PRE-FEASIBILITY REPORT
FOR
CAPACITY EXPANSION OF INTEGRATED
IRON & STEEL PLANT TO 1.5 MTPA
AT BELHA, DISTRICT BILASPUR, CHHATTISGARH
TO
NOVA IRON & STEEL LIMITED
NOVEMBER 2014
M. N. DASTUR & COMPANY (P) LTD CONSULTING ENGINEERS
KOLKATA
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
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TABLE OF CONTENTS
Page
1 −−−− INTRODUCTION Background .. 1-1 Authorisation .. 1-2 Structure of the report .. 1-2 Acknowledgement .. 1-2
2 −−−− PLANT LOCATION AND LAYOUT Location of proposed site .. 2-1 Features .. 2-3 Infrastructural facilities .. 2-3 Transport linkages .. 2-3 Water .. 2-4 Power .. 2-4
3 −−−− RAW MATERIALS Major raw materials .. 3-1 Iron ore fines .. 3-1 Coal .. 3-2 Limestone .. 3-3 Dolomite .. 3-3 Quartzite .. 3-4 Pyroxenite .. 3-4 Iron ore pellet .. 3-4 Coke .. 3-4
4 −−−− MAJOR PLANT FACILITIES Raw materials handling and storage system .. 4-1 Requirement of raw materials .. 4-1 Unloading and storage facility .. 4-1 Base-mix preparation system .. 4-4 Despatch of raw materials to the consuming units .. 4-5 Charge-mix feed to the DR kiln .. 4-7 Product handling system .. 4-7 Facilities associated with the raw material handling systems .. 4-8 Coal washery .. 4-8 Design basis/consideration .. 4-9
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
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TABLE OF CONTENTS (Continued)
Page
4 −−−− MAJOR PLANT FACILITIES (cont’d) Direct reduction (DR) plant .. 4-10 Design basis .. 4-10 Product quality .. 4-10 Raw materials .. 4-10 Major facilities .. 4-10 Sinter plant .. 4-11 Production programme .. 4-11 Design basis .. 4-11 Raw materials .. 4-11 Consumption of input materials .. 4-12 Sinter quality .. 4-12 Major facilities .. 4-13 Blast furnace .. 4-13 Production programme .. 4-13 Design basis .. 4-13 Analysis of raw materials .. 4-14 Coal for PCI application .. 4-14 Input materials quantity .. 4-14 Hot metal quality (typical) .. 4-15 Facilities in blast furnace .. 4-15 Steelmelt shop-1 (SMS-1) .. 4-16 Design basis .. 4-16 Requirement of raw materials and supplies .. 4-17 Equipment and facilities for steelmelt shop-1 .. 4-18 Steelmelt shop-2 (SMS-2) .. 4-20 Design basis .. 4-20 Requirement of raw materials and supplies .. 4-22 Equipment and facilities for steelmelt shop-2 .. 4-22 Calcining plant .. 4-26 Wire rod mill (WRM) .. 4-27 Design basis .. 4-27 Major equipment .. 4-28 Medium merchant mill (MMM) .. 4-29 Design basis .. 4-29 Major equipment .. 4-30 Light merchant mill (LMM) .. 4-31 Design basis .. 4-31 Major equipment .. 4-32
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
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TABLE OF CONTENTS (Continued)
Page
4 −−−− MAJOR PLANT FACILITIES (cont’d) Captive power plant .. 4-32 Technical profile of the captive power plant .. 4-33 Top recovery turbines (TRT) .. 4-33 Air separation plant (ASP) .. 4-33 Oxygen .. 4-33 Nitrogen .. 4-34 Argon .. 4-34 Facilities proposed .. 4-34 Plant materials flowsheet .. 4-34
5 −−−− UTILITY AND SERVICE FACILITIES
Power distribution system and electrics .. 5-1 Plant power requirements .. 5-1 Characteristics of plant loads .. 5-1 Source of power .. 5-2 Power distribution philosophy .. 5-2 Instrumentation and automation systems .. 5-3 Structure of proposed automation system .. 5-3 Instrumentation and level-1 automation .. 5-4 Process automation (level-2) system .. 5-6 Supervisory control and data acquisition system (SCADA) .. 5-6 Manufacturing execution (level-3) system .. 5-7 IT infrastructure .. 5-7 Plant communication system .. 5-8 Plant telephone system .. 5-8 Loudspeaker intercommunication (LSIC) system .. 5-8 Closed circuit television (CCTV) system .. 5-8 Wireless communication system .. 5-8 Plant optical fiber cable (OFC) backbone .. 5-9 Fire detection and alarm system .. 5-9 Water system .. 5-9 Water requirement .. 5-9 Source of water .. 5-11 Plant water system .. 5-11 Waste water and effluent treatment management .. 5-15 Distribution pipework .. 5-15
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
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TABLE OF CONTENTS (Continued)
Page
5 −−−− UTILITY AND SERVICE FACILITIES (cont’d) Utility system .. 5-16 Fuel system .. 5-16 Availability of by-product gases for power generation .. 5-16 LPG/propane manifold .. 5-17 Process steam .. 5-17 Plant and instrument air system .. 5-17 Air pollution, ventilation and air conditioning .. 5-18 Chilled water plants .. 5-18 Overhead yard pipework .. 5-19 Central utility monitoring and control .. 5-19 Auxiliary facilities .. 5-19 Laboratories .. 5-19 Repair shops and stores .. 5-19 Ancillary facilities .. 5-20 Drainage and sewerage system .. 5-20 Roads .. 5-21
6 −−−− ENVIRONMENTAL POLLUTION CONTROL MEASURES Review of pollution potential .. 6-1 Proposed mitigation measures .. 6-2 Air pollution mitigation measures .. 6-2 Water pollution control measures .. 6-4 Zero Discharge Concept .. 6-5 Work Zone Pollution control measures .. 6-5 Solid waste generation and utilisation .. 6-6 Plant safety .. 6-6 Plant greenbelt and landscaping .. 6-7 Design targets for APC and WPC measures .. 6-7 Environmental Monitoring .. 6-8
7 −−−− IMPLEMENTATION SCHEDULE Implementation schedule .. 7-1
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
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TABLE OF CONTENTS (Continued)
Page
8 −−−− CAPITAL COST ESTIMATE Capital cost estimate .. 8-1 Plant cost .. 8-1 Interest during construction .. 8-2
TABLES Table 3-1 – Major raw materials .. 3-2 Table 4-1 – Annual consumption of various raw materials and mode of receipt .. 4-2 Table 4-2 – Requirement of wagon tippler .. 4-3 Table 4-3 – Base-mix and trimming materials .. 4-4 Table 4-4 – Specific consumption of raw materials for the DR plant .. 4-10 Table 4-5 – Design basis of sinter plant .. 4-11 Table 4-6 – Typical analyses of raw materials for sinter production .. 4-11 Table 4-7 – Consumption of input materials .. 4-12 Table 4-8 – Design basis of blast furnaces .. 4-13 Table 4-9 – Typical raw materials analysis (dry basis).. 4-14 Table 4-10 – Input material quantities .. 4-14 Table 4-11 – Requirement of major raw materials and supplies .. 4-17 Table 4-12 – Requirement of major raw materials and supplies .. 4-22 Table 4-13 – Estimated power generation capability .. 4-33 Table 4-14 – Technical profile of CPP .. 4-33 Table 5-1 – Make-up water requirement .. 5-10 Table 5-2 – Major water systems .. 5-13 Table 5-3 – Generation of by-product gas .. 5-16 Table 5-4 – Surplus by-product gas availability .. 5-16
FIGURES
Fig. 2-1 – Location map of existing plant .. 2-2 Fig. 7-1 – Implementation schedule .. 7-2
DRAWINGS
Dwg. 11330-02-0001 – Plant general layout Dwg. 11330-04-0001 – Plant materials flowsheet Dwg. 11330-05-0001 – Schematic water flow diagram
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
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SUMMARY
1. Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron
plant of capacity 500 tons per day (TPD) adopting coal based
rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state.
NISL is now contemplating expansion of the above mentioned
sponge iron plant to 1.5 million tons per annum (MTPA)
integrated steel plant along with a 260 MW power plant. The
area of the existing plant is 370.2 acres out of which the
existing facilities occupy only 30 acres and the rest of the
land is vacant. In addition to the above, BPSL has purchased
412.03 acres of land. Accordingly, total land area available
for the project will be 782.23 acres.
2. After expansion, the plant would produce saleable products
consisting of wire rods, billets, beams, channels, rounds,
squares, angles and flats, as listed below:
Rounds .. 675,000 Beams .. 245,000 Squares .. 50,000 Channels .. 280,000 Angles .. 200,000 Flats .. 100,000
Apart from above finished products, about 514,700 tons per
annum pig iron would be used for sale.
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
Summary (Cont’d)
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3. Based on the BF-DRI-EAF-IF process route following major
plant facilities have been envisaged for the proposed
expansion plan.
Sinter plant .. 1 x 248 sqm
Blast furnace .. 1 X 1008 cum
.. 1 X 550 cum
DR Kiln .. 4 X 500 tpd
Calcining Plant .. 2 x 600 tpd
Steelmaking .. IF - 3 x 15 ton LF – 1 X 15 ton EAF – 2 X 90 ton LF – 2 x 90 ton VD - 1 x 90 ton
Casting and Rolling .. Light Merchant Mill .. Medium Merchant Mill .. Wire rod mill
Captive Power Plant .. 2 x 130 MW (CPP-1) .. 2 x 7.5 MW (CPP-2)
4. Nova Iron and Steel Limited (NISL) is located at Belha tehsil
of Bilaspur district in the State of Chhattisgarh, between
latitudes 22°53'N to 22° 55' N and longitudes 82° 00' E to 82°
05' E and 268 m above mean sea level (MSL). The site is
approximately 40 km from Bilaspur town. The site is located
on the eastern side of national highway NH-130 and
connected with the bypass road from NH-130. The bypass
road is connecting NH-130 and village Belha at the northern
side of proposed plant. The NH-130 is about 9 km away from
the site. The nearest railway station is Dagori, situated
about 6 km. on the north-east side of the plant.
5. Requirement of some of the major raw materials considered
for the production viz. anthracite coal and PCI coal would be
met through import. Iron ore fines, coke, non-coking coal,
iron ore pellet, BF & SMS grade limestone, dolomite, quartzite
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
Summary (Cont’d)
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and pyroxenite would be procured from indigenous sources.
Wagon tipplers/truck tipplers are envisaged for unloading of
the raw materials and mechanised systems are considered for
storage and distribution of various raw materials.
6. Requirement of fuel, power and other utilities viz. plant and
instrument grade compressed air, steam, industrial gases
(oxygen, nitrogen & argon), chilled water would be fulfilled
through installation of new facilities. Blast furnace gas would
be available as by-product gas inside the plant for various
process needs and heating applications of the plant, besides
being a source of power generation. Total make-up water
requirement for the plant after full implementation would be
about 2,040 cu m per hour, which would be drawn from the
Sheonath river.
The requirement of power for the expansion would be
1,288 Million KWh, which would be met partly through
captive power generation from coal & gas fired captive power
plant and from TRT of blast furnace.
7. In view of the aforementioned plant facilities, there would be
pollution load, for which adequate mitigation measures would
be adopted to keep the pollution load within the stipulated
norms.
8. It is envisaged that the project would be completed within 36
months from the ‘Go-Ahead date’.
9. The estimate of capital cost includes plant cost, preoperative
expense, working capital margin and interest during
construction. The plant cost comprises the costs of plant &
equipment (as erected) together with the cost of pollution
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
Summary (Cont’d)
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control, design, engineering, consultancy & administration
during construction and contingency. The capital cost is
estimated to be Rs. 10,834 crore approximately. About
7 - 9 per cent of the total plant cost has been kept for
environment management measures.
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
1−1
1 – INTRODUCTION
BACKGROUND
Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron
plant of capacity 500 tons per day (TPD) adopting coal based
rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state. NISL
is now contemplating expansion of the above mentioned sponge
iron plant to 1.5 million tons per year (MTPA) integrated steel
plant along with a 260 MW power plant.
M/s Bhushan Power & Steel Limited (BPSL) has taken over
NISL in 2011. BPSL is a leading manufacturer of flats, rounds
and long products including value added products with billets, HR
coils, pig iron, CR coils, GP/GC, precision tubes, black pipe/GI
Pipe, cable tapes, tor steel, wire rod and special alloy steel.
BPSL has successfully commissioned a greenfield steel and
power plant in Odisha with hot rolled coil making facility - first in
private sector in the state of Odisha. BPSL is selling its value
added range of products in secondary steel sector through a large
distribution network in India (comprising more than 35 sales
offices) and abroad.
The area of the existing plant is 370.2 acres out of which the
existing facilities occupy only 30 acres and the rest of the land is
vacant. In addition to the above, BPSL has purchased 412.03 acres
of land. Accordingly, total land area available for the project will be
782.23 acres.
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
1 – Introduction (cont’d)
1−2
AUTHORISATION
NISL, vide its letter No. NISL/WO/BSP/RKG/RNY/14-
15/166 dated 02.07.2014 commissioned M. N. Dastur & Company
(P) Ltd. (CONSULTING ENGINEERS), Kolkata, for preparation of an
Environmental Impact Assessment (EIA) study for its 1.5 MTPA
integrated steel plant. According to the Ministry of Environment
and Forests (MoEF) regulations, this Pre-Feasibility Report (PFR)
has been prepared as an appendage to the EIA study for the
proposed project. This PFR, along with Form I, needs to be
submitted to MoEF for obtaining prior environmental clearance for
the project.
STRUCTURE OF THE REPORT
The Pre-Feasibility Report is presented in eight chapters.
Following this introduction, the project concept and site conditions
are discussed in Chapter 2. Chapter 3 describes annual
requirements of major raw materials and their availability for the
project. Major plant facilities envisaged for the project including
plant layout are discussed in Chapter 4. Chapter 5 describes
various utility services, like power system, instrumentation,
automation and plant communication systems, water and utility
systems and auxiliary facilities, like laboratories, workshops, and
stores, etc. Environmental pollution control measures proposed
are indicated in Chapter 6. Chapter 7 describes plant construction
schedule and volume of construction. The capital cost estimate is
indicated in Chapter 8.
ACKNOWLEDGEMENT
CONSULTING ENGINEERS gratefully acknowledge the
co-operation and assistance extended by the officials of NISL and
BPSL during the site visit and the preparation of the Pre-Feasibility
Report.
NOVA IRON & STEEL LTD. M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh P re −−−− Fe as i b i l i t y Rep or t
2-1
2 – PLANT LOCATION AND LAYOUT
This chapter presents the location of proposed plant site, its
features and briefly reviews the infrastructure facilities available at
site.
LOCATION OF PROPOSED SITE
Total land area available for the project will be 803.05 acres.
The location map of the existing plant is shown in Fig. 2-1 on the
next page. The plant general layout of the proposed plant is given
in Drawing No. 11330-02-0001. The site is approximately 40 km
from Bilaspur town. The site is located on the eastern side of
national highway NH-130 and connected with the bypass road from
NH-130. The bypass road is connecting NH-130 and village Belha
at the northern side of proposed plant. The NH-130 is about 9 km
away from the site. The nearest railway station is Dagori, situated
about 6 km. on the north-east side of the plant.
River Sheonath is flowing by the southern boundary of the
proposed site. It is a perennial river. It is envisaged that the
requirement of water will be fulfilled from this river for expansion
project.
NOVA IRON & STEEL LTD. M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh P re −−−− Fe as i b i l i t y Rep or t
2 – Plant location and layout (cont’d)
2-2
NOVA IRON & STEEL LTD. M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh P re −−−− Fe as i b i l i t y Rep or t
2 – Plant location and layout (cont’d)
2-3
FEATURES
The acquired additional area for plant comprises
predominantly barren/single crop agricultural land. The village
Dagori is located at the northern side of the proposed plant.
The finished ground level of the existing plant is RL+268.0
m. The land at its northern side is higher than the existing plant
which varies from RL+268.0 m to RL+269.5 m. Land is fairly plain
with small undulations for developing a good layout. The soil
predominantly consists of moorum, clay, slit and sand. There are a
few rocks outcrops within plant site.
INFRASTRUCTURAL FACILITIES
Transport linkages
Rail: The nearest railway station, Dagori, located in Bilaspur
–Raigarh railway line, is situated about 6 km away from the plant
site. Dagori railway station is located in between Belha and
Nipania Railway Stations.
Major raw materials will be transported by rail. Anthracite
coal will be imported through Paradip port and then will be
transported by rail to the plant site. Suitable rail link has been
envisaged from the proposed railway siding at Dagori station to the
plant site for receipt of raw materials, as well as for despatch of
finished products.
Road: Nearest national highway NH-130 is about 9 km away
from plant approach. There is a bypass road connecting NH-130
and village Belha at the northern side of proposed plant. The
condition of approach road from the existing plant to the bypass
road needs to be improved under expansion project.
NOVA IRON & STEEL LTD. M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh P re −−−− Fe as i b i l i t y Rep or t
2 – Plant location and layout (cont’d)
2-4
Port: Paradip port is situated about 640 km from proposed
site. Imported raw materials will be handled through Paradip port.
Suitable interaction with the port authorities will be necessary to
finalise this arrangement.
Water
To meet the make-up water requirement, it is necessary to
have a reliable water source. The main source of make-up water is
river Sheonath which is about 100 m from the existing southern
boundary of the plant. The river is a perennial source of water.
The river Sheonath has been considered as a probable source
of water. To ensure an uninterrupted supply of water, a reservoir of
14 days storage capacity has been considered within the plant
premises. However, suitable study on impounding arrangements in
the form of a pick-up weir at the river source and intake facilities
will have to be assessed at an appropriate time to meet the plant
water requirements.
Power
The nearest 220 kV sub-station is located at 20 km away
from the proposed plant site. The plant power requirement will be
met from the captive power plant as well as from the grid.
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
3-1
3 – RAW MATERIALS
This Chapter discusses the annual requirement of major raw
materials, reviews their availability, quality and probable sources
of supply.
MAJOR RAW MATERIALS
The major raw materials required for the proposed project
are iron ore fines, coal, limestone, dolomite, etc. Estimated gross
requirement of raw materials to be procured annually on net and
dry basis are given in Table 3-1 in the next page.
Iron ore fines
Iron ore in the form of fines will be required for use in sinter
plant. The entire requirement of iron ore fines will be met from the
mines located in Madamnar region, Narayanpur district of
Chhattisgarh. The procurement size of iron ore fines and their
likely chemical analysis are as follows:
Size Fe SiO2 Al2O3 LOI
mm % % % %
-10 63.07 2.65 2.04 2.24
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
3 – Raw materials (cont’d)
3-2
TABLE 3-1 – MAJOR RAW MATERIALS
Consuming unit
Raw materials
Indicative source
Net & dry requirement
Gross procurement
tons/year tons/year(1)
Iron ore fines Narayanpur, Chhatisgarh
1,653,511 1,834,000
Limestone fines
Keonjhar, Odisha
218,678 136,910 (2)
Dolomite fines Baradwar, Chhattisgarh
17,230 - (3)
Pyroxenite Local 69,056 74,180
Sinter plant
Anthracite coal Australia 34,569 37,200
Non-Coking coal
Jharsuguda , Odisha
592,746 230,400 (4)
Dolomite Baradwar, Chhattisgarh
18,480 19,300
Injection coal Jharsuguda , Odisha
254,034 281,800
DR plant
Pellet Local 991,320 1,120,900
Quartzite Local 21,964 23,340 PCI coal Australia 175,715 190,750 Coke Local 696,300 773,700
Blast furnace
Pellet Local 480,300 543,000
Coal washery
Non-Coking coal
Jharsuguda , Odisha
1,500,000 1,663,710
Power plant Thermal coal Jharsuguda , Odisha
770,880 855,020
Limestone Keonjhar, Odisha
606,880 686,170 Calcining plant
Dolomite Baradwar, Chhattisgarh
114,660 129,640
Notes:
(1) Includes moisture, handling and screening losses as applicable. (2) Excludes about 91,220 tons of limestone fines generated in calcining
plant, which is to be utilized in sinter plant. (3) Excludes about 17,230 tons of dolomite fines generated in calcining
plant, which is to be utilized in sinter plant. (4) Excludes about 385,050 tons of washed coal produced in coal washery,
which will be used as a non-coking coal in DRI plant.
Coal
Anthracite: Anthracite coal will be used in sinter plant. As
such coal is not available in India, the same will be met through
imports from Australia.
Pulverized coal injection: Coal with low volatile matter
and ash content will be used for pulverized coal injection (PCI) in
blast furnace. As such coal is not readily available in India,
requirement of the same is planned to be met through imports from
Australia.
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
3 – Raw materials (cont’d)
3-3
Non-coking coal: Raw non-coking coal will be sent to coal
washery and the entire washed coal will be used in the DR plant.
To meet the balance requirement of coal in the DR plant, suitable
grade of non-coking coal will be procured from collieries of IB
Valley region, Jharsuguda, Odisha. The middling from coal
washery and char from DR plant will be used in the thermal power
plant. The balance requirement of suitable grade thermal coal will
be procured from collieries of IB Valley region, Jharsuguda,
Odisha.
Limestone
BF grade limestone will be used in the sinter plant and SMS
grade limestone will be used in the calcining plant. It is envisaged
that, the total requirement of limestone for use in sinter plant and
calcining plant will be procured from Banspani region within a size
range of (+) 40 to (-) 80 mm. A typical chemical composition of
limestone considered for this report is tabulated below:
SiO2 Al2O3 CaO MgO LOI
% % % % %
0.99 0.52 52.27 1.98 42.34
Dolomite
It is envisaged that the entire requirement of dolomite for use
in sinter plant, DR plant and calcining plant will be met from
Baradwar region in Chhattisgarh. Size of the dolomite to be
procured will be in the range of (+) 40 to (-) 80 mm. The typical
analysis of Baradwar dolomite considered is as follows:
SiO2 Al2O3 CaO MgO LOI
% % % % %
0.86 0.29 30.80 19.12 46.05
NOVA IRON & STEEL LTD
M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report
3 – Raw materials (cont’d)
3-4
Quartzite
Quartzite will be used in the blast furnace. It is envisaged
that the entire requirement of quartzite will be procured from
local sources in the size of (+)10 to (-)40 mm. A typical chemical
analysis of quartzite considered for this report is as follows:
SiO2 Al2O3
% %
96.92 0.92 Pyroxenite Pyroxenite will be used in the sinter plant. It is envisaged
that the entire requirement of pyroxenite will be procured from
local sources. A typical chemical analysis of pyroxenite considered
for this report is as follows:
SiO2 Al2O3 CaO MgO
% % % %
47.0 0.83 0.80 32.0
Iron ore pellet
It is envisaged that, the entire requirement of pellet for use
in blast furnace and DR plant will be procured from local sources.
Coke
It is envisaged that, the entire requirement of coke for use in
blast furnace will be procured from local sources.
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
4−1
4 – MAJOR PLANT FACILITIES
The major production facilities of the steel plant will
comprise coal washery, direct reduction plant, sinter plant, blast
furnaces, steelmelt shops and long product mills. The plant will
also have captive air separation plant on Build-Own-Operate (BOO)
basis to meet the plant oxygen requirement. Power generation
units are also envisaged utilising surplus blast furnace gas and
in-plant char and middlings. Additionally, boiler coal will be used
in the power plant. This chapter describes the major facilities
envisaged for the project.
RAW MATERIAL HANDLING AND STORAGE SYSTEM
Requirement of raw materials
The annual consumption of various raw materials and mode
of receipt is indicated in Table 4-1 in the next page.
Unloading and storage facility
All rail-bound materials viz. pellet, iron ore fines, non-coking
coal for power plant and coke will come in an open top BOXN
wagon. These materials will be unloaded by crescent type rotary
wagon tippler. Materials unloaded by wagon tippler will be drawn
by apron feeder/belt feeder located below the wagon tippler
hoppers and fed to the conveyor system for its onward
transmission to the storage yard.
The tippling rate of wagon tippler will be 25 tips per hour
and the same will be designed as per Research Designs and
Standards Organisation (RDSO) stipulated norm G-33, May 2010.
Handling of DFC wagons is not envisaged in this Report.
NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh
Pre-Feasibility Report
4 – Major plant facilities (cont’d)
4−2
TABLE 4-1 – ANNUAL CONSUMPTION OF VARIOUS RAW MATERIALS AND MODE OF RECEIPT
Sl. No.
Material
Receipt
size
Gross (1) annual
quantity
Gross daily(2)
quantity
Mode of receipt
mm ton ton A. For Sinter Plant
Iron Ore Fines (IOF)
(-)10
1,834,000
5,558
Rail Limestone 40-80 136,900 415 Road Pyroxenite 40-80 74,200 225 Road Anthracite (-)20 37,200 113 Road
B.
For Blast Furnace
Iron Ore Pellet 5-18 543,000 1,552 Rail Quartzite 10-40 23,300 67 Road PCI Coal (-)50 190,800 545 Road Coke 10-80 797,600 2,211 Rail
C.
For DR Plant
Iron Ore Pellet 5-18 1,120,900 3,397 Rail Non-coking coal 5-20 512,200 1,552 Road Dolomite (-)8 19,300 58 Road
D.
For Coal Washery
Raw coal (-)600 1,663,700 5,455 Road
E.
For Calcining Plant
Limestone 40-80 686,200 2,079 Road Dolomite 40-80 129,600 393 Road
F.
For Power Plant
Boiler coal 0-100 855,000 2,375 Rail
G.
For SMS-1
Ferro-alloy - 2,400 7 Road
H.
For SMS-2
Ferro-alloy - 25,500 80 Road Direct reduced iron - 235,500 736 Road
Note: (1) Above figures are derived based on the following losses:
- 2 per cent handling loss - 5 per cent screening loss - 5-10 per cent moisture loss
(2) Above figures are derived based on the following operating day/year:
- 330 days for Sinter plant - 350 days for BF - 330 days for DR plant - 305 days for Coal washery - 330 days for Calcining plant - 360 days for Power plant - 330 days for SMS-1 - 320 days for SMS-2
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The number of rakes to be handled per day and requirement
of wagon tippler are given in Table 4-2.
TABLE 4-2 – REQUIREMENT OF WAGON TIPPLER
Material
Daily quantity
No. of rakes(1)
No. of rakes(2) at peak load
ton
Iron Ore Fines 5,558 1.46 1.95 ≈ 2 Pellet 4,949 1.30 1.69 ≈ 2 Coke 2,211 1.05 1.40 ≈ 2 Boiler coal for power plant
2,375 0.63 0.83 ≈ 1
Note:
(1) A rake load of 2,100 ton for coke and 3,800 ton for other materials has been considered.
(2) Bunching factor of 1.33 for indigenous and 1.5 for imported materials have been considered for finding out peak load.
Based on number of rakes to be handled per day at peak
load and keeping in view the contamination of materials for process
requirement, two (2) nos. ‘C’ type rotary wagon tipplers have been
envisaged.
Road-bound materials will be unloaded in the ground hopper
in the storage yard and the same will be stored in the respective
storage yard by stacker/reclaimer. (-)600 mm raw coal required for
coal washery will be brought to the site by 130-ton dumper and the
same will be stored in the storage yard. Unloading of all road-
bound materials will be done by external agency.
Purchased coal for DR plant having size of 5-20 mm will be
unloaded in the ground hopper and will be stored in an overhead
bunker and then fed to the day-bin of DR plant through conveyor
system.
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Materials unloaded by wagon tippler will be stored in the
respective storage pile with the help of stacker/reclaimer with
by-pass facility. Open storage piles system has been considered
for all material except PCI which will be kept under the covered
storage.
PCI coal delivered by road will be unloaded to a separate
ground hopper. PCI will be stored in the covered store by using
travelling tripper.
A storage capacity of seven (7) days for indigenous materials
and fifteen (15) days storage for imported materials has been
considered.
Base-mix preparation system
A base-mix yard has been envisaged to get good quality of
sinter. Base-mix and trimming materials required to be despatched
to the sinter plant and their respective quantities are indicated in
Table 4-3 below:
TABLE 4-3 – BASE-MIX AND TRIMMING MATERIALS
Estimated daily gross quantities
tons
Constituents of base-mix:
Iron ore fines .. 5,558 Limestone (purchased) .. 322 Limestone fines from LCP .. 221 Dolomite fines from DCP .. 52 Pyroxenite .. 180 Coke breeze/Anthracite .. 302
Total .. 6,635
Trimming materials:
Limestone (purchased) .. 83 Limestone fines from LCP .. 55 Pyroxenite .. 45 Coke breeze/Anthracite .. 76
Total .. 259
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Twin boom stacker has been considered for stacking of
base-mix.
Seven (7) days storage with 2 nos. of pile of base-mix have
been considered, one (1) under stacking mode and the other on
reclaim mode.
Despatch of raw materials to the consuming units Despatch of coke, pellet, sinter and quartzite to BF:
Material (one at a time) will be reclaimed by stacker/ reclaimer in
reclaim mode and dispatched to the bins at blast furnace stock
house through series of conveyors. Sinter received from sinter
plant will be fed to the BF stock house through conveyor system.
Despatch of PCI to BF: PCI from covered shed will be
reclaimed by pay loader and fed to the yard hopper. Materials from
yard hopper will be withdrawn by vibrating feeder located below
and fed to the hammer mill for sizing of (-)10 mm. This (-)10 mm
material will be then fed to the bunker for its onward pulverization
suiting the requirement for injection system to BF.
Despatch of base-mix to sinter plant: Base-mix will be
reclaimed by barrel reclaimer and fed to the bunkers at the
proportioning bin of sinter plant for its onward transmission to the
sinter machine after final adjustment of chemistry of the sinter-
mix.
Transfer car has been considered to transfer barrel reclaimer
from one bay to the other.
Despatch of limestone to LCP: Limestone will be reclaimed
by stacker/reclaimer in reclaim mode and fed to screening station
through conveyor system.
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(-)40 mm size fraction separated out will be dumped to the
ground. 40-80 mm will be fed to the respective bins at LCP area.
Despatch of lime and DRI to SMS: Lime received from LCP
will be stored in a bin having storage capacity of 600 ton. Lime is
then fed to the bins at SMS building through conveyor system.
DRI will be fed to the bins at SMS by conveyor system.
Additional DRI purchased for SMS will be transported to SMS by
conveyors.
Despatch of raw coal to washery: Raw coal (- 600 mm)
stored at storage yard by dumper (by external agency) will be
reclaimed by pay-loader and fed into the dumper (35-ton).
Dumper will dump the coal into the hopper. Material drawn
by apron feeder located below the hopper will be fed into the
primary sizer to crush down (-) 120 mm.
Secondary sizer will be used to crush down further upto (-)20
mm. (-)20 mm size will be stored in bunker through series of
conveyors. Six (6) nos. bunkers, each having 1,000-ton capacity,
have been envisaged to store 6,000 ton of coal, which is the daily
requirement for the coal washery. Material drawn by belt feeder
will be then transported to top of de-sliming screen.
Despatch of middling char and boiler coal to power
plant: Middlings (0.5 to 6 mm) stored at ground will be reclaimed
by pay-loader and fed into the conveyor system for its onward
transportation to the bins at Power Plant.
Char generated in the DR plant will be transported to the
stock yard and stored beside boiler coal stock pile. It will be
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transported to the power plant from the yard by means of conveyor
system.
Boiler coal will be reclaimed by stacker/reclaimer on reclaim
mode and fed to the crushing unit to size down into (-) 25 mm with
the help of hammer mill. Then, (-) 25 mm boiler coal is fed to the
bins at power plant through conveyor system. Necessary grinding
arrangement of coal will be kept in the power plant, to suit the feed
requirement of boiler.
Despatch of raw materials to DR Plant: The following raw
materials will be despatched to the DR Plant:
Despatch of pellet: Pellet will be reclaimed by stacker
/reclaimer in reclaim mode and after screening, (+) 5 mm to (-) 18 mm size will be stored in the day-bin. (-)5 mm iron ore of pellet separated out after screening, will be stored in the ground and disposed off from time to time (by external agency).
Non-coking coal: Coal generated in the coal washery will be
stored on ground in coal washery plant. The size fractions of coal will be +5-20 mm and (-) 5 mm to 0.5 mm. Different size of coal will be reclaimed by pay-loader and stored in the respective bins at day-bin building.
A mixture of two (2) fractions of coal will be used for
injection system. Dolomite: Dolomite will be reclaimed by pay loader and fed
to the yard hopper for onward transmission to the day-bin. Charge-mix feed to the DR kiln
Raw materials namely pellet, coal and dolomite will be drawn
from the respective storage bunkers of day-bins as required by
weigh feeders in pre-determined proportion and conveyed to the
kiln inlet buildings as co-current feed.
Product handling system
Cold DRI will be discharged at 100 0C and screened to
separate out magnetic and non-magnetic materials.
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An emergency bypass system will also be provided for
intermediate storing and handling of cooler discharge material in
the event of temporary break down of finish product screening and
separation system.
Electromagnet belt scale and mechanical hoist will be
provided in the system as required for DRI conveyor also.
Adequate facilities will be provided for dust extraction and
suppression system to minimize the dust level.
Facilities associated with the raw material handling system
The following facilities have also been provided:
- Belt weighing facilities - Belt charging facilities - Maintenance facilities - Air-conditioning and ventilation facilities - Dust suppression facilities
COAL WASHERY
A coal washery of 1.5 million tons per annum (mtpy)
throughput capacity will be installed. The washed coal will be
consumed in DR plant. The plant will be operated at rated capacity
of 250 tons per hour (tph).
In order to achieve the raw coal throughput rate of 250 tph,
the washery will be designed with single stream process. Heavy
media cyclone process will be used for optimizing the yield. The
products are clean coal and middling. Tailings generated from disc
filter will be dumped via conveyors to the designated area of
washery. The clean coal will be sent to DR plant. Due to higher
requirement of washed coal in DR plant, NISL will purchase clean
washed coal from different sources for continuous feeding to DR
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plant. The middlings will be used in power plant for power
generation.
Design basis/consideration
Capacity: The main washery plant will have a throughput
capacity of 1.5 mtpy. The coal washing plant will be designed for
throughput rate of 250 tph based on 6000 effective working hours
per year. However, 20% design margin will be considered for
selection of the plant equipment. The washing plant will be
designed for washing crushed raw coal of size -20 mm.
Coal feed: Raw coal (0-20 mm) will be brought from coal
handling plant via conveyor and fed into a desliming screen with
throughput capacity of 250 tph.
The raw coal is expected to have characteristics as given
below:
Top size of raw coal .. -20 mm
Raw coal ash .. 52 to 55%
Angle of repose .. 35 to 40 degrees
HGI of raw coal .. 40 to 60
Size of coal to be fed to the washery .. (-) 20 mm
Desired product characteristics: The washery will be
designed to produce clean coal with an ash content of 32-35% on
dry basis for feeding to DR plant. Two types of washed clean coal is
generated from washery circuit one is washed fines (-5 +0.5 mm)
and the other one is clean coal coarse (-20+5 mm).
Middling have a size fraction of -6mm to 0.5 mm. Middling
with ash content about 70-72 % (on dry basis) will be used in
power plant.
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DIRECT REDUCTION (DR) PLANT
Design basis
The DR plant will have four numbers of 500 tpd rotary kilns,
out of which one 500 tpd kiln is already present and three new 500
tpd kilns will be installed at the plant site. Each DR kiln will be
based on rated production of about 500 tons of direct reduced iron
(DRI) per day. The annual production from all four number of kilns
will be about 660,000 tons of DRI based on 330 days operation
using iron ore pellets. Commercially established coal based rotary
kiln process will be adopted for the DR plant.
Product quality
It is expected that the DRI produced will contain about
88 per cent of Fe (total), around 0.15 per cent carbon and the
degree of metallization will be about 88.5 per cent.
Raw materials
The rotary kiln charge will consist of iron ore pellets, non
coking coal and dolomite. The specific consumption of various raw
materials are indicated in Table 4-4.
TABLE 4-4 – SPECIFIC CONSUMPTION OF RAW MATERIALS FOR THE DR PLANT
Raw materials Specific consumption (1) Kg/ton DRI
Iron ore pellets .. 1,502 Non-coking coal .. 1,283 Dolomite .. 28
NOTE: (1) Net and dry basis. Major facilities
The facilities within the DR plant will comprise the following
major units:
- Raw materials feeding system - Rotary kiln
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- Rotary cooler - Product (DRI) handling system - Waste gas system
SINTER PLANT
Production programme
One sinter machine of about 248 sq m will be installed to
produce 1.918 mtpy charge sinter, which will be adequate for 80
per cent sinter feed in BF-1 & BF-2.
Design basis
The design basis considered for sinter plant is given in
Table 4-5 in the next page.
TABLE 4-5 - DESIGN BASIS OF SINTER PLANT Product sinter, tons/year .. 2,256,700 Charge sinter, tons/year .. 1,918,200 Screening at BF stock house, % .. 15 Operating days/year .. 330 Daily product sinter, tons/day .. 6,840 No. of strand .. 1 Approx. suction area, sq m .. 248 Product sinter size, mm .. 5 - 50 Temperature of sinter at cooler discharge, oC .. 100
Raw materials
The typical analyses of input raw materials (dry basis) for
sinter production are given in Table 4-6 in the next page.
TABLE 4-6 – TYPICAL ANALYSES OF RAW MATERIALS FOR SINTER PRODUCTION
Fe SiO2 Al2O3 CaO _MgO LOI % % % % % %
Iron ore fines .. 63.07 2.65 2.04 - - 2.24 Limestone .. 0.24 0.99 0.52 52.27 1.98 42.34 Coke breeze .. 1.74 7.02 3.64 0.80 0.45 85.00 Flue dust .. 36.30 9.75 1.55 6.20 1.60 37.50 Mill scale .. 51.10 0.90 0.30 0.68 0.25 5.00 Lime .. - 3.00 2.50 83.00 3.20 4.00 Dolomite .. 0.22 0.86 0.29 30.80 19.12 46.05
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Pyroxenite .. 5.00 47.00 0.83 0.80 32.00 14.00
Consumption of input materials
The annual input material consumption for production of
1.918 mtpy charge sinter is given in Table 4-7 in the next page.
Sinter quality
The expected chemical analysis of sinter production from
sinter plant is as follows:
Fe FeO SiO2 Al2O3 CaO MgO CaO/SiO2
% % % % % % ratio 56.25 8.0-9.0 4.70 2.15 8.00 1.70 1.70
Physical and metallurgical properties of sinter will be as
follows:
ISO tumbler index (+6.3 mm) .. 76% (min) Reducibility index .. 65% (min) RDI (-3.15 mm) .. 28% (max)
Sinter size range .. 5−50 mm Sinter mean size .. 18 mm
TABLE 4-7 – CONSUMPTION OF INPUT MATERIALS Annual Materials consumptions(1) tons/year Iron ore fines .. 1,653,500 Limestone .. 218,700 Dolomite .. 17,300 Calcined lime .. 35,500 Pyroxenite .. 69,100 Flue dust .. 17,300 Mill scale .. 40,800 Coke breeze and anthracite .. 124,700
NOTE: (1) Quantities are approximate net input for
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sinter plant on dry basis. Major facilities
The sinter plant will comprise:
- Proportioning section - Mixing and nodulizing section - Sinter machine section - Sinter cooler section - Sinter stabilizing section - Sinter storage and despatch - Waste gas cleaning section - Plant dedusting system - Cranes, hoists and elevator - Plant electrics - Instrumentation and Level-1 automation system - Plant communication system - Utility system - Air-conditioning and ventilation system - Fire fighting system
BLAST FURNACE
Production programme
Two (2) blast furnaces (BF-1 and BF-2) of useful volume
(U.V.) of about 1008 cu m and 550 cu m respectively will be
installed to produce 1.464 mtpy of basic grade hot metal in a year.
Design basis
The design basis of blast furnaces is given in Table 4-8.
TABLE 4-8– DESIGN BASIS OF BLAST FURNACES
Item Blast furnaces
Hot metal production, mtpy .. 1.464 Daily production capacity, thm/day (avg) .. 4,184 No. of furnaces .. 2 Useful volume, cu m (approx) .. 1008 and 550 Productivity, t/(useful volume)/day (approx.) .. 2.65(1008 cu m BF) 2.75 (550 cu m BF) Operating days .. 350 Burden: Sinter, % .. 80 Pellet, % .. 20 Top gas pressure, kg/sq cm (g) .. 1.5 (1008 cu m BF) 1.2 (550 cu m BF) O2 enrichment, % .. 3 to 4 Coke rate (including nut), Kg/thm .. 414 Coal rate, Kg/thm .. 120
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Slag rate, Kg/thm .. 310 Coke ash, % .. 12.5 Hot blast temperature, 0C .. 1150 Si in metal, % .. 0.6-0.8
Analysis of raw materials
The major raw materials for blast furnaces comprise sinter,
pellet, additives and coke. Pulverised coal will be injected through
tuyeres as auxiliary fuel in furnaces. The typical analysis of raw
materials envisaged is given in Table 4-9.
TABLE 4-9 – TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS)
Fe SiO2 Al2O3 CaO MgO % % % % % Sinter .. 56.25 4.70 2.15 8.00 1.70 Pellet .. 65.00 2.50 1.75 0.40 0.30 Quartzite .. 0.50 96.92 0.92 - -
Ash
basis Moisture CSR
CRI % % % %
Coke .. 12.5 5.0 62 (min) 21-23
Coal for PCI application
Ash, % (dry basis) : 10-11 Fixed carbon, % : 78-78.5
Input materials quantity
The annual input materials required for the envisaged hot
metal production of 1,464,300 mtpy from blast furnaces are given
in Table 4-10.
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TABLE 4-10 – INPUT MATERIAL QUANTITIES
Material
Annual Consumption
tons/year(1)
Fluxed sinter (charge) .. 1,918,200 Pellet .. 480,300 Quartzite .. 21,950 Charge coke (hard+nut) .. 606,200 Injection coal .. 175,700
NOTE:
(1) All quantities are approximate net input to blast furnaces on dry basis. Hot metal quality (typical)
The expected hot metal quality is as follows:
Facilities in blast furnace
The blast furnaces will comprise of the following facilities:
- Stock house and charging system - Blast furnace proper - Cast house and cast house equipment - Hot blast stoves - Gas cleaning system - Slag granulation plant and dry slag pit - Blowers - Pig casting machine and hot metal ladle repair shop - Coal dust injection system - Electrics, instrumentation and automation - Plant communication system - Utility system - Water system - Top gas recovery turbine - Cranes and hoists - Fire fighting system
- Air-conditioning and ventilation system
Si S P
% % %
0.6-0.8 0.045 (max) 0.15 (max)
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STEELMELT SHOP–1 (SMS-1)
Design basis
Steelmelt shop–1 (SMS-1) will be designed with IF route with
installation of induction furnace (IF), ladle furnace (LF) and
continuous casing machine (CCM) for production of about 130,300
tons per year of billets. Balance requirement of billets for mills will
be met with production from SMS-2.
Induction furnace (IF): (3) nos. 15 ton/7.2 MVA capacity Ifs
are envisaged in the project. The estimated quantity of liquid steel
from the IFs works out to be around 133,700 tpy as per detailed on
the next page. Consent to establish is already available for the
manufacturing of 30,000 tpy.
No of furnaces .. 3
Capacity of IF .. 15T/7.2 MVA
Net operating days .. 330
Charge mix .. 70% DRI 20% Pig Iron 10% return scrap
Tap–to–Tap time, mins .. 140
Average number of heats possible from one (1) IF
.. 10
Average number of heats/day from 3 IFs
.. 30
Average number of heats/day considered from 3 IFs (1)
.. 27
Liquid steel, tons / year .. 133,700 NOTE: (1) Although 30 heats/day can be produced from 3 IFs
(each IF will be capable to produce 10 heats/day), taking combined availability of logistics, furnaces, caster and other variables into account, consideration of 27 heats/day from three (3) furnaces to be cast for 330 days will be rational.
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Ladle furnace (LF): It is proposed to provide one no.
matching capacity LF i.e 15 tons equipped with arc heating, inert
gas stirring and alloy addition facilities to treat the heats tapped
from IF.
All the 27 heats produced from IFs will be conveniently
treated at one LF with an average treatment cycle time varying
between 35-45 minutes per heat depending on the extent of
treatment required.
Continuous casting machine: It is proposed to install one
(1) no. 2-strand billet continuous casting (CC) unit in order to cast
the envisaged liquid steel production. A casting time of 45-46 mins
will be adopted to match with the three IFs being operated in
staggered way of 46 mins considering each IF tap-to-tap time of
140 mins, thus making one heat available in every 46 minutes for
casting sequence. One (1) no. 2-strand billet caster will be able to
cast the entire quantity of 133,700 tpy of liquid steel on the basis
of casting 27 heats/day. Assuming a yield of 97.5 % from liquid
steel to cast billets, the annual quantity of billets will be 130,300
tpy.
Annual production from SMS-1: The annual production
of SMS-1 will be as below:
Liquid steel, tpy .. 133,700
Semis (Billets), tpy .. 130,300
Requirement of raw materials and supplies
The requirement of the raw materials and major supplies for
annual production of 130,300 tons of billets is presented in the
Table 4-11.
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TABLE 4-11- REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES Raw materials and supplies Annual consumption,
tons/year DRI .. 112,700 Pig .. 32,200 Scrap (return) .. 16,100 Ferro alloys .. 2,000 Burnt lime .. 2,700 Fluorspar .. 330 Electrode .. 60 Pet coke .. 700 Oxygen, N cu m/yr .. 0.27 x 106 N2/Ar, N cu m/yr .. 0.06 x 106 Propane/LPG, N cu m/yr .. 0.07 x 106
Equipment and facilities for steelmelt shop-1
The major equipment and facilities proposed to be installed
in the steelmelt shop-1 are briefed below:
Induction Furnace (IF): Three (3) nos. 15 ton capacity IFs
consisting of two (2) crucibles each are envisaged for melting DRI,
pig iron and return scrap. Major technical parameters are given as
follows:
No. of units .. Three (3)
No of crucibles .. Two (2)/furnace
Capacity .. 15 tons
Transformer rating .. 7.2 MVA
IF and LF gas cleaning system: A common system for
collection and cleaning of fumes from IFs and LF is proposed to be
provided.
Fume collecting hood dedicated for two crucibles of each IF
will be provided. This will be of swinging type and is operated on
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the crucible which is under operation. Fumes from each IF will be
joined in one common duct. Fume from LF will also be collected
through a water cooled hood, sleeve and ductwork. The ducts
carrying fumes from the LF and the duct carrying fume from IFs
will join in the mixing chamber, from where the gases will be led to
the bag house, by means of ID fans. Clean gases having less than
50 mg per N cu m dust content will be exhausted through a stack.
Ladle furnace (LF): The relevant parameters of the LF are as
follows:
No. of units .. One (1)
Nominal capacity .. 15 tons
Heating rate .. 4-5 deg C/min
Transformer rating .. 3.6 MVA
Type of unit .. Lift/lower roof type
This unit will also be utilized to hold the heats for an
extended period of time, should it be necessary for any reason,
such as, sequencing of casting in CC machine, hold up in CC
machine, etc. All the required features including both top and
bottom rinsing, multi-strand wire feeding, automatic temperature
measurement and sampling facilities will be provided.
Billet casting machine (CCM): The salient features of the
CCM are indicated below:
No. of machines .. One (1)
No. of strands .. Two (2)
Type of machine .. Conventional billet caster, radial bow type
Mould .. Tubular mould
Casting practice .. open/closed
Ladle capacity, ton .. 15
Billet Size .. 130 sq mm & 150 sq mm
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The continuous casting machine will be inclusive of ladle
turret, ladle shroud manipulator, tundish preparation facilities,
mould and segment assembly, testing and storage facilities, etc.
Necessary automatic control system for casting speed,
primary/secondary cooling water system and billet transfer system
up to the end of cooling bed will also be provided. Provision of
emergency water supply to caster in case of power failure will be
provided.
Shop auxiliary and maintenance facility: Suitable shop
auxiliary equipment will also be considered. Facilities for
debricking/relining/drying of refractory for ladles & tundishes,
slide gate nozzle and porous plug setting, tundish nozzle setting,
mould preparation, testing and assembly will be provided.
STEELMELT SHOP–2 (SMS-2)
Design basis
Steel melt shop-2 (SMS-2) will be designed with installation
of electric arc furnace (EAF), ladle furnace (LF), vacuum degasser
(VD) and continuous casting machine (CCM) for production of
about 1,460,200 tons per year of billets/blooms. The EAF has
been designed considering use of DRI, hot metal and scrap as
metallics. A hot metal pretreatment facility (hot metal
desulphurization plant) is also envisaged in the shop. The billet
quantity per year of 1,460,200 tpy is considered with optimum
number of heats produced from two (2) EAFs that can be cast
through two (2) nos. 4-strand billet cum bloom caster. The total
quantity of semis produced from both SMS-1 and SMS-2 meets the
mill production requirement.
Electric arc furnace (EAF): In order to achieve the
required production of billets, it is proposed to install two (2) nos.
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90ton/70 MVA capacity EAFs. The estimated quantity of liquid
steel from the EAFs works out to be around 1,497,600 tpy as per
the basis detailed below.
No of furnaces .. 2
Capacity of EAF .. 90 tons/70MVA
Number of operating days .. 320
Charge mix .. 52% hot metal 45% DRI 3% return scrap
Tap-to-Tap time, mins .. 55
Average number of heats/day/EAF .. 26
No of heats from 2 EAFs .. 52
Liquid steel, tons/year .. 1,497,600
Ladle furnace (LF): It is proposed to provide two nos
matching capacity LFs i.e 90 tons equipped with arc heating, inert
gas stirring and alloy addition facilities to treat the heats tapped
from EAF. All the 26 heats produced per day per EAF can be
conveniently treated at one LF with an average treatment cycle
time varying between 40 to 50 minutes per heat depending on the
extent of treatment required. Hence, two (2) nos LFs will suffice the
shop requirement.
Vacuum degassing (VD): While the LFs will be adequate to
produce almost all the steel grades, certain special grades
requiring low gas levels need to be degassed to obtain the required
quality. These heats after LF treatment will be transferred with
adequate superheat to VD unit for degassing. Minor additions may
be required at VD unit as well. It is proposed to install one no. of
VD unit, in case if all the heats are required to be processed
through VD. Normally, the refining cycle time will be 20-40
minutes.
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Continuous casting machine: It is proposed to install two
(2) nos. 4-strand billet cum bloom continuous casting units in
order to cast the envisaged liquid steel production. The product
sizes of the billet caster include 130 mm to 200 mm square billets.
The speed will be adjusted for different billet sections according to
steel grades and facilitating sequence casting operation. A casting
time of 54-55 mins is adopted to match with EAF tap-to-tap time of
55 mins. Two (2) nos. 4-strand billet cum bloom caster will be able
to cast the entire quantity of 1,497,600 tpy of liquid steel on the
basis of casting 26 heats/day/caster. Assuming a yield of 97.5 %
from liquid steel to cast billets, the annual quantity of billets will
be 1,460,200 tpy.
Annual production from SMS-2: The annual production of
SMS-2 will be as below.
Liquid steel, tpy .. 1,497,600
Semis (Billets/Blooms) .. 1,460,200
Requirement of raw materials and supplies
The requirement of the raw materials and major supplies for
annual production of 1,460,200 tons of billets is presented in the
below Table 4-12.
TABLE 4-12 - REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES
Raw materials and supplies Annual consumption tons/year
Hot metal (after HMDP) .. 905,500 DRI .. 782,800 Return Scrap .. 53,000 Ferro alloys .. 40,000 Additives .. 7,500 Burnt lime .. 97,400 Burnt dolo .. 22,500 Fluorspar .. 3,700 Pet coke .. 4,500 Steam .. 8,100
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Electrode .. 3,600
Oxygen, N cu m /yr .. 54.8 x 106 Ar/N2, N cu m/yr .. 0.77 x 106 Propane/LPG, N cu m/yr .. 0.75 x 106
Equipment and facilities for steelmelt shop-2
The major equipment and facilities proposed to be installed
in the steelmelt shop-2 are described below:
Hot metal desulphurization plant: The sulphur content in
hot metal will be 0.045 percent (max). In order to meet the
requirement of low sulphur content in steel, desulphurisation of
hot metal will be installed prior to feeding the hot metal into EAF.
Hot metal will be desulphurised by deep injection of a combination
of desulphurising reagent (calcium carbide and magnesium) in
charging ladle by injection lances. Provision for mono-injection
(CaC2) and co-injection (CaC2 +Mg) as well as deslagging will be
provided.
Electric arc furnace (EAF): The salient features of the EAF
are indicated below:
Number of furnaces .. Two, EBT type
Furnace capacity .. 90 tons
Furnace transformer .. 70 MVA
Metallic charge, approx .. 52% Hot metal, 45% DRI + 3% return scrap
Method of charging .. Continuous charging of DRI/flux, and charging of hot metal by charging crane or via a launder
Hot metal will be charged to EAF by means of hot metal ladle
held with shop EOT cranes either by opening the furnace roof or
via a hot metal launder through the slag door. Water cooled side
panels and water cooled roof have been envisaged.
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EAF and LF gas cleaning system: A common system for
collection and cleaning of fumes from EAF and LF and dust from
the raw material handling system of the steelmelt shop is proposed
to be provided.
Fumes and dust will be evacuated directly from EAF roof
through water cooled elbow, movable sleeve, combustion chamber,
water cooled ducting, forced air cooler and mixing chamber to the
bag house. The secondary fumes arising during hot metal charging,
deslagging, tapping, etc. and those escaping from the annular
spaces around electrodes will be collected through a canopy hood
located in the building roof above crane level.
The fume from LF will also be collected through a water
cooled hood, sleeve and ductwork. The ducts carrying fumes from
the LFs and from the roof canopy, as well as ducts carrying dust
from the dust extraction points of the raw material handling
system will join the mixing chamber, from where the gases will be
led to the bag house, by means of ID fans. Clean gases having less
than 50 mg per N cu m dust content will be exhausted through a
stack.
Ladle furnace (LF): The relevant parameters of the LF are as
follows:
No. of units .. One (1)
Nominal capacity .. 90 tons
Heating rate .. 4-5 deg C/min
Transformer rating .. 14 MVA
Type of unit .. Lift/lower roof type
This unit can also be utilized to hold the heats for an
extended period of time, should it be necessary for any reason,
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such as, sequencing of casting in CC machine, hold up in CC
machine, etc. All the required features including both top and
bottom rinsing, multi-strand wire feeding, automatic temperature
measurement and sampling facilities will be provided.
Vacuum degassing (VD) unit: VD unit will primarily be used
for ladle degassing to reduce the entrapped as well as the dissolved
gases in steel such as hydrogen, nitrogen and oxygen to desired
levels, and chemical homogenization.
The salient features of the VD unit are given below:
No. of units .. One
Ladle capacity, tons .. 90
Type of unit .. Stationary vacuum vessel with cover lift and travel car
Vacuum system .. Multi-stage stream ejector with
boosters and condenser units
Billet cum bloom casting machine (CCM): The salient
features of the CCM are indicated below:
No. of machines .. Two (2)
No. of strands .. Four (4) Type of machine .. Conventional billet cum bloom
caster, radial bow type Mould .. Tubular mould Casting practice .. open/closed Ladle capacity, ton .. 90 Billet Size: .. 130 sq mm to 200 sq mm
The continuous casting machine will be inclusive of ladle
turret, ladle shroud manipulator, tundish preparation facilities,
mould and segment assembly, testing and storage facilities, etc.
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Necessary automatic control system for casting speed,
primary/secondary cooling water system and billet transfer system
up to the end of cooling bed will also be provided. Provision of
emergency water supply to caster in case of power failure will be
provided.
Raw material handling and conveying: Facility for DRI
conveying from DR plant to SMS storage bunker and further
conveying and charging to EAF will be considered. Lime will be
either conveyed from lime plant or brought by transport vehicle
and stored in storage bunkers for further charging to EAF. Ferro
alloys will be brought by transport vehicle from stores and stored
in storage bunkers for further charging to EAF & LF. Facility for
storage and charging of lime and ferro alloy will be provided.
Shop auxiliary and maintenance facility: Suitable shop
auxiliary equipment will be provided. Facilities for debricking/
relining/drying of refractory for ladles & tundishes, slide gate
nozzle and porous plug setting, tundish nozzle setting, mould
preparation, testing and assembly will be provided.
CALCINING PLANT
The production of calcined lime & burnt dolomite has been
considered based on the following requirements:
Calcined product
Net requirement for steel melt
shop
Net requirement for other
plant/sale tpa tpa tpa
Calcined lime 100,000 150,900
Burnt dolomite 22,500 22,500 In view of the above, total net production of calcined lime
and burnt dolomite is estimated as around 250,900 tpa and 45,000
tpa respectively. In case of future expansion, the calcined materials
for other plant/sale will be used to meet the in-plant requirement
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first and then the excess calcined products, if any, will be sent to
the Odisha plant or sold out in market.
The calcined product will be screened before dispatch to the
steel melt shop or other plant and the undersize fraction of
calcined products will be used in sinter plant. Considering
handling and screening losses as well as fluctuation in the specific
consumptions of calcined lime and burnt dolomite, the daily peak
production requirement is estimated as 984 tons for calcined lime
and 176 tons for burnt dolomite based on 330 days working
annually. The installation of a separate dolomite kiln for the above
requirement will make non uniform kiln size in comparison with
other plants. Hence, it is proposed to install two (2) Nos. each of
600 tpd capacity vertical shaft kilns for the production of calcined
lime and burnt dolomite in separate campaign.
The high grade limestone and dolomite in the size range of
40 – 80 mm is proposed to be used. The annual net requirement of
limestone and dolomite in the size range of 40-80 mm has been
estimated at about 606,880 tons and 114,660 tons respectively.
The calcining plant will comprise raw materials storage and
handling, kilns with kiln feed building, calcined product handling
and storage facilities. Various utilities, such as fuel, electric power,
water, compressed air, etc., will be made available to the plant.
The plant will be provided with kiln waste gas cleaning
system and dedusting system for raw material and product
handling facilities.
WIRE ROD MILL (WRM)
It is proposed to install a wire rod mill of 500,000 tpy
capacity under the 1.5 mtpy expansion plan.
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Design basis
Product-mix: The finished product will be produced in
following sizes:
Rounds .. 5.5 – 20 mm
Coil weight (max.) .. 2 ton
The grades of steel for wire rods considered are low &
medium carbon steel, spring steel, welding rod, tyre bead, cold
heading quality (CHQ) steel, ball bearing steel.
The size-wise and grade-wise product-mix for the proposed
single strand 0.5 mtpy capacity wire rod mill (WRM) is given in the
next page.
Product-mix, size in mm
Description 5.5 6.0-7.5 8.0-16.0 17.0-20.0 Total
tpy tpy tpy tpy tpy Low carbon 45,000 35,000 25,000 25,000 130,000
Medium carbon
30,000 30,000 30,000 30,000 120,000
Spring steel 15,000 15,000 25,000 15,000 70,000
Tyre cord 35,000 - - - 35,000
Welding rod 40,000 30,000 - - 70,000
Ball bearing 15,000 10,000 10,000 - 35,000
Cold head quality
- - 40,000 - 40,000
Total 180,000 120,000 130,000 70,000 500,000
Billet requirements: It is proposed to use 150 mm sq (with
a provision for 160 mm sq) and 12 m long billets which would give
a coil weight of about 2.114 tons. However, the wire rod mills will
be capable of rolling 130 & 160 sq mm.
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Yield: Material losses in the production of wire rods arise
due to scale, shear, cropping, trimming, cobbles, etc. In a modern
mill, average yield is 97 per cent. Hence an yield of average 97%
has been considered. Thus total billet requirement will be 515,500
ton for a annual production of 500,000 tpy wire rods.
Reheating furnace capacity: A 150 tph walking beam type
furnace has been selected for the wire rod mill.
Major equipment
Continuous cast (CC) billets from the Steel Melt Shop will
be transferred through roller table of caster bay or cross transfer
(cold billet) to storage bay of this shop. The mill will comprise of
the following major facilities:
- Billet charging and discharging equipment - Walking hearth type reheating furnace (150 tph) - Descaler - Roughing train - Intermediate train - Prefinishing blocks - Finishing blocks - Post Finishing blocks (optional) - Water boxes before & after finishing blocks - Shears - Pinch rolls - Laying head - Air cooling conveyor - Reform station - C-hook conveyor - Coil compacting, trimming and strapping machine - Weighing device - Unloading stations
The mill will be provided with its own roll/rings and guide
shop, express laboratory, recirculating water treatment facilities,
etc.
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MEDIUM MERCHANT MILL (MMM)
A medium merchant mill (MMM) of 650,000 tons per year
capacity will be installed. It will roll continuous cast (CC) billets
received from the steel melt shop. The CC billets will be stored,
inspected and conditioned in the continuous cast billet storage
aisles, and then transferred and stocked in the finished billet
storage aisles.
Design basis
Product-mix: Low, medium and construction grade steel of
following sizes will be rolled in this mill:
Size Quantity
mm tons/year Beams (ISMB, ISJB, ISLB) .. 100-175 195,000 Channels (ISMC, ISJC, ISLC) .. 75-175 205,000 Rounds .. 45-90 25,000 Squares .. 45-80 25,000 Angles .. 55-100 125,000 Flats .. 70-180 x 12,15 75,000
Total .. 650,000
Billet requirements: The billet size and requirement is given
below:
Billet size .. 200 mm sq, 12 m long,
Yield .. 95%
Billets required .. 684,200 tons
Mill characteristics: MMM will be designed to roll at a
maximum speed of 16 meters per second.
The mill stands are divided into three groups – roughing,
intermediate, finishing groups. The finishing group will have
convertible stands for rolling beams.
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Reheating furnace capacity: A walking beam type furnace
of 180 tph has been selected for MMM.
Major equipment
Continuous cast (CC) billets from the Steel Melt Shop will be
transferred through roller table of caster bay or cross transfer (cold
billet) to storage bay of this shop. The mill will comprise of the
following major facilities:
- Billet charging and discharging equipment - Walking hearth type reheating furnace (180 tph) - Descaler - Roughing train - Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers
and fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - weighing and collecting station
LIGHT MERCHANT MILL (LMM)
A light merchant mill (LMM) of design capacity 400,000 tons
per year capacity will be installed. However, the plant will produce
371,300 tons of finished product. It will roll continuous cast (CC)
billets received from the steel melt shop. The CC billets will be
stored, inspected and conditioned in the continuous cast billet
storage aisles, and then transferred and stocked in the finished
billet storage aisles.
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Design basis
Product-mix: Low, medium and construction grade steel of
following sizes will be rolled in this mill:
Size Quantity
mm tons/year Rebars & Rounds .. 10-40 150,000 Squares .. 22-50 25,000 Channels .. 25-100 75,000 Angles .. 25-75 75,000 Beams .. 75-120 50,000 Flats .. 25x5-75 x 12,15 25,000
Total .. 400,000
Billet requirements: The billet sizes and requirement is
given below:
Billet size .. 130 & 150 mm sq, 12 m long Yield .. 95% Billets required .. 390,800 tons Mill characteristics: LMM will be designed to roll at a
maximum speed of 22 meters per second for rolling of rebars and
round of size 10 to 40 mm.
Reheating furnace capacity: A walking beam type furnace
of 100 tph has been selected for LMM.
Major equipment
Continuous cast (CC) billets from the Steel Melt Shop will be
transferred through roller table of caster bay or cross transfer (cold
billet) to storage bay of this shop. The mill will comprise of the
following major facilities:
- Billet charging and discharging equipment - Walking hearth type reheating furnace (100 tph) - Descaler - Roughing train
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- Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers and
fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - Weighing and collecting station CAPTIVE POWER PLANT The following captive power plants have been envisaged to
generate the electrical power in the plant:
- 2 x 130 MW power plant (CPP-1) - 2 x 7.5 MW in-plant gas based power plant (CPP-2). This
plant will also generate 20 MW mechanical power for BF blowers.
The power demand of the steel plant facilities are indicated
in Chapter 5. The installed capacity, average power and energy
generation, etc. are given in Table 4-13 in the next page.
TABLE 4-13 – ESTIMATED POWER GENERATION CAPABILITY
Sl. No.
Description
CPP-1
CPP-2
TRT
1. Installed capacity, MW 2 x130 2 x 7.5 4.5 2. Average electrical power
generated, MW 260 15 4.5
3. Send out power, average, MW 234 13.5 3.6 4. Send out energy, MU, yearly 1,638 94.5 25.2
Technical profile of the captive power plant
The technical profile of the CPP-1 and CPP-2 are indicated in
Table 4-14.
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TABLE 4-14 – TECHNICAL PROFILE OF CPP
Sl. No.
Description
CPP-1
CPP-2
1. Nos. and size of boilers
4 Nos. coal fired boilers (AFBC) of 250 TPH each and 4 Nos. Waste heat recovery boilers of 50 TPH
2 Nos. by-product gas fired boilers 80 TPH each
2. Nos. and size of turbines
2 Nos. x 130 MW 2 Nos. x 7.5 MW
TOP RECOVERY TURBINES (TRT)
The TRT has been envisaged to recover energy from the top
gas of blast furnace and convert to power. Around 4.5 MW of power
will be available from top recover turbine of blast furnace.
AIR SEPARATION PLANT (ASP)
The industrial gases viz. oxygen, nitrogen and argon are
envisaged to be received through pipeline supply at Battery Limit
from the ASP.
Oxygen
Oxygen (99.5% purity) will be required in EAF, cutting
operation in caster, scrap and for other general purpose usage.
Low purity oxygen will be required in blast furnace for enrichment
purpose.
Nitrogen
Nitrogen (99.9% purity) will be required for gas line purging
process purpose and general purpose (e.g. instrumentation, etc.)
applications in blast furnace, sinter plant, EAF, casters and rolling
mills, etc.
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Argon
Argon (99.995% purity) will be required in Vacuum Degasser
(VD) in SMS-2.
Facilities proposed
An ASP of capacity 600 TPD will be required to meet the
above demand of oxygen, nitrogen and argon. The ASP will be
installed in Build-Own-Operate (BOO) basis. Besides, the oxygen
plant will have adequate liquid generation and storage capacity so
as to supply 72 hours of oxygen, nitrogen and argon in the event of
stoppage of operation of the ASP.
Oxygen will be available at pressure levels of 40 kscg and
8 kscg from the ASP. Nitrogen will be available at pressure of 20
kscg. Argon will be available at the pressure of 10–12 kscg.
Buffer vessels and pressure reducing stations for oxygen,
nitrogen and argon will be provided to cater to the various peak
requirements of the process.
PLANT MATERIALS FLOWSHEET
The plant materials flowsheet for the proposed steel plant is
given in Drawing No. 11330-04-0001.
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5 – UTILITY AND SERVICE FACILITIES
This Chapter presents electric power distribution system,
water system, various utility systems and auxiliary facilities of the
proposed project.
POWER DISTRIBUTION SYSTEM AND ELECTRICS
This section presents the estimated power requirements,
characteristics of plant loads, source of power and power
distribution philosophy for the proposed steel plant at Bilaspur,
Chhattisgarh.
Plant power requirements
The estimated power requirements for the proposed plant are
indicated below:
Annual Energy Consumption, million kWh
.. 1,288
15–min. maximum demand: in MW in MVA (0.9p.f.)
.. ..
196 217
1–min. peak demand, MVA .. 248 Note: The power balance reveals that around 62 MVA power
will be exported from the plant to the grid considering all proposed captive power generations.
Characteristics of plant loads
The major consumers of power for the proposed plant will
impose a more or less steady load on the power system.
The electric arc furnaces (EAF), ladle furnaces (LF) and main
drives of Mills will be fluctuating power consumers and will impose
flicker and harmonics in the power system.
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In order to mitigate the effect of flicker adequately rated
static var compensation (SVC) equipment will be provided.
In order to mitigate the effect of harmonics, reactive power
compensation equipment with power factor improvement capacitor
banks arranged in harmonic filter circuits will be provided. The
plant overall power factor will be maintained in the range of 0.9.
Source of power
The power requirement of the proposed plant will generally
be met from the following captive power plant sources:
(i) Two (2) captive power plants, each having capacity of
130 MW, with coal fired boilers.
(ii) Two (2) captive power plants, each having capacity of 7.5 MW, from by-product gas. This plant will also generate 20 MW mechanical power which will be sent to blast furnace blower.
(iii) One (1) captive power plant of capacity 4.5 MW with top pressure recovery turbine (TRT) of blast furnaces.
Further, it is given to understand that there will be
connectivity over 220 kV over head lines with the nearby 220 kV
grid substation located approximately 20 km away from the
plant.
Power distribution philosophy
A new 220 kV Main Receiving & Step down Substation
(MRSS) will be established in the proposed area for the expansion
project.
The transmission line from grid substation will be terminated
at the incoming line gantries of MRSS. The switchyard at MRSS
will be laid out with double busbar arrangement with one incomer,
one outgoing and one bus-coupler bays. The space for future
expansion will be kept in the MRSS.
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The power distribution system will be so developed that the
electrical power generated from 2 X 130 MW CPP, 2 X 7.5 MW CPP
and 1 X 4.5 MW TRT will be utilized for feeding plant loads. The
excess generation will be evacuated to grid. The start-up power for
CPPs will be arranged from 220 kV MRSS over suitable power
distribution arrangement.
The power will be stepped-down to 33 kV for feeding bulk
power. The EAFs, LFs and Induction Furnaces will be fed from from
33 kV dirty bus and other steady loads like existing DR plant,
sinter plant, BFs, continuous casting machines and rolling mill
loads will be fed from 33 kV clean bus.
The power will be further stepped-down to 6.6 kV at
respective plant units for feeding HT motors and 6.6 kV/415-240 V
load centre substation transformers.
The LT consumers will be fed from respective 415 V
switchboards of load centre substations.
INSTRUMENTATION AND AUTOMATION SYSTEMS
This section describes the automation systems proposed in
general for various individual process plant units as well as on
overall organization basis for the project. The automation systems
are envisaged to enable NISL to achieve higher productivity with
better quality in a planned and well-co-ordinated manner using
state-of-the-art equipment and facilities.
Structure of proposed automation system
The automation systems proposed have been structured
application-wise into four hierarchical levels as follows:
Level 1 - Instrumentation and Basic Automation
Level 2 - Supervisory Computer and Process Automation
Level 3 - Manufacturing Execution (Level 3) System (MES)
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The salient features of Level 1, Level 2, Level 3 automation
systems as well as the SCADA systems, Communication and FDA
systems are presented in the following:
Instrumentation and level-1 automation
The various plant units will each be provided with dedicated
DCS/PLC based Level 1 automation systems and necessary
instrumentation, which will perform all the functions for
controlling, regulating, data acquisition, alarms and interlocks
including material tracking, drive control and other process
specific technological control system (TCS) functions, wherever
required. The system will have necessary hardware and software
features to ensure plant safety as well as ease in operation and
maintenance. As far as possible, it is proposed to adopt common
type of hardware and software. The system will be suitably
interfaced with higher level (level 2) process computer system,
wherever required.
The instrumentation and Level 1 automation system will be
configured around an Open System Architecture for implementing
smooth interoperability among different systems as well as
maximum unit availability, using an integrated, functionally
distributed Programmable Logic Controller (PLC)/Distributed
Control System (DCS) based system.
The digital control system will mainly comprise required No.
of intelligent HMI’s and Process Stations / PLCs interconnected
over the data communication bus system. The HMI’s will consist of
Personal Computers along with TFT-LED monitors, keyboard,
alarm, event and report printers.
HMI’s will also include engineering and programming
terminals. Laptop type programming terminal will be provided for
programming of PLCs and drives.
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The Process Stations / PLCs will be of the latest state-of-art
technology suitably connected to the bus system. The data
communication bus as well as CPU, communication processors and
power supply unit in PLCs will be in redundant configuration.
Package PLCs will be conceived where ever essential and will be
suitably interfaced with the corresponding main PLC, etc.
Remote input/output units connecting inputs/outputs
in different plant areas with the PLC system will be envisaged. I/O
bus will be fiber optic if required based on distance between PLC
and Remote I/O units.
Parallel redundant type UPS will be envisaged for power
supply to Automation, Instrumentation, Communication and FDA
system equipment with battery back-up for a duration of minimum
30 mins.
The design of control system and related equipment will
adhere to the principle of “Fail Safe Operation” at all system levels.
The software for the Level-1 automation and
instrumentation system will be simple, user friendly and have the
provision of on-line editing and programme development without
interrupting the process lines and the same will support on-line
diagnostic features.
All field sensors and instruments will be of latest state-of-
the-art design. All transmitters will be “Smart” type conforming to
HART/FF protocol. Field bus (Profibus/FF) technique will be
adopted wherever found suitable.
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Process automation (level-2) system
The proposed steel plant will be equipped with state-of-the
art supervisory computer and process automation system (Level 2)
for improved quality, process optimisation management, product
tracking and reporting functions. The systems will be configured
based on client-server architecture and will have provision for
future expansion and upgradation, when needed.
The production units such as blast furnace, hot metal
desulphurization station, electric arc furnace, ladle furnace,
vacuum degasser, continuous billet casting machines, wire rod
mill, medium merchant mill, light merchant mill as well as the
reheating furnaces will have dedicated Level 2 systems to achieve
higher productivity with better quality in a planned and
coordinated manner. All necessary control functions including
process models as well as supervisory functions like PDI handling,
product tracking, data archival, reporting, etc. will be considered
for optimized operation of the units.
Also, following automation systems may be considered for
better tracking & utilization of process units for optimized
operation:
- Laboratory Management System
- Yard Management System
- SMS area Ladle tracking System
Supervisory control and data acquisition system (SCADA)
A supervisory control and data acquisition system will be
implemented at specific places for monitoring & control (if
required) of production, distribution and consumption of the
different utilities and water systems as well as for the electric
power system.
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The SCADA system will be installed in a central location in
the plant and will be based on Client/Server architecture with
server and HMI clients and necessary Remote Terminal Units (RTU)
located at various strategic points.
Manufacturing execution (level-3) system
A production planning and control system, more commonly
known as ‘Manufacturing Execution System’, at the next higher
level of the automation hierarchy is proposed on overall plant
basis. The system will be used for execution of various production
automation related functions like Provision for order entry,
Technical dressing of commercial order, Production planning,
Detailed production scheduling, Resource allocation, Production
progress control & monitoring, Quality data collection and
assessment, Data acquisition and archival, KPI monitoring, etc.
The system will be designed considering servers housed in a
central location in the plant and clients distributed in various
areas and departments.
IT infrastructure
Data communication network will be proposed for providing
intranet/internet facility for all kind of business related data with
required servers and application software. The network will include
switches and related cabling within the plant area. The proposed
network will have 3-tier star topology based architecture. Access
switches will be at the lowest level and connected to the
corresponding zonal switches. Zonal switches will be connected to
the centralized core switches at the top level. The proposed
network will also have the facility to further integrate/ interface
with the future expansion.
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PLANT COMMUNICATION SYSTEM
Following communication facilities are envisaged for reliable
and quick communication amongst various units of the plant:
Plant telephone system
Plant telephone system as envisaged will comprise of
required nos. of exchanges/gateways located at strategic nodes of
the plant along with associated cable network, for providing
telephone facilities all over the plant. These exchanges/gateways
will be interconnected over Plant OFC backbone to work together
as an integrated virtual single telephone exchange.
Loudspeaker intercommunication (LSIC) system
Independent loudspeaker intercommunication (LSIC) system
is envisaged in respective plant unit to ensure quick
communication facility amongst various sections inside the
respective plant unit. Each LSIC system will provide announcement
and point to point calling facility.
Closed circuit television (CCTV) system
Independent closed circuit television (CCTV) system is
envisaged in respective plant unit for viewing and monitoring
critical operating areas from control rooms. Each CCTV system will
be IP based and will comprise of cameras, PC based monitors and
other equipment.
Wireless communication system
VHF Wireless Communication system is envisaged for
communication between cranes or moving machine operators and
control room/supervisory personnel on shop floor as well as
amongst operation & maintenance personnel.
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Plant optical fiber cable (OFC) backbone
An optical fiber cable (OFC) backbone is envisaged inside the plant
covering a number of strategic nodes at different plant units. This
OFC backbone will be used for integration of various systems (e.g.
plant telephone system, SCADA, fire detection and alarm system,
etc.)
FIRE DETECTION AND ALARM SYSTEM
Intelligent addressable microprocessor based fire detection
and alarm (FDA) system is envisaged in each plant unit in order to
have an early detection and location details in case of possible fire
outbreak in the plant premises. All the FDA systems will be
monitored from central fire station of the Plant.
WATER SYSTEM
Water is primarily required in the steel plant for equipment
cooling. In addition, it is also used for process use, for collecting
and conveying of scales, control of dust and debris; for drinking
and sanitation; for fire-fighting and for other miscellaneous
purposes.
Water requirement
It is estimated that the total make-up water requirement for
the proposed plant will be 2,040 m³/hr out of which 20 m³/hr will
be soft water, 60 m³/hr will be DM water and 20 m³/hr will be
used for drinking and sanitation purpose.
Total make–up water requirement of 2,040 m³/hr is
considered based on water cooled condenser of the power plants
and wet handling type gas cleaning plant (GCP) for blast furnace.
Out of the estimated make-up water requirement of 2,040 m³/hr,
about 905 m³/hr make-up water is required for proposed
expansion to 1.5 mtpy integrated steel plant and balance 1,135
m³/hr make-up water is required for the power plants.
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Estimated shop-wise break-up of the make-up water
requirement is given in Table 5-1.
TABLE 5-1 – MAKE-UP WATER REQUIREMENT
Sl. No. Consumers Make-up water requirement
Cu m per hour
1. Raw Material Handling System
30
2. Coal washery 15
3. Lime calcining plant 7
4. Oxygen plant 57
5. Sinter Plant 11
6. Blast Furnace including pig casting machine & slag granulation plant
219
7. DR plant 105
8. Steel Melt Shop (SMS-1) consisting of induction furnace, ladle furnace, billet caster
49
9. Steel Melt Shop (SMS-2) consisting of electric arc furnace, ladle furnace, vacuum degassing unit, billet cum bloom caster
329
10. Wire rod mill 74
11. Medium section mill 91
12. Light section mill 36
13. BF TRT power plant 22
14. Surplus BF gas based power plant
168
15. Coal based power plant 1248
16. DM Plant 60
17. Softening Plant 20
18. Drinking & Sanitation 20
19. Fire water 5
20. Miscellaneous Requirement 30
Total
2596
Recovery from treated effluent from the system and reused
556
Grand Total
2040
Note: Blow down/waste effluent from the various water systems will be collected in blow down sump and common effluent plant and the same will be treated and reused for various consumers.
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Source of water
The water source for the proposed steel plant is from river
Sheonath.
The proposed plant is located about 100 m away from the
river. An existing intake pump house had already been constructed
and rising main of 250 mm was laid from the intake pump house to
the plant for supplying water to the existing plant comprising one
(1) no. 500 TPD DR plant.
It is understood from NISL that the existing intake pump
house is not capable to handle additional water requirement. So, a
separate intake pump house will be installed to meet the water
requirement for proposed expansion project. It is also understood
from NISL that at present, withdrawal of about 560 m³/hr water on
a continuous basis is allowed from river Sheonath. Out of the 560
m³/hr water available, 250 m³/hr water has to be delivered by the
existing intake pump house to one (1) no. existing 500 TPD DR
plant. So, remaining 310 m³/hr make-up water can be drawn by
the new intake pump house and delivered to the proposed plant
facilities. NISL will arrange to provide additional 1,730 m³/hr by
obtaining permission from the State Water Resource Department to
meet the requirement of proposed plant.
Plant water system
A raw water reservoir, of 14 days storage capacity, will be
provided within the plant boundary. The requisite quantity of water
will be continuously withdrawn from the reservoir to be treated in
the Raw Water Treatment Plant to makeup water quality.
This grade of water will be supplied as make-up to the
various re-circulating water systems. In addition to this, a portion
of this water will be further treated to produce soft water, to be
supplied as make-up to various close-loop systems, and drinking
water for the plant personnel.
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In order to conserve water to the maximum possible extent,
independent recirculating system with cooling towers, pump
houses and treatment units, wherever required, have been
proposed for the units envisaged for this project. Make-up water of
desired quality will be supplied to each individual recirculating
system. In certain contaminated circuits make-up water will be fed
from blowdown of non-contaminated circuit to conserve water
consumption.
The plant water system comprises make-up water system,
recirculating water systems, drinking water system and water
based fire-fighting system, emergency water supply system for the
vital units of the plant, waste water, effluent and sewage generated
in the plant will also be reused after treatment. Adequate
arrangement will be made for rain water harvesting by collecting
the rain water in the plant.
The schematic water flow diagram for the proposed plant is
given in Drawing No. 11330-05-0001.
The different plant water systems considered in this section,
their respective consumers and broad facilities provided for each
system indicated in Table 5-2 in the next page which reflects a
conceptual water supply scheme for plant water systems.
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TABLE 5-2 – MAJOR WATER SYSTEMS Sl. No.
System
Main consumer/source
Main facilities
1. Make-up water
system Cold wells of various recirculating systems, consumptive and once-through water systems, Softening Plant, DM Plant, etc.
Make-up water storage tank, pumphouse with pumpsets and accessories, raw water treatment plant, distribution pipework.
2. Drinking water
system Plant Personnel and laboratory.
Pumpsets, filters, chlorination unit, overhead tank, pipework.
3. Water based
fire fighting system
Yard/shop hydrant. Motor driven and diesel engine driven pumpsets, storage reservoir of required capacity, ring main, yard and shop hydrant system.
4. Soft water
system Various close-loop cooling systems, By-product plant.
Softening plant with regeneration system, supply pumps and pipework.
5. Coal washery
recirculating system
Contaminated open cooling circuit.
Pumphouses, pumps and associated equipment, settling tank, etc.
6. Lime calcining
plant recirculating system.
Open-loop indirect cooling systems.
Pumphouses, pumps and associated equipment, cooling towers.
7. Oxygen Plant
recirculating system.
Open-loop indirect cooling system
Pumphouse, pumps and associated equipment and cooling tower.
8. Sinter Plant
recirculating system
Open-loop indirect cooling systems.
Pumphouses, pumps and associated equipment, cooling towers.
9. Blast Furnace
recirculating system
Various close-loop and open-loop indirect cooling systems, contaminated Gas Cleaning Plant water system
Pumphouses, pumps and associated equipment, cooling towers, heat exchangers, waste water treatment plant.
10. Slag
Granulation Plant water system
Contaminated open cooling circuit.
Pumphouses, pumps and associated equipment, settling tank, etc.
11. Pig Casting
Machine recirculating system
Contaminated open cooling circuit.
Settling tank, sump and pumpsets.
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TABLE 5-2 – MAJOR WATER SYSTEMS (cont’d) Sl. No.
System
Main consumer/source
Main facilities
12. DR plant recirculating system
Open-loop indirect cooling systems.
Pumphouses, pumps and associated equipment, cooling towers, settling tank.
13. SMS-1 consisting of induction furnace, ladle furnace, caster recirculating system
Various close-loop and open-loop indirect cooling systems.
Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant.
14. SMS-2 consisting of electric arc furnace, ladle furnace, vacuum degassing unit, caster recirculating system
Various close-loop and open-loop indirect cooling systems.
Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant.
15. Wire Rod Mill recirculating system.
Various close-loop and open-loop indirect cooling system and contaminated direct cooling system
Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters.
16. Medium Section Mill recirculating system.
Various close-loop and open-loop indirect cooling system and contaminated direct cooling system
Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters.
17. Light Section Mill recirculating system.
Various close-loop and open-loop indirect cooling system and contaminated direct cooling system
Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters.
18. BF TRT power plant
Condenser cooling and other open-loop indirect cooling systems, DM water Plant.
Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc.
19. Surplus BF gas based power plant
Condenser cooling and other open-loop indirect cooling systems, DM water Plant.
Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc.
20. Coal based captive power plant
Condenser cooling and other open-loop indirect cooling systems, DM water Plant.
Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc.
21. Effluent Water Treatment system
Waste effluent generated from various shops
Effluent water treatment plant.
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Waste water and effluent treatment management
Waste water generated from the different areas of the plant
will be treated to the desired extent in suitable treatment facilities
and recycled back to the process, to attain “zero” discharge,
facilitating adequate reuse of water in the respective recirculating
systems and economizing on the make-up water requirement.
Sewage generated from toilet blocks, etc., will be collected by
means of suitable sewer system for treatment in package type
Sewage Treatment Plant (STP) and the treated sewage will be
transported to Effluent Treatment Plant (ETP). The blow down from
the indirect cooling water will be collected in a blow down sump.
The water accumulated in the blow down sump will be reused as
make up to low end users such as pig casting machine, slag
granulation plant contaminated open cooling circuit, raw material
handling system and make-up to fire water reservoir. Balance
waste effluent generated from the various units will be treated in
ETP and the treated effluent will be used as make–up in make-up
water system.
Distribution pipework Mild steel or pipes of suitable material of construction are
considered for various units of plant water system. All the
pipelines except fire water line, drinking water line & treated waste
water line will be routed over ground in the yard. Fire water line,
drinking water line & treated waste water line will be routed in
buried condition with necessary corrosion protection. However, for
railway crossing, pipe tunnel has to be considered. Shop internal
pipes with protection-painting will be routed through the building
structure. The pipe-work will comprise all necessary pipes, valves,
fittings and hydrant complete with all other accessories as required
as per relevant standards.
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UTILITY SYSTEM
Fuel system
The by-product BF gas generated i.e. blast furnace gas will
be mixed with LPG/propane and utilised as fuel for various heating
applications of the steel plant. Balance available gas will be
utilised in power plant for steam and power generation.
The major consumers of fuel gas in the steel plant are for
blast furnace stove heating, sinter plant, heating equipment in the
steel melt shop, furnaces in the mills, lime calcining plant and the
boilers. Small quantities of fuel would also be required for the
repair shops, etc.
By-product gas generation: The generation of by-product gas
is given in Table 5-3.
TABLE 5-3 - GENERATION OF BY-PRODUCT GAS
By-product gas Volume Energy N cu m/hr 109 kcal/yr
BF gas .. 268,000 1,823
Availability of by-product gases for power generation
Surplus by-product gases, which will be available after
meeting the plant demands, will be as given in Table 5-4.
TABLE 5-4 – SURPLUS BY-PRODUCT GAS AVAILABILITY (N cu m/hr)
By-product gas Quantity
N cu m/hr BF gas .. 120,000
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LPG/propane manifold
In addition to being used as a fuel, LPG/propane will be
required for cutting operation of the caster. To meet the
requirement of LPG/propane, one (1) no. LPG/propane manifold
system with distribution piping of suitable capacity is envisaged.
Process steam
Process steam required for the plant will be made available
through controlled extraction of the condensing turbine of the
by-product gas fired power plant. Steam network of around 13 kscg
and temperature of 2200C has been envisaged within the plant for
process steam.
Plant and instrument air system
Plant grade compressed air for general service purpose usage
like pneumatic conveying, bag filter pulsing and dry instrument
grade compressed air for the operation of pneumatic devices for
instruments and controls, pneumatic tools, etc., will be required in
each of the production shops and other ancillaries.
Requirement of plant grade compressed air and balance
requirement for dry instrument grade compressed air will be met
from one centralised compressed air station of suitable capacity of
centrifugal compressor, along with required nos. air receivers of
requisite capacities. The pressure of the available compressed air
will be around 7-8 kscg.
Suitable nos. of refrigerated air dryers along with required
nos. air receivers of requisite capacities have been envisaged to
meet the balance oil-free dry instrument grade compressed air
requirement. The pressure of the available dry instrument grade
compressed air will be around 5-7 kscg.
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Air pollution, ventilation and air conditioning
Air pollution control systems: The scheme proposed for
prevention of air pollution is as follows:
- Collection of fumes from deslagging station and argon
rinsing station and discharging them to the atmosphere through stacks after cleaning.
- Removal of dust generated during various operations by
local exhaust systems.
Ventilation systems: The ventilation systems proposed to
achieve desired conditions in different areas are as follows:
- Switchgear rooms, cable tunnel, cable basement, oil and
hydraulic cellars: Mechanical ventilation system using fan-filter units for supply and exhaust fans.
- Compressor Building, transformer rooms: mechanical
ventilation system using exhaust fans. - Production building: natural ventilation by roof monitors
as necessary. Natural ventilation arrangement will be adopted in most of
the production buildings.
Air conditioning systems: The air-conditioning systems are
proposed to be designed to maintain the following condition in the
spaces serviced:
- 25 ± 2 0C dry bulb temperature and 55 ± 5 percent relative humidity for control rooms, control pulpits, computer rooms, PLC rooms, laboratory, etc.
- To meet the above requirement, chilled water based air
conditioning are envisaged throughout the plant. Chilled water plants
Vapour compression type chilled water plant of adequate
capacity are envisaged to satisfy the air conditioning and
ventilation needs of various units. Chilled water inlet and outlet
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temperature will be maintained at 160C and 70C respectively. Ring
mains for both supply and return pipelines will be suitably
provided around the shops.
Overhead yard pipework
The Steel plant will have a piping network for distribution of
the air separation plant products, various utility services, steam,
water, etc. The yard portion of the pipework for all services (except
water) will be laid on towers and trestles with a clear height of 7 m
above finished ground level (FGL). Shop internal pipework will
generally be routed in multiple rows through building columns
taking support from buildings and girders.
Central utility monitoring and control
A centralised control room for utilities and water services will
be located at the Energy Management Centre (EMC) in Fuel
Management building for overall monitoring of critical parameters
of utility systems provided for the new facilities.
AUXILIARY FACILITIES
Laboratories
To meet the analytical and testing needs of the proposed
plant, suitable laboratory facilities will be considered at different
locations in the plant.
Repair shops and stores
Repair and maintenance shops are important units of any
integrated steel plants not only for the manufacturing spares and
replaceable items but also for catering to the capital and running
maintenance requirement of the various units of plant.
It has been envisaged that total repair and maintenance
work of the steel plant including manufacturing operational spares
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will be outsourced to the competent agencies. NISL will provide
the following infrastructural facilities:
- Shop with EOT cranes/hoists
- Open yard, wherever necessary.
- Shop lighting arrangement without light fittings
- Electric power at one point near the equipment/machine
tools for operation
- Portable and industrial water at one point
- Industrial grade compressed air at one point
- Metering facilities for the utility services
Facilities for repair shops and stores: It is envisaged that
the following repair shops and stores will cater to the need of
maintenance services and repair activities:
- Central repair shop,
- Electrical repair shop,
- Mobile equipment repair shop
- General store
- Refractory store
- Alloy store
- Oil and lubrication store
ANCILLARY FACILITIES
Necessary ancillary facilities, such as administrative
building, canteen, car park, cycle and scooter stands, first-aid
station, etc., will be provided based on the manpower requirement
for the plant.
Drainage and sewerage system
Open type drain has been envisaged for the plant storm
water drainage. The drains will be laid generally by the side of the
roads. Storm water run-off, collected through arterial and trunk
drain, will be discharged to the existing river Sheonath.
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Sanitary faecal sewage will be collected from the ablution
blocks through pipeline and the same will be connected to a
sewage treatment plant. The effluent from sewage treatment plant
will be utilized for the development and maintenance of greenery.
Roads
Adequate plant road system will be provided considering the
types of vehicles and the traffic volume. The road system will be
designed to minimize cross movement of vehicles. Adequate vehicle
parking facilities and road weighbridges will be provided.
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6 - ENVIRONMENTAL POLLUTION MITIGATION MEASURES
The proposed project involving the expansion of Integrated
steel plant of NISL to 1.5 MTPA crude steel production, comprises of
coal washery, sintering, iron making, steelmaking, casting and
rolling etc. have been discussed in the previous chapters. This
production would generate wastes in different forms, the recipient
of which would be air, water and land environment causing
pollution of these environmental elements.
This Chapter accordingly outlines the various mitigation
measures in compliance with the prevailing Environment Protection
Acts & Rules and amendments thereof taking into consideration of
the proposed production facilities envisaged for the project.
Review of Pollution Potential
The production from new production units; namely, Sinter
Plant, Coal Washery, Blast furnace, DR Kiln, Lime Calcining Plant,
SMS and the mills. The off gases would be utilized for in-plant use
and power generation. Also power would be generated from BF top
gas heat recovery turbine.
Hence, the project would generate particulate dusts, Volatile
organic compounds (VOCs), Dioxins, Furans, oxides of sulphur and
nitrogen and carbon dioxide to the air environment.
Likewise, there would be generation of waste water due to
enhanced capacities, contaminated with total suspended solids
(TSS), B.O.D, C.O.D, oil and grease etc. which are of major concern
from environment perspective.
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The land environment may get disturbed due to generation of
the solid wastes like BF slag, SMS slag, mill scales etc which may
call for other secondary environmental problems.
Proposed Mitigation Measures
In view of the aforementioned plant facilities, there would be
pollution load, for which adequate mitigation measures as described
below have been considered:
Air Pollution Control (APC) Measures
Material Handling Area: There would be fugitive dust
emission from the handling and stockpiling of the added raw
material, which would be controlled by Dry Fog (DF) system. The
raw material handling section is provided with dust suppression
(DS) by water sprinkling at open stockyard. All conveyors would be
of covered types and leak proof to prevent any emission of dusts
during transport of raw materials and products. All closed zone
working areas such as raw materials handling zone, conveyor
transfer points, dust generation points at screen is provided with
multiple dust extraction (DE) systems/dry fogging (DF) at several
emission points to control the fugitive dust emissions. DE system
shall consist of suction load followed by bay filter, ducts, extraction
fans and stack of adequate height.
Coal Washery: In coal washery, the primary air pollution
control measure would dust suppression system (DS). During
conveying the coal, dust emissions from junction house and
discharge points would be mitigated by Dust Extraction (DE)
systems. Other areas would be facilitated with water sprinklers to
minimize suspended dust levels.
Sinter Plant: In Sinter Plant, the principal air pollution
control system is dust extraction (DE) or fume extraction (FE)
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systems and ESPs with stacks of appropriate heights. Stretching of
the capacity of sinter plant would add to the present pollution level,
requiring augmentation of present APC equipments.
Blast Furnace: In addition to cleaning of BF gas in gas
cleaning plant (GCP), which is a process requirement, dust and
fumes emission in stock house and cast house areas would be
controlled by dust and fume extraction (DE & FE) systems
respectively in all the operating BFs.
DR Plant: The exhaust gas from the kiln would be
contaminated with dust particulates, SO2, NOx and carbon. At the
kiln inlet, a dust settling chamber (DSC) would be provided for
allowing the dust to settle before entering the After Burning
Chamber (ABC). The ABC would be provide with additional
combustion air fans for proper burning of the combustibles
contained in the kiln off-gas. The dust collected at the DSC would
be emitted from time to time through a wet scraper, located at the
bottom of the DSC and dispatched to the dumping yard. The DR
Kiln off gas would pass through the Post Combustion Chamber to
burn out CO in the flue gas before it is taken to the Waste Heat
Recovery Boiler (WHRB) for generation of power.
Calcining Plant: The emissions arising due the fuel burning
in lime calcining plant is taken through a bag filter to separate out
the lime fines. The kilns would be provided with separate DE
systems, complete with bag filters and stack of adequate height.
EAF and IF: The primary emissions would be extracted by
fume extraction (FE) system. Fumes would be indirectly cooled and
cleaned through a bag filter for separation of particulates and the
clean gas would be vented into the atmosphere through a tall stack
of adequate height. The secondary emissions would be controlled
through canopy hood extraction, integrated with the main system to
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clean the fugitive emissions during charging and tapping
operations. The gas cleaning system would be complete with water
cooled duct, fume & gas cooler, bag house, ID fan and stack of
adequate height.
LF: The primary emissions extracted from the LF area
collected by fume extraction (FE) devices. Dust laden fumes are
indirectly cooled and cleaned through a bag filter for separation of
particulates and the clean gas is vented into the atmosphere
through a tall stack of adequate height.
Mills: The reheating furnaces are incorporated with low NOx
burner and controlled combustion would take place. The flue gas,
which is fairly clean, is vented through a stack of adequate height.
These pollution control measures would be carried on and
additional APC measures would be adopted as per requirement.
Water Pollution Control (WPC) Measures: The source water
for the plant would be the Sheonath river which is situated adjacent
to the plant. The wastewater from various units would be treated in
the Common Effluent Treatment Plant (CETP) to make it suitable for
recycling to the plants direct make up water circuit.
Three different types of process effluent streams would be
generated from the steel plant complex.
For Type-I effluent streams, mostly physico-chemical
treatment schemes like oil separation, settling, clarification, pH
adjustment etc, would be employed.
Type-II effluent, CT blow downs would be taken to the treated
waste water storage reservoir for recycling purpose after treatment
in the CETP.
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Type-III effluent, which is plant sanitary wastewater, would
be separately treated in a sewage treatment plant before the same is
also routed to the treated effluent storage reservoir.
Zero Discharge Concept
In order to have a ‘near zero discharge’ of the proposed plant,
the CT blow down along with all other primary treated wastewater
streams with high TDS levels may be further subjected to Reverse
Osmosis (RO) treatment to reduce the TDS levels and the residual
oil & grease, BOD and COD levels, so that this treated waste water
as RO permeate can be added to the plants make up water circuit.
Work Zone Pollution Control Measures
The work zone pollution would be mostly fugitive dust, heat
and noise. The fugitive dust emission would be controlled by DS
and DE system as described earlier.
All the process vessels would be lined with adequately thick
refractory bricks to contain the surface heat emission and in some
cases they would be indirectly cooled by water. In addition to this,
there would be provision for adequate ventilation of the closed zone
work environment.
Noise arising from the mechanical machineries like crushers,
screens, compressors, blowers, pumps etc can not be ruled out.
Such noise-prone equipment would be installed in a separate
housing so as to enhance the noise attenuation. Isolation of the
operational staff from the high noise prone zone would be adopted
by providing noise proof control room so that they are not exposed
to the noise level exceeding the allowable limit.
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Solid Waste Generation and Utilization
There would be generation of solid by-products like BF slag,
EAF slag, LF slag, IF Slag, mill scales, caster scrap, refractory
debris, flue dusts, coal washery rejects etc from the proposed
project. It is estimated that the proposed expansion would
generated nearly 2.1 MTPA solid wastes comprising mainly of BF &
EAF, IF & LF slags, dusts, etc.
TABLE 6-1 - SOLID WASTE GENERATION 1.5 MTPA STAGE
Sl. No. Solid By-product
Expected generation at 1.5 MTPA crude steel
stage, TPA
1. BF slag 453,900 2. EAF slag 265,300 3. IF slag 13,400 4. LF slag 19,600 5. Dust, mill scales and
sludges 58,100
6. Coal Tailings 451,500 7. CPP Ash 993,693
BF slag would be required to be granulated before it is sold
off. The flue dusts, mill scales and scraps would be recycled to the
Sinter plant and SMS. EAF and IF slag would be processed for
metal recovery and also partly recycled in Sinter Plant, EAF and IF.
The non metallic part would be used for various construction
purposes. Coal middlings/reject from the washery would be reused
in the power plant. CPP ash would be disposed in an earmarked
area.
Plant Safety
Plant safety measures would be an integral part of the
environment protection plan of the proposed plant. Workers’ safety
would be of highest degree of concern as required by the Factories
act-1948 and OSHAS 18001-2007 so as to avoid any personal
injury or untoward incident. In-built safety measures of the plant
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and machinery would be made adequate in order to avoid
hazardous events causing damage to the life and property.
Plant Greenbelt and Landscaping
As per the recent regulatory requirement, 33% of the plant
area has to be reserved for peripheral greenbelt, gardening and tree
plantations. This would not only prevent the fugitive dust emissions
but also improve the plant peripheral appearance from aesthetics
view point. This would be considered while planning for the
expansion facilities.
Design Targets for Environmental Protection
The proposed mitigation measures would be adopted the
following design targets:
I. Stack emissions
Particulate matter : 50 mg/N cu m SO2 emission : 500 mg/N cu m NOx emission : 500 mg/N cu m II. Wastewater discharge
Temperature : Ambient pH : 5.5 to 9 Total Suspended Solids : < 100 mg/l BOD3 (270C) : < 30 mg/l COD : < 250 mg/l Oil and grease : < 10 mg/l Iron (as Fe) : < 3 mg/l
III. Workzone Environment
Exposure to Dusts : 3 mg/cu m (max) in a closed environment 500 mcg/cu m (max) in an open environment within
20 to 30 m aerial coverage Exposure to Noise : Leq 85 dB(A) for a continuous period of 8 hours exposure
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Environmental Monitoring
While design and engineering of the plant, the principal
pollution sources like BF, EAF, IF, DR Kilns and captive power
plant stacks would be provided with on-line monitoring device for
routine monitoring of pollutants like TSP, SO2 and NOx. In addition,
conformance to the ambient air and waste water discharge
standards would also be monitored.
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7 – IMPLEMENTATION SCHEDULE
This chapter deals with the construction aspects of
project-overall construction schedule and construction facilities for
implementation of the project are also presented in this chapter.
IMPLEMENTATION SCHEDULE
The preliminary overall implementation schedule for the
project, indicating the time required to complete the major
activities like engineering, construction, procurement of
equipment, erection, testing/trial run and commissioning and hook
up of the various plant facilities is shown in the form of a bar chart
in Fig. 7-1 on the following pages.
It is envisaged that the project will be completed within a
period of 36 months from “Go-Ahead date”.
The schedule has been developed on the basis of the
estimated quantum of work, expected delivery and installation
periods of plant and equipment and the need to commission the
plant facilities in the shortest possible time. Scheduled
commissioning of the plant can only be achieved if construction,
delivery and erection periods, as shown in the bar chart, can be
met by respective suppliers and contractors.
Completion time of major Plant units:
Coal washery .. 24 months DR plant .. 30 months
Sinter plant .. 30 months Calcining plant .. 25 months Blast furnace .. 30 months SMS-1 .. 30 months SMS-2 .. 36 months Rolling mills .. 36 months Captive power plant .. 25 months
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8 – CAPITAL COST ESTIMATE
The order of magnitude estimates of capital cost for this
capacity augmentation is presented in this chapter. The estimates
are based on the information available with CONSULTING
ENGINEERS for similar projects. The estimates are based on price
levels, taxes & duties and exchange rates prevailing during
2nd quarter 2014-15.
CAPITAL COST ESTIMATE
The estimate of capital cost includes plant cost, preoperative
expense, working capital margin and interest during construction
(IDC). The plant cost comprises the costs of plant & equipment (as
erected) together with the cost of pollution control, design,
engineering, consultancy and administration during construction
and contingency.
Plant cost
The plant cost consists of the following components:
Plant and equipment (as erected): It includes cost of plant
and equipment and civil and structural. Additionally, taxes, duties,
transportation and erection (on normative basis) have been
considered to arrive at the cost of plant and equipment (as
erected).
Pollution control equipment: It includes the cost towards
air pollution control, water conservation, energy conservation etc.
A provision has been made at 10 per cent of the project cost.
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Design, engineering, consultancy, administration during
construction (DE and ADC): A provision has been made at 5 per
cent on the supply cost of plant and equipment including civil,
structural and erection.
Contingency: A contingency provision has been made at 5
per cent on the plant cost towards unforeseen items. Forward
escalation and exchange rate variation are not included in the
above provision.
INTEREST DURING CONSTRUCTION
Interest during construction (IDC) has been calculated based
on the following:
- Implementation period of 36 months for the project - Interest rate at 12 per cent per year
Based on the above, capital cost estimated for the project
works out to about Rs.10,834 crore. About 7-9 per cent of the
total plant cost has been kept for environment management
measures.
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