SLO STEELS LIMITED MINI STEEL PLANT CHINNAMBEDU VILLAGE, PONNERI TEHSIL, THIRUVALLUR DISTRICT,TAMIL NADU PROJECT REPORT MARCH 2018

Transcription

1 SLO STEELS LIMITED MINI STEEL PLANT CHINNAMBEDU VILLAGE, PONNERI TEHSIL, THIRUVALLUR DISTRICT,TAMIL NADU MARCH 2018 HIQ POWER ASSOCIATES PRIVATE LIMITED No.8, C Wing, 5 th Floor, Parsn Manere, No.442, Anna Salai, Chennai , Tamil Nadu, India. Phone Nos / / / hiqpower@gmail.com Website : ISO:

2 SLO STEELS LIMITED CONTENTS S. No. DESCRIPTION Page No EXECUTIVE SUMMARY i to xi 1.0 INTRODUCTION 1.1 General Authorization Structure of the Report Acknowledgement PRODUCT-MIX, PLANT CAPACITY & TECHNOLOGY 2.1 Products-Mix Suggested Plant Capacity And Plant Flow Sheet Technological Considerations Major Production Facilities PLANT SITE AND GENERAL LAYOUT 3.1 Proposed Location Infrastructure, Power & Water Plant General Layout Landscaping And Afforestation RAW MATERIALS 4.1 Annual Raw Material Requirements Quality Requirements Of Major Raw materials PLANT PRODUCTION FACILITIES 5.1 Raw material handling system Sponge Iron Plant And Auxiliaries Steel making facilities Continuous Casting Layout of SMS and Concast Plant Light Structural Mill WATER, UTILITIES & AUXILIARY FACILITIES 6.1 Water System Fuels Compressed air Oxygen, Nitrogen and Argon Acetylene Auxiliary Facilities CAPTIVE POWER PLANT 7.1 General 7.1 i

3 Contents (Contd.) SLO STEELS LIMITED S. No. DESCRIPTION Page No 7.2 Selection Of Generation Capacity Operating Logic Of CPP Fuel For CPP Description Of Thermal Cycle Selection Of Steam Parameters And Unit Size Configuration of CPP Brief Description of Plant and Equipment PLANT ELECTRICS AND INSTRUMENTATION 8.1 Electrical Design Selection of Voltages for Interfacing Power Supply Grid, Generation and Distribution 8.3 Harmonic Filters and Capacitors Selection Of Earthing System Power Interfacing Systems Load Block Distribution Board And HT System Generator And Generator Switch Board L.T. Distribution System Diesel Generator Set Lightning Protection Controls & Instrumentation System Communication System ENVIRONMENTAL CONTROL 9.1 Introduction Air Pollution Water Pollution Noise Pollution Thermal Pollution Solid Wastes Environmental Monitoring PLANT CONSTRUCTION & IMPLEMENTATION SCHEDULE 10.1 Construction Schedule ORGANIZATION AND MANPOWER 11.1 Organisation Manpower Estimate And Wage Bill ii

4 Contents (Contd.) SLO STEELS LIMITED LIST OF TABLES Table No Description Pg. No Table 2-1 Technology Options for the SLO Steel, Plant 2.2 Table 2-2 Status of Coal-based Sponge Iron Processes 2.3 Table 2-3 Major Production Facilities 2.7 Table 4-1 Specific Consumption & Gross Quantities of Raw Materials 4.1 Table 5-1 Raw Materials To Be Handled 5.1 Table 5-2 Major Technological Parameters Sponge Iron Kiln 5.2 Table 5-3 Approximate Composition Of Sponge Iron 5.3 Table 5.4 Production Programme Of Steel Melt Shop 5.6 Table 5-5 Parameters of Medium Frequency Induction Furnace 5.6 Table 5-6 Requirements of Major Raw Materials and Consumables for Steel Making Table 5-7 Technological Parameters of Billet Caster 5.9 Table 5-8 Casting Cycle Time Of Billet Caster 5.10 Table 5-9 Major Dimensions & Crane Capacities in SMS and Concast 5.12 Table 5-10 Technological Parameters of Structural Mill 5.14 Table 6-1 Plant Make Up Water Requirement 6.1 Table 6-2 Plant Water Systems 6.2 Table 6-3 Requirement of Oxygen & Acetylene 6.4 Table 7-1 Plant Power Requirement 7.1 Table 7-2 Technical Parameters Of WHRB & FBC Boilers 7.7 Table 7-3 Technical Parameters of Turbogenerator And Auxiliaries 7.8 Table 7-4 Details of Electrical System in CPP 7.9 Table 7-5 Details of Instrumentation and controls 7.10 Table 8-1 Parameters For Different Distribution Voltage Levels 8.3 Table 9-1 Proposed Air Pollution Control Facilities 9.1 Table 9-2 Permissible Noise Levels 9.8 Table 11-1 Approximate Area-Wise Manpower Requirement LIST OF APPENDICES No. Description Appendix No 1 National Steel Policy List of Major Plant and Equipment 5.1 iii

5 Contents (Contd.) SLO STEELS LIMITED LIST OF DRAWINGS No. Description Drawing No 1 Flow Sheet & Material Balance HIQ-SLO R6 2 Plant General Layout HIQ-SLO R10 3 Sponge Iron Layout HIQ-SLO R4 4 Steel Melting Plant Layout HIQ-SLO R4 5 Rolling Mill Layout HIQ-SLO R4 6 Scheme for water system HIQ-SLO R3 7 Power Plant Layout HIQ-SLO R4 8 Single Line Diagram for Electrical System HIQ-SLO R1 9 Implementation schedule HIQ-SLO R0 10 Scheme for waste water generation & sewage water HIQ-SLO R2 11 DM plant flow diagram HIQ-SLO R0 12 Process flow chart for Power Plant HIQ-SLO R1 13 Process flow chart for Sponge Iron Plant HIQ-SLO R2 14 Typical General Arrangement of ESP HIQ-SLO R0 15 Energy Balance HIQ-SLO R2 16 Typical General Arrangement of 200tons Ash storage silo HIQ-SLO R0 17 Typical General Arrangement of Bagfilter HIQ-SLO R0 LIST OF ANNEXURES No. Description Annexure No 1 Process Flow Chart for Induction Furnace & Rolling Mill 2 Stack Emission Details 2 1 iv

6 SLO STEELS LIMITED EXECUTIVE SUMMARY A. INTRODUCTION 1. M/s. SLO Steels Limited (SLO), are planning to put up mini integrated steel plant at Chinnambedu village, Ponneri tehsil, Thiruvaloor district, Tamilnadu. The plant will produce light structures in size upto 500 mm with an annual production capacity of around 180,000 Tons. The proposed production facilities will comprise of two sponge iron kilns each of capacity 100 TPD along with a steel melt shop with two induction furnaces, one 3 strand continuous billet casting machine and a structural mill. A captive thermal power plant of capacity 16 MW with waste heat recovery boilers as part of the sponge iron kilns and a fluidised bed combustion boiler fired by coal char and coal is also envisaged as part of the facilities. 2. Structural steel products comprising angles and channels are in demand to meet the requirements of the construction industry. Hence, it is proposed to install a structural mill which can roll continuous cast billets/blooms into various structural sections up to a size of 500mm. The sizes and quantities to be rolled will be kept flexible and decided on market demand. It is to be noted that the above product-mix is primarily intended for evolving the overall project parameters. The actual productmix of the mill would have to be evolved based on the market requirements that are likely to prevail at the time when the mill goes into operation. B. PROCESS & TECHNOLOGY 1. The various process steps involved in production of finished steel products of the desired tonnage and quality would be the following: Iron making : Production of hot metal / direct reduced iron (DRI) as feed material for production of liquid steel. Steel making : Production of liquid steel for casting Secondary refining : Adjustment and homogenisation of steel chemistry and temperature Casting : Casting of liquid steel into desired billet sizes Rolling : Rolling of produced billets to structural sections 2. The selection of the most optimum process route for the proposed plant needs critical analysis and evaluation. The evaluation process is more relevant due to the emergence of a large number of new competitive technologies in various fields of iron and steel making. An attempt has been made to evaluate the technologies available and suggest the optimum one for the proposed steel plant of SLO. An evaluation of this type involves analyses of past achievements, present status and future prospects of each technology under consideration keeping in view the following criteria,. - i -

7 Executive Summary (Cont d.) Capacity of the plant Selected product-mix SLO STEELS LIMITED Conservation of scarce and costly energy input Amenability of available raw materials Cost considerations Availability of infrastructure facilities and logistics of operation. 3. SLO intend to install an integrated mini steel plant of capacity of about T/Y of finished steel with minimum capital expenditure. SLO also wants to install a captive power plant for minimising dependence on the state grid, reducing the expenditure towards electricity bill, tariff for which has been ever increasing in the country and also to utilise available waste energy from the plant processes such as the kiln waste gases, coal char etc. which otherwise would have been wasted. 4. In order to select the appropriate technologies for rolling, casting, steel making and iron making, the various options available for the desired plant capacity level are given in following Table: Iron making Hot metal Direct reduced iron Steel making Secondary refining Casting Rolling Electric pig iron furnace (EPIF), Blast furnace (BF) process. Direct Reduction (DR) processes based on solid reductant. Induction furnace (IF) & Electric are furnace (EAF), Basic Oxygen Furnace (BOF) Ladle furnace(lf) Continuous casting (CC) Light structural mill 5. The technological route proposed for the mini-integrated steel plant of SLO is as follows : Iron Making : Coal based sponge iron plant Steel Making : Induction Furnace Casting : Continuous Casting Rolling : Light Structural Mill C. LOCATION 1. The SLO mini integrated steel plant is proposed to be located In Chinnambedu village, Ponneri tehsil, Thiruvaloor district, Tamilnadu. The site is located about 30 Kms from Chennai. SLO has acquired about 31.3 acres of land at this location for setting up the plant.. ii

8 Executive Summary (Cont d.) SLO STEELS LIMITED 2. The proposed area is located to the east of National Highway-5 running from Chennai to Vijayawada. The terrain of the land is reasonably plain. There is no agricultural activity in the area. There are no houses or habitation in the area. Top soil is filled up soil up to a depth of 2.5 m and silty clay beyond a depth of 2.5 m. There are a number of industries in the area and the Gumudipoondi Industrial Estate is about 10Km from the site. The nearest railway station is Gumudipoondi on the broad gauge line connecting Chennai and Gudur at a distance of about 10 kms from the proposed area. The location under consideration is approximately 40 kms from Chennai and Ennore ports. The nearest air port is at Chennai about 50 Kms from the site. The area is well developed and all supporting facilities necessary for completing the steel plant including skilled labour will be available in the area. For this location, iron ore will have to be sourced from the Bellary -Hospet area which is around 550 kms by road from the site. Coal and scrap will have to be imported through Chennai port. The main water source at the proposed site is bore wells in the area. Water analysis report available shows an average TDS of around 1100 mg/l. D. RAW MATERIALS 1. The major raw materials required for production of coal based sponge iron and steel are iron ore, non-coking coal, limestone and steel scrap / pig iron. Other materials like ferroalloys are used in small quantities as alloying elements and for carbon adjustment in steel making. 2. Some of the raw materials to be procured will contain some moisture and will undergo some losses during handling and transportation. Considering all such losses, the specific consumption per ton of finished bars and rods and estimated gross quantities of the raw materials to be procured annually is presented in Table Raw Material Specific Consumption per Ton of product Gross Quantity (Tons/Yr) Sized iron ore for SI plant Non-coking coal for SI plant Non-coking coal for CPP Non coking coal for Coal gas plant Crushed and screened fines from SI plant Limestone for SI plant Steel Scrap / Pig Iron for IF iii

9 Executive Summary (Cont d.) Raw Material SLO STEELS LIMITED Specific Consumption per Ton of product Gross Quantity (Tons/Yr) Ferro-alloys for IF Fuel oil for SI, IF & RM E. MAJOR FACILITIES 1. The major production facilities envisaged for the proposed integrated mini steel plant are given in Table Sl. No. Shop / unit Capacity 1. Sponge iron plant 2x100 Tonnes/day 2. Induction furnace 2 x 25 Tonnes 3. Billet caster 1 x 3 strand 4. Structural mill 180,000 Tonnes/year 5. Captive power plant 16 MW F. CAPTIVE POWER GENERATION 1. Generation capacity is selected based on the following criteria: a) Average power requirement of the steel plant: The average electric power requirement of the steel plant is estimated as around 19 MW. The details of requirement is given in Table below: Description Estimated Load (MW) Sponge Iron Kilns (Two Kilns) 0.8 Induction furnaces and CCM 15.0 Rolling mills and CCM 3.2 Power Plant Auxiliaries and other plant auxiliaries 3.0 Total 22.0 b) Quantum of steam and the corresponding power, which can be generated by waste heat recovery from kiln off gas.. iv

10 Executive Summary (Cont d.) SLO STEELS LIMITED c) Load fluctuations that are expected in induction furnace and rolling mill operations and possibility of export of power in low load operation and import of power during high load operation. d) Availability of waste materials such as char, coal fines etc. from the steel plant operations, which can be used for steam generation in a fired boiler. 2. Experience from existing operating sponge iron plants indicate that the average power generated by the steam produced in the WHRB attached to one kiln is around 1.8 MW. Thus the 2 WHRB attached to the 2 kilns will have the potential to generate around 3.6 MW. Hence it is proposed to install a fluidized bed combustion boiler with adequate capacity to generate steam necessary to meet the balance steam requirement of the proposed CPP. In addition to the coal fines and char from the sponge iron plant, purchased coal will also be used as fuel in this boiler. 3. The induction furnaces proposed for the steel plant will have an average production cycle/ tap to tap time of about 120 minutes with 10 minutes charging time, 10 minutes of stabilising time around 90 minutes of heating/melting time and 10 minutes for tapping. The steady state requirement of power for each furnace is around 9 MW. On averaging the consumption over the entire cycle the average power requirement for each induction furnace will be around 7.5 MW. Similarly the rolling mill loads are also fluctuating with peaks when the billet is fed into the roughing mill and the load dropping towards the end of the rolling cycle. The power generation capacity of the CPP will be 16 MW, which can meet the major power requirements of the miniintegrated steel plant. 4. In order to meet the above fluctuating load requirements and ensure a fairly steady operation of the power plant, it is proposed to operate the power plant in parallel with the state grid. Operating the power plant in parallel with the grid will also enable export and banking of the power generated ensuring operation of the power plant at a fairly steady load. 5. SLO will have a contract with TNEB for drawl of about 7.5 MVA of power. This will enable export and banking of the surplus power generated during the charging of the furnace and the same can be imported during the heating/melting cycle of the induction furnaces and also meet the peak power needs in the rolling mill. 6. Considering the above the power plant will comprise of the following major facilities: 2 nos. waste heat recovery boilers one for each kiln each with a capacity of 10 TPH at 65 Ksca and 490 C in bypass configuration at the down stream of ABC to recover sensible heat of kiln off gases.. v

11 Executive Summary (Cont d.) SLO STEELS LIMITED One fluidized bed combustion (FBC) boiler utilizing coal fines and char as fuel with a capacity of 55 TPH (MCR) at 65 Ksca and 490 C One turbo generators with a rating of 18 MW with steam inlet conditions of 64 Ksca at 485 deg C 7. All necessary boiler and TG auxiliaries including deaerator and boiler feed pumps with associated system, electrics such as generators, transformers, switchgear, water supply facilities, instrumentation and controls, auxiliary service systems such as fuel handling, ash handling and disposal, telecommunication, fire fighting and miscellaneous facilities. G. UTILITIES 1. The source of water for the plant is bore wells to be sunk at the proposed site. 2. The make up water requirement of the plant is given in Table below. Consumer Requirement, M3/hr Sponge Iron Plant 10 Induction furnace and continuous casting plant. 13 Captive Power Plant 10 Rolling Mills 7 Miscellaneous uses such as for ablution block, drinking water, losses etc Total Fuel oil is required for start up of the sponge iron kilns; start up of the FBC boiler and in the reheating furnace in the Rolling Mills. The total fuel oil requirement for the above uses is estimated to be about 1900 tons/year. This will be procured from the nearest terminal of any of the major suppliers e.g. HPCL, IOCL or BPCL. About 15 days storage of fuel will be maintained in the plant. 4. In the rolling mill furnace it is proposed to fire coal gas as main fuel with a small quantity of furnace oil as support in the final stages of the furnace. A coal gasifier of required capacity will be installed which will use Indonesian coal as fuel. 5. In addition to fuel oil, about 200 tonnes/year of LDO and HSD will be needed for the ladle pre-heaters in SMS and for the transport equipment in the plant. Suitable storage tanks with metering devices for these fuels will also be provided. 6. The plant requirement of service air is estimated at about 300 N cu m/hr. Instrument air requirement is estimated at around 200 Ncum/hour. Service air will be supplied from a centralised compressor plant with two (2) air compressors (including one standby) each of capacity 300 N cum/hr at a discharge pressure of 7 Kscg. The units will be complete with after coolers, air receivers and other accessories. To meet the requirement of dry oil free instrument grade air, two non-lubricated type air.5. vi

12 Executive Summary (Cont d.) SLO STEELS LIMITED compressors each of capacity about 200 N cum/hr at a discharge pressure of 7 to 8 Kscg. will be provided. The system will be complete with necessary air-drying units, air receivers etc. 7. Oxygen is required for scrap cutting and miscellaneous oxy-acetylene cutting operations including billet cutting on the continuous casting machine. Argon is required for secondary refining of liquid steel in the ladle furnace. Nitrogen is required for rinsing in ladles and acetylene for cutting purposes. The annual requirement of these gases is given in the following Table Consumer Oxygen Acetylene Scrap and billet cutting and miscellaneous uses Oxygen, nitrogen, argon and acetylene will be purchased from outside agencies in standard cylinders. Suitable facilities for storage and distribution of oxygen, nitrogen and argon in the form of cylinder manifolds etc. will be provided in the plant. 9. A central store for storage of equipment, spares, consumables, lubricants etc. will be provided in the plant. The stores will be furnished with handling and storage facilities. A storage room has also been envisaged inside the stores building for storage of valuable items. A refractory and Ferro-alloys storage area will also be provided. Various types of refractories, Ferro-alloys and additives will be stored in this area. Adequate handling and storage facilities will be provided in this building. 10. Repair and maintenance facilities have been centralised in one building to take care of routine activities. The repair and maintenance shop will be equipped with facilities for machining, fabrication, assembly, auto servicing, electrical repairing, hydraulic and pneumatic equipment repairing, mould repairing etc. 11. A well-equipped integrated test laboratory for carrying out testing at various stages of production will be provided. The laboratory is envisaged for rapid evaluation of chemical composition of various grades of steel during refining stages. The laboratory will also be utilised for testing of incoming raw materials and testing of products and by-products at various stages of production. H. ENVIRONMENT 1. The operation of plant units such as sponge iron kilns, induction furnaces, structural mill, auxiliary units and utilities generate pollutants, which contaminate the air, water and soil. If these pollutants are discharged without treatment they will cause deterioration in the quality of the environment. Therefore suitable pollution control equipment and systems and instruments for monitoring of air and water quality will be included to treat and monitor the emissions and effluents such that the pollutant discharges to the environment will be within the statutory norms laid down by regulatory agencies.. vii

13 Executive Summary (Cont d.) SLO STEELS LIMITED 2. Air Pollution Control facilities comprising various dust extraction and dust suppression systems are envisaged as given in following Table Sl. No Location/Shop Facilities Standards and emission limits As per MOEF notification dated 30 th May Sponge iron rotary kiln ESP Particulate Matter < 100 mg/nm3. CO <1 % Stack Height (Minimum) 45m and top diameter 1 m 2 DRI screen 3 4 Ore screening & coal crushing, screening Different conveyor transfer points in raw material handling systems De-dusting system comprising of suction hood, duct, bag filters, fan, stack etc. De-dusting system comprising of suction hood, duct, bag filters, fan, stack etc De-dusting system comprising of suction hood, duct, bag filters, fan, stack etc Particulate Matter < 50 mg/nm3. Stack Height about 35m and top diameter 0.9 m Exhaust duct will be terminated 3m above the building roof with bird screen 5 Raw Material Storage area Dust suppression system with water spray Fugitive emission < 2000 micro grams/m3. 6 SMS Induction Furnace area Adequate natural ventilation by proper design of the building and provision of local fume extraction systems in furnace operating zones. The fume extraction system will comprise movable hoods, ducting, dry cyclone, bag filter, fan and chimney. Stack Height (Minimum) 40m and top diameter 0.9 m 7. Rolling Mill Chimney of adequate height for Reheating Stack Height (Minimum) 35m and top diameter. viii

14 Executive Summary (Cont d.) SLO STEELS LIMITED Sl. No Location/Shop Facilities Standards and emission limits Furnace. Adequate natural ventilation by proper design of the building m 8. Power Plant ESP for cleaning the flue gases from the FBC boiler. Dust extraction systems for conveyor transfer points, crusher and screen house with hoods, bag filter and fans. As per New Emission Standards for TPP vide notification S.O 3305(E) dated Particulate 30mg/Nm3. SO2 100mg/Nm3 NoX 100mg/Nm3 Matter Chimney height 60 m & top Dia 1.2 m 3. The plant employs recirculating water systems for both direct and indirect cooling of equipment. During use in direct cooling, the water becomes contaminated. Therefore the pollutants will be removed before the water is cooled and re-circulated back into the plant. Typical major pollutants of concern are suspended solids, oil and grease. Treating and reusing the water thus minimises the consumption of fresh water for make-up. The entire plant cooling water system is designed as a Zero Discharge system and no effluents or waste will be discharged outside the plant boundary. The pollutants present in the wastewater will be reduced to acceptable levels by adoption of the following schemes. Recirculating water in the process whereby discharged volume is considerably reduced. Clarifier and sludge pond for removal of suspended solids. Removal of oil and grease from the contaminated water by means of oil traps and skimming devices Water from billet caster secondary spray cooling and open machinery cooling will be collected in a scale pit. Oil skimming facility will be provided. The overflow will be pumped through high-rate pressure filters to cooling tower for cooling. Chemical dosing facilities will be included. The water collected in a cold well will be recirculated to the system by cold well pumps. The waste backwash from pressure filters will be treated in a thickener. Thickener overflow will be recycled while the underflow will be dewatered in vacuum drum filters to produce an inert filter cake. A similar facility will be provided for treatment of direct cooling water for rolling mill.. ix

15 Executive Summary (Cont d.) SLO STEELS LIMITED 4. The plant and equipment will be designed and specified with a view to minimise noise pollution. Major noise producing equipment such as turbo generators and air compressors will be provided with acoustic enclosures. The rotating equipment in the plant will be designed to operate with a total noise level of not exceeding to 85db (A) at 1m distance as per the stipulations of Occupational Safety and Health Administration (OSHA) Standards. The rotating equipment will be provided with silencers wherever required to meet the noise pollution standard. 5. Heat constitutes a form of pollution if it is above acceptable levels. Therefore control measures become necessary to minimise thermal pollution. Plant building will be designed for adequate air circulation through natural ventilation. In addition, air conditioning systems will be provided for specific areas. Man coolers will be installed at hot work spots like furnaces and casting sections. Special thermal proof linings will be provided in the high temperature zones like Kiln, Furnaces etc. to bring down their surrounding temperature. A closed circuit auxiliary cooling water system with cooling towers has been proposed. This eliminates the letting out of high temperature water into the canals and prevents thermal pollution. Blow down from the cooling tower will be trenched out and ultimately conveyed to the effluent ponds. Hence, there is no separate pollution on account of blow down from cooling water system. Ventilation and air-conditioning systems will be provided in control rooms and office buildings. Thermal insulation in equipment and Pipework will be provided such that all surface temperature will be limited to 65deg.C i.e. 20 deg. C over maximum ambient of 45deg.C 6. Solid wastes from the plant comprise fly ash and bottom ash from boiler, slag, mill scale, dust, sludge, used refractories, scrap and miscellaneous trash and debris. The steel melt shop slag will be removed to a slag dump area for future productive use. The plant sludge will be stored in the plant site in an area specially marked for the purpose. The dump materials are inert. Scrap will be reused in the process or commercially disposed. Fly ash will be disposed off to cement plant or fly ash brick making units. 7. The air emissions and waste water discharges into the environment will be monitored regularly for assessing the levels of pollutants and for estimating the efficiency of treatment plants and related equipment. The ambient and work zone monitoring will be performed as per the guidelines of regulatory agencies. I. CONSTRUCTION SCHEDULE 1. The construction of the plant including erection of all plant facilities is expected to be completed in 15 months from Go-Ahead. The plant is expected to go into commercial production after trial run and commissioning and stabilisation by the end of 15th month from Go-Ahead which corresponds to the date by which all statutory and other clearances are available for start of project implementation.. x

16 Executive Summary (Cont d.) J. O & M MAN POWER SLO STEELS LIMITED 1. It is estimated that the total requirement of manpower including all categories for the whole organisation will be around 315 men on pay roll. Approximate area-wise manpower requirement is given in the following Table Department Shift General I II III Total per weekday Total on payroll Administration, sales and works office RMHS and Sponge Iron plant SMS & Concast Rolling mills CPP Services, transport, lab etc Total xi

17 SLO STEELS LIMITED 1.0 INTRODUCTION 1.1 GENERAL M/s. SLO Steels Limited (SLO), are planning to put up a mini steel plant at Chinnambedu village, Ponneri Tehsil in Thiruvallur district, Tamilnadu. The plant will produce light structural sections such as angles, channels etc. in size range of 500 mm with an annual production capacity of around 180,000 Tons. The proposed production facilities will comprise of two sponge iron kilns each of capacity 100 TPD along with a steel melt shop with two induction furnaces, one 3 strand continuous billet casting machine and a structural mill. A captive thermal power plant of capacity 16 MW with waste heat recovery boilers as part of the sponge iron kilns and a fluidised bed combustion boiler fired by coal char and coal is also envisaged as part of the facilities. 1.2 AUTHORISATION SLO have commissioned HIQ Power Associates Private Ltd, Consulting Engineers, for the preparation of a Project Report (PR) for the proposed Mini Steel Plant. 1.3 STRUCTURE OF THE REPORT This DPR contains thirteen (13) chapters of texts supported by appendices and drawings. Following this introductory chapter, the suggested product-mix and plant capacity are discussed in Chapter-2. The plant location, requirement of infrastructure facilities and the suggested layout are discussed in Chapter-3. The requirement of various raw materials and the source of these raw materials are discussed in Chapter-4. The major production facilities of the steel plant and auxiliary facilities such as water system, electrics and utilities are highlighted in Chapter-5 and Chapter-6 respectively. The power plant & auxiliaries and the power generation capacity of the captive power plant are discussed in Chapter-7. The plant electrics, instrumentation and control facilities are explained in the Chapter-8. Chapter-9 presents a brief picture of the various environmental control measures proposed for the steel plant. The plant construction and implementation schedule and requirement of manpower for the plant are discussed in Chapters-10 and Chapter-11 respectively. 1.4 ACKNOWLEDGEMENT Consulting Engineers gratefully acknowledge the co-operation and assistance extended by the officials of SLO during the course of preparation of this Project Report

18 SLO STEELS LIMITED 2.1 PRODUCT MIX 2.0 PRODUCT-MIX, PLANT CAPACITY & TECHNOLOGY Structural steel products comprising angles and channels are in demand to meet the requirements of the construction industry. Hence, it is proposed to install a structural mill which can roll continuous cast billets and blooms into various structural sections up to a size of 500mm. The sizes and quantities to be rolled will be kept flexible and decided on market demand. It is to be noted that the above product-mix is primarily intended for evolving the overall project parameters. The actual product-mix of the mill would have to be evolved based on the market requirements that are likely to prevail at the time when the mill goes into operation. 2.2 SUGGESTED PLANT CAPACITY AND PLANT FLOW SHEET The gist of National Steel Policy 2017 as envisaged by Government of India is enclosed as Appendix 2-1. As per the New Steel Policy a production capacity of 300 Million Tons is envisaged by the year Considering the supply-demand gap for light structural products and considering the economic sizes of various production units, a total plant production capacity of 180,000 Tons/Year is planned. The flow sheet and material balance for the plant is given in drawing no. HIQ-SLO R6 and separate process flow chart for induction furnace to produce steel billet and rolling mill is also enclosed as Annexure TECHNOLOGICAL CONSIDERATIONS Need for technology evaluation The selection of the most optimum process route for the proposed plant needs critical analysis and evaluation. The evaluation process is more relevant due to the emergence of a large number of new competitive technologies in various fields of iron and steel making. This section evaluates the technologies and suggests the optimum one for the proposed steel plant of SLO. An evaluation of this type involves analyses of past achievements, present status and future prospects of each technology under consideration keeping in view the following criteria, Capacity of the plant Selected product-mix Conservation of scarce and costly energy input Amenability of available raw materials Cost considerations

19 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) Availability of infrastructure facilities and logistics of operation Possible Technology Options SLO intend to install an integrated mini steel plant of capacity of about 180,000 t/yr of finished steel with minimum capital expenditure. SLO also wants to install a captive power plant for minimising dependence on the state grid, reducing the expenditure towards electricity bill, tariff for which has been ever increasing in the country and also to utilise available waste energy from the plant processes such as the kiln waste gases, coal char etc. which otherwise would have been wasted. The various process steps involved in production of finished steel products of the desired tonnage and quality as per the suggested product mix would be the following: Iron making : Production of hot metal / direct reduced iron (DRI) as feed material for production of liquid Steel. Steel making : Production of liquid steel for casting Secondary refining : Adjustment and homogenisation of steel Chemistry and Temperature. Casting : Casting of liquid steel into ingots or into CC billets. Rolling : Rolling the ingots or billets into finished products In order to select the appropriate technologies for rolling, casting, steel making and iron making, the various options available for the desired plant capacity level are given in Table 2-1. Table-2.1: Technology Options for the SLO Plant Iron making Hot metal Direct reduced iron Steel making Secondary refining Casting Rolling Electric pig iron furnace (EPIF), Blast furnace (BF) process. Direct Reduction (DR) processes based on solid reductant. Induction furnace (IF) & Electric are furnace (EAF), Basic Oxygen Furnace (BOF) Ladle furnace(lf) Continuous casting (CC) Light structural mill The above technology options have been analyzed in the following paragraphs and the optimum one for the SLO plant recommended

20 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) Iron Making Both steel scrap and DRI, which are the main input materials for steel making in the mini steel plants, are not easily available in the country and their prices have been fluctuating and are on the increase. Hence SLO propose to put up an integrated mini steel plant, starting from iron ore as plenty of good quality iron ore is available in the nearby Bellary- Hospet area. At least a part of the input for still making can thus be produced within the plant and dependence on purchased scrap can be minimised. The commercially viable and technologically established processes for production of iron from iron ore are direct reduction (DR) process based on solid reductant and hot metal production processes EPIF, BF etc. Being highly power-intensive, EPIF process has not been considered for the proposed project. If BF process is considered for iron making, downstream process for converting hot metal into liquid steel is to be BOF steel making or high-capacity EAF steel making (since hot metal optimally constitutes about 30% of metallic charge in EAF steel making). BOF steel making has not been considered relevant for the proposed project due to its small capacity. High capacity EAF steel making also does not suit the capacity required for the proposed project. Further if a BF is considered for iron making, coke need to be imported and the cost of coke in the international market is very high and highly volatile leading to high production cost. Hence BF process is not considered further for the proposed project. Thus the best options available for the SLO project for iron making is production of sponge iron or direct reduced iron (DRI) based on solid reductant and hence the same has been considered for the proposed project Coal Based Direct Reduction (DR) Process Direct reduced iron (DRI) is produced by direct reduction process in which oxides of iron ore are reduced by non-coking coal at a temperature range of deg C, much below its melting point. Of the installed DR plants based on solid reductant, SL/RN process accounts for over 50 % of total production. The balance is shared by ACCAR, Codir, DRC, TDR, OSIL, Kinglor Metor and other processes. The different coal based sponge iron processes which have reached industrial scale application are detailed in following Table 2 2: Table-2.2: Status of Coal Based Sponge Iron Processes PROCESS RETORT/SHAFT Echeverria PRESENT STATUS One 250,000 TPA unit installed in Lagazpia, Spain is shut down. Process not marketed any more

21 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) Kinglor Metor Wiberg PROCESS PRESENT STATUS Two units of 20,000 TPA each are in operation in Mymo, Burma. Two units of same capacity installed in Italy are abandoned. Three units installed, two in Sweden and one in Japan. In Sweden one unit converted to plasma red process, another shut down. Process not marketed any more. TUNNEL KILN Hoogovans Three units with total capacity of 23,000 TPA installed in Sweden and shut down. Process not marketed any more. ROTARY KILN ACCAR DRC TDR CODIR SL/RN Two industrial units one in Canada and other in India installed. Unit in Canada shut down. In India it is modified and de rated. Two units of 75,000 TPA in operation in South Africa. Only one unit of 90,000 TPA set up in Orissa. Later modified by Lurgi. And capacity augmented to 120,000 TPA. Three units set up, two in India and one in South Africa. Of the two units set up in India, one is 150,000 TPA and another two modules of 115,000 TPA. Large number of units set up all over the world of various capacities ranging from 30,000 TPA to 150,000 TPA. Most of the plants are in operation From Table 2-2, it will be noted that two of the three retort / shaft based processes are not marketed any more. The third process,kinglor Metor process has only one reference plant of smaller capacity of tons/year and even this plant has been shut down. The Hoogovans process, which is tunnel kiln process, is also not marketed any more. From Table 2-2, it can be seen that rotary kiln processes are by far more well established amongst all coal-based processes. There are a number of rotary kiln plants in operation and a number of them are under installation in the states of Chattisgarh and also Karnataka. Most of the operating plants based on the rotary kiln process especially those of smaller capacities with unit size around tons/year are based on SL/RN originally developed and marketed by Lurgi, Germany. The first two kilns, each of annual capacity Tons, were put up in India based on this technology at Sponge Iron India Ltd at Paloncha in Andhra Pradesh in A large number of similar units have been put up

22 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) since then in various parts of the country and the technology for this capacity is available indigenously. Larger kilns of capacity tons/year each based on SL/RN process are in operation at Bihar Sponge Iron, Prakash Industries and Novo Iron & Steel in India. A few plants based on the other rotary kiln processes such as those of Sunflag Iron & Steel Co Ltd and Goldstar Steel & Alloys Ltd based on the CODIR process, Orissa Sponge Iron Ltd based on ACCAR process and IPITATA based on the TDR process were also built. The rotary kiln processes are by far the most commercially established processes available for manufacture of coal based sponge iron. Of the different rotary kiln processes available the SL/RN process is the most widely adopted process and has the maximum population of operating plants especially with annual capacity in the range of Tons. The original technology supplier for SL/RN process is Lurgi, Gemany. However this technology is now available locally and there are a number of suppliers who can give the technology and drawings with process guarantees. All the equipment can be sourced locally. An evaluation of the available technology suppliers will be done and the most appropriate one selected during the implementation phase of the project. Hence it is proposed to adopt the proven and commercially established SL/RN process for the SLO plant. In the proposed SLO plant two kilns each of capacity 100 TPD which will give an annual production capacity of sponge iron of around tons while operating for 310 days in the year is proposed to be installed. This will meet about 28% of the induction furnace charge and balance will be scrap Steel making The steel making processes worth consideration for production of liquid steel using sponge iron as the main input are are as follows: Induction furnace Electric are furnace Induction furnace India has witnessed an unprecedented growth in induction furnace (IF) steel making since the 1970 s. The factors, which contributed to the growth in induction furnace steel making over electric arc furnace steel making in India, are as follows. For a given power input, the daily liquid steel melting capacity of a medium frequency IF is more than that of a regular powered arc furnace due to its inherent characteristics like nearly unit power factor operation, insignificant refining operation, etc. IF can be connected with even weak power grids without any power disturbance on the mains supply. Elimination of expensive graphite electrodes

23 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) Use of inexpensive refractories. Low investment and operating costs. IF steel makers are now successfully making tonnage steel by using even about % of DRI with addition of 25-20% scrap and cold pigs in the charge-mix and banking on some secondary refining unit for a good part of refining load Electric arc furnace EAF can melt 100% solid charge comprising appropriate proportion of scrap and DRI/HBI. This is also an established process in creating an integrated steel plant of capacity in the range of Mt/yr. In fact more than 33% of total steel produced in the world today is through EAF. There have been continuous developments in this process to increase productivity, decrease energy consumption and produce cleaner steel. However, for the proposed low capacity integrated mini steel plant, operation of small-size EAF based on DRI (coal based) will call for requirement of high MVA power connection thereby dependence on heavy grid support and also high specific consumption of power, leading to poor commercial viability of steel making Steel Making Equipment Proposed Considering the above, induction furnace is envisaged as the equipment for steel making in the proposed plant of SLO. The production of liquid steel has been based on the maximum utilization of in plant produced DRI plus utilization of plant return scrap and purchased cold pigs/scrap. The average percentage of DRI in the charge-mix will be around 28% and the balance will be made up of plant-return scrap and purchased scrap or cold pigs. Based on this charge-mix, the production of liquid steel per year will be about tons/yr for an annual finished product production of about Tons. It is proposed to install two IF s in the steel melt shop each of capacity 25 Tons. A transformer of capacity 9000 KW will feed each furnace. Each furnace will have two crucibles, one operating and other as standby, fed by a transformer. An average tap to tap time of about 120 to 135 minutes has been considered to be optimum for the IFs Casting of liquid steel The finished products from the plant are structural products. The feed to rolling mills producing such products is billets or blooms in various sizes. The liquid steel from the induction furnaces can be cast either into pencil ingots in conventional moulds or cast into billets in continuous casting machines. The quality of ingots cast in conventional moulds is not dependable and the yield both of ingots from liquid steel and of finished product rolled from such ingots is lower compared to billets cast in a continuous casting machine. Hence a continuous billet-casting machine has been envisaged for SLO plant. For reasons of better yield and better utilization of the machine, casting a number of heats in a sequence has been considered. One 3-strand billet caster capable of casting billets from 100 mm to

24 SLO STEELS LIMITED MINI STEEL PLANT IN TAMI Product-Mix, Plant Capacity & Technology (Cont d) mm square is proposed Rolling mill A structural mill to roll light, medium and heavy structures upto 500 mm has been considered. The mill will be of semi-continuous type. The mill will be equipped with reheating furnace of suitable capacity Captive power plant (CPP) A CPP will be installed to operate the proposed plant with minimum support from the state power grid for reducing electricity bill. The hot flue gas and char generated from the DRI kiln and excess coal fines generated during processing of as-received non coking coal, required for the DR process, will be fully utilized for power generation. Additional purchased coal will also be used in order to achieve the full power generation in the CPP. The CPP will operate synchronised with the state grid which will supply the balance power requirement of the steel plant over and above the CPP generation. The proposed power plant will thus be equipped with both waste heat recovery boilers and fluidized bed boiler for steam generation and associated turbo generator for generation of power. The estimated average requirement of power for the proposed plant works out to about 22 MW. Hence, to meet the major electricity demand of the plant a CPP of 16 MW capacity has been selected. The plant will consist of 2 nos waste heat recovery boilers each of capacity 10 Tons/hr per sponge iron kiln, one FBC boiler of capacity 55 Tons/hr and one turbo generator of capacity 16 MW with an air cooled condenser. 2.4 MAJOR PRODUCTION FACILITIES The major production facilities envisaged for the proposed integrated mini steel plant are given in Table 2-3. Sl. No. Shop / Unit Table 2-3 Major Production Facilities Capacity 1. Sponge iron plant 2 x100 Tons/day 2. Induction furnace 2 x 25 Tons, 9000 KW each 3. Billet caster 1x 3 strand 4. Slight, medium and heavy structural mill 180,000 TPA 5. Captive power plant 16 MW

25 SLO STEELS LIMITED 3.0 PLANT SITE AND GENERAL LAYOUT 3.1 PROPOSED LOCATION The SLO mini steel plant is proposed to be located in Chinnambedu village, Ponneri tehsil, Thiruvallur district, Tamilnadu. SLO have acquired around acres of land at the above location for setting up the plant. 3.2 INFRASTRUCTURE, POWER AND WATER The site is located about 1.0 Km from NH5-the Vijayawada-Chennai highway. A grid substation exists at Durainallur town at a distance of 2.5 Km from the site. This SS has power at 110 KV and the proposed mini steel plant will be connected to this SS for power supply and evacuation. Another 110 KV EB SS is available at Panjetty about 9.1 KMs from the site. The main water source at the proposed site is bore wells in the area. 3.3 PLANT GENERAL LAYOUT The plant general layout indicating the disposition of the different plant units is presented in Drawing No. HIQ-SLO R10 plant: The following aspects have been considered in laying out the various facilities in the Location of various production facilities to ensure smooth and uninterrupted flow of incoming, in process and outgoing material with minimum counter flow Rational arrangement of plant facilities so as to minimise the plant cost. Unhindered expansion and diversification possibilities in future with minimum Interference to existing operation. Provision of a green belt for environmental consideration Raw material receiving yard All raw materials are proposed to be received at site by road. All raw materials except purchased scrap are proposed to be unloaded in the raw material receiving yard. Scrap will be unloaded in the scrap yard adjacent to the Steel Melt Shop Raw material handling system The raw material handling system for storage and supply of various raw materials has been located in the raw material receipt and storage yard. All the major users are connected to this system by conveyors

26 Plant Site and General Layout (Cont d) Major plant facilities SLO STEELS LIMITED The sponge iron kilns, steel melt shop and rolling mill, are laid out considering the need for rational material flow, economy in operations and the space requirements for any future expansion. The layout also takes into account the stage-wise commissioning of the plant units Utilities and services The power plant has been located suitably considering need for integrating with the main receiving substation and location of the sponge iron kilns which is the source waste heat recovery steam for the power plant Other facilities The raw water storage and treatment facilities have been located to the east of the main production facilities. The dump for slag and other debris/muck is located at the south west corner of the plant area. The main entrance to the plant will be through a gate on the east boundary abutting the main road. 3.4 LANDSCAPING AND AFFORESTATION The general layout of the plant has been developed with requisite provisions for landscaping and greenbelt with a view to avoid adverse impact on the environment. Adequate space is earmarked for this purpose

27 SLO STEELS LIMITED 4.0 RAW MATERIALS This chapter indicates the annual requirements of various raw materials and purchased fuels such as fuel oil and their possible sources of supply. The quality requirements of major raw materials have also been discussed in this chapter. 4.1 ANNUAL RAW MATERIAL REQUIREMENTS The major raw materials required for production of coal based sponge iron and steel are iron ore, non-coking coal, limestone and steel scrap / pig iron. Other materials like ferroalloys are used in small quantities as alloying elements and for carbon adjustment in steel making. Some of the raw materials to be procured will contain some moisture and will undergo some losses during handling and transportation. Considering all such losses, the specific consumption per ton of finished products and estimated gross quantities of the raw materials to be procured annually is presented in Table 4-1. Table 4-1 Specific consumption & Gross Quantities of Raw Materials Raw Material Specific Consumption per Ton of product Gross Quantity (Tons/Yr) Sized iron ore for SI plant Non-coking coal for SI plant Non-coking coal for CPP Non coking coal for Coal gas plant of Rolling mill Crushed and screened fines from SI plant Limestone for SI plant Dolo char for CPP From SI plant Purchased Steel Scrap / Pig Iron for IF Ferro-alloys for IF Fuel oil for SI, IF & RM

28 Raw Materials (cont d) SLO STEELS LIMITED 4.2 QUALITY REQUIREMENTS OF MAJOR RAW MATERIALS The quality requirements of the major raw materials are discussed below Iron Ore Sized iron ore will be used for the production of sponge iron. The chemical and physical properties of the iron ore suitable for sponge iron manufacture through the rotary kiln route and the possible source of supply for the proposed plant are given below: Chemical Characteristics Iron ore should be of high grade to ensure that the sponge iron produced contains low gangue materials and is suitable for use in steel making. The iron content of the ore should preferably be around 62 to 63%. Since the gangue (silica + alumina) cannot be removed during the process of direct reduction, it should preferably be below 6%. Phosphorous (P) should preferably be lower than 0.04% and Sulfur (S) below 0.02%. In the steel making processes such as the BOF or EAF higher P and S content in sponge iron would increase the refining time during steel making and would need more flux. This will result in higher slag volumes and longer refining time which will make steelmaking uneconomical due to lower productivity and higher power and refractory consumption. In the case of use of an induction furnace for steel making no control of P or S is possible and the entire P and S will pass into the product steel thus contaminating the steel produced. Hence for steel making through the sponge iron induction furnace route, it will be necessary to use iron ore with as low a P and S content as possible. Although it is desirable to use high grade iron ore on steelmaking considerations, under Indian conditions it may be necessary to make some compromises, considering the chemical and physical characteristics of the iron ore available in the country. As such even iron ore with lower Fe content can be used in the process which will determine the percentage of metalization in the product Physical Properties The sized iron ore should possess high strength and good thermal stability during reduction. Friable ores which deteriorate during the process of reduction will result in generation of a large amount of fines Size The lump ore used for sponge iron production should be closely calibrated. The top size generally recommended lies within 25 mm to 15 mm while the bottom size is 5mm. The ideal size will be determined by the reducibility characteristics and chemical and physical properties of the ore to be used

29 Raw Materials (cont d) SLO STEELS LIMITED Possible Sources of Iron Ore The proposed SLO mini steel plant will be located in Tamilnadu. The Bellary - Hospet area. which is one of the largest iron ore deposits in the world is the nearest source of iron ore for the project. Total reserves in this region has been estimated at about 1000 million tons upto a depth of 60 m. The iron ore deposits in the area have been grouped into five main ore bodies as follows: Donimalai Ramandurg Kumaraswamy NEB range Ettinahatti Donimalai is the captive mine of M/s. National Mineral Development Corporation Ltd. (NMDC) producing iron ore with 65% Fe. The mine is fully mechanized with benificiation facilities with a processing capacity of 4.0 million tons. NMDC have also investigated the Ramandurg deposit and a portion of the Kumaraswamy deposit and have estimated proven reserves of 213 million and 180 million tons respectively. Part of these areas are proposed for leasing to the new integrated plants such as JVSL coming up in the Bellary - Hospet area. NEB range having high grade deposits constitutes the major mining activity in the region. There are a number of private mines in the range which produce high and super grade ores which are partially exported through Mineral and Metals Trading Corporation of India Ltd. Over 5 million tons of ore from this area is exported annually through Chennai port. Ore from the area is also supplied to some steel plants and sponge iron plants in the southern part of the country. SLO will have no difficulty in sourcing their iron ore needs of the proposed sponge iron plant from the Bellary - Hospet area. The deposits at Sandhur, Chitradurga and Chikkanahalli area are identified as the source of iron ore for the plant. Calibrated iron ore from the Bellary-Hospet area will be transported to the plant site in trucks. It will be screened at site before being fed to the kilns. The following is the average analysis of the iron ore available for the SLO plant from the above mines: Fe /- 2%, Si + Al - 6% -4.3-

30 Raw Materials (cont d) SLO STEELS LIMITED Coal For Sponge Iron Plant Non-coking coal will be used as reductant in the sponge iron making process. The quality requirements of the coal and the source of supply are indicated below Quality Requirements The coal to be used as reductant should possess the following properties: Reactivity Good reactivity Low ash content High ash fusion temperature Low Sulphur content Non-coking properties Reactivity influences the extent of reduction and therefore, the degree of metallisation of the sponge. In general, coals with higher reactivity permit operation of kiln at lower temperature and higher kiln throughput rates Ash content Low ash content in coal results in a smaller volume of kiln being occupied by inert materials, thus increasing the capacity and effective kiln volume Ash Fusion Temperature Coals with low ash fusion temperature result in formation of low-melting compounds, resulting in accretion and build-up inside the kiln which restricts the output. Hence it is necessary to have coal with as high ash fusion temperature as possible and should be at least 100 deg C over the normal kiln operating temperature of 1050 to 1100 deg C Sulphur Content: To limit the sulphur content in the sponge iron it will be necessary to have low sulphur content in coal as possible, preferably below 1 % Non-coking characteristics: The coal should be non-coking to avoid formation of rings which hinder the reduction process and operation of the kiln. The caking and swelling indices should be as low as possible

31 Raw Materials (cont d) SLO STEELS LIMITED Other characteristics: Besides the above major requirements, other properties will also have to be considered in choosing the reductant. The calorific value, which denotes the heat value available from the coal, should be high. A high fixed carbon content and low volatile matter are also essential as they influence the fuel consumption. The Indian Standard on Guidelines for Solid Reductant (IS 11860) has suggested the following chemical composition for non-coking coal used as reductant: Constituent % (Dry Basis) Ash, Max 24 Volatile matter Fixed Carbon By difference in Proximate analysis Sulphur, Max Possible Sources of Coal SLO will be importing the above coal from Indonesia where coal of required properties are abundantly available. The coal imported will generally have the properties as given in Para above. ROM Coal of size less than 250 mm will be received at the plant and crushed and screened to the required size in the plant Lime stone Blast Furnace grade limestone will be used as flux and for sulphur control in the kiln. The limestone should have the following approximate characteristics: CaO + MgO Minimum 45% SiO 2 + Al 2 O 3 Maximum 5 % For the SLO sponge iron plant the above quality of limestone can be sourced from the Bagalkote District of Karnataka. The mines in this region have adequate reserves and are the main source of supply of limestone to many sponge iron plants Scrap or Pig Iron Steel scrap or pig iron is used as metallic charge along with sponge iron in the induction furnaces for Steel Making. Scrap generated by cutting and cropping of billets and bar and rods will be used for this purpose and the balance requirement will be met through import and /or procurement from local sources

32 Raw Materials (cont d) Ferro-alloys SLO STEELS LIMITED Ferro-silicon and Ferro-manganese are the major ferro-alloys used in steel making. It is proposed to procure the entire requirement of ferro-alloys and other additives, like aluminium and fluorspar from indigenous sources Coal for Power Plant The power plant will be using coal to meet its fuel requirement. Coal for power plant is proposed to be imported from Indonesia. The approximate analsysis of the coal is as follows. Proximate Analysis : Volatile Matter : 31.40% Moisture : 31% Fixed Carbon : 28.50% Ash : 8.6% Sulphur : 0.50% GCV : 4500Kcal /kg Ultimate Analysis: Fuel Oil Carbon : 52.79% Hydrogen : 7% Nitrogen : 0.77% Oxygen : 19.49%. Fuel oil to IS 1593 grade LV will be used as fuel for ladle heating in the SMS, Tundish heating on the CCM and for the rolling mill billet reheating furnace. These requirements will be met by purchase from the nearest supply point of one of the leading suppliers like IOCL, BPCL or HPCL. Specification of Fuel Oil IS 1593 Flash Point Ash Content Gross Calorific value 66 C Min 0.1 % Max. By weight 11000kcal /kg (approx.) Kinematic Viscosity at 50 C 170 TO 370 cst max. Sediment by weight 0.25% max

33 Raw Materials (cont d) SLO STEELS LIMITED Total sulphur content by weight 4.5 % max. Water content by Volume 1% max Coal for Gasifier of RM Coal fines generated in the coal crushing and screening plants at SI plant and CPP will be used in the coal gasifier of the Rolling Mill

34 SLO STEELS LIMITED 5.0 PLANT PRODUCTION FACILITIES The major production facilities of the proposed mini steel plant comprising of the raw material handling system, sponge iron plant and its auxiliaries, steel melt shop, light structural mill and captive power plant are discussed in this chapter. A list of major equipment is given in Appendix RAW MATERIAL HANDLING SYSTEM DESIGN BASIS Iron ore from the mines in the Bellary Hospet area will be received at the site by road. All other raw materials including coal, limestone, scrap, ferro alloys etc. will also be transported by road to the site The design of the raw material handling system is based on the estimated quantities of annual raw materials requirements indicated in Table 4-1 of Chapter-4 and as given in Table 5-1 below. Table-5.1: Raw Materials to Be Handled Purchased Gross requirement Quantity received Tons/Yr (1) Tons/day (2) Average Tons/day (3) Peak Tons/day Sized iron ore Non-coking coal for SI plant Non coking coal for CPP Non coking coal for coal gas plant Fines from SI plant and CPP Limestone Steel scrap/pig iron Ferro alloys Fuel oil Notes 1. Based on annual operating days of 330 days for all units. 2. Based on 365 days per year for receipt of all raw materials. 3. Peak factor of 1.5 for receipt of all raw materials

35 Plant Production Facilities (cont d) SLO STEELS LIMITED From the above Table, daily average receipt of raw materials is estimated at around 1156 tons RECEIPT AND UNLOADING OF RAW MATERIALS The above table also shows that even with bunching the peak load factor of raw material receipt will be only around 1400 Tons/day which can be easily handled by road. The iron ore, coal and limestone received by dump trucks will be unloaded and stacked in their respective yard stockpiles using front-end loaders. Separate open-air storage areas have been considered for the different raw materials for maintaining necessary plant stock. The materials from yard stockpiles will be reclaimed by front-end loaders and transported to the respective consuming unit through a conveyor system. Materials such as Ferro-alloys etc. received by road will be unloaded at their respective ground stock areas in the SMS. Scrap received in trucks will be unloaded and stored in the scrap storage yard. Fuel oil received in trucks will be unloaded and stored in the storage tank provided in the fuel oil storage area RAW MATERIAL SUPPLY TO SPONGE IRON PLANT Iron Ore, Coal and limestone from the raw material storage yard will be transported by a system of conveyers to the day bins in the sponge iron plant. Necessary crushing and screening facilities for iron ore and coal will be provided. 5.2 SPONGE IRON PLANT AND AUXILIARIES The sponge iron plant will comprise of two (2) ported rotary kilns and related accessories including waste heat steam generating units. Each Kiln will have a production capacity of 35,000 Tons/year based on 310 days operation per year. The total annual production capacity of the plant will be around Tons TECHNOLOGICAL PARAMETERS OF THE SPONGE IRON KILN The major technological parameters of Sponge iron kiln are given in the following Table 5.2. Table-5.2: Major Technological Parameters - Sponge Iron Kiln Number of kiln & cooler 2 sets Diameter of kiln, m 3.0 Length of kiln, m 42 No of Supports 2 Slope, % 2.5 Kiln speed, rpm Diameter of cooler, m

36 Plant Production Facilities (cont d) SLO STEELS LIMITED Length of cooler, m 22 No of Supports 2 Slope, % 2.5 Cooler speed, rpm Production, t/d/kiln (Av.) 100 Generation of DRI fines(-3mm),% 30 Minimum Working days per year, no. 300 Shifts per day, no QUALITY OF SPONGE IRON PRODUCED The approximate composition of sponge iron produced in the plant will be as given in the following Table 5.3; Table-5.3: Approximate Composition of Sponge Iron Degree of metallisation, % 90 2 FeO, % 10 SiO2 + Al2O3, % 6.0 S, % 0.02 P, % 0.04 C, % 0.20 (max.) CaO, % MgO, % Trace Trace Facilities in Sponge Iron Plant The major facilities in the sponge iron plant will include the following: Day Bins Rotary kiln and cooler Off gas system including waste heat steam generation Product processing facilities and product storage bins. A typical sponge iron plant layout is show in drawing no.hiq-slo r Day Bins The day bin building for the DR kiln will have separate bins for storage of about one day's requirement of screened iron ore (5-20mm), coal (6-25mm), injection coal (3-25mm) and limestone (2-4mm). Weigh feeders will be provided to draw various materials

37 Plant Production Facilities (cont d) SLO STEELS LIMITED in the required proportion from the bins and deliver to the conveyers for feeding into the kiln Rotary Kiln and Cooler Two (2) ported rotary kilns each of 3.0 m dia (ID) and 42 m length will be provided for reduction of iron ore into sponge iron using non-coking coal as reductant. One kiln with the day bins and raw material preparation system is already installed and the second kiln will be installed as part of this programme of expansion of the mini steel plant. The kiln will have a slope of about 2.5%. The main drives will be by AC motors with thyristor speed control and an auxiliary drive shall be provided for slow speed rotation during emergencies. The speed of the kilns will be in the Rotary Kiln range rpm. The kiln will have 1 plain riding ring and one thrust riding ring and will be provided with 2 sets of support rollers at the 2 piers and one set of thrust rollers with bush bearings at thrust riding ring pier. A start up burner using fuel oil will also be provided for initial heating and start up. The other main components of the kiln will include: Feed end and discharge end housing of welded steel construction with refractory lining including feed chute. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end. On board equipment like fans, manifolds, valves, piping, actuators, air inlet ports, slip ring housing, etc. Cooling fans at feed end and discharge end. Start up fuel-on-system Feed end double flap valves and dust valves. The kiln will be lined with alumina castable refractories throughout its length with dams at feed end and discharge end. The kiln feed from the charging end will consist of screened iron ore, coal and limestone. Air will be supplied to the kiln through ports provided on kiln periphery over almost ⅔rd length of the kiln. This ensures a controlled combustion resulting in a very even temperature profile. A part of required coal shall be thrown from kiln discharge end. The slinger coal will be discharged from the bins and pneumatically injected into the kiln. Necessary rotary feeder, compressor, piping and valves will be provided for the slinging system

38 Plant Production Facilities (cont d) SLO STEELS LIMITED In the kiln, the iron ore will be dried and heated to the reduction temperature of about 1000 deg. C. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide generated in the kiln from coal. The heat required for the reduction process will also be supplied by the combustion of coal. Thermocouples will be installed along the length of the kiln shell for determination of thermal profile of the kiln. The temperature will be controlled by regulating the amount of combustion air admitted into the kiln through ports with the help of fans mounted on the kiln shell and by controlled coal slinging. The reduced material from the kiln will be cooled indirectly in a rotary cooler by water spray. The rotary cooler will be of 2.3 m dia (ID) and 22m length and will be supported on two piers with a slope of about 2.5%. The cooler will have a main drive and an auxiliary drive with AC motors. The speed range of the main drive will be from rpm. The cooler will be provided with one plain riding ring and one thrust riding ring along with two sets of supporting rollers with bush bearings at two piers. About 0.5m length at the discharge end of the cooler will act as a screening section which separates all the accretions larger than 50mm from the reduced material. These lumps will be discharged separately via lump gate. Rest of the material will be discharged on to a conveyor via a double flap valve. The other main components of the cooler will be the following : Feed end housing (part of reactor to cooler transition) of welded steel construction with refractory lining. Cooler discharge end housing of welded steel construction. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end. Feed end cooling fan. The cooler will be lined with castable refractories for about 4m length from the feed end. Bypass arrangement will be provided at the discharge end of the cooler for emergency discharge of materials. The cooled product will be conveyed to the product processing building by a system of belt conveyors. The cooling water will be collected in the trough below the cooler and sent to the cooling tower for cooling. The cooled water will be re-circulated. The rotating parts of the kiln and cooler will be sealed suitably against the stationary parts at the connecting points to avoid leakage of dust laden gases Off-Gas System Hot waste gases leave the rotary kiln at about 900 deg. C through reactor feed end housing cum dust settling chamber and come to the after burning chamber (ABC) where combustibles are burnt completely by supplying excess air. The off gas leaving ABC at about 950 C is led to a Waste Heat Recovery Boiler (WHRB) to generate steam from waste heat. The gas will then be cleaned in the

39 Plant Production Facilities (cont d) SLO STEELS LIMITED Electrostatic Precipitator (ESP) before being released to atmosphere through ID fan and stack Product Processing Facilities and Product Storage Bins The product from the cooler discharge contains sponge iron, chars and spent limestone/dolomite. The product from the cooler can either be stored in a surge bin or sent to the product processing building. Provision shall be kept to by-pass the surge bin and stockpile the product on ground. Product from surge-bin can be withdrawn through vibrating feeder and fed to the Product Processing Building. In the Product Processing Building, the product will first be screened in a double deck screen having 3 mm and 20mm screens. The screened product, i.e. +3mm to +20mm and - 3mm fraction shall be subjected to magnetic separation. The magnetic fraction of 3 to 20mm will be stored in separate product storage bins. Char generated in the plant shall be stored separately for use as fuel in the power plant. 5.3 STEEL MAKING FACILITIES The induction furnace continuous casting route is proposed to be adopted for the plant Production Programme The production programme of steel melt shop is given in the following Table 5.4 Table-5.4-Production Programme of Steel Melt Shop No. of operating days/ year 330 Production - Liquid steel, Tons/ year - Continuous cast billets, Tons/ year Steel grades produced Mild steel Steel Making Equipment The steel making equipment include two (2) Induction Furnaces each having a power rating of 9000 KW to meet the annual requirement of liquid steel. To match the production from furnaces a single 3-strand continuous billet-casting machine has been considered. The availability of the plant has been considered as 330 days per year. The plant will operate for 7 days a week on 3-shifts/day. The technological parameters of induction furnaces are given in Table 5.5. Table-5.5: Parameters of Medium Frequency Induction Furnace Sl. No Parameter Unit Value/Feature 1 Liquid steel production T/yr

40 Plant Production Facilities (cont d) SLO STEELS LIMITED Sl. No Parameter Unit Value/Feature Average T/Day No. of furnaces No. 2 ( 2 crucibles each) 3 Type of furnace - A.C, medium frequency, coreless, twin shell each with common power pack per furnace 4 Nominal transformer rating per furnace KW Average heat weight T 25 6 Average heat time, approx. Min. 120 to Heats/day/furnace(Max) Heats/day/furnace(Normal) No. No Charge mix, approx. 8 - DRI % 29 - Scrap % 71 9 Steel grades - Mild Steel Process Description Scrap will be charged into the crucibles for generating the hot heel for DRI charging. Pig iron also will be used for maintaining proper operating conditions. Once the molten bath has been formed and the minimum temperature of the bath has been achieved, sponge iron will be charged in small batches and the slag formed will be removed periodically. After the completion of charging of sponge iron a sample will be drawn to determine the composition of the bath. After achieving the desired melt analysis, the temperature will be raised to the tapping temperature taking into account additions of predetermined amount of Ferro alloys to achieve the required tapping composition of the melt. Plant return scrap from various generating points and purchased scrap will be transported to the scrap bay of steel melting shop. EOT cranes with magnets will be provided in the scrap bay for unloading and loading of scrap in scrap buckets. The scrap buckets will be weighed in the scrap bay. Scrap will be stored on furnace working platform near the furnace for charging

41 Plant Production Facilities (cont d) SLO STEELS LIMITED Sponge iron from the sponge iron plant will be transferred by suitable means to the steel melt shop and charged into the furnace Auxiliary Facilities The following major auxiliary facilities will also be provided in the steel melt shop: EOT cranes for Ladle Handling, EOT cranes for handling scrap, additives, refractories etc. Ferro-alloys and additives storage, handling and supply system Steel ladles and steel ladle preparation facilities Temperature measurement and sampling facilities Refractory storage systems, crucible, ladle and tundish relining system Make up and closed circuit water supply, cleaning and storage system Services facilities, such as, compressed air, fuel, gases, etc. Electrics, instrumentation, etc. Pollution control equipment and waste disposal facility Raw Materials and Consumables The annual requirement of major raw materials and consumables for steel making are indicated in Table 5.6 Table-5.6: Requirements of Major Raw Materials and Consumables for Steel Making Sl. No. Item Annual Requirement, Tons 1 Direct Reduced Iron Return Scrap Purchased Scrap Total scrap Ferro-alloys CONTINUOUS CASTING The continuous casting technology has gained worldwide acceptance mainly because of higher yield, economics of operation and better product quality. Hence it has been chosen for the proposed mini steel plant for casting the liquid steel into billets Technological Features A 6/11 m radius, 3-strand, curved mould; radial type design billet caster is proposed. Two self propelled tundish transfer cars will be provided for transferring the tundish from reserve position to the casting position

42 Plant Production Facilities (cont d) SLO STEELS LIMITED The continuous casting machine will be equipped with moulds, mould oscillating mechanism, secondary cooling segments, withdrawal and straightening unit, gas cutting unit, dummy bar insertion system, run-out roller tables, cross transfer mechanism and cooling bed. The billets will be marked with the help of the marking unit. The caster will be controlled from the pendant control panels, and also from main control room located on the casting platform and the auxiliary control room near the gas-cutting unit. A control post will also be provided at the end of the run-out roller tables of the continuous casting machine Continuous Casting for transfer of billets from the run-out roller tables on to the cooling bed and discharge grid. Other facilities such as tundish preparation repair and assembly of moulds and secondary cooling segments, mould testing etc. will also be provided. The continuous casting machine will work on three shifts basis for 330 operating days in a year. The basic technological parameters of continuous billet caster are given in the Table 5.7. Table-5.7: Technological Parameters of Billet Caster Sl. No. Item Parameters 1 Type of machine Curved mould bow type 2 Number of machines 1 3 Number of strands 3 4 Machine equipped to cast 100 to 150 mm.sq billets. 5 Casting Radius 6/11 6 Billet length 6 m 7 Type of ladle Bottom pouring with slide gate system 8 Ladle support Ladle stand 9 Heat size 25 t average 10 Type of cutting device Manual, torch cutting 11 Method of discharge On horizontal discharge roller table to

43 Plant Production Facilities (cont d) Sl. No. SLO STEELS LIMITED Item cooling beds Parameters 12 Steel quality Commercial grades 13 Dummy bar Link type 14 Casting practice Open casting 15 Tundish practice Cold 16 Casting speed Variable 17 Mould Support Short Lever arm oscillation. 18 Withdrawal speed 0 6 m/min The casting cycle time and the basis of selecting the number of strands for the caster are indicated in the following Table 5.8: Table-5.8: Casting Cycle Time of Billet Caster Heat size, Tons Size of cast billet, mm x mm 130 x x x 150 Casting speed, m/ min Weight of cast billet, Kg/ m Throughput in 3 strands, Kg /min Sequence casts Total metal cast in sequence, tons Casting time, min Machine Preparation Time, min Total Cycle time, min Daily Production, Tons The tap-to-tap time of the induction furnaces will be matched with the casting cycle time so as to have maximum number of sequential casts Concast Process Description The ladle will be picked up by ladle handling crane and placed on the ladle stand. A refractory lined tundish, fully dried and fitted with preheated nozzles mounted on tundish car will be moved from the reserve position to the casting position

44 Plant Production Facilities (cont d) SLO STEELS LIMITED Prior to the start of the casting operation, the dummy bars will be introduced into the mould. The gap between the dummy bar head and mould walls will be sealed with asbestos chords and small pieces of steel scraps will be placed over the dummy bar head for chilling of initial metal. Water supply to mould, secondary cooling zone and machine cooling will be switched on at this stage. When the liquid steel level in the tundish reaches a predetermined Steel Melt level, the tundish nozzles will be opened. When the metal level in the mould reaches about mm from its top the drive of the mould oscillating mechanism as well as withdrawal and straightening unit will be switched on. The withdrawal of dummy bar begins at the minimum speed and gradually increased to normal casting speed within few minutes. The mould will be lubricated with liquid lubricant. During casting operation, the metal level in the mould will be maintained within predetermined limits by adjusting flow of metal into the mould or by adjusting the withdrawal speed. The liquid metal level in the tundish will also be kept within permissible range by adjusting the opening of ladle slide gate. The partially solidified billets after leaving the mould will pass through strand guide roller segment where intensive but water spray nozzles will effect controlled cooling of billets. The solidified billets will be guided through withdrawal and straightening unit before entering the gas cutting zone. The dummy bar will be separated from the billet after the gascutting unit and will be stored till its introduction is required for start of the next heat. The cast billet will be cut to the predetermined length by oxy-acetylene gas cutting torches. The sized billets will be delivered to the cooling bed through run out roller table and cross transfer mechanism. The billets will be marked on cooling bed by the marking unit for identification/tracking. The cast billets will be stored in the billet bay. Conditioning facilities have also been envisaged in this bay. During an emergency, the casting operation can continue and the overflow of metal from the tundish will be received into a slag box through the tundish spout and the overflow launder. In case the casting operation has to be stopped, the ladle shall be lifted from the ladle stand and the liquid metal inside shall be poured back into the induction furnace. For chemical analysis of liquid steel, the samples will be taken from the ladle and sent to the laboratory. The samples will also be cut from cast billets and sent to the laboratory for macro etching, sulphur prints and for determining other quality parameters. After the liquid steel in the ladle is emptied, the ladle-handling crane will remove it. The slag from the ladle will be poured into a slag pot kept at the ground