported to silo for disposal. The clean gases invisible to eyes are discharged to atmosphere through high chimney. The dust load emission shall be limited to 50 mg/NM3 which will be spread over a large area through chimney. Thus, pollution is totally controlled.



Dust Particles on Dust Particles on Dust Particles on Dust Particles on Ground:Ground:Ground:Ground: Iron Ore and Coal dust present on ground spread all over due to wind and pollute air. This is being controlled effectively by installing nos. of water sprinkers at various locations. Fine water particles mix with dust fines and make them to settle on ground.

Gases Gases Gases Gases Pollutants:Pollutants:Pollutants:Pollutants: Gases pollutant arises primarily from the by-products of combustion process like SO2, NOx etc. Which are exhausted from the chimney. Source of SO2 is Sulphur present in coal. Regular analysis of flue gas indicates nil / traces of SO2. This is because coal used in kiln has very low sulphur. Therefore, Atmospheric Air Pollutants like Sox and NOx will be controlled within Pollution Control Board norms. NOx is to be controlled during process. In case of industries particulate emission controls are adopted to the limits prescribed, the stack height can be relaxed to H = 74 Qp0.27 Where Qp = Particulate Emission in Tonnes/hour.

Chimney HeightChimney HeightChimney HeightChimney Height :::: Chimney height should be sufficient to disperse the undesirable solid/ gaseous pollutants in a wider area to nullity its harmful effect. Height is decided based on: Boiler capacity, Fuel to be burnt etc. Boiler type - AFBC Capacity - 55 TPH Fuel - Coal, coal fines & char Fuel to be burnt - 17.16 Ton / hr (Approx) Flue gas - 92000 NM3 / hr Sulpher in fuel - 0.3% Gas temperature - 1500C Gas Density - 0.85 kg/m3 SO2 produced (kg/hr) = 51.68 kg/hr



Particulate present in flue gases by formula:Particulate present in flue gases by formula:Particulate present in flue gases by formula:Particulate present in flue gases by formula: Hmin = 74Qp0.27 When Qp is particulate emission in Tons/hr. As stated above dust load emission shall be restricted to 50 mg/NM3. Fuel quantity emitting from chimney at 1500C will be 92000 NM3/hr approx. Qp = [(50 x 92000) / 109] MT/hr = 0.0046 MT/hr Hmin = 74 x (0.0046)0.27 = 17.30 M. SO2 present in flue gases by formulaSO2 present in flue gases by formulaSO2 present in flue gases by formulaSO2 present in flue gases by formula : : : : Hmin = 14(Qs)0.3 where Qs = SO2 produced in kg/hr Coal burnt /hr = 17.16 MT Sulphur in coal = 0.30% Sulphur burnt = [17160 × (0.30)/100] = 51.48kg/hr SO2 produced = 51.48 kg/hr × 2 = 102.96 kg/hr H min = 14 × (102.96)0.3 = 56.0 M. Since calculate height at 6.5.2 is more than 6.5.1. Selected Chimney height = 56.0 M. Water PollutionWater PollutionWater PollutionWater Pollution :::: Effluent from Water Treatment PlantEffluent from Water Treatment PlantEffluent from Water Treatment PlantEffluent from Water Treatment Plant :::: Hydrochloric acid and sodium hydroxide will be used as re-generants in the proposed mixed bed of water treatment plant. The acid and alkali effluents generated during the process of the ion-exchangers would be drained into an epoxy lined underground neutralizing pit. Generally these effluents are self neutralizing. However provision will be made such that the effluents will be neutralized by addition of either acid or alkali to achieve the required pH of about 7.0 Effluent will then be pumped into the effluent treatment ponds which from part of the power plant effluent disposal system. The neutralizing pity will be sized approximately for 15 Cu. m capacity. The rejects from RO plant will have TDS which could be diluted and used for cleaning purposes in the project. This water can be used for plantation.



Steam Generator Blow Steam Generator Blow Steam Generator Blow Steam Generator Blow Down:Down:Down:Down: The salient characteristics of blow down water from the point of pollution are the pH and temperature of water since suspended solids are negligible. The pH would be in the range of 9.8 to 10.3 and the temperature of blow down water will be about 139 0C. The quantity of about 0.38 Tone/Hr of blow down is very small and hence, it is proposed to put the below down into the trench and leave it in the effluent ponds. Sewage from various Building iSewage from various Building iSewage from various Building iSewage from various Building in the n the n the n the Plant:Plant:Plant:Plant: Sewage from various building in the power plant area will be conveyed through separate drains to the septic tank. The effluent from the septic tank will be disposed in solid by providing disposing trenches. There will be no ground pollution because of leaching due to this. Sludge will be removed occasionally and disposed off as land fill at suitable place. Waste Water Waste Water Waste Water Waste Water Treatment:Treatment:Treatment:Treatment: Waste water treatment for the plant will be based on discharges of various waste waters to ponds for clarification and filtration. Only waste will be treated separately to remove oil / grease before discharge into effluent ponds. The oily water collection in the plant is basically due to floor clearing, leaky oil filters, etc. Clarification is used to settle out large suspended particles and condition smaller colloidal particles to make them settle. A pond, reservoir tank or tank to allow large particle to settle in a matter of hours. The finer particles overflow and are made to settle more quickly by the addition of chemical agents, coagulants and polymers that cause agglomeration to sizes large enough to settle out of suspension. Filtration will be made to a porous barrier across flowing liquid to remove suspended materials. Filtration can be used to supplement clarification and reducing suspended solids to the parts per billion levels. As required and with approvals from appropriate regulating bodies, final waste steam pH is controlled by combining various steams to provide a neutral pH product. Where needed, acid or alkali addition will be used to achieve the final pH. Noise Noise Noise Noise Pollution:Pollution:Pollution:Pollution: The rotating equipment in the power Plant will be designed to operate with a total level of not exceeding 85 to 90 db (A) as per the requirement of Occupational Safety and Health Administration (OSHA) Standards. The rotating equipments are provided with silencers



wherever required to meet the noise pollution. As per OSHA, protection from noise is required when the sound levels exceed those given in the following Table. PERMISSIBLE NOISE LEVELS Exposure Duration /Day Sound Level db (A) 8 90 6 92 4 95 3 97 2 100 1 102 Monitoring of Monitoring of Monitoring of Monitoring of Effluents:Effluents:Effluents:Effluents:

The Characteristics of the effluents from the proposed plant will be maintained so as to meet the requirements of state Pollution Control Board and the minimum national standards for effluent from thermal power plants. Air quality monitoring will also be undertaken to ensure that the dust pollution level is limits. Air Quality Monitoring Air Quality Monitoring Air Quality Monitoring Air Quality Monitoring Program:Program:Program:Program: The purpose of air quality monitoring is the acquisition of data for comparison against the prescribed minimum standards and thereby assures that the air quality is maintained within the prescribed levels. The following will be monitored from the stack emissions. ● Suspended Particulate Matter. ● Since Sulphur Di-Oxide is not present in the gas as per Analysis data, monitoring is not required for the same. The Laboratory attached to the Power plant will be equipped with necessary instruments for carrying out air quality monitoring. It is also proposed to monitor the particulate emission at the stack to keep a continuous check on the performance of the ESP. Adequate sampling opening will be provided in the stack. Impact of the Pollution on the Impact of the Pollution on the Impact of the Pollution on the Impact of the Pollution on the Environment:Environment:Environment:Environment: As all the necessary pollution control measures to maintain the emission levels of dust is taken (SO2 is not present in the gas) and other effluents will be treated in the effluent



treatment plant, there will be no adverse impact o eight the air or water quality in and around the Power Plant site on account of the installation of the plant. Quantity and quality of the Effluents from the Power Quantity and quality of the Effluents from the Power Quantity and quality of the Effluents from the Power Quantity and quality of the Effluents from the Power Plant:Plant:Plant:Plant: The figures given below are for the normal operation of the plant for 330 days in a year. Gaseous Effluents from Gaseous Effluents from Gaseous Effluents from Gaseous Effluents from the Power the Power the Power the Power Plant:Plant:Plant:Plant: Flue Gases from stack (NM3/hr) : 92000 NM3/hr Temperature of the gases leaving the Stack (0C) : 1400C SO2 Emission (ppm) : Nill NOx Emission (ppm) Gases (mg/Nm30 : < 80 Particulate Emission through flue gases (mg/Nm3) : 50 Solid Wastes from the Plant: Solid Wastes from the Plant: Solid Wastes from the Plant: Solid Wastes from the Plant: Dry Fly Ash (MT/Hr) : 1.238 Liquid EffluentsLiquid EffluentsLiquid EffluentsLiquid Effluents:::: Boiler Blow down Water (TPH) : 0.38 Total Dissolved Solids (ppm), Max. : 100 pH @25 Deg. C : 9.8 to 10.2 Waste Water from Neutralizing pit(TPH), average : 2 Total Dissolved Solids (ppm) : < 2000 pH @25 Deg. C Equipments to be installed tEquipments to be installed tEquipments to be installed tEquipments to be installed to control Air o control Air o control Air o control Air Pollutants:Pollutants:Pollutants:Pollutants: 1. Three field ESP of latest design --- already installed in WHRB & will be installed for AFBC. 2. ID fans with VFD 3. Chimney 4. Dense Phase Ash Handling System 5. Ash Silo with Bag Filter and Ash Conditioner 6. Sprinkler System to control group Air Pollution 7. Water Hydrant System to clean Plant Area Equipment / System to be installed to control Water Equipment / System to be installed to control Water Equipment / System to be installed to control Water Equipment / System to be installed to control Water Pollutant:Pollutant:Pollutant:Pollutant:

1. Underground Neutralizing Pit of 15 M3 capacity. 2. Construction of Effluent Pond of adequate capacity.



3. Construction of Septic Tank. 4. Clarification and

3.3.30 3.3.30 3.3.30 3.3.30 OPERATION AND OPERATION AND OPERATION AND OPERATION AND MAINTENANCE:MAINTENANCE:MAINTENANCE:MAINTENANCE: MAN POWER MAN POWER MAN POWER MAN POWER REQUIREMENT:REQUIREMENT:REQUIREMENT:REQUIREMENT: Man Power requirement has to be assessed on the basis of:

● Arrangement of Plant as conceived. ● Service facilities available. ● Number of Plant operating shift. ● Extent of mechanization. ● Philosophy of control. ● Executive oriented Operational practice. ● Executive oriented Maintenance planning. Condition monitoring and predicative Maintenance practice. ● Preventive and breakdown Maintenance through contracts under supervision of

Plant Executives.

For the Operational and reliability point of view, the plant has to be operated on three shifts basis. It would, therefore, be recommended that to handle the Plant and Equipment and to run this smoothly, efficiency and safety, at least the basic Operation and Maintenance staff will be draw from trained personnel having experience in Operation and Maintenance of the similar Plant and Equipment. The new recruits are to be given requisite training. Imparting of such training will have to be discussed and agreed with the related Plant supplier. While estimating Man Power requirement, due consideration has been given to the weekly offs, holydays, leaves, etc. Provision is also to be considered for leave reserves and other leaves such as National holidays, Festival holidays, Casual leaves Earned leaves, etc.



The manpower requirement for maintenance will be as fThe manpower requirement for maintenance will be as fThe manpower requirement for maintenance will be as fThe manpower requirement for maintenance will be as follows:ollows:ollows:ollows:

CATEGORYCATEGORYCATEGORYCATEGORY NO. OF PERSONSNO. OF PERSONSNO. OF PERSONSNO. OF PERSONS

Management Staff

General Manager 1

Accounts Officer, Purchase and Store 1

TECHNICAL STAFF

Dy. General Manager 1

Electrical Engineers 1

Mechanical Engineers & Supervisor 2

Instrumentation Engineers 1

Manger, Fuel Handling Plant 1

Plant Operation Staff

Shift In charge 4

OPERATION – (CAT –A) ● Boiler operator (Skilled) ● TG operator (Skilled) ● DCS operator (Skilled) ● Fuel handling operator (Skilled) ● ETP & Ash handling operator (Skilled)

4 4 4 4 4

Skilled Helper /Fitter (CAT – B) ● Boiler Operation ● TG Operation ● Electrician/Technician/C&I ● Millwright Fitters ● Fitters ● Skilled Helper

10 4 4 6 2 2 8

Chemist Cum Operator 3

TotalTotalTotalTotal 71717171



The above manpower is needed from the time of commissioning / initial start up. The equipments in the power plant mainly comprises of Boiler, TG Set, Electrical & Controls and Instrumentation. The overall operation & maintenance department of Power Plant will be headed by a Dy. General Manager with the support of a General Manager. The GM will basically look after the administrative of the power plant. He will be assisted by Accounts/Stores Officers. As for as operational part is concerned, there will be a DGM who will be the overall in charge of operation of all the equipment. His responsibilities include supervision and over seeing of the respective operators of boiler, turbine generator, electrical and C & I and all connected auxiliaries. His responsibilities also include TG set synchronization with the Grid and ensure safe and economic operation of the plant, as well as maintaining close liaison with the Board officials. He should be capable of dealing with emergencies of any nature that may arise while in shift including startup, hot and cold start, normal operations, complete shutdown, partial shutdown, breakdowns normal and emergency, synchronizing etc. 3.4.3.4.3.4.3.4. SMS & CONCASMS & CONCASMS & CONCASMS & CONCASTSTSTST:::: 3.4.13.4.13.4.13.4.1 PROJECT AT A GLANCEPROJECT AT A GLANCEPROJECT AT A GLANCEPROJECT AT A GLANCE

PROJECT PROFILE AT A GLANCE

No. Particulars Parameters

1. Plant Capacity 450 TPD

2. Plant Load Factor 80% in 1st Year, 85% in 2nd Year

3. Steel Melting

3 (a) Induction Furnace 3 X 15 Ton

3 (b) Continuous Casting Machine 6 / 11 radius, 2 strand

4. D. G. Set 750 KVA

5. Cooling System Cooling Tower

6. Power generation Source From Captive Power plant

7. Raw Material used Sponge iron – 81.6%

8. Water Source (Plant based on Air Cooled ADDA pipe line

9. Water required /day 110 m3

10. Water Tank Capacity 300 m3



11. Chimney height 30 m

12. Emission from stack < 50 mg/ Nm3

13. Construction & Commissioning Period 12 months

14. Nos. of working days in a year 300 days

15.(a) Billet Production in 1st Year (Net) 120000 TPA

15.(b) Billet Production from 2nd Year onwards 135000 TPA

3.3.3.3.4.2 4.2 4.2 4.2 Project HighlightsProject HighlightsProject HighlightsProject Highlights :::: 1. The Induction Furnace will have a capacity of 135000 MT per annum. Raw material of Billet will be Sponge Iron, MS Scrap & Ferro Alloys. The average power requirement will be 12 MW. 2. There will be 3 no Induction Furnace of capacity 15 Ton along with 1 no. 6/11 radius 2 strands Continuous Casting machine (with provision of 3rd) for producing Billets of sizes ranging from 100mm X 100mm to 200mm X 250mm. 3. The plant will operate load factor of 85% & above. 4. The Induction Furnace will be equipped with the latest design of 24 Pulse to reduce the harmonics and increase the melt rate. Continuous Casting machine will also be of the design having latest features as per the market trend. WaWaWaWater ter ter ter Requirement:Requirement:Requirement:Requirement: Water shall be required for- (a) Induction Furnace Coil & DM Water Unit Heat Exchanger cooling water line. (b) Continuous Casting primary and secondary cooling water line. (c) Make up for Cooling Towers for Induction furnace & CCM. (d) Make up for evaporated water in secondary line of CCM. (e) Service water for various cleaning purpose. The Estimated quantity of water- (a) Induction Furnace: 300m3 water (under circulation) for coil & DM water Unit Heat Exchanger of two furnaces. Above mentioned water requires to be replaced with fresh one approx. after 1 year.

(a) Continuous Casting Machine:



175m3, 160m3 & 120m3 water (under circulation) for mould tube circuit (closed), Mould tube heat exchanger cooling circuit & secondary spray cooling circuit respectively. Above mentioned water requires to be replaced with fresh one approx. after 1 year.

(b) Make up water for Cooling Towers (Induction Furnace). Assuming 0.3 % loss of the flow, Make up water = 240 CMH x 0.3 % = 0.72 CMH = 0.72 x 24 m3 /day = 17.28 m3 / day

(c) Make up water for Cooling Towers (CCM). Assuming 0.3 % loss of the flow, Make up water = 600 CMH x 0.3 % = 1.8 CMH = 1.8 x 24 m3 /day = 43.2 m3 /day

(d) Make up water for Evaporation in CCM Secondary. Assuming 1.5 % loss of the flow, Make up water = 60 CMH x 1.5 % = 1.8 x 24 m3 / day = 43.2 m3 / day

(e) Service water considered 6.32 m3 /day TOTAL Make Up water : 110 m3 / dayTOTAL Make Up water : 110 m3 / dayTOTAL Make Up water : 110 m3 / dayTOTAL Make Up water : 110 m3 / day

3.3.3.3.4444.3.3.3.3 PLANT TECHNICAL FEATURESPLANT TECHNICAL FEATURESPLANT TECHNICAL FEATURESPLANT TECHNICAL FEATURES :::: GENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTIONGENERAL DESCRIPTION:::: The proposed 135000 TPA Billet Plant will have 3 x 15 Ton Induction Furnace and 6/11 radius, 2 strand (with provision of 3rd ) CCM with auxiliaries. The Raw material like Sponge Iron, Scrap & Ferro Alloys will be melted and returned in Induction Furnace and the refined liquid metal will be cast through continuous casting machine. In addition to the above, the plant will have EOT cranes (for material handling), slag crushing machines (for processing of solid waste), Water treatment plant (to soften the water), Dust extraction System (to remove the dust from hot air), Fire protection system, Air compressors, Air conditioning and ventilation system and electrical system.



Induction Induction Induction Induction Furnace:Furnace:Furnace:Furnace: Induction furnaces are basically furnaces meant for reuse of melting scrap (steel) though it is also being used in recent years to produce mild steel from Sponge iron. These furnaces work on the principle of electromagnetic induction. HT power supply is transferred to the converter though step down transformers where power is converted from AC to DC. The frequency of the electrical power in then changed to approx. 500 Hz which is fed to the induction furnace coils. This power to induction effect increases the temperature of scrap resulting in melting of scrap or sponge. Continuous Casting Continuous Casting Continuous Casting Continuous Casting Machine:Machine:Machine:Machine: Continuous casting machine (CCM) is used to produce billets (continuous cross sections ranging from 100mm x 100mm to 200mm x 250mm) directly from molten metal by passing the same through mould tubes designed to produce specific sections. Molten metal passes through the mould tube by gravity where solidification of outer layer of the metal occurs due to Mould tube cooling by cooling water. As the metal moves out of the tube & progresses along a curve from vertical to horizontal direction, water through nozzles is sprayed over the metal shell which results in thickening of the shell. This thickness continuously increases with cooling, as the metal (section produced after passing through mould tube) progresses & the section finally becomes solid. As the section becomes horizontal, it is passed through straightening & withdrawal unit where it is straightened. The section (billet) is then gas cut into pieces of desired length. Cooling Cooling Cooling Cooling Tower:Tower:Tower:Tower: Cooling towers in the plant are used to decrease the temperature of the cooling water circulated through machine parts (CCM or Induction Furnace) subject to high temperature. The cooling water being at a lower temperature attracts heat from the hot metal (molten or solidified) which otherwise would have transferred to the machine parts resulting in the melting/ distortion/ malfunctioning of the machine. The cooling tower is designed at the WBT as per the records of weather department for that area. Each Induction furnace (set of two crucibles) requires one cooling tower which is meant cool hot water from copper coil of furnace & heat exchanger of DM Water Unit. Flow as well as ‘In’ & ‘Out’ temperature are dependent on suppliers equipment design.



Each CCM needs two cooling towers; one for mould cooling water (primary circuit) & second for spray cooling water (secondary circuit). Flow as well we ‘In’ & ‘Out’ temperature are dependent on suppliers equipment design. Water Treatment Water Treatment Water Treatment Water Treatment Plant:Plant:Plant:Plant: The plant requires treated water in the water circuits meant to cool the equipments. Raw water is made to pass through the “Dual Media Filter” to arrest the suspended particles, turbidity and iron present in water. Filtration systems remove particulate matter and, because of the large surface area of filter media, they also can be used to drive chemical reactions that result in the removal of several contaminants. The filtered water is then made to pass through the “Softener” which will remove the calcium and magnesium salts present in water by exchanging the same by sodium salts, by passing the filtered water through a bed of cation exchange resin. Soft water will be stored in a storage tank. Soft water is than used in primary cooling & secondary cooling of CCM as well as coil cooling of Induction furnace. Apart from the above, the electrical control panel of Induction furnace needs to be cooled by De-mineralized water or Distilled water instead of soft water primarily to avoid any electrical conduction through cooling water. To achieve this, a mixed bed ionizer is installed. This controls the dissolved ions controlling the conductivity. The equipment details given by the furnace & CCM suppliers set basis of capacity calculation. Moreover, following factors are taken into consideration while deciding the capacity:

1. The evaporation loss in Cooling towers & spray cooling in secondary circuit of CCM. 2. The rate by which the hardness or conductivity of water increases in the Circulating water due to contamination.

PlantPlantPlantPlant Water Water Water Water System:System:System:System: Water will be required in Cooling Tower as make up. Water will also be required to produce treated water to maintain it’s ppm or conductivity increased due to contamination in cooling line. Raw water requirement for Cooling Tower, DM plant, area cleaning system etc will be will met from Bore wells. Water tank of adequate capacity (depending upon equipment requirement & workforce) will be constructed within the premises.



Cranes:Cranes:Cranes:Cranes: 2 No. 35/10MT, 1No. 10MT and 1No. 15 MT Double girder, EOT Cranes will be required to handle the raw material and finished product. All cranes will comply IS 4137 which is meant for EOT Cranes in Steel Plants. Compressed Air Compressed Air Compressed Air Compressed Air System:System:System:System: Compressed air is required primarily at three locations in the plant viz. in Induction Furnace, in CCM & in Dust Extraction System (bag filter). CCM & Induction Furnace require 60 to 100 cfm (FAD) air compressed upto 10-12 kg/cm2. Bag filter requires 2.1 Nm3/min (FAD) of air compressed to a pressure of 6 to 7 kg/cm2. Two (2) air compressors will be installed along with the drier to cater the above demands. Air Conditioning and ventilation Air Conditioning and ventilation Air Conditioning and ventilation Air Conditioning and ventilation System:System:System:System: The CCM control room, panel rooms for furnace will be air conditioned using window/spilt type air conditioners. The capacity of the conditioning units will be decided based on the area of the room heat load dissipated in the room. Fire Protection Fire Protection Fire Protection Fire Protection System:System:System:System: Following systems of fire protection is to be provided in the steel plant.

- CO2 flooding system - Portable fire extinguishers.

Adequate number of portable fire extinguishers will be provided at various locations in the plant shed, LT panel room & DG Set Room. Plant Electrical Plant Electrical Plant Electrical Plant Electrical System:System:System:System: Plant electrical system will have a 33 kV outdoor type substation. It will have one incomer with CT, PT, surge arrestor, isolators etc. It will have five outgoing feeders (two for furnace transformers of approx. 7200 kVA (33kV/ 1000-1000V)). The power supply through furnace transformers will be supplied to furnace whereas power supply through aux. transformer which will be used for EOT crane operations, CCM operations, furnace auxiliaries, pumps for cooling water lighting etc. Cables, Cable Trays & Cable Cables, Cable Trays & Cable Cables, Cable Trays & Cable Cables, Cable Trays & Cable Trenches:Trenches:Trenches:Trenches: Cables for Breaker operated feeders shall be chosen based on:



• Load current with de-rating factor for ambient temperature, mode of laying, grouping factor etc.

• Short time current rating with 0.2 seconds withstand time. • Cable for Switch-fuse controlled feeders shall be chosen based on: • Load current with de-rating factor for ambient temperature, mode of laying, grouping

factor etc. Emergency Emergency Emergency Emergency power:power:power:power: 1 X 750 KVA silent type DG sets have envisaged to power to the auxiliaries of Plant when JSEB power is not available. This will also be useful for Emergency power to take care of safe shut down of important auxiliaries of Plant. During total power failure, above DG set will also support for Emergency lighting for personnel movement in important steel plant locations. Auxiliary Auxiliary Auxiliary Auxiliary Transformers:Transformers:Transformers:Transformers: One (1) number 1750 kVA, 33KV / 433V transformers will be provided for all the plant auxiliary loads. These transformers will be two winding, three phase type with ONAN Cooling. Off Circuit tap changer has been envisaged. Control & Control & Control & Control & Relaying:Relaying:Relaying:Relaying: The Steel plant Electrical power control is done at two different locations. One control & Relay panel is installed in 33 kV substation for feeders whereas LT control is done by LT control panels installed in LT panel Room or near the equipment (if required). All required control, protective relays and metering for electrical installations to against abnormal system conditions will be provided in these control rooms. Protective Protective Protective Protective System:System:System:System: For protection of equipment against abnormal system conditions, adequate protective devices will be installed in the respective switchgears and/or control and relay panels. A group of such protective devices will be necessary to protect the equipment under different abnormal conditions arising in the system. The following protection will be provided for major electrical equipment:- (a) For Furnace Transformer.



1. Over Current Relay. 2. Earth Fault Relay. 2. Winding Temperature Trip. 3. Buchholze Relay.

(b) For Auxiliary transformers:

1. Inverse time over-current relay with high set instantaneous unit for phase faults. 2. Definite time over current relay for earth fault. 3. Back-up earth fault on LV-neutral. 4. Buchholze.

The protections provided for different kind of feeders in 33 kV switchgears are as follows: (a) Incomer(a) Incomer(a) Incomer(a) Incomer //// TieTieTieTie //// Feeder:Feeder:Feeder:Feeder:

1. Inverse time over current relay for phase fault. 2. Definite time over current relay for earth fault.

(b) Motors: (b) Motors: (b) Motors: (b) Motors: 1. Comprehensive motor protection relay. 2. Differential protection for motors rated above 1 MW (if any).

In all cases, proper discrimination would be achieved so as to isolate the faulty elements only, keeping the healthy part of the system in service. 3.3.3.3.4.4 CIVIL4.4 CIVIL4.4 CIVIL4.4 CIVIL ENGINEERING ASPECTENGINEERING ASPECTENGINEERING ASPECTENGINEERING ASPECT :::: SOIL SOIL SOIL SOIL CHARACTERISTICS:CHARACTERISTICS:CHARACTERISTICS:CHARACTERISTICS: Soil investigation report is under preparation. Contour survey has been received. The area has contour difference of approx. 4m which will be taken into consideration while deciding the shop floor level. On visual inspection, soil seems to be reasonably good hence open foundations have been considered for all Buildings and Equipment foundations. GENERAL CONSIDERATION FOR BUILDING AND GENERAL CONSIDERATION FOR BUILDING AND GENERAL CONSIDERATION FOR BUILDING AND GENERAL CONSIDERATION FOR BUILDING AND STRUCTURES:STRUCTURES:STRUCTURES:STRUCTURES: Main building of steel plant includes Steel structure Shed (Steel melting shop & billet yard) & RCC Structures (CCM foundation, Water Tank, Induction Furnace platform, LT panel Room, DG set Room, Lab Workshop & other auxiliaries)



RCC RCC RCC RCC Buildings:Buildings:Buildings:Buildings: Reinforced concrete foundation will be provided for all Steel Structural shed columns, Equipment foundation and other Structures. Operating floor at different levels will be of reinforced concrete slab supported on RCC beams and will be provided with necessary cutouts and inserts to suit technological requirements.

• The Transformers will be installed in the open area. Foundation for installation of Transformer will be provided along with RCC oil pit and Cable trenches etc.

• RCC foundation will be provided for all Equipment, Induction Furnace, CCM, Softening plant and other related auxiliaries.

• Steel Chimney has been envisaged and height and outlet size at top will be in conformity with provisions in IS codes and Pollution Control Stipulations.

DESIGN DESIGN DESIGN DESIGN FEATURES:FEATURES:FEATURES:FEATURES: All Civil Engineering design will be based on the norms laid down in relevant specification on Indian Standards such as IS 800, 456, 1893 etc. Where such norms are not available in Indian Standards, the relevant International Standards will be adopted. The Plant area is having maximum basic wind speed of 47 m/sec. It also falls under seismic zone no. II. The Building and Structures will be designed for such wind and seismic loads along with technological loading requirements. Foundations of all Structures have been considered to be open isolated or mat footing over leveling course. Reinforced Concrete of grade not than M-20 will generally be used. Locations like water tank etc. where higher grade of concrete is required, reinforced concrete grade M25 or M30 will be used. Reinforcement will be of high strength deformed bars conforming to IS: 1786-1985. All foundations and concrete Structures shall be designed to resist full operating dead and live loads, with appropriate combination of wind and seismic forces and with due allowance for impact, vibration etc. as secondary effects of live loads, temperature variation etc. While designing Structures and foundations, either the effect of seismic forces or wind loads, whichever produces the worst effect, shall be considered along with usual load conditions.



3.4.53.4.53.4.53.4.5 CONSTRUCTIONAL FEATURESCONSTRUCTIONAL FEATURESCONSTRUCTIONAL FEATURESCONSTRUCTIONAL FEATURES :::: Concrete works shall be generally in cast-in-situ. The pre-cast concrete shall be used for drain covers, cable trench covers etc. Ordinary Portland cement will generally be used. All construction shall conform to prevailing and practices for quality and safety. All underground and water retaining Structures shall be of water tight construction. The water proofing, wherever found necessary, shall be done by pressure grouting with non-shrink polymeric water proof grouting compound as per manufacturer’s specification. Locally available good quality bricks having minimum crushing strength 5 N/mm2 shall be used. FLOORING:FLOORING:FLOORING:FLOORING: Flooring shall be provided to suit the function requirement of the Buildings. In general all floors on ground shall be of concrete with normal reinforcement laid over soling course. Paving shall generally consist of reinforced cement concrete supported on hard core. FINISHING:FINISHING:FINISHING:FINISHING: Granolithic floor shall be provided in the Buildings in general. The Control Room, laboratory, turbine hall etc. shall be provided with terrazzo floor finish. For heavy duty floors, Ironite topping shall be provided. The masonry walls of Building shall be plastered with cement mortar. The external surface of all the Building shall be painted with two coats of distemper paint over a coat of primer and the internal surface shall be given two coats of white wash. Superior finishing shall be given to the walls of laboratory, Control Room etc. as per the requirement. DOORS AND DOORS AND DOORS AND DOORS AND WINDOWS:WINDOWS:WINDOWS:WINDOWS: Steel doors and windows, rolling Steel shutter, air tight and fireproof Steel doors with two coats of synthetic enamel paint over two coats of primer shall be provided in the Building to suit technological requirements. Special areas like Control Rooms shall be provided with Aluminum doors and windows. STRUCTUREAL STRUCTUREAL STRUCTUREAL STRUCTUREAL WORKS:WORKS:WORKS:WORKS: Structural Steel work will cover Steel construction in Columns, Crane girders, Roof trusses, Bracings, Platforms, Stair cases, Ladders, handrails, Gutters, Down take pipes etc.



Steel Structures are envisaged in the SMS shed, Billet yard & overhead emergency water tank structure for CCM etc. Steel Structures will be designed to meet the Technological requirements and general conditions of the Project. Design of Steel Structures will be carried out as per IS: 800 (Latest) and superimposed loads for design will be according to IS: 875 (Latest). All Structural Steel will conform to IS: 2062 – 1992 Grade A or Grade B as per requirements of design. Steel Structures will generally be of Welded Construction at shop. Site connections and Splice Joints will be made by Bolting followed by site Welding. Fabrication of Structure will conform to IS: 800 (Latest) and other relevant standards mentioned therein. All Steel Structures will be subjected to inspection for acceptance by the Purchaser / Purchaser’s authorized representative. Erection of Structures will be carried as per IS: 800 (Latest) and other relevant standards, Drawings and Specifications. The Erection tolerance will be within standard specified limits. PAINTING:PAINTING:PAINTING:PAINTING: All fabricated Structures will receive one coat of primer paint ay shop after inspection. After erection the Structures will receive another coat of the same primer and two coats of finishing paint. All paints will be of approved color and quality. All surfaces will be thoroughly cleaned of dirt, grease, rust and mill scales before application of paint. Areas which become inaccessible after assembly will be painted before assembly after cleaning of surfaces as described above. 3.3.3.3.4.6 POLLUTI4.6 POLLUTI4.6 POLLUTI4.6 POLLUTIONONONON CONTROL ASPECTSCONTROL ASPECTSCONTROL ASPECTSCONTROL ASPECTS :::: Introduction:Introduction:Introduction:Introduction: This Project is an attempt to make the project as an integrated mini steel plant. Existing setup includes Sponge Iron plant as well as Power plant. This project is being implemented with a target to use the output from the two plants (sponge Iron &Electrical Power) as an input. This plant will have it’s own pollution control system and will not be associated with sponge Iron or Power plant. Important Consideration for Pollution Important Consideration for Pollution Important Consideration for Pollution Important Consideration for Pollution Control:Control:Control:Control: a) Reduction in the generation of pollutants by selecting the best pollution control process. b) Reduction of emission of air pollutants generated from the process to level well below the prescribed minimum standards.



c) Adhering strictly to the safety rules of the Central and State Governments. d) Adopting control for regulation and monitoring of waste effluents such as air emissions, solid waste management etc. in the most proven manner. e) Selection of requisite stack heights to keep ground level concentration of pollutants well below the ambient air quality norms. AIR POLLUTANTS: AIR POLLUTANTS: AIR POLLUTANTS: AIR POLLUTANTS: ParticulParticulParticulParticulate matter i.e. Dust Particles in Gate matter i.e. Dust Particles in Gate matter i.e. Dust Particles in Gate matter i.e. Dust Particles in Gasesasesasesases :::: The waste gases evolved from the crucible during melting process & removal of slag contains the fine dust particles of iron, coal etc. The dust particles are passed through bag filters having efficiency of 99.90%. Dust collected from Dust collectors through hoppers is filled & packed in bags which are sold in local market. This dust is used for filling up of low lands etc. The clean gases invisible to eyes are discharged to atmosphere through high chimney. The dust load in emission shall be limited to 50 mg/NM3 which will be spread over a large area through chimney. Thus, pollution is totally controlled. Dust Particles on GroundDust Particles on GroundDust Particles on GroundDust Particles on Ground :::: Sponge Iron present on ground spread all over due to wind and pollute air. This is being controlled effectively by installing nos. of water sprinkers at locations. Fine water particles mix with dust fines and them to settle on ground. Gases Gases Gases Gases Pollutants:Pollutants:Pollutants:Pollutants: Gases pollutant arises primarily from the by-products of combustion process like SO2, NOx etc. Since no fuel is burnt in the crucible, emission of flue gases also becomes negligible. Source of SO2 is Sulphur present in sponge Iron. Regular analysis of flue gas indicates nil / traces of SO2 or NOx. This is because the sponge iron used has low sulphur and other impurities. Therefore, Atmospheric Air Pollutants like Sox & NOx discharged are will within Pollution Control Board norms. Chimney Chimney Chimney Chimney Height:Height:Height:Height: Chimney height should be sufficient to disperse the undesirable solid/ gaseous pollutants in a wider area to nullity its harmful effect. Height is decided based primarily on Furnace capacity.



EfflueEfflueEfflueEffluent from Water Treatment Plant & waste nt from Water Treatment Plant & waste nt from Water Treatment Plant & waste nt from Water Treatment Plant & waste disposal:disposal:disposal:disposal: Hydrochloric acid and sodium hydroxide will be used as regenerates in the proposed in the mixed bed of water treatment plant. The acid and alkali effluents generated during the process of the ion exchangers would be drained into an epoxy underground neutralizing pit. Generally these effluents are self neutralizing. However provision will be made such that the effluents will be neutralized by addition of eight acid or alkali to achieve the required pH of about 7.0 Effluent will then be pumped into the effluent treatment ponds which from part of the steel plant effluent disposal system. The neutralizing pit will be sized approximately for 15 Cu. m capacity. The rejects from tank (having greater hardness or impurities) used for cleaning purposes as well as sprinkling purposes to subside the dust on the ground in the project. Air Quality Monitoring Air Quality Monitoring Air Quality Monitoring Air Quality Monitoring Program:Program:Program:Program: The purpose of air quality monitoring is the acquisition of data comparison against the prescribed minimum standards and thereby assures that air quality is maintained within the prescribed levels. The following will be monitored from the stack emissions. ● Suspended Particulate Matter. ● Since Sulphur Di-Oxide is not present in the gas as per analysis data, monitoring is not required for the same. The Laboratory attached to the Steel Plant will be equipped with the necessary instruments for carrying out air quality monitoring. It is also proposed to monitor the particulate emission at the stack to keep a continuous check on the performance of the Bag Filters. Adequate sampling opening will be provided in the stack. Impact of the pollution the Impact of the pollution the Impact of the pollution the Impact of the pollution the Environment:Environment:Environment:Environment: As all necessary pollution control measures to maintain the emission levels of dust is taken (SO2 is not present in the gas) and other effluents will be treated in the effluent treatment plant site on account of the installation of the plant. Quantity and Quantity and Quantity and Quantity and Quality of the Effluents from the induction Quality of the Effluents from the induction Quality of the Effluents from the induction Quality of the Effluents from the induction Furnace:Furnace:Furnace:Furnace: The figures given below are for the normal operation of the plant for 300 days in a year.



3.3.3.3.4.7 4.7 4.7 4.7 Pollution Control Pollution Control Pollution Control Pollution Control Equipment:Equipment:Equipment:Equipment: For 15 Ton x 3 Nos. Induction Furnace, a Centralized fume / dust extraction system of 135000 m3/h capacity is provided. The offered system shall comprised of a low canopy hood, connecting ducting, an induced draft fan driven by an electric motor and pulse Jet type Bag Filter. The operating Temperature of the Bag house and Blower shall be limited to 130 deg C. The hood is located centrally over the furnace within about one to two feet from the furnace top. The melting fumes extracted are directed to a bag filter house through appropriately sized ducts made up by mild steel sheets. In the bag filter, the dust enters inside the filter bags and gets filtered on the cloth and only clean air comes out of the cloth which is discharged to the atmosphere above roof level through a stack. The loosen dust falls in the hopper below from where it can be discharged through rotary air lock valve. The dust could be collected in plastic coated bags and disposed off in sealed condition to avoid any secondary escape of dust due to wind blowing etc. After installation of the above system, the shop floor condition will improve substantially by way of elimination of smoke/ furnace dust etc. and also heat from the gases. As a result, apart from meeting pollution control regulation, it improves the efficiency of the workers due to improved working condition. Basic equipments to control air Control pollution

1. Swiveling type Suction Hood 2. Pulse jet bag Filter 3. Centrifugal blower 4. Spark Arrestor 5. Chimney 6. Sprinkler System to control ground Air pollution 7. Water Hydrant System to clean plant Area

3.3.3.3.4.8 4.8 4.8 4.8 Equipment / SysteEquipment / SysteEquipment / SysteEquipment / System to be installed to be installed to control Water pollutantm to be installed to be installed to control Water pollutantm to be installed to be installed to control Water pollutantm to be installed to be installed to control Water pollutant :::: 1. Underground Neutralizing Pit of 15 M3 capacity. 2. Construction of Effluent Pond of adequate capacity. 3. Construction of Septic Tank. 4. Clarification and Filter System to arrest Oil Pollutant.



3.3.3.3.4.9 4.9 4.9 4.9 Construction Construction Construction Construction Water:Water:Water:Water: The water requirement for the construction purpose shall be draw from the bore wells operating within the plant. The water shall be pumped to a masonry tank and construction water shall be supplied at different places with the help of pumps. 3.3.3.3.4.10 4.10 4.10 4.10 Construction Construction Construction Construction Power:Power:Power:Power: Construction power shall be available from the existing system. Dedicated feeder shall be provided for this purpose. DG sets shall also be used to meet construction power requirement. 3.3.3.3.4.11 Construction4.11 Construction4.11 Construction4.11 Construction EquipmentEquipmentEquipmentEquipment :::: Construction equipment like Trucks. Pumps, Air compressors. DG sets, and Welding equipments shall be made available at the site by executing Agency / Contractor. Sufficient number of vehicles like Cars, Jeeps shall also be deployed at the site for manpower mobilization. 3.3.3.3.4.124.124.124.12 Construction Construction Construction Construction Manpower:Manpower:Manpower:Manpower: Construction Manpower with adequate people from different disciplines like Civil, Mechanical, Electrical, Instrumentation and Administration shall look after day to day execution of the project at site. It is envisaged that an experienced and well-equipped project management group of the Project Authority would be employed to overview and steer the project from inception to commissioning. The team would co-ordinate and control all the following basic activities:- Interfacing with different organizations entrusted with engineering supply and erection activities. 1. Procurement activities covering control and monitoring of preparation of specification, tender evaluation, negotiation, ordering, vendor drawing review etc. 2. Material Management and Quality Assurance as per contract. 3. Supervision of construction and erection activities as per contract. 4. Preparation of Progress Reports and updating project schedule. 5. Certification of Performance Testing and acceptance in association with Consultant. Basic engineering and specification for procurement of service of the discrete contract packages may be carried out by an Engineering Consultant to be appointed by the Project Authority.



Supervisory field support would be provided by Consultants as considered necessary. It is envisaged that involvement of the Consultants from the early phase of the project can enhance the engineering progress and site construction smoothly. 3.3.3.3.4.134.134.134.13 Project Monitoring Information Project Monitoring Information Project Monitoring Information Project Monitoring Information System:System:System:System: Progress of each activity at every stage would be physically monitored by respective supervising engineers. All detailed information would be passed on to the Central Monitoring Cell to keep track of the work progress. The detailed PERT/CPM network for the project would be monitored on monthly/fortnightly basis to compare with scheduled vs. actual progress achieved at site. CoCoCoCo----ordination:ordination:ordination:ordination: Regular meetings would be held at site among the representatives of the Contractors, the Consultants and the Engineering of Projects Department to review the progress of each activity. At these meetings, slippages in progress would be identified and corrective measures taken. The problems arising out of site material constraints would be promptly sorted out. The meetings would also be attended by one of the senior executives of the company to facilitate on-the-spot decision. Minutes of meeting would be circulated among all concerned for necessary follow-up action. Co-ordination between the Consultants and the senior executives of the Project Authority would be held regularly for major decisions in regard to planning o0f various plant and equipment, execution procedures, manpower deputations, industrial relations, security, etc. Steps would be taken to ensure regular interactions between the Contractor, the Consultants and projects Department. Reporting:Reporting:Reporting:Reporting: Various reports would be generated in regard to the physical and financial progress of the project on monthly, quarterly and yearly basis for forwarding to the various Government Departments, Financial Institutions as well as for internal use. Daily progress of the major item of work, along with their weekly/monthly targets, would be reported to the project head. Financial Control:Financial Control:Financial Control:Financial Control: Actual cost records would be regularly monitored against forecasts, which would be forwarded to Finance Department by the Projects Department on monthly, half-yearly and



yearly basis, depending on the actual progress of delivery and erection/construction. Fund requirements would be assessed and arranged accordingly. 3.3.3.3.4.14 4.14 4.14 4.14 OPERATION & MAINTENACE OPERATION & MAINTENACE OPERATION & MAINTENACE OPERATION & MAINTENACE PHILOSOPHY:PHILOSOPHY:PHILOSOPHY:PHILOSOPHY: The objectives of plant operation and maintenance shall be to maximize the plant output and availability with safe, reliable and efficient mode of plant operation, meeting all regulatory requirements. Since the plant operation and control shall be achieved by a modern state-of-the-art control and instrumentation system employing DDCMIS, the plant O&M is proposed to be carried out by a limited number of highly qualified and motivated operating staff. To achieve high degree of efficiency in plant management and operation, proper training scheme consisting in-house training as well as at manufactures’ works shall be developed during execution stage of the project. Project authority will recruit the required personnel to operate and maintain the steel plant. Beside, the Operators will be trained by the Original Equipment Manufacture (OEM) specialists at their shop and at site to develop requisite expertise for operation of Induction furnaces & CCM. The O&M staff would be in place during commissioning stage so that they will be associated with the OEM team during pre-commissioning stage of the units. The operation and maintenance of the station would be the overall responsibility of the Plant Chief, who would be assisted by a team of experience Executives and Operators in the respective field. Since the infrastructure for maintenance of the specialized plant and machinery may not be readily near site, adequate maintenance facilities for day-to-day and minor plant maintenance including a well-equipped workshop and trained technicians shall be developed for the project. Major maintenance and annual overall will be contracted out to manufactures or reputed agencies. Odd jobs like, plant cleaning, hiring of vehicles, road and drainage maintenance, plant security, gardening/green belt development etc. will be locally contracted out. 3.3.3.3.4.154.154.154.15 MAN POWER MAN POWER MAN POWER MAN POWER REQUIREMENT:REQUIREMENT:REQUIREMENT:REQUIREMENT: Man power requirement has to be assessed on the basis of:

• Arrangement of Plant as conceived. • Service facilities available. • Number of Plant operating shift.



• Extent of mechanization. • Philosophy of control. • Executive oriented Operational practice. • Executive oriented Maintenance planning. Condition monitoring and predicative

Maintenance practice. • Preventive and breakdown Maintenance through contracts under supervision of

Plant executives. For the Operational and reliability point of view, the Plant has to be operated on three shifts basis. It would therefore, be recomme3nded that to handle the Plant and Equipment and to run this smoothly, efficiency and safety, at least the basic Operation and Maintenance staff will be draw from trained personnel having experience in Operation and Maintenance of the similar Plant and Equipment. The new recruits are to be given requisite training. Imparting of such training will have to be discussed and agreed with the Plant supplier. While estimating Man Power requirement, due consideration has been given to the weekly offs, holydays, leaves, etc. Provision is also to be considered for reserves and other leaves such as National holidays, Festival holidays, Casual leaves, Earned leaves, etc. The manpower requirement for operation and maintenance will be as follows:



CATEGORYCATEGORYCATEGORYCATEGORY NO. OF PERSONSNO. OF PERSONSNO. OF PERSONSNO. OF PERSONS

Management StaffManagement StaffManagement StaffManagement Staff

General Manager 1

Account Officer, Purchase and Store 5

Technical StaffTechnical StaffTechnical StaffTechnical Staff

Dy. General Manager 1

Electrical Engineers 2

Mechanical Engineer & Supervisor 2

Instrumentation Engineers 1

Plant OPlant OPlant OPlant Operation Staffperation Staffperation Staffperation Staff

Shift In charge 4

SMS Production, Maintenance & CCMSMS Production, Maintenance & CCMSMS Production, Maintenance & CCMSMS Production, Maintenance & CCM

Metter 4

Skilled HelperSkilled HelperSkilled HelperSkilled Helper

Electrician 5

Operator & Fitter 16

Chemist 3

TTTTotalotalotalotal 45454545

The above manpower is needed from the time of commissioning / initial start up. The equipments in Steel plant mainly comprises of Induction Furnace, CCM, EOT Cranes, Electrical & Controls and Instrumentation. The overall operation & maintenance department of Steel Plant will be headed by a Dy. General Manager with the support of a General Manager. The GM will basically look after the administrative requirements of the Steel plant. He will be assisted by Accounts/Stores Officers. As far as operational part is concerned, there will be a DGM who will be the overall in charge of operation of all the equipment. His responsibilities include supervision and over seeing of the respective operators of Induction Furnace, CCM, electrical and C & I and all connected auxiliaries. His responsibilities also include ensuring safe and economic operation of the plant. He should be capable of dealing with emergencies of any nature that may arise while in shift



including startup, normal operations, complete shutdown, partial shutdown, breakdown normal and emergency, etc. As the plant will be running around the clock on all days during the year, it is proposed to have 3 groups of shift-in-charge, three for 3 shifts in a day and forth to work as leave reserve for 3 days in and to carryout maintenance of equipment for another 3 days, availing one weekly off in a week. • There will be two main production teams one for caster & other for Induction Furnace

Operations. • There will be operators for operations of water utility systems & equipments, electrical

and C & I operations, etc. • In addition, there will be fitters / operators (Semi-skilled category) attached to main

operators mentioned above. These persons shall have basic ITI qualifications coupled with experience in respective fields.

3.3.3.3.4.154.154.154.15 TRAINING OF TRAINING OF TRAINING OF TRAINING OF PERSONNEL:PERSONNEL:PERSONNEL:PERSONNEL: It is proposed to employ a General Manager in the initial stages. He shall have adequate experience in the installation / operation of Steel Plants. Initially his services shall be utilized for project execution. He shall be given requisite managerial inputs orders in to enable him to take up the responsibility. His earlier experience in operation and maintenance of Steel plants should help him to carryout commissioning activities and a smooth change over from Project management to operation and maintenance. The suppliers of equipment shall be insisted upon the carryout erection of their respective supplies. During the erection stage itself, concerned supervisors / operators shall be attached to the erection agencies. This should enable them to gain adequate project and equipment knowledge and their involvement at the time of pre-commissioning and commissioning stages would enable them to acquire proficiency in time to take up operational responsibilities. Documentation of individual equipment of suppliers shall be called for along with supply of equipment and will be provided to supervisors / operators and connected staff. During the period of commissioning, the supervisors / operators shall be provided with hand on experience for system commissioning. The suppliers’ representatives of major equipment shall be requested to provide requisite data and erection / operation instructions to enable



the Operation and Maintenance staff to gain adequate knowledge of the products and systems. The training of personnel is recognized as a major aspect necessitation close monitoring. Depending on the number of suppliers and availability of useful documentation, corrective action as needed shall be taken to ensure that the Operation and Maintenance staff is equipped with sufficient knowledge. If needed, an outside agency shall be employed to fulfill this requirement. 3.3.3.3.4.164.164.164.16 FACILITIES TO BE EXTENDED TO THE FACILITIES TO BE EXTENDED TO THE FACILITIES TO BE EXTENDED TO THE FACILITIES TO BE EXTENDED TO THE EMPLOYEES:EMPLOYEES:EMPLOYEES:EMPLOYEES: The following facilities will be provided in the power plant;

• Administration building and technical office • Construction offices and stores • Time and security offices • First aid and fire fighting station • Canteen and welfare center • Toilets and charge rooms • Car parks and cycle/scooter stands.

. LIST OF MAJOR PLANT & MACHILIST OF MAJOR PLANT & MACHILIST OF MAJOR PLANT & MACHILIST OF MAJOR PLANT & MACHINARY WITH CIVIL NARY WITH CIVIL NARY WITH CIVIL NARY WITH CIVIL WORK:WORK:WORK:WORK: Civil and Structural Civil and Structural Civil and Structural Civil and Structural Works:Works:Works:Works:

SI No.SI No.SI No.SI No. DescriptionDescriptionDescriptionDescription Area/ Volume/ TonnageArea/ Volume/ TonnageArea/ Volume/ TonnageArea/ Volume/ Tonnage

1. R.C Foundations (32 nos. for SMS Bay +14nos. for Billet Bay).

11.5m3 x 32 Nos. +10.5m3 x 14 Nos.

2. Steel Structure including fabrication. 892 MT

3. G.C Sheets for Roofing and Side Sheeting (24 gauge with zinc coating not less than 275 gm/m2).

~12250 SQ. M

4. Emergency Water Tank . [Surface Tank and Pump House 28m X 17m + R.C. Overhead tank 10m X 11m with staging (upto 19m)].

625 m3

5. Overhead Steel Structure for 110 sq. m platform for CCM Emergency Tank.

25 MT

6. Workman’s Quarters. 700 Sq. m



7. Furnace Platform (2 Units). 576 Sq.m

8. L.T. room DG Set room and Lab room. 189 Sq.m

9. CCM Foundations (including CCM Control Room & Scale Pit).

525 m3

10. Foundation of Machines and Equipments. Lump Sum

Plants and MachineriesPlants and MachineriesPlants and MachineriesPlants and Machineries :::: Sl. No.Sl. No.Sl. No.Sl. No. DescriptionDescriptionDescriptionDescription Qty.Qty.Qty.Qty.

1. Induction Furnace ( Coreless Type 15 MT Capacity with extra crucible rated 4500 kW (24 pulse system).

3 Nos.

2. Furnace Transformers (5500 kVA/ 33kV, indoor type, ONAN cooling cooling type).

2 Nos.

3. Transformers. 3 Nos.

4. Auxiliary Transformer ( 1750 KVA /33kV, Outdoor, ONAN cooling).

1 Nos.

5. E.O.T Crane (as per IS 4177, Double box girder, Indoor, cabin operated). - 35/10 T capacity – 22m span. - 10T capacity – 22m span. - 15T capacity – 15m span.

2 No. 2 No. 1 No.

Circular Lifting Magnets for scarp handling (Ø1800mm, 15m lift, ‘H’ class insulation, heavy duty).

2No.

6. Rectangular Lifting Magnet for billet lifting, 900mm x 600mm x 2nos. with spreader bead, 10m lift, H class insulation.

1 No.

7. Water Treatment Plants - DM unitDM unitDM unitDM unit (TSS < 7mg/l, particle size < 0.2mm, TDS<20 mg/l, SO4< 4mg/1, Cl < 8 mg/l, Total hardness as CaCo3 < 0 mg/l, pH value : 7-8.5, conductivity < 10 mho/cm. - Softening Softening Softening Softening plantplantplantplant (TSS < 10mg/l, particle size < 0.2mm,

1 No. each



TDS < 250 mg/l SO4 < 100 mg/l, Cl < 75 mg/l, Total hardness as CaCo3 < 50 mg/l, pH value : 7-8.5).

8. Cooling Towers (Open Type). (2 Nos. for CCM & 3 Nos. for Induction Furnace).

5 Nos. (2+3)

9. Fume Extraction Unit (Bag Filter, gas flow rate : 30,000 m3 / hr at 130o C, chimney height : at least 30m, guaranteed emission level: 50mg/Nm3).

2 sets

10. Centrifugal Pumps & motors (for Induction Furnace emergency, coil cooling and for DM units, CCM primary, secondary, scale pit & emergency) plus piping work complete.

~18 Nos.

11. Continuous Casting Machine (6/11m radius, 2 Strand with provision of 3rd Strand).

1 Nos.

12. Auxiliaries for CCM. Lump Sum

13. Ladles with lifting Arm Bails, Slide Gates & Accessories. 4 Nos.

14. Ladle Pre heater & Tank. (both Horizontal)

3 Nos.

15. Lab Equipments (with Spectrometer). 1 Set

16. Former Bending M/C set, Gas Cutting Equipment. 1 Set

Welding M/C Set and Lathe M/C.

17. Weigh bridge 60 MT Capacity. 1 No.

18. D.G.Set 750 KVA (with sound proof enclosure). 1 No.

19. Compressors. 2 No.

Electrical Electrical Electrical Electrical Installations:Installations:Installations:Installations:

SI.No.SI.No.SI.No.SI.No. DescriptionDescriptionDescriptionDescription Qty.Qty.Qty.Qty.

1. Electric Substation 33 KV (HT Breaker complete with CT, PT energy meter etc.)

1 Set

2. LT panels 1 Set

3. HT & LT Cables Lump Sum

4. Bus bar & Bus Dust Lump Sum



3.53.53.53.5 M.S. Bars (TMT) M.S. Bars (TMT) M.S. Bars (TMT) M.S. Bars (TMT) 3.5.13.5.13.5.13.5.1 Manufacturing ProcessManufacturing ProcessManufacturing ProcessManufacturing Process:::: The billet manufactured as described above is cut into required sizes and then fed into Roughing Mill at temperatures of 800 0C to 850 0C, the rate at which the billet has to be controlled to avoid partial rolling. Normally it takes 3 – 4 minutes to transfer Hot Billet to the Rolling Stand. The adequately heated billet pieces are introduced into the re-rolling mill in which a number of carbon steel and chilled steel rolls work successively. The hot metal is passed through number of rolls, which are driven with the help of motor & flywheel. The section of the material reduces by pre-determined amount after every pass. Products of desired cross sections can be obtained by adjusting the roll passes and designing. The desire shaped product is obtained from last or finishing rolls. There after the product is passed through the Thermex Water Quenching system. Thermex is a simple to use unique ‘Quenching & Self Tempering’ QST, Technology that was developed by Mr. Franz Tamm, Managing Director of Hennigsdorfer Stahl Engineering GMbh, of Germany. The Thermex® Quenching Technology is a process licensed worldwide. The license holder, M/s Hennigsdorfer Stahl Engineering Gmbh of Germany has signed a collaboration agreement with H&K for exclusive marketing and technology rights for India, Nepal, Bangladesh, Bhutan, Pakistan, Myanmar and Sri Lanka for the know-how and equipment for the production of thermo processed reinforcement steel bars (rebars) as per the Thermex Quenching System and have the rights to license customers in this region the use of this Licensed Thermex Quenching Technology. They are also assigned the right to control the quality of Thermex rebars produced. All Thermex® QST Systems are designed for Grade 500 as per international demands of civil engineers. The bar as it leaves the rolling mill is guided through specially designed proprietary Thermex® Pipes wherein the surface temperature of 850o C -1000o C is brought down drastically in a relatively short period of time on account of the intense and uniform water cooling. The temperature of the core is largely unaffected. The amount of water and time for quenching depends on the parameters of the rolling mill. This is a very important part of the engineering. The pre-determined cooling of the bar periphery transforms the peripheral structure to marten site and then annealed through the heat available at the core. The peripheral and core temperature difference finally equalizes at



around 600o C and the resultant bar structure is of tempered marten site at the periphery and of fine-grained ferrite-pearlite at the core. Generally speaking, the resultant soft core forms about 65 – 75% of the area (depending upon the desired minimum yield strength) and the rest are the hardened periphery. The entire Thermex manufacturing process will be operated through Computerized Programmed Logic Control (PLC) to ensure consistency in quality. It is this Thermex® QST process which results in a product with high yield strength, surface hardness, toughness, ductility and weld ability. To ensure proper and uniform ribbing of the Thermex TMT bars, REPL proposes to install special CNC Machines to cut the rib patterns on the finishing rolls of the rolling mill. After processing through water quenching system, the finished product is kept over the cooling bed for the cooling. The product is then cut to standard lengths and is properly bundled and tagged for dispatch. Raw material Requirement for Rolling Mill: 400 TPD

Raw materialRaw materialRaw materialRaw material Sp. Sp. Sp. Sp.

Cons. T per Cons. T per Cons. T per Cons. T per TTTT TPDTPDTPDTPD TPATPATPATPA SourceSourceSourceSource

Billets 1.03 412 123600 In House production.

3.63.63.63.6 Captive Power PlantCaptive Power PlantCaptive Power PlantCaptive Power Plant ::::

3.6.1 3.6.1 3.6.1 3.6.1 Ash Handling Ash Handling Ash Handling Ash Handling System:System:System:System: The bed overflow ash from the furnace of the steam generator would be removed continuously and the fly ash from the air pre-heater and electro static precipitator (ESP) hoppers would be removed in cyclic batch fashion continuously. 3.6.2 3.6.2 3.6.2 3.6.2 Fly Ash Fly Ash Fly Ash Fly Ash System:System:System:System: Fly ash generated is collected in the ESP hoppers would be conveyed pneumatically to the fly ash storage silo. Fly ash from the fields of ESP hoppers would be conveyed by one pipeline to fly ash silo. Similarly separate pipeline would be utilized for conveying the fly ash collected in other fields. The fly ash collected in the economizer hopper and air pre-



heater hoppers would be conveyed pneumatically by another pipeline to the ash storage silo. • Ash will be generated during the operation of the power plant and this ash will be cooled and removed manually. The fly ash from the economizer, APH, and ESP will be conveyed by dense Phase Pneumatic conveying. • The solid waste from Captive Power Plant is sold to cement manufacturers or brick manufacturers. 3.6.3 Ambient3.6.3 Ambient3.6.3 Ambient3.6.3 Ambient Air Pollution Air Pollution Air Pollution Air Pollution Control:Control:Control:Control: Air in and around the plant area and beyond its boundaries get polluted with gases, fumes and dust particles emanating from the processes, chimney, transfer point of conveying and handling equipment. The air pollutants in an iron making plant are mainly dust and gases like sulphur dioxide, carbon monoxide, nitrogen oxides etc. Measures to control the air pollution will ensure the ambient air quality standard given by State Pollution Control Board for industrial and mixed used areas. In addition, the emission from the chimney will be kept below the permissible limits of statutory norms for dust. Gaseous emission will be released through stacks of required height so as not to exceed ambient air quality norms due to the entire plant. 3.6.43.6.43.6.43.6.4 Stack Emission StandardsStack Emission StandardsStack Emission StandardsStack Emission Standards :::: • Particulate matter (PM) : 50 mg/Nm3 (Coal based)

• Combustion efficiency (CE) : Shall be at least 99.9% and of After Burner

Chamber (ABC) be computed as below: CE=%CO2/[%CO2+%CO]*100

(i) The Kiln off gas stack height should be calculated for proper dispersion of SO2 (with the formula of H= 14Q0.3. Where Q= emission of SO2 in kg/h) as per emission regulations Part III of CPCB. Sulphur percentage shall be the percentage of sulphur in coal. The stack height in no case should be less than 45 m.5 m.5 m.5 m. Sampling Portholes and Platforms etc shall be provided as per CPCB regulation. Adequately designed ESP or Bag Filter or Wet scrubbing system or any other adequate air pollution control system/combination of system should be installed to achieve the prescribed stack emission standards.



(ii) All Pollution control equipment should be provided with separate electricity meter

and totaliser for continuous recording of power consumption. The amperage of the ID fan should also be recorded continuously. Non-functioning of Pollution control equipment should be recorded in the same logbook along with reasons for not running the Pollution Control Equipment

(iii) The safety cap/emergency stack of rotary kiln type plant, which is generally installed above the After Burner Chamber (ABC) of feed end column, should not be used for discharging untreated emission, bypassing the air pollution control device.

(iv) In order to avoid bypassing of emissions, interlocking facility should be provided to ensure stoppage of plant if safety cap of the rotary kiln is not in operation.

3.6.5 3.6.5 3.6.5 3.6.5 Stack Emission Standards from deStack Emission Standards from deStack Emission Standards from deStack Emission Standards from de----dustindustindustindusting g g g units:units:units:units: • Particulate matter (PM) : <50 mg/Nm3 All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions. 3.6.6 3.6.6 3.6.6 3.6.6 Fugitive Emission Fugitive Emission Fugitive Emission Fugitive Emission Standards:Standards:Standards:Standards: The fugitive emissions of suspended particulate matter (SPM) should not exceed 2000 µg/m3 at a distance of 10 m (approx.) from the sources, identified and mentioned below, where fugitive dust emissions are anticipated. The measurement may be done, preferably on 8-hour basis with high volume sampler. However, depending upon the prevalent conditions at the site, the period of measurement can be reduced.

Sr. No.Sr. No.Sr. No.Sr. No. AreaAreaAreaArea Monitoring LocationMonitoring LocationMonitoring LocationMonitoring Location

1. Raw material handling area Screen area, Transfer Points, Stock Bin area

2. Crusher area Crushing plant, vibrating screen, transfer points



3. Raw material feed area Feeder area, Mixing area, transfer points

4. Cooler discharge area Over size discharge area, Transfer Points

5. Product processing area Intermediate stock bin area. Screening plant, Magnetic Separation unit, Transfer Points, Over size discharge area, Product separation area, Bagging area

6. Other areas Areas as specified by State Pollution Control Board

3.6.7 3.6.7 3.6.7 3.6.7 Effluent Discharge StandardsEffluent Discharge StandardsEffluent Discharge StandardsEffluent Discharge Standards ::::

• All efforts shall be made to reuse and re-circulate the water and to maintain zero effluent discharge.

• Strom water / garland drain should be provided in the plant. • In case of maintenance/ cleaning of the system the settling tanks effluent of wet

scrubbing system or re-circulation system is required to be discharged, it should be treated suitably to conform to the following standards. pH - Between 6.5 to 9.0 Total Suspended Solids (TSS) - 100 mg/l Chemical Oxygen Demand (COD) - 250 mg/l Oil and Grease (O&G) - 10 mg/l

3.6.8 3.6.8 3.6.8 3.6.8 Fugitive Fugitive Fugitive Fugitive Emissions:Emissions:Emissions:Emissions: To control fugitive emission, an elaborate dust extraction system has been proposed for all transfer points, starting from transferring raw material into ground hoppers to charging material including crushing and screening. Several suction hoods planned at all relevant material transfer points lead the dust through a bag filter into a stack. The dust collected in bag filter hopper will be recycled in the process. For fugitive emissions from the stockpile area, plantation is proposed to arrest whatever little emissions are expected. For the other areas, de-dusting systems, consisting of air blower, bag filters, hoods and ducts are proposed to take care of fugitive emissions.



3.6.9 3.6.9 3.6.9 3.6.9 Air Pollution Control Measures for Fugitive EmissionsAir Pollution Control Measures for Fugitive EmissionsAir Pollution Control Measures for Fugitive EmissionsAir Pollution Control Measures for Fugitive Emissions ::::

Sr. Sr. Sr. Sr. No.No.No.No.

Fugitive Emission Fugitive Emission Fugitive Emission Fugitive Emission SourcesSourcesSourcesSources

Control TechniqueControl TechniqueControl TechniqueControl Technique Control EquipmentsControl EquipmentsControl EquipmentsControl Equipments

1 Active storage plies • Watering

• Wind screens • Plantations

Water sprinkler on yard

2 Conveyor & Transfer Points

• Water Sprays • Hooding & Ducting

Dust Separation system Bag Filters

3 Product Handling • Wind screen

• Hooding & Ducting Bag Filters

4 Loading & Unloading • Wind screens

• Water sprays Water sprinklers on yard

5 Internal Road Transportation

• Water spray • Concrete /Tar Road • Plantation

Dust Separation system Bag Filters

6 Waste gas • Heat recovery

• Dust collection WHRB Electrostatic Precipitator

3.6.10 3.6.10 3.6.10 3.6.10 Waste WaterWaste WaterWaste WaterWaste Water TreatmentTreatmentTreatmentTreatment :::: Water Pollution mainly comprises of inorganic solids, oil, grease etc. in suspension, solution, and emulsion. Two aspects to be considered for water treatment are: 1. Conservation of water. 2. Waste water treatment and recycle and reuse. 1. 1. 1. 1. Conservation of WaterConservation of WaterConservation of WaterConservation of Water::::

• Rain water harvesting. • Design of units for less amount of water and recycle of water to the maximum by

cascading use of water. • Use of boiler blow downs and cooling water blow downs for slag quenching, green

belt development. 2. Waste Water Treatment & recycle and reuse.



• Wastewater will be generated in individual production facilities. It is recommended that each of the production units be designed to utilize less amount of water and recycle of water to the maximum by cascading use of water. In view of the technological constraints, there will be blow downs from each of the systems to ensure safe operations of the plant. It is suggested that the blow downs water be collected centrally and treated to make the water usable in less critical applications like slag quenching, green belt development etc. Clarifier (Thickener) and sludge pond for removal of suspended solids, Neutralization of acidic water by lime are to be used.

• All efforts will be made to re-use and re-circulate the water and to maintain zero effluent discharge. The following schemes are proposed for wastewater management comprising treatment, recycling and disposal systems.

Zero Discharge ConceptsZero Discharge ConceptsZero Discharge ConceptsZero Discharge Concepts:::: The design of the waste water management system needs to be aimed towards zero discharge which means practically no discharge or bare minimum discharge to the nala outside the plant boundary. It may be difficult to attain zero discharge, as repeated recycling would disturb the quality of recycled water, making the plant operations unsafe. Hence, a part of treated effluent needs to be discharged through the plant drain for maintaining the quality of recycled water. It is proposed that in spite of having total recycling based design of the plant, for all practical purposes, the plant should have drainage provisions for 15-20 cu m/hr of treated water, in compliance with the regulatory standards. Thus the water usage in the steel plant will be around 99.7%. The drainage of treated waste water would be made through the treated wastewater lagoon, serving as a guard pond for quality control of effluent to be drained. It is noted that during the monsoons, the storm water will also be collected in guard ponds and the treated water will be let out of the boundary of the works. The characteristic of the treated wastewater to be discharged to the public nalla would not be inferior to the quality specified by the Central Pollution Control Board.



Effluent Effluent Effluent Effluent Generation:Generation:Generation:Generation:

S. No.S. No.S. No.S. No. SourceSourceSourceSource

1 Cooling Tower blow down

2 Boiler blow down

3 UF+ RO+ MB+ Softner + Filter rejects

Domestic Waste Domestic Waste Domestic Waste Domestic Waste Water:Water:Water:Water: Domestic and sanitary wastewater generated from offices and all sections of the integrated steel plant will be collected from a closed drain and treated by fluidized aerobic biological treatment. The treated wastewater is utilized for green belt development.

3.73.73.73.7 Pollution Control Devices / System :Pollution Control Devices / System :Pollution Control Devices / System :Pollution Control Devices / System :

Sl NoSl NoSl NoSl No UNITUNITUNITUNIT AIR POLLUTION CONTROL SYSTEMAIR POLLUTION CONTROL SYSTEMAIR POLLUTION CONTROL SYSTEMAIR POLLUTION CONTROL SYSTEM

1 SPONGE IRON PLANT

ESP will be used to control dust emission through flue gases from DRI kilns after WHRB. All conveyors will be covered. Bag filters will be used at Coal injection point, Intermediate bin & Cooler discharge section to control fugitive dust pollution Solid waste (dolochar & coal fines) used as fuel in captive power (AFBC) plant.

2 CAPTIVE POWER PLANT

Separate ESP will be provided to control dust emission through flue gases from WHRB & AFBC. AFBC will use dolochar & coal fines generated from process as fuel. Fly ash generated will be supplied to cement industries Pneumatic conveying of fly ash in closed pipes and storage of fly ash in silos. Transportation of fly ash in closed containers.



3

RAW MATERIAL & PRODUCT HANDLING (FUGITIVE EMISSIONS)

Bag filters will be used at Coal handling section, Iron ore handling section, Stock house & Product house section to control fugitive dust pollution Water sprinkling will be done during unloading/loading of trucks to control fugitive emissions Raw materials & Products will be kept in covered sheds or bunkers & all conveyors will be covered.

4 SMS & CCM 3 Nos of Bag Filters, Spark Arrester and separate chimney will be installed for Emission from Induction Furnace.

5 ROLLING MILL Hot billet is directly feed to the Rolling Stand so No inter mediate heating is required. So APCD is not Required.

4 WATER HANDLING SYSTEM

Process wastewater collection and treatment for reuse in water sprinkling for dust suppression. No discharge of water outside premises. Domestic wastewater partly disposed through septic tank – soak pit combination and partly reused for green belt development.

5 OVERALL PLANT AREA

Pucca roads within the premises, water sprinkling in dusty areas and green belt/green cover in 33.4% of total area to arrest the fugitive dust emission

3.8 3.8 3.8 3.8 Disposal of Solid Waste :Disposal of Solid Waste :Disposal of Solid Waste :Disposal of Solid Waste : Sponge Iron Plant :Sponge Iron Plant :Sponge Iron Plant :Sponge Iron Plant : During manufacturing process, dust in cooler, & kiln being controlled by installation of bag filter system, which shall be used to take care of dust to control air pollution at Cooler Discharge, Burner platform, Product separation. In the case of flue gases, which comes out from kiln inlet, are being cleaned at different stages of waste gas system. Gases from the kiln leave at kiln inlet at a higher velocity and enter a specially designed Dust Settling Chamber (DSC). Dust Settling Chamber is the primary dust collecting equipment, which is designed on the principle energy transformation of dust particles. The height and length of the DSC is designed in such a way that the dust particles gain the



potential energy and settles down at the bottom of the DSC is conditioned in a water seal and scrapped out in Dump Bin. The dust thus collected is either sold or used in Brick making. Residual carbon monoxide if any present in the waste gas is burnt and neutralized in the After Burning Chamber (ABC) by injecting an additional quantity of Air through an ABC Blower. The finer dust particles present in the waste gases are entrapped by the comparatively larger diameter but finely atomized high-pressure water molecules, which moves in a Turin motion, the dust particles, which are entrapped by the water particles gains weight and hence potential energy falls and collected at the bottom of the DSC. The gases thus cooled and cleaned by Heat Exchanger (WHRB, incase Power Plant is in operation) are passed through an ESP and finally vented in to atmosphere through a chimney. • The solid waste generated from the plant will be collected in bunkers through bag filters and magnetic separation system. • The dust with fly ash, which is collected below heat exchanger, ESP will be stored in the solid waste disposal yard. This fly ash will be sold to cement manufacture and brick manufacturing. • The sludge collected will also be stored in the solid waste disposal yard and shall be used for land filling. • Dolochar and dust will be collected in the product house and will be used in AFBC boiler.

3.3.3.3.9999 Utility Requirement :Utility Requirement :Utility Requirement :Utility Requirement : 3.9.1 3.9.1 3.9.1 3.9.1 Land :Land :Land :Land : The Company has already acquired & running DRI at Hijalgora, P.S: Jamuria, Dist: Paschim Bardhaman, W.B. and proposed to set up expansion on existing land area 8.31 acre has already been registered in the name of the Company.



Proposed additional land is fallow barren land with gentle slope. Acquisition of land has almost been completed within the time schedule. Work for leveling and preparation of land is pending which company expects to complete very soon. Work of boundary wall of the proposed site will be started after obtaining Terms of Reference for Environmental clearance of the proposed project on the site from the concerned authority. R0AD :R0AD :R0AD :R0AD : The proposed project site is located near NH - 19, which connects KOLKATA and DELHI via Asansol. The proposed site is thus connected to all the states of Eastern region through a network of National and State Highways. The location is also just 12.0 Kms away from Asansol. The other major industrial towns like Durgapur, Kolkata, Dhanbad, Rourkela are nearer to the site. RAIL :RAIL :RAIL :RAIL : The Railway siding is ASANSOL, 12 Km from site connected by the highway. 3.9.2 3.9.2 3.9.2 3.9.2 Power :Power :Power :Power : Power sourced initially from India Power Ltd. for construction/erection and preliminary work. Initially 1.5 MW load sanctioned. Later on power is sourced through the CPP as it is commissioned simultaneously with the sponge iron plant.

3.9.3 3.9.3 3.9.3 3.9.3 WATER :WATER :WATER :WATER : Water is one of the most important resources of any manufacturing unit. For this unit water will be drawn from both surface and ground water sources. . Ground water will be sourced through bore wells for domestic and other allied uses in the plant. Permission for withdrawal of ground water will be obtained from state GWID/CGWA. Make up water requirement is estimated:

UnitUnitUnitUnit ExistingExistingExistingExisting m3/daym3/daym3/daym3/day

ProposedProposedProposedProposed m3/daym3/daym3/daym3/day

Total MakeTotal MakeTotal MakeTotal Make----upupupup m3/daym3/daym3/daym3/day


POWER PLANT - 645 645

SMS - 110 110



ROLLING MILL - 90 90

WATER SPRINKLING & GREEN BELT

10 10 20

DOMESTIC USE 8 12 20

TOTALTOTALTOTALTOTAL 111190909090 1010101067676767 1111222257575757

3.9.43.9.43.9.43.9.4 MANPOWER :MANPOWER :MANPOWER :MANPOWER : Total requirement of manpower in the proposed production and power plant comes to approximately 336 numbers for 3 shift work and general shift administration. These persons will be on Company Payroll and balance will be arranged through contractors. From unloading of raw materials to loading of finished goods one or more labour contracts will be awarded to local contractors. They in turn will employ work men with the required grades of skill on their payroll.

UnitUnitUnitUnit ExistingExistingExistingExisting ProposedProposedProposedProposed TotalTotalTotalTotal


SMS & CCM - 45 45

ROLLING - 55 55

CPP/AUXILLARY - 71 71

ADDM. STAFF 5 10 15

TOTAL 125125125125 211211211211 336336336336



CHAPTER –IV

SITE ANALYSISSITE ANALYSISSITE ANALYSISSITE ANALYSIS 5.1 LOCATION :5.1 LOCATION :5.1 LOCATION :5.1 LOCATION : The site is located at Hijalgora, P.S: Jamuria, Dist: Paschim Bardhaman in the state of West Bengal and is about 10.0 Km from ASANSOL and 5.6 Km from NH 19, and 4 Km from NH - 14. Impact due to project location is envisaged in absence of proper pollution abatement measures and environment monitoring plan, as it is situated at a close distance from various environmental sensitive locations like human habitation, railway line, water course, etc. Adjacent habitation at village Jamuria is in the vicinity of 3.5 Km, Densely populated area- Raniganj at 7.6 Km, Ajay River at 7.4 Km and a Nala close by. The land is Industrial as existing Plant is within that premises. The site is located close to the raw material area and even closer to users of product. Electricity for the plant will be sourced through INDIA POWER. Transportation facilities to access various markets are readily available. Both skilled and unskilled labour is available in the area. Also the location of the plant is suitable as it meets distance criteria from the various landmarks for environment related requirements.

Environmental consiEnvironmental consiEnvironmental consiEnvironmental consideration while selecting the sitederation while selecting the sitederation while selecting the sitederation while selecting the site: • Proximity to Raw Material sources. • Non - presence of Eco-Sensitive landmarks in the study area. • Easy accessibility of rail & road infrastructure. • Existing topography of land with slope & drainage in the area. • Near By JAMURIA INDUSTRIAL AREA. • Availability of land avoiding.

Forest Land. Prime Agriculture Land. Displacement & Rehabilitation or Scarce resources.

The plant layout will be developed looking into the placement of technological and services units so that there is no interference and the movement of man and material is easy and minimum.



No residential colony is proposed. However if any labour quarters/rest rooms are constructed it will be located in upwind direction with respect to the plant and wind direction.

LLLLOCATION MAP IN DISTRICTOCATION MAP IN DISTRICTOCATION MAP IN DISTRICTOCATION MAP IN DISTRICT

THE PLANT LOCATED AT:

Site: At – Hijolgora

P.O. Hijolgora, P.S. Jamuria

Dist. –Paschim Burdwan, West Bengal, .

N

PLANT SITE

Latitude : 230 41’ 52.9” N

Longitude : 870 06’ 52.9” E

Type of Land : Industrial land

Topography : Flat

3



Details of the site Details of the site Details of the site Details of the site :::: No.No.No.No. FeaturesFeaturesFeaturesFeatures DetailsDetailsDetailsDetails

1 Village, District and State Village: Hijalgora, P.S. Jamuria, District – Paschim Bardhaman, State: West Bengal.

2 Survey of India Topo. sheet covering 73 M/2

3 Latitude 23°41'52.9" N

4 Longitude 87°06'52.9" E

5 Land use at the proposed project site Industrial.

6 Nearest Highway/State High Way National Highway No. 19 – 5.6 KM

7 Nearest Railway Station Raniganj– 9.5 Km

8 Nearest major habitation Hijalgora - 2.0 Km Jamuria – 3.5 Km

9 Nearest River Ajay - 7.4 Km

10

Protected areas as per Wildlife Protection Act, 1972 ( Tiger reserve, Elephant reserve, Biospheres, National parks Wildlife sanctuaries, community reserves and conservation reserves)

Not Available within 10 km.

11 Ecologically sensitive zone Not Available within 10 km.

12 Nearest Port Haldia in West Bengal ( about 270 Km)

13 Defense Installation Nil within 10 Km radius

14 Historical Places Nil within 10 Km radius

15 Dams and Barrages Nil within 10 Km radius

Land Land Land Land :::: The general layout of the proposed plant has been developed keeping in the view the following factors:

• Uninterrupted flow of materials in accordance with the technological requirements.



• Contours and gradient of the site • Optimum lead for transport of materials and for service lines • Predominant wind direction • Logistic approach in location of technological units as well as service facilities • Safety clearances & statutory provisions • Close proximity to rich raw material sources

LAND USE BREAK UP:LAND USE BREAK UP:LAND USE BREAK UP:LAND USE BREAK UP:

SL SL SL SL TYPE OF USETYPE OF USETYPE OF USETYPE OF USE AREA (Acres)AREA (Acres)AREA (Acres)AREA (Acres)

1 Manufacturing Plant & Storage 2.20

2 Administrative offices, canteen, security, maintenance 0.20

3 Entrance, Roads and Paved Area 0.80

4 Green Belt 2.75

5 Rolling & SMS 1.10

6 Captive Power 0.86

6 Vacant land 0.40

TOTAL LAND ACQUIREDTOTAL LAND ACQUIREDTOTAL LAND ACQUIREDTOTAL LAND ACQUIRED 8.31 Acres8.31 Acres8.31 Acres8.31 Acres

Site Selection & Location Site Selection & Location Site Selection & Location Site Selection & Location Advantage:Advantage:Advantage:Advantage: While selecting the site for the proposed plant; the following factors were carefully evaluated: • Proximity to the market • Availability of power • Transportation facilities and proximity to the raw material • Availability of skilled & unskilled work force • Regulatory laws – environmental angle • Site characteristics Proximity of The MarketProximity of The MarketProximity of The MarketProximity of The Market :::: The existing location is well connected to all the districts of West Bengal. It is also close to roads leading to Jharkhand. The main market for the product is iron & steel sector – Durgapur and Jamshedpur the iron-steel hub is within 25 - 200 Km of the site.



AvailabilAvailabilAvailabilAvailability of Electric Power: ity of Electric Power: ity of Electric Power: ity of Electric Power: Presently power is available from India Power . After expansion the unit will require 18.5 MW power for normal operation of the plant. Out of this 22 MW is available from CCP, 3.5 3.5 3.5 3.5 MW is surplus which will be supplied to StateMW is surplus which will be supplied to StateMW is surplus which will be supplied to StateMW is surplus which will be supplied to State / Grid/ Grid/ Grid/ Grid.... Transport System & Proximity to RawTransport System & Proximity to RawTransport System & Proximity to RawTransport System & Proximity to Raw----MaterialMaterialMaterialMaterial The proposed site is located near the National Highway and E railway line. The Raw materials and products can easily be transported to the site. The site is also close to the raw material availability area for the project. The connectivity of the site is very good – a pitch road connects the site to the nearest highway at NH -19, Railway station at Asansol 10 Km. Water Source and Supply:Water Source and Supply:Water Source and Supply:Water Source and Supply: The requirement of make up water including domestic & other purposes will be 1257 m3/day. This requirement will be met from ADDA water Supply line. Availability of skilled & unskilled work forceAvailability of skilled & unskilled work forceAvailability of skilled & unskilled work forceAvailability of skilled & unskilled work force :::: The total requirement of manpower in the plant will be available without much difficulty as the area has industrial exposure in iron & steel sector. However, specialized training for operation and maintenance will have to be given to selected candidates well in advance before commissioning of the plant.

UNITUNITUNITUNIT EXISTINGEXISTINGEXISTINGEXISTING PROPOSEDPROPOSEDPROPOSEDPROPOSED TOTALTOTALTOTALTOTAL


SMS - 45 45

ROLLING - 55 55

CPP/AUXILLARY - 71 25

ADDM STAFF 5 10 15

TOTAL 125125125125 211211211211 336336336336

Since most of the workers will be from the local area, hence captive colony within the premises is not proposed.



Site Site Site Site Characteristics:Characteristics:Characteristics:Characteristics: The land selected needs no clearance of vegetation and buildings as the proposed beneficiation plant will be constructed in the open space available in the existing premises. Construction of above ground buildings and structures for plant, roads etc. will be done inside the proposed premises. There are no existing buildings inside the premises and all the construction will be as per the approved plan. Land & TopographyLand & TopographyLand & TopographyLand & Topography :::: The rocky undulating topography with Laterite soil found in Paschim Bardhaman district is a sort of extension of the Chota Nagpur plateau. For ages the area was heavily forested and infested with plunderers and marauders. The discovery of coal in the 18th century led to industrialization. Most of the forests in the coal-bearing areas have been cleared but some areas in the eastern part of the district remained thickly forested till more recent times and some are still there. The eastern part of the district gradually slopes down to the rice plains of the agriculturally rich Purba Bardhaman district. Soil CharacteristicSoil CharacteristicSoil CharacteristicSoil Characteristic The soil in the area is generally brownish and coarse. The details available from secondary sources are presented below:

No Parameters S1 S2 S3 S4 S5 S6

1 Colour yellowish yellowish yellowish yellowish yellowish yellowish

3 Moisture Content (%)

2.69 2.27 2.98 2.20 3.09 2.96

4 pH 6.84 6.47 6.85 7.04 6.98 6.82

5 Soil Texture Clayey Clayey Clayey Clayey Clayey Clayey

6 Bulk density (gm/cc)

2.22 1.81 1.934 2.195 2.2816 2.294

7 Infiltration rate (cm/hr)

4.464 4.216 5.084 4.638 4.7864 4.34

7 Water Holding

79.86 76.38 70.43 74.9 72.168 69.07



capacity (%)

8

Calcium Carbonate as CaCO3

(%)

11.73 11.85 10.89 5.654 7.0556 7.031

9 Organic Matter (%)

1.996 1.29 1.711 1.575 1.6988 1.823

10 Nitrogen as N

0.006 0.008 0.008 0.009 0.007812 0.007

11 Phosphorus 0.029 0.018 0.031 0.019 0.029016 0.017

as P2O5 0 0 0 0 0 0

12 Potassium as K

0.005 0.006 0.006 0.006 0.00682 0.006

13 Chloride % 8.568 7.192 10.49 6.808 7.477 9.362

14 Sulphate % 0.033 0.084 0.035 0.064 0.046 0.025

15 Iron % 4.253 7.558 3.013 8.558 6.467 3.509

InfrasInfrasInfrasInfrastructuretructuretructuretructure :::: The area is well connected with rail & road to Durgapur, Kolkata, Dhanbad, Jamshedpur, Ranchi. The nearest major railway station is Asansol. Corporation supplied water is the major source of drinking water for local population. Public conveyances and Communication facilities viz. Telephone, etc are available on the highway. The water supply and electricity supply in Adityapur Industrial area is in far better position than other locations. Industries in the area:Industries in the area:Industries in the area:Industries in the area: Industries close to the plant site are Alloy, Cement, Concast, , Induction, Sponge etc at Jamuria, Raniganj and Durgapur. Medical facilities:Medical facilities:Medical facilities:Medical facilities: Major Medical facilities are available at Asansol & Durgapur.



LocationLocationLocationLocation AAAAdvantagedvantagedvantagedvantage :::: West BengalWest BengalWest BengalWest Bengal shares its border with the states of Jharkhand to the West and South, Orissa in South. The commercial city is Durgapur & Kolkata. The other major cities and industrial centers are Bardhaman, Siliguri & Asansol. Advantage Advantage Advantage Advantage West BengalWest BengalWest BengalWest Bengal :::: Abundant Minerals:Abundant Minerals:Abundant Minerals:Abundant Minerals: The state is in close to Jharkhand which has huge reserves of minerals with approximately forty percent of the country's resources being available in the state. The state is the major producer of Iron Ore, Bauxite, Coking coal, Uranium and Pyrite. It ranks first in the production of Coal, Mica, Kyanite and Copper in India. There exists further potential for exploration and exploitation of Gold, Metals, Decorative stones, Precious stones, etc. Skilled Manpower:Skilled Manpower:Skilled Manpower:Skilled Manpower: There are a number of renowned institutions such as NIT at Durgapur, Indian Institute of Coal Management at Ranchi, BIT at Sindri, ISMU Dhanbad etc. These institutions produce highly skilled and qualified workforce. • The state also has adequate power generation and efforts are being made to enhance it. West Bengal also has adequate availability of surface and ground water and is sufficient with immense biodiversity supported by a moderate climate. Locational Locational Locational Locational AdvantageAdvantageAdvantageAdvantage:::: West Bengal is located close to Kolkata, Haldia and Paradeep Ports. Kolkata, the state capital & Jamshedpur the industrial hub, is well connected by air, rail and road. Industrial towns have excellent rail and road connectivity with major market places in the country. Conducive R&D Facilities: the state houses top most metallurgical institutions like NIT Durgapur, CMPDIL Asansol, SAIL R&D Ranchi, MECON Ranchi, etc. RailwaysRailwaysRailwaysRailways • The state has extensive and well-developed railway system providing vital links to mining industry and tourism with important cities and ports of the country. The state has extensive goods-handling facilities available at Shalimar, Howrah, Ranchi, Bokaro,



Dhanbad and Jamshedpur (Tata Nagar). In addition, ore loading facilities are available at Kiriburu, Lohardaga and all the coal mines of ECL, BCCL & CCL.

AviationAviationAviationAviation • Asansol is connected with Kolkata, Bardhaman, Siliguri, Delhi, Patna and Mumbai. Jamshedpur, Bokaro, Giridih, Deoghar, Hazaribagh, Daltonganj and Noamundi have airstrips. • The state government has taken steps to set up Air Cargo Complex at Kolkata. This would provide boost to export oriented industries, specifically, those operating in the area of high value and perishable commodities.

PowerPowerPowerPower :::: The installed capacity of power in West Bengal is 2590 MW. This includes India Power / DSPP / DVC / NTPC/ State GOVT.

SteelSteelSteelSteel IndustryIndustryIndustryIndustry :::: Steel is an inseparable part of human civilization and is essential to the country's economic development. Today, India is developing as an emerging giant in the field of Iron and Steel and the National steel policy envisages production of 110 million ton steel by 2020. The demand for steel is increasing within the country with all round acceleration in industrial activity. West Bengal & Jharkhand has total reserve of 3218.08 million tonnes hematite areas accounting for about 30 per cent of the national reserves. Large public and private sector industrial units including IISCO, DSP. ASP, Tata Steel, Bokaro Steel and Usha Martin among others have utilized the immense opportunities in the steel sector in Jharkhand and have triggered an industrial revolution in the process. West Bengal has majors steel Plant as IISCO Burnpur, DSP Durgapur, ASP Durgapur, JAI BALAJI STEEL, Shyam Steel Etc. selected the state and identified a number of thrust areas on the basis of the following criterion: • Availability of raw material • Market • Manpower resources • Linkage with larger units



• Sustainability aspects • Capacity to generate employment

Industrial Industrial Industrial Industrial Areas:Areas:Areas:Areas: The State has at present three Industrial Area Development Authorities with Head Quarters at: • Jamuria Industrial Area. • Bamunara Industrial Area. These authorities are responsible for acquisition of land, development of infrastructure facilities like road, drainage, park, water supply, public utilities, etc. within their jurisdiction. It is contemplated to establish an Industrial Area Development Authority. Site in District Site in District Site in District Site in District –––– Paschim BardhamanPaschim BardhamanPaschim BardhamanPaschim Bardhaman:::: The area is having a very good infrastructural facility in terms of road connectivity as NH 2 connecting Kolkata- Delhi at distance of 5.5 Km. the site is well connected by District Road.

Location and Land UseLocation and Land UseLocation and Land UseLocation and Land Use:::: The area is having a very good infrastructural facility in terms of road connectivity as NH 2 connecting Kolkata and Delhi via Asansol is at a distance of 5.5 Km. Site is located at at Hijalgora, P.S: Jamuria, District : Paschim Bardhaman, West Bengal. Total Land Area: 8.31 Acres. Transportation facilities to access various markets are readily available. Both skilled and unskilled labour is available in the area. No major impacts due to project location is envisaged as it is situated at a considerable distance from various environmental sensitive locations like dense human habitation, forest, water course, mountain, etc. Factors taken into consideration while selecting the site: • Availability of land, present land use / conditions & geography • Communication facility for procurement of raw materials & supply of finished goods. • Availability of resources for such project. • Overall impact on environment • Socio – economic background • Other infrastructural facilities



CHAPTER -V

PLANING BRIEF Existing & Existing & Existing & Existing & Proposed Proposed Proposed Proposed ConConConConfiguration figuration figuration figuration & Implementation& Implementation& Implementation& Implementation

M B M B M B M B SPONGE & POWER LTD.SPONGE & POWER LTD.SPONGE & POWER LTD.SPONGE & POWER LTD. is promoting Sponge Iron Plant for which the configuration of the unit is as follows:

ExistingExistingExistingExisting 2 x 100 TPD Sponge Iron Plant ProposedProposedProposedProposed 1 x 350 TPD Sponge Iron Plant 3 x 15 Ton SMS with 6/11 radius 2 strand CONCAST 400 TPD ROLLING MILLS 22 MW Power Plant using WHRB and AFBC boiler

The Group has a long experience in mineral and metal trade and implementation of the project in time not is a problem. Schedule of implementation of the project is the most reasonable time during which the proposed project can be implemented. This takes into account the time required for various activates i.e. acquisition of land, detailed engineering of the unit including architectural and structural designs, civil construction Procurement of equipment and machinery including utilities and services, equipment test and trial runs etc. Key factors that would facilitate successful and timely project implementation are: o Proper choice of technology and machinery suppliers. o Adequate diligence in formulating the technical concept and system design / selection of the plant. o Proper choice of contractors for civil construction and erection of equipment. o Formulation of effective project team led by an experienced Project Manager. o Establishment of an efficient system for project planning & monitoring including reporting procedures for progress review & co-ordination. o Customization of project execution plan to suit the promoter’s profile.



Implementation Implementation Implementation Implementation Strategy:Strategy:Strategy:Strategy: Typically any project has four core dimensions viz: o Engineering: this directly impacts the smooth operations of the plant over its entire life. o Procurement: is critical on account of the impact that it has on investment and performance benchmarks and also in ensuring the choice of appropriate technology. o Construction: is critical in terms of its impact on completion quality and the duration of the project phase. o Project Management: other than its obvious impact on project timeliness it also contributes to risk minimization for the promoter. “Zero date” for a project is generally reckoned as the date on which the contract for “main machinery” becomes effective. The plant & machinery for a project can be procured in three modes: o Turnkey/ Semi-turnkey o Package o Shopping For the project the turnkey mode of procurement for project execution is proposed. The proposed solution shall help AICL in optimizing project investment and minimizing entrepreneur risk due to cost escalation. In the proposed solution, two agencies one for off shore activities and the other for on shore activities have been considered. Based on the consideration that pre-project activities are accomplished prior to the award of the main machinery order, an implementation period of 18 months from the date of signing / effectiveness of the contract is foreseen for the Phase – I of project and 12 months for the Phase - II. Both the phases will be implemented 18-20 months apart.



CHAPTERCHAPTERCHAPTERCHAPTER----VIVIVIVI

PROPOSED INFRASTRUCTUREPROPOSED INFRASTRUCTUREPROPOSED INFRASTRUCTUREPROPOSED INFRASTRUCTURE Processing Area:Processing Area:Processing Area:Processing Area: The processing area will comprise of various plant facilities within the premises they are Raw material handling plant, DRI Kiln, Boiler Area, TG House, Condenser, Cooling Tower, Induction Furnaces, CCM, Rolling Mill Roads & infrastructure and water reservoir. Thus total area of 18 acres will be developed as processing area.

Non Non Non Non ---- processing areaprocessing areaprocessing areaprocessing area There is no proposal of any residential colony as the required manpower will be sourced from local populace. Few highly skilled posts may be filled from outsiders for whom houses will be leased in nearby residential area. Non-processing area will comprise of facilities within the premises such as – Store & administrative block, road & yards and vacant area1.00 Acres. Thus total area of 2.36 acres will be non-processing area.

Green beltGreen beltGreen beltGreen belt AAAArearearearea :::: Green belt will be developed over 33% of the plant area. Indigenous trees will be planted in three tier system. Plantation will be started along with the construction. Total area of 2.75 acres will be developed as green belt.

Occupational HazardsOccupational HazardsOccupational HazardsOccupational Hazards No major occupational health hazards are envisaged in wet beneficiation plants. The personnel will be trained to take sufficient precautionary measures for safety and hygiene. Project activities are not likely to cause changes in occurrence of disease or affect disease vector. Though, medical check up of workers will be regularly done as per statute. DETAILS OF MAJOR PLANT & DETAILS OF MAJOR PLANT & DETAILS OF MAJOR PLANT & DETAILS OF MAJOR PLANT & MACHINERY:MACHINERY:MACHINERY:MACHINERY: DRI Power preparation system consist of following equipment.

1. Row Materials ground hopper 2. Coal Crusher 3. Iron Ore Crusher 4. Bunker 5. DRI Kiln 6. WHRB 7. AFBC Boiler



8. ESP 9. Bag Filter

Equipment list for Equipment list for Equipment list for Equipment list for DRIDRIDRIDRI.... S.No. Description QTY

1. Ground Hopper of 40T 2

2. Vibratory feeders 50TPH 2

3. Belt conveyors of 650mm width 2

4. Belt conveyors of 500 width 18

5. Roll Crusher 1

6. Impact Crusher 1

7. Vibrating Screens 4

8. Weigh Feeders feeder 16

9. Rotary kiln set complete 2

10. Shell Air fans and Cooling air fans 14

11. Double pendulum flaps 8

12. Hydro-thrust mechanism 2

13. Central oil/coal burner system 2

14. Transfer chute 2

15. Air compressor 2

16. Coal injector with piping 2

17. Roots blower 2

18. Rotary cooler set complete 2

19. Water pumps 6

20. Double pendulum valve 4

21. Magnetic Separators 2

22. Dust settling chamber 2

23. After burner chamber 2

24. Water spraying system in ABC 2

25. Wet scraper 2

26. Emergency stack system 2



27. D.G. Set 1

28. Pay Loader 1

29. Pollution Control equipment (Bag House) 5

30. Ash handling System 1

31. Weigh bridge 1

32. Gas Cleaning System (FD Cooler with ESP)2 2

STEEL MELTING SECTIONSTEEL MELTING SECTIONSTEEL MELTING SECTIONSTEEL MELTING SECTION ::::

1. Induction Furnace. 2

2. Ladles. 4

3. EOT. 3

4. CCM. 1

5. APC. 1

ROLLING MILLROLLING MILLROLLING MILLROLLING MILL::::

1. Roll Stand. 1

2. Hot Billet Conveyor. 1

3. TMT Unit. 2

SHED & BUILDINGSHED & BUILDINGSHED & BUILDINGSHED & BUILDING::::

1. Office Building. 1

2. Control Room. 1

3. Maintenance Shed. 1

4. Lab. 2

ElectricalElectricalElectricalElectrical::::

Furnace transformer rating - 3 nos. 4.0 MVA three phase per furnace. The furnace shell shall be lined with graphite paste inside. Layers of high heat duty firebricks and insulation bricks will back this.. The bottom lining will be thick layer of tamping paste and layers of high alumina brick of 55%, 45% and 35% Al203 and suitable castable refractories. Silicon carbide bricks will be used for tap hole lining. The furnace shall be provided with water-cooling system for:



1. Cooling of current conducting pipes and contact clamp. 2. Cooling of electrode holder ring 3. Cooling of electrode shell 4. Cooling of supporting framework exposed to heat from furnace top.

HOT METAL HOT METAL HOT METAL HOT METAL HANDLING:HANDLING:HANDLING:HANDLING: The hot metal tapped from the spout will be collected in a ladle. The slag will be collected in C.I. Pots mounted on rails. The liquid metal from the ladle will be poured to CCM mould with the help of a crane. Storage Storage Storage Storage Facilities:Facilities:Facilities:Facilities:

The Raw material storage is proposed as follows:

SLSLSLSL NoNoNoNo

MaterialMaterialMaterialMaterial No. of days No. of days No. of days No. of days storagestoragestoragestorage

Mode of StorageMode of StorageMode of StorageMode of Storage

1 Iron Ore 30 days Open area

2 Coal 30 days Under covered shed, closed from 3 sides

3 Dolomite 30 days Under covered shed, closed from 3 sides

4 Pig Iron 30 days Under covered shed, closed from 3 sides

5 TMT Bar 15 Days Under covered shed, closed from 3 sides

6 Billet 15 Dys Under covered shed, closed from 3 sides

Resource Resource Resource Resource optimization:optimization:optimization:optimization: Graded raw material with minimum impurities will be used for manufacture of DRI, Rolled

Product. Handling of material will be done in an environment friendly manner. Process water will be kept in closed circuit and will be recycled. Any waste water generated will be reused for horticulture or dust suppression within the premises. Water Water Water Water RRRRequirement:equirement:equirement:equirement: Water is one of the most important resources of any manufacturing unit. For this unit water will be drawn from ground water sources. Ground water will be sourced through bore wells for domestic and other allied uses in the plant.



Unit Total Make-Up

Process & Cooling 1217

Water Sprinkling & Green Belt 20

Domestic Use 20

TOTAL 1111222257575757

MANPOWER MANPOWER MANPOWER MANPOWER REQUIREMENREQUIREMENREQUIREMENREQUIREMENT:T:T:T: The total requirement of manpower in the plant will be available without much difficulty as the area has industrial exposure in iron & steel sector. However, specialized training for operation and maintenance will have to be given to selected candidates well in advance before commissioning of the plant.

UnitUnitUnitUnit ExistingExistingExistingExisting ProposedProposedProposedProposed TotalTotalTotalTotal

DRI / Sponge Iron 120 30 150

SMS & CCM - 45 45

Rolling - 55 55

CPP/Auxiliary - 71 71

Administrative Staff 5 10 15

TOTAL 125125125125 NosNosNosNos 211211211211 NosNosNosNos 333333336666 NosNosNosNos

Since most of the workers will be from the local area, hence captive colony within the premises is not proposed. ENEENEENEENERGY BALANCE & POWER REQUIREMENT:RGY BALANCE & POWER REQUIREMENT:RGY BALANCE & POWER REQUIREMENT:RGY BALANCE & POWER REQUIREMENT: Based on the above specific consumptions the total power requirement for the plant is estimated as 18.5 MW which will be available from CPP & INDIA POWER. D G set of 250 KVA x 2 & 750 KVA x 1 will be installed for Emergency power supplying to various critical areas like cooling water pump, crane and lighting to take care of on process work during main power soupy failure.



FIRE FIRE FIRE FIRE FIGHTING FIGHTING FIGHTING FIGHTING FACILITIES:FACILITIES:FACILITIES:FACILITIES: In order to combat any occurrence of fire in plant premises the fire protection facilities have been envisaged for the various units of the plant. All plant units, office buildings, stores, laboratories, etc will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances. TRANSPORTATION TRANSPORTATION TRANSPORTATION TRANSPORTATION SYSTEM:SYSTEM:SYSTEM:SYSTEM: All the materials required for construction and operation of the plant will be transported through road. NH is at a distance of nearly 5.6 Km from the site which connects KOLKATA. The site has also good connectivity with other major cities. Hence transportation of materials by road is feasible as the existing network of roads is adequate to accommodate increase of traffic due to the project. COMPRESCOMPRESCOMPRESCOMPRESSED AIR SED AIR SED AIR SED AIR FACILITIES:FACILITIES:FACILITIES:FACILITIES: Facilities have been provided for supply of industrial quality compressed air and dry quality instrumentation air as per requirement. The total requirement of air shall be 5 Nm3 per min industrial quality air at 7 kg per cm2 Other Gas facilities – Oxygen and acetylene shall be required for opening of tap holes prior to tapping and for maintenance jobs. VENTILATION & AIR CONDITIONINGVENTILATION & AIR CONDITIONINGVENTILATION & AIR CONDITIONINGVENTILATION & AIR CONDITIONING:::: Building and shops will generally be provided with natural ventilation. The control rooms of plants shall be provided with window type air conditioner to maintain the temperature as per requirements. QUALITY CONTROL FACILITIESQUALITY CONTROL FACILITIESQUALITY CONTROL FACILITIESQUALITY CONTROL FACILITIES:::: A quality control laboratory has been foreseen fro the following function:

• Analysis of raw materials • Analysis of product • Testing of water and gas samples.



MITIGATIVE MEASURES FOR ENVIRONMENT MITIGATIVE MEASURES FOR ENVIRONMENT MITIGATIVE MEASURES FOR ENVIRONMENT MITIGATIVE MEASURES FOR ENVIRONMENT MANAGEMENT:MANAGEMENT:MANAGEMENT:MANAGEMENT: With increasing environmental awareness, it is imperative that due attention is paid to this aspect right at the planning stage. Of the three major identified areas of pollution viz. air, water & noise, the extent of water pollution & noise pollution significant. As regards air pollution, while gaseous emission are naturally well within the stipulated limits, necessary control measures will be put in place to ensure that particulate emission from the furnaces are also well below the acceptable / prescribed safety norms. a)a)a)a) Ambient Air Quality ManagementAmbient Air Quality ManagementAmbient Air Quality ManagementAmbient Air Quality Management :::: � Fume extraction system for suction of fugitive emissions from raw material charging area and then to bag filter � Water sprinkling and green belt development for maintenance of other areas � Bag filter system for control of emissions and dust from charging of furnace through fume extraction system � Fugitive emissions can also be kept low by making pucca haul roads within the premises and making arrangements for water spraying at all the dusty places in the premises and during loading, unloading process. � Control of Stack Emissions and Fugitive Emissions will have a direct impact on the ambient conditions. � Development of planned green belt in the industry will also control ambient conditions b)b)b)b) Solid WasteSolid WasteSolid WasteSolid Waste Quantity of solid waste generation is considerable at final stage after commissioning of the expansion unit. Appropriate disposal program must be undertaken. The solid waste is not hazardous in nature. It shall be re-used to the extent possible. c)c)c)c) Noise Pollution ControlNoise Pollution ControlNoise Pollution ControlNoise Pollution Control To avoid noise pollution, the DG sets and compressors shall confirm to the norms of the pollution control board. Separate enclosures will be provided for heavy noise generating equipments.



Environmental DataEnvironmental DataEnvironmental DataEnvironmental Data :::: Material BalanceMaterial BalanceMaterial BalanceMaterial Balance Sponge Iron PlantSponge Iron PlantSponge Iron PlantSponge Iron Plant ::::

InputInputInputInput OutputOutputOutputOutput

Iron Ore 1.60 Tons Sponge Iron 0.79 Tons

Coal 1.30 Tons By product Char 0.38 Tons

Dolomite 0.03 Tons By product Char 0.03 Tons

Air 5.00 Tons Waste 0.43 Tons

Air (as flue gas) 6.20 Tons

Total input 7.83 Tons Total output 7.83 Tons

Solid waste generation & its TreatmentSolid waste generation & its TreatmentSolid waste generation & its TreatmentSolid waste generation & its Treatment : : : :

SOLID WASTE GENERATION POINT QUANTITY IN TPD

UTILISATION

Dolo Char After magnetic separator (DRI Unit)

60.00 Dolo-char will be burnt in AFBC boiler for power generation as mixed fuel.

Fly ash ESP - WHRB 33.50 Fly ash bricks or cement plants

Dust WHRB 8.00 Land filling

Dust Bag filter 36.00 Land filling/ partly used in power plants

Accretions Plant 350 TPA Base of road making

Fly Ash ESP – AFBC Boiler

65.80 Cement plant

Bottom Ash Power Plant 18.00 Used as coarse aggregate for fly ash brick-blocks / for land filling

ByByByBy----product/product/product/product/Solid waste management:Solid waste management:Solid waste management:Solid waste management:

COAL CHAR COMES OUT OF THE PROCESS

- Used for burning in the AFBC Boiler as fuel



ASH COMES FROM THE PROCESS at all the Boilers and ESP - sold to other process industries like Cement Plants, Fly ash Bricks etc. DUST COLLECTED AT THE BAG FILTERS in the coal circuit - Used in AFBC boiler as fuel ASH COLLECTED AT DSC, AND THE BAG FILTERS - a mixture of coal and iron ore - Used for making fly ash Blocks.

Green Belt Green Belt Green Belt Green Belt Development:Development:Development:Development: Total Green belt area will be about 2.75 acres being 33% of total pant area. Species of tree to be used for plantation should be such that they are fast growing, strong, and pollutant resistant. The plantation should be a mix of different varieties. A three tier plantation scheme comprising of: Outer ring of tall thick canopy tree – Middle ring of less taller trees – Inner core layer of tolerant species. In addition parallel rows of trees will be planted on either side of roads with traffic movement. • At plant boundary • At road side • Around various mills / workshops / units • Around other utility buildings • Width of greenbelt around the boundary : 5.00 Mtrs. • Total Greenbelt area : 2.75 Acres • Nature of Plant Species : Native



CHAPTERCHAPTERCHAPTERCHAPTER----VVVVIIIIIIII

REHABILITATION & RESETTLEMENT (R&R) PLANREHABILITATION & RESETTLEMENT (R&R) PLANREHABILITATION & RESETTLEMENT (R&R) PLANREHABILITATION & RESETTLEMENT (R&R) PLAN R&R Plan R&R Plan R&R Plan R&R Plan –––– not requirednot requirednot requirednot required The land has been purchased from the Villagers. Full amount has been paid and land acquired and bounded. There is no displacement of any houses, habitation or livestock. Also the land acquisition has not rendered any rayat land less or any worker on the land job less, thus the project is not covered under R&R plan. However preference in employment will be given to land donors and laborers previously working on the land.



CHAPTERCHAPTERCHAPTERCHAPTER----VVVVIIIIIIII

PROJECT SCHEDULE & COST ESTIMATEPROJECT SCHEDULE & COST ESTIMATEPROJECT SCHEDULE & COST ESTIMATEPROJECT SCHEDULE & COST ESTIMATE Tentative Cost & Estimate for Integrated Steel Plant of capacity:Tentative Cost & Estimate for Integrated Steel Plant of capacity:Tentative Cost & Estimate for Integrated Steel Plant of capacity:Tentative Cost & Estimate for Integrated Steel Plant of capacity: Statutory ClearancesStatutory ClearancesStatutory ClearancesStatutory Clearances M BM BM BM B SPONGE & PPOWER PVT. LSPONGE & PPOWER PVT. LSPONGE & PPOWER PVT. LSPONGE & PPOWER PVT. LTDTDTDTD has initiated to get clearances from the statutory bodies. The site selected and land for the project is industrial land to establish the project. The Consents required under Air, Water Acts will be obtained from WBSPCB giving details of Processes involved. As land is Industrial land and not belongs to Forest, no clearance under Forest Act is required. Project Implementation ScheduleProject Implementation ScheduleProject Implementation ScheduleProject Implementation Schedule The project schedule includes various activities like civil works, engineering, procurement, erection and commissioning. It will be imperative to complete many activities before the zero date and soon afterwards. These include:

� Basic engineering � Clearance from statutory authorities � Land acquisition � Preparation & issue of tender document for major technological units � Placement of orders for major technological units � Financial tie-ups, if any and � Finalization of terms with overseas agencies if any.

The schedule for implementing the proposed project is as under :

Particulars Start Completion for SMS, CCM & Rolling Mill

Civil Works Zero date 04 months

Placement of Orders 1 months 2 months

Fabrication 2 months 8 months

Erection & Installation 8 months 12 months

Trial ProductionTrial ProductionTrial ProductionTrial Production 13 months

Commercial ProductionCommercial ProductionCommercial ProductionCommercial Production 14 months



1111 TOTAL COST OF EXPANSION PROJECT:TOTAL COST OF EXPANSION PROJECT:TOTAL COST OF EXPANSION PROJECT:TOTAL COST OF EXPANSION PROJECT:

SL.SL.SL.SL. NO.NO.NO.NO.

PARTICULARSPARTICULARSPARTICULARSPARTICULARS SSSSPONGEPONGEPONGEPONGE INDUCTION INDUCTION INDUCTION INDUCTION & CCM& CCM& CCM& CCM

ROLLINGROLLINGROLLINGROLLING POWERPOWERPOWERPOWER TOTALTOTALTOTALTOTAL (Rs.In acs)(Rs.In acs)(Rs.In acs)(Rs.In acs)

1. Land & Site Development

-- -- -- -- --

2. Civil Buildings 232.00 50.00 45.00 -- 327.00

3. Structural Buildings

694.25 400.00 456.00 699.75 2250.00

4. Plant, Machinery & Electrical

2235.00 2400.00 2800.00 8185.00 15620.00

5. Erection & Installation

220.00 200.00 280.00 350.00 1050.00

6. Waste heat cleaning system

225.00 50.00 -- 375.00 650.00

7. Miscellaneous Fixed Assets

130.00 160.00 120.00 400.00 810.00

8. Contingencies 100.00 100.00 150.00 150 500.00

9. Engineering & Consultancy charges

100.00 50.00 25.00 100.00 275.00

10 Working Capital 2250.00 760.00 1240.00 1750 6000.00

TTTTotal Rs. in lacs.otal Rs. in lacs.otal Rs. in lacs.otal Rs. in lacs. 22227474747482.0082.0082.0082.00



2.2.2.2. SOURCE OF SOURCE OF SOURCE OF SOURCE OF FINANCEFINANCEFINANCEFINANCE ::::

3.3.3.3. Cost of production Per Ton Cost of production Per Ton Cost of production Per Ton Cost of production Per Ton : : : : Sponge Iron:Sponge Iron:Sponge Iron:Sponge Iron:

S.NOS.NOS.NOS.NO DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION CONSUMPTION CONSUMPTION CONSUMPTION CONSUMPTION

NORMSNORMSNORMSNORMS UNITUNITUNITUNIT

RATE / TonRATE / TonRATE / TonRATE / Ton (IN RS.)(IN RS.)(IN RS.)(IN RS.)

AMOUNT AMOUNT AMOUNT AMOUNT (IN RS)(IN RS)(IN RS)(IN RS)

Variable Cost

1) Iron Ore 1.60 Tons 3200.00 5120.00

2) Coal 1.30 Tons 6500.00 8450.00

3) Dolomite 0.040 Tons 240.00 969.00

4) Fuel Oil 4.50 Liters 67.00 301.50

5) Power 80 KWH 6.00 480.00

6) Consumables, Repairs & Maintenance

… 100.00 100.00

Sub Total 15420.00

FIXED COST

1) Salaries & Wages 500.00

2) Overheads 150.00

3) Interest 288.00

4)

Depreciation 228.00

Sub Total 1166.00

TotalTotalTotalTotal 16586.0016586.0016586.0016586.00

SL.NOSL.NOSL.NOSL.NO PARTICULARSPARTICULARSPARTICULARSPARTICULARS AMOUNTAMOUNTAMOUNTAMOUNT

( Rs. In lacs )( Rs. In lacs )( Rs. In lacs )( Rs. In lacs )

1. Promotor 6982.00

2. Un- Secured Loan 1000.00

3. Term Loan Bank 15000.00

4. W. C. Loan Bank 4500.00




Cost of Production per Ton of Billet :Cost of Production per Ton of Billet :Cost of Production per Ton of Billet :Cost of Production per Ton of Billet :

SPECIFICATIONSSPECIFICATIONSSPECIFICATIONSSPECIFICATIONS UNITSUNITSUNITSUNITS

CONSUMPTIONCONSUMPTIONCONSUMPTIONCONSUMPTION / / / / TTTTonononon

PRPRPRPRICE ICE ICE ICE ////UNITSUNITSUNITSUNITS inininin RSRSRSRS

PRODUCTION PRODUCTION PRODUCTION PRODUCTION COSTCOSTCOSTCOST inininin RSRSRSRS

RAW MATERIAL

Sponge iron MT 0.710 16586.00 11776.00

Cast iron MT 0.185 18500.00 3423.00

Scrap MT 0.240 18000.00 4320.00

Ferro alloy MT 0.011 60960.00 671.00

Refractory +CCM Cost Rs Amount 320.00 320.00

Industrial Gases Rs Amount 25.00 25.00

Misc. Rs Amount 30.00 30.00

Repair & Maintenance Rs Amount 100.00 100.00

Power UNITS 725 6.00 4350.00

25015.00

Fixed COST

Salary & wages

Rs Amount 200.00 200.00

Administration expenses Rs Amount 50.00 50.00

Interest Rs Amount 134.00 134.00

Depreciation Rs Amount 91.00 91.00

475.00

Grand Total (In Rs)Grand Total (In Rs)Grand Total (In Rs)Grand Total (In Rs) 25490.0025490.0025490.0025490.00



3.3.3.3.3.3.3.3. COST OF PRODUCTION PER TON OF ROLL PRODUCT :COST OF PRODUCTION PER TON OF ROLL PRODUCT :COST OF PRODUCTION PER TON OF ROLL PRODUCT :COST OF PRODUCTION PER TON OF ROLL PRODUCT :

Sl. NoSl. NoSl. NoSl. No Raw MaterialRaw MaterialRaw MaterialRaw Material UnitsUnitsUnitsUnits Consumption Consumption Consumption Consumption

NormsNormsNormsNorms Cost / MTCost / MTCost / MTCost / MT Total CostTotal CostTotal CostTotal Cost

Variable Cost

1* Billets MT 1.06 25490.00 27020.00

2 Refractory for Reheating Furnace 50.00 50.00

3 Rolls 0.003 120000 360.00

4 Guides, Bearings and Stores 200 200.00

5 Lubricants & Hyd. Oil 50 50.00

6 Oxygen & D A Gas 25 25.00

7 Power 120 6.00 720.00

8 Furnace Oil (ltr.) .035 16500 578.00

9 Repairs 250 250.00

Total 29253.00

Fixed Cost

10 Salary 250 250.00

11 Overheads 50 50.00

12 Interest (10.5%) 147 147.00

13 Depreciation (5%) 100 100.00

Total 547.00

Total Cost of Production of long products (In Rupees)Total Cost of Production of long products (In Rupees)Total Cost of Production of long products (In Rupees)Total Cost of Production of long products (In Rupees) 29800.0029800.0029800.0029800.00

4.4.4.4. Final Cost of Finished Products from each unit per Ton:Final Cost of Finished Products from each unit per Ton:Final Cost of Finished Products from each unit per Ton:Final Cost of Finished Products from each unit per Ton:

(Before Tax and Duties.)(Before Tax and Duties.)(Before Tax and Duties.)(Before Tax and Duties.)

SL. NO.SL. NO.SL. NO.SL. NO. COST OF COST OF COST OF COST OF PRODUCTION PRODUCTION PRODUCTION PRODUCTION

AMOUNTAMOUNTAMOUNTAMOUNT (IN RS.)(IN RS.)(IN RS.)(IN RS.)

SELLING PRICESELLING PRICESELLING PRICESELLING PRICE (IN RS.)(IN RS.)(IN RS.)(IN RS.)

PROFIT (MIN)PROFIT (MIN)PROFIT (MIN)PROFIT (MIN) (IN RS.)(IN RS.)(IN RS.)(IN RS.)

1. Sponge Iron 16586.00 18500 min. 1914

2. Billets 25490.00 28000 min 2510

3 TMT Bars 29800.00 35000 min 5200



CHAPTER IXCHAPTER IXCHAPTER IXCHAPTER IX

ANALYSIS OF PROPOSALANALYSIS OF PROPOSALANALYSIS OF PROPOSALANALYSIS OF PROPOSAL 5. ANALYSIS OF PROPOSAL ( FINAL RECOMMENDATIONS ) :

The technical feasibility and financial viability of the project has been reviewed with reference to the proposed project with reference to overall company as a whole. Our review has been done on the basis of the present scenario and documents made available to us by the company. We have made the assessment afresh and made the changes in assumptions wherever felt required. Based on our analysis it may be inferred that The project is technically feasible and financially viable. The overall financial liquidity and profitability parameters of the project appeared

to be reasonable and satisfactory. We conclude the capital expenditure of the company as a viable option subject to

the weakness and threats associated with a business venture. The operation of plant has significant positive impact on the socio-economic

environment of the area. It helps to sustain the development of this area including further development of physical infrastructure facilities.

In the interest of development and improve the social conditions of the local habitants this project should be allowed after considering all the environment aspects.

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