PRE FEASIBILITY REPORT

Transcription

1 PRE FEASIBILITY REPORT FOR PROPOSED INSTALLATION OF SPONGE IRON PLANT (2X100 TPD), WHRB (2x10 TPH), INDUCTION FURNACE (1X7 T), HOT ROLLING MILL (1,00,000 TPA), SINTER PLANT (35 TPD), SUBMERGED ARC FURNACE (45 MVA) AND TG SET (1X4 MW) UNDER FORWARD INTEGRATION, EXPANSION AND PRODUCT DIVERSIFICATION PROGRAMME OF EXISTING MINI STEEL PLANT AT Palitpur Road, Village & PO Mirzapur, PS + District: Bardhaman, PIN , West Bengal PROJECT PROPONENT: SALAGRAM POWER AND STEEL PVT LTD 29 Ganesh Chandra Avenue, 1 st Floor Kolkata NOVEMBER, 2017

2 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO CONTENTS 10 INTRODUCTION 20 THE PROJECT 30 INDUSTRY SCENARIO 40 LAND AND SITE LOCATION 50 MAJOR PLANT UNITS AND AUXILIARY UNITS 51 Sponge Iron Plant 52 Induction Furnace 53 Continuous Casting Plant 54 Rolling Mill 55 Sinter Plant 56 Submerged Arc Furnace 57 Power Plant 60 RAW MATERIALS, CHEMICALS & UTILITIES 61 Raw Materials 62 Fuel 63 Water 64 Other Utilities 65 Power Pre-feasibility Report 1

3 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 70 ENVIRONMENTAL ASPECTS 71 Air Pollution Control 72 Water Pollution Control 73 Solid Waste Management 74 Noise Pollution Control 80 FIRE PROTECTION SYSTEM 90 GREEN BELT DEVELOPMENT OBJECTIVE 100 RAIN WATER HARVESTING 110 MANPOWER REQUIREMENT 120 PROJECT SCHEDULE 130 FINANCIAL DETAILS 140 CONCLUSION Pre-feasibility Report 2

4 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 10 INTRODUCTION M/s Salagram Power and (SPSL), a Private Limited Company, was incorporated on September 29, 2011, having its registered office at 29, Ganesh Chandra Avenue, First Floor, Kolkata The Company was previously known as M/s Shyam Sel & Power Limited under Shyam Group of Industries Shyam Group was subsequently demerged Vide Memo No /WPBD-Cont(752)/99 (Pt-II) dated , West Bengal Pollution Control Board has recorded change of Name of the Company as M/S SALAGRAM POWER AND STEEL PRIVATE LIMITED (SPSL) for the existing Mini Steel Plant at Dewandighi, Bardhaman The Mini Steel Plant is located at Mirzapur Village, about 5 Km away from Burdwan Town Vide Consent Letter Number CO , Memo Number /WPBD-Cont(752)/99 dated (and also Memo on Renewal of Consent to Operate dated and Memo on Change of name and correction of capacity dated ), WBPCB has granted the Company (SPSL) Consent to Operate for 3 years (from till ) this Existing Mini Steel Plant having DRI Kilns (3 x 50 TPD producing 45,000 TPA Sponge Iron), Induction Furnaces (1x4 T, 2x35T and 1x6 T producing TPA liquid steel), one Twin Strand Billet Caster (54,000 TPA MS Billets), WHR Boilers (3x45 TPH), one AFBC Boiler (1X24 TPH) and Power Plant (1x8 MW TG Set) Salagram Power and is promoted by Mr Pawan Kumar Agarwal, Mrs Santosh Devi Agarwal and Mr Suyash Agarwal Pre-feasibility Report 3

5 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 20 THE PROJECT To take full advantage of improved market scenario in near future as projected by the Industry, SPSL intends to undertake forward integration, expansion and also product diversification of the Mini Steel Plant Existing Process Route of DR-IF-CC (Direct Reduction Induction Furnace Continuous Casting) will be adopted for rationalization and ease of operation by existing manpower, which has already gained adequate skill and experience to operate these units Additional manpower of required skill will be employed for operation and maintenance of new units under expansion The Company is contemplating forward integration to produce TMT Bars and Rods, Flats and Structurals It is proposed to install a Hot Rolling Mill of 1,00,000 TPA capacity About 1,05,000 TPA of MS Billets will be required for production of above quantity of 1,00,000 TPA TMT bars and rods Existing Twin Strand Billet Caster is having in-built capacity to produce 1,05,000 TPA MS Billets No additional Billet Caster is therefore envisaged under expansion About 1,10,000 TPA liquid steel (which is double of existing capacity) will be required for production of 1,05,000 TPA MS Billets To meet above liquid steel demand, it is proposed to expand Steel Making Capacity by installing one No 7 T Induction Furnace in addition to modernization / up gradation of existing 4 Induction Furnaces to higher capacity (3x 7 T + 1x6T) as indicated by Equipment Suppliers Sponge iron is a major feed material for Induction Furnace Steel Making and constitutes about 80% of Charge Mix Sponge Iron requirement will be about 98,000 TPA for production of 1,10,000 TPA liquid steel The Company presently operates 3 Nos 50 TPD DRI kilns to produce 45,000 TPA Sponge Iron To meet additional requirement of Sponge Iron 2 Nos of standard sized 100 TPD DRI Kilns will be installed This will ensure continuous availability of sponge iron for steel making even if one of the kilns is under shut down for maintenance Total Capacity of Sponge Iron after expansion will be 1,05,000 TPA After meeting the requirement of 98,000 TPA Sponge Iron for steel making, about 7,000 TPA Sponge Iron will be available for Sale in Domestic Market Existing 8 MW TG Set of Power Plant is designed based on steam generated in 3 Waste Heat Recovery (WHR) Boilers utilizing waste hot flue gases of DRI Kilns and AFBC Boiler burning Char / Coal / Husk Char generation in existing DRI Kilns being insufficient to meet steam balance, the Company has to purchase costly fuel (Coal / Husk) for existing AFBC Boiler Pre-feasibility Report 4

6 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Proposed 2x100 TPD DRI Kilns will have WHR Boilers (2x10 TPH) All Char generated in 5 DRI Kilns (existing and proposed) will be utilized in the existing AFBC Boiler Total Steam generation from existing and proposed WHR Boilers and existing AFBC Boiler will be about 575 TPH Above steam will be sufficient to generate about 12 MW of Power It is therefore proposed to install 1x4 MW TG set in the expansion stage increasing Power Plant Capacity to 12 MW It is further proposed to diversify into production of Silico Manganese (Si Mn) by installing a 45 MVA Submerged Arc Furnace (SAF) To utilise fines generated during handling of coal and iron ore lumps / iron ore pellets (raw material feed to DRI Kilns), a 35 TPD Sinter Plant will be installed Dust recovered from Bag Filters & ESP of DRI Plant and scales from CCP & Rolling Mill will also be utilised in Sinter Plant Sinter produced will be utilised in Charge Mix to SAF SPSL has rightly decided to expand the capacity of the Plant by installing additional Sponge Iron Kilns (2x100 TPD), WHR Boilers (2x10 TPH Steam), modernization / up gradation of existing Induction Furnaces, one additional Induction Furnace (1x7 T), one Rolling Mill (1,00,000 TPA) for forward integration, one Sinter Plant (35 TPD), one Submerged Arc Furnace (45 MVA) for product diversification and a TG Set (4 MW) Existing CCM is having adequate in-built Capacity All existing Service Facilities will be suitably augmented as well as additional Service Facilities are proposed to be installed to meet the requirement of the Mini Steel Plant after Expansion Configuration of Major Units of Existing Plant and Plant after Expansion is indicated in Table 21 Pre-feasibility Report 5

7 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO CONFIGURATION OF MAJOR UNITS OF THE PLANT: TABLE 21 Sl No Existing Units 3x50 TPD Sponge Iron Kilns 1x4 T, 2x35 T7 T and 1X6 T Induction Furnaces 6/11 m, 2 Strand Continuous Casting Machine Present Production Capacity * 48,000 TPA Sponge Iron 56,000 TPA Liquid Steel 54,000 TPA MS Billets for sale -100x100 mm, 125x125 mm & 160x160 mm 4 Nil Nil 5 Nil Nil 6 Nil Nil 7 3XWHR Boilers 3x45 TPH Proposed Units under Expansion 2x100 TPD Sponge Iron Kilns 1x7 T Induction Furnace and modernization / up gradation of existing Induction Furnaces to augment capacity (to 3x7 T + 1x6 T) Nil 1 No Hot Rolling Mill 1x35 TPD Sinter Plant 1x45 MVA Submerged Arc Furnace (SAF) 2XWHR Boilers (2x10 TPH) Total Production Capacity after Expansion 350 TPD or 1,05,000 TPA 1,10,000 TPA 1,05,000 TPA (In-built Capacity) 1,00,000 TPA 10,500 TPA 6,480 TPA 335 TPH 8 1x AFBC Boiler 1x24 TPH Nil 24 TPH 9 1x 8 MW TG Set for Captive Power Plant 8 MW 1x4 MW TG Set 12 MW Product (For Sale) Sponge Iron (7,000 TPA) Liquid Steel (Nil) MS Billets (Nil) TMT Bars, Rods, Flats and Structurals (1,00,000 TPA) Sinter (Nil) Silico - Manganese (6,480 TPA) Steam (Nil) Steam (Nil) Power (Nil) *Present Production Capacity is as per WBPCB s Memos Adequate Pollution Control Facilities will be installed to conform to Pollution Norms Pre-feasibility Report 6

8 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO SPSL is having 258 Acres of land in their Possession The proposed expansion will be accommodated within the existing Plant Boundary and also some adjoining land (approximately 20 Acres) which will be acquired The land is generally flat and does not come under flood zone There is no human settlement in the project site Adjoining land (to be acquired) will be reformed / developed from its existing land use Pre-feasibility Report 7

9 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 30 INDUSTRY SCENARIO Indian steel industry is the major backbone in the country s economic growth According to Joint Plant Committee (JPC), Ministry of Steel, Govt of India, India produced about 956 Million Tonne of Crude Steel in 2016 and remained, for two consecutive years, Third Largest Crude Steel Producer in the World after China (8084 MT) and Japan (1048 MT) In 2016, the world crude steel production reached 1628 million tonnes and showed a growth of 08% over 2015 Demand-Supply Gap On a conservative estimate, the steel demand in India is expected to touch around 150 MTPA by 2020 Steel supply is, however, expected to reach only around 145 MTPA by same time World Steel Association has projected Indian steel demand to grow by 57% in 2017 while globally steel demand has been projected to grow by 05% in 2017 The National Steel Policy 2017 has been formulated keeping in mind the rapid developments in the domestic steel industry (both on the supply and demand sides) as well as the stable growth of the Indian economy The National Steel Policy 2017 aims to achieve 300 million tonne of steel-making capacity which will require an additional investment of Rs 10 lakh crore by setting a target of 160 kilograms per capita steel consumption by 2030 In comparison, per capita finished steel consumption in 2015 is placed at 208 kg for world, 489 kg for China and only 61 kg for India As a facilitator, the Government monitors the steel market conditions and adopts fiscal and other policy measures based on its assessment In view of rising imports, the Government had earlier raised import duty on most steel items twice, each time by 25% and imposed a gamut of measures including anti-dumping and safeguard duties on a host of applicable iron and steel items The liberalization of industrial policy and other initiatives taken by the Government have given a definite impetus for entry, participation and growth of the private sector in the steel industry This had led to expansion, forward integration, diversification and modernization of existing units The Cabinet also cleared another policy which will mandate giving preference to iron and steel products that are manufactured in India for all government tenders At least 15 percent value has to be added to the notified steel product in India to qualify as domestic steel Pre-feasibility Report 8

10 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO There is a distinct relation between steel consumption and the GDP growth rate world over In India, GDP is expected to remain a figure of above 7% in Current and Next Financial Years while it is expected to touch thereafter Double Digit Figures of 11-12% This will be possible with National Focus on Large Infrastructure Development with huge Investment and India is bound to witness sustained growth in the steel requirement in the years to come India will emerge as the Second Largest Producer of Crude Steel in near future It is foreseen that there will be sufficient demand in local/indian Market of Sponge Iron for Steel Making, TMT Bars and Rods for constructional needs and Silico Manganese for Steel Making M/s SPSL has drawn up a growth plan with the objective of increasing its market share in Indian steel industry Keeping all these in mind, the Company has planned expansion, forward integration and diversification of the existing Mini Steel Plant in a effective environment friendly way Pre-feasibility Report 9

11 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 40 LAND AND SITE LOCATION The Plant is located at Palitpur Road in Village & PO Mirzapur, Saraitikar Gram Panchayat, PS & Dist Burdhaman, West Bengal, Pin Its graphical coordinates are Latitude 23 17'0925" N and Longitude 87 52'0976" E with mean sea level as 107 ft The Plant is located adjacent to and at the west side of M/s Shyam Ferro Alloys on Palitpur Road Plant location is indicated in subsequent Maps and satellite Pictures Pic 1 - Burdwan District Map Pic2 Satellite Picture showing Burdwan Railway Station and Palitpur Pre-feasibility Report 10

12 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Pic 3 Satellite picture showing Dewandighi and Palitpur Road Pic 4 Satellite Picture showing Dewandighi, Palitpur Road and Shyam Ferro Alloys Bardhaman Town (District HQ) is about 45 km from project site Burdwan Railway Station is about 40 km from the Plant Site National Highway-2 (NH-2) is passing through the south direction, at a distance of around 40 km away River Damodar is passing approx 81 km distance in south direction There is no National Park & Reserve Forest within 10 km radius of the project site Pre-feasibility Report 11

13 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO The Plant Site Area is well developed and has all necessary infrastructure facilities such as motorable road up to the plant site, nearness to rail head, Power lines and Sub Stations, telephone facilities etc The nearest industrially developed town Durgapur is situated at around 60 km away in the north-west direction Kolkata city is located at a distance of about 95 km from the Plant Distance from Howrah Railway station to the plant site is about 92 km The nearest airport is Kolkata which is about 93 km from the plant site Kolkata Port is around 95 km away and Haldia Port is 135 km away from the plant site Pre-feasibility Report 12

14 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 50 MAJOR PLANT UNITS AND AUXILIARY UNITS 51 SPONGE IRON PLANT As already indicated earlier, two (2) Sponge Iron Rotary Kilns, having a capacity of 100 TPD each, will be installed for production of 60,000 TPA sponge iron With this expansion measures, Production Capacity of Sponge Iron will be increased to 1,05,000 TPA The Charge Mix of Induction Furnace for steel making consists of Sponge Iron (80%) and Scrap / Pig Iron (20%) After meeting internal demand for steel making, about 7,000 TPA of Sponge Iron will be available for Sale Manufacturing Process In the Existing Plant, Sponge Iron is produced through well-established Non Coking Coal based Technology in Rotary Kilns Same Technology will be adopted for Expansion Iron ore lump/ pellet will be reduced with non-coking coal in rotary kilns to produce sponge iron The rotary kiln used in Sponge Iron Making Process functions as: a conveyor of solids a vessel for carrying out complex chemical reactions a heat exchanger From Day Bins, metered quantity of Iron Ore lumps ( 5-18mm) and Iron Ore Pellets (12 mm MPS) along with Coal (3-20 mm) and Dolomite (- 6 mm) are conveyed at the feed end of the Rotary Kiln and fed into the preheated kiln through a feed pipe mounted through the feed end housing Because the rotary kiln is inclined from the feed end to the discharge end, its rotation causes the feed material mix to traverse downward towards the exit The rotational speed of the rotary kiln can be adjusted to maintain the desired loading of the kiln and ensuring the required time to complete the reduction of the iron ore Inside the bed of Charge Mix in rotary kiln, CO gas is generated from coal at around 950 C The CO reacts with Fe2O3 in iron ore lump / pellet and reduces it to metallic Fe Shell air fans are mounted on the kiln Shell, which inject air in controlled manner into the kiln for creating reducing atmosphere and also to generate heat The kiln is lined with refractory for sustaining high temperature at desired level (up to 1050 C) in different points of preheating and reducing zones of the rotary kiln Coal fines are pneumatically injected into the kiln from discharge end to keep desired temperature profile and carbon balance at different zones Pre-feasibility Report 13

15 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Main reduction reactions in Rotary Kiln are: Fe2O3+CO=FeO+CO2 FeO+CO=Fe+CO2 C+CO2=2CO 2CO+O2=2CO2 C+O2=CO2 Iron Ore reducing reactions are endothermic in nature This heat requirement is met by combustion of over bed gas which heats up the refractory lining as well as the bed surface Tumbling of material transfers the heat from the surface particles to the bed The hot kiln wall which enters the bed also releases its heat to the bed By the end of its travel through the Rotary Kiln (about 8 hours), iron ore is metalized to about 90% and falls through a transition chute into the Rotary Drum Cooler at about 1000 C The Cooler is an inclined steel cylinder The cooler shell is sprayed with water The water serves as the indirect coolant of the sponge iron Heat from the product is conducted through the cooler shell to water The water is collected in a trough beneath the cooler and is re circulated through cooling tower and pump house The product gets cooled to 150 C at the outlet of cooler The cooled product will be conveyed to the product processing building by a system of belt conveyors Product Separation The sponge iron along with unburnt coal in the form of Dolo Char comes out of the cooler The cooled product is subjected to screening and magnetic separation to separate magnetic product and non-magnetic Dolo Char Sponge Iron Lumps and fines are stored in their designated product bins Bypass arrangement will be provided at discharge end of the cooler for emergency discharge of materials The gases generated in the rotary kiln flow counter current to the flow of solids and exit the reactor at the feed end The gases leave the reactor at about o C through reactor feed end housing The flue gas that contains coal volatile matter, fine carbon particles, iron ore fines and sponge iron dust is treated separately in the waste gas handling system before releasing through the Chimney to the atmosphere ensuring environmental norms In-plant de-dusting system Reverse air jet bag filters shall be installed for catching the dust from various conveyors, material handling equipment and-product handling equipment Pre-feasibility Report 14

16 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Raw Materials The main raw materials for sponge iron production are iron ore lump / pellet, non-coking coal, and dolomite The specific consumption and annual requirement of these raw materials for 1,05,000 TPA Sponge Iron from existing 3x50 TPD Kilns and proposed 2x100 TPD Kilns are shown in Table 51 ANNUAL REQUIREMENT OF RAW MATERIAL FOR SPONGE IRON PLANT: TABLE 51 Sl No Raw material Specific Consumption Quantity in TPA T/T 1 Iron Ore Lump/Pellet 15 1,57,500 2 Coal 10 1,05,000 3 Dolomite 003 3,150 The iron ore lump/pellet should have Fe - 65%, SiO2+Al2O3-5%, Sulphur 001%, Phosphorus -005%; Tumbler Index of Iron Ore 90% Non Coking Coal should have high reactivity, FC 45%, low ash content (20% max), medium volatile matter (25-30%), high ash fusion temperature (1400 C), low Sulphur (less than 1%) and low caking index (3% max) Dolomite is used as desulphuriser to fix Sulphur present in coal and should have MgO 22% minimum and CaO 28% maximum Product characteristics of coal based Sponge Iron is as follows: Item Value Fe (total) 92% min Fe (met) 83 % max Metallization 90 % Carbon 025 % max S 0025% max P 005% max Pre-feasibility Report 15

17 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Major plant facilities The major plant facilities for the sponge iron plant envisaged are as follows: Day bins 1 Day Bins 2 Rotary Kiln and Cooler 3 Off-gas System including WHRB 4 The Water Circuit 5 Product Processing and Storage There shall be a day bin building to cater to raw material requirement of the kiln These bins will generally have storage of about one day s requirement of iron ore lump/pellet, feed coal and injection coal & dolomite Weigh feeders will be provided to draw the required quantity of various materials in proportion from the bins and the same will be conveyed to the kiln feed and discharge end Buildings Rotary kiln and cooler The 100 TPD Rotary Kilns with 32 m diameter and 40 m long will be installed The kiln will be lined with abrasion resistant refractory castables throughout its length with dams at feed end and discharge end The rotary kiln will be supported on 3 piers A slope of about 25% shall be maintained The main drive of the kiln will be by AC motors with VVVF drive control The speed of the kiln will be in the range of & rpm The auxiliary drive of the kiln will be by AC motors Rotary Kiln is mounted on tyres and supported by support rollers The transverse motion of the Kiln is controlled with the help of hydro thruster and thrust rollers The kiln is rotated with the help of a girth gear mounted on the kiln and connected with pinion drives, which in turn are coupled with gear boxes and motors The other main components of the kiln will be as given below: a Feed end and discharge end transition housing of welded steel construction with refractory lining including feed chute b Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating at feed end and discharge end c On board equipment like fans, slip ring, instrumentation etc d Cooling fans at feed end and discharge end Pre-feasibility Report 16

18 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO e Feed end double pendulum valve & dust valves Rotary Drum Cooler of 24 m diameter and 22 m long will be installed Cooleris having a slope of 25% and is rotated at variable speed of rpm with the help of a girth gear mounted on the cooler and connected with single pinion drive, which is coupled with a gearbox and motor To facilitate conduction of heat from hot product through Cooler to Cooling Water (sprayed on to Cooler Shell), lifters are provided inside the cooler The cooler shell is perforated up to a certain distance from the discharge end to form a trommel inside the discharge end housing The trommel serves to screen the normally sized product from over-sized lumps or fused materials which may have been formed in the rotary kiln during processing Some quantity of accretion material/aggregate comes out of the Kiln into the Cooler These are separated from the product at the trommel and stored at the lump gate This lump gate is opened time to time for discharging Off-gas System The Off-gas System consists of: (a) Feed End Housing and Dust Settling Chamber (DSC) Coarse dust particles from waste flue gases, coming out of the Rotary Kiln, is settled in DSC (b) After Burning chamber (ABC) - Air is blown by Fans into the ABC for converting any un-burnt CO (in waste flue gases) to CO2 Water is injected in ABC to control temperature rise (c) Auxiliary Stack and Stack Cap These are provided in the off gas circuit to evacuate the Kiln off gases in case of any failure of equipment in the downstream side after ABC Normally the cap will remain closed The stack cap is opened through a hydraulic power pack either from operator s desk in control room or from local control panel as per requirement (d) Waste heat recovery boiler (WHRB) Latent heat of waste flue gases is utilized to produce steam for power generation Gases are then passes to ESP at 200 C (e) Electrostatic precipitator (ESP) Fine dust particles gets electrically charged and is deposited in electrodes Clean waste gases are then let out to the atmosphere at around 80 C (f) ID fan Creates required draft in the Kiln and forcing clean waste gases to atmosphere through a chimney The motor of ID Fan is provided with necessary control system to vary the Draft as required (g) Chimney The height of Chimney will conform to Environmental Norms Pre-feasibility Report 17

19 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO The Water Circuit Make up water will be available at the battery limit of the plant to provide water for the following circuits : a) Rotary cooler water circuit b) Kiln bearing cooling water circuit c) Dust Handling System d) Off Gas Circuit e) Misc Equipment like compressor, DG etc Product Processing and Storage There shall be one product processing unit for handling the cooler discharge The product containing sponge iron and dolo-char from the cooler discharge will be conveyed to the product processing building The product will first be screened in a double deck screen having 3 mm and 10 mm screens +10 mm materials shall be passed through magnetic Drive Pulley of the Belt conveyor to separate non-magnetic particles The screened product ie mm and -3 mm fraction shall be separately subjected to magnetic separation for removal of dolo char Magnetic Product will be sent to the product storage bins and fines bunker The sponge iron lump and fines will be further conveyed from the respective bunkers by truck to the steel making unit as per the requirement The dolo char shall be stored in separate bins from where it will be sent to the existing AFBC Boiler for generation of steam for Power Plant Typical Process Flow Diagram of Sponge Iron Plant is presented below Pre-feasibility Report 18

20 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Coal Injection Coal DSC Dust Settling Chamber; ABC After Burning Chamber; WHRB Waste Heat Recovery Boiler; ESP Electro Static Precipitator; ID Fan Induced Draft Fan; TG Set Turbo Generator Set; MS -Magnetic Separator; PB 1 Product Bunker for Sponge Iron Lumps; PB 2 Product Bunker for Sponge Iron Fines; PB 3 & PB 4 Bunkers for Dolo Char Pre-feasibility Report 19

21 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 52 INDUCTION FURNACE In addition to the existing Induction Furnaces, it is proposed to install one (1) more 7 T Induction Furnace under expansion With installation of above, Steel Making Capacity of the Plant will increase from present 54,000 TPA to 1,10,000 TPA Liquid Steel Liquid Steel will be cast into MS Billets (100x100mm & 125x125 mm) in the existing 2 Strand Billet Caster which has sufficient in-built capacity to produce 105,000 TPA MS Billets The process flow sheet for steel making and continuous casting is shown below Pre-feasibility Report 20

22 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Steel Making by Induction Furnace Induction Furnace (IF) is used for melting of metals and holding it in liquid condition Due to improved reliability and technological advancement of power electronics, Inverters are now available at economical rate and application of Induction Furnace has spread widely for Steel Making Melting the Charge Sponge Iron (80%), Pig Iron and Scrap constitute major raw material for steel making in the induction furnace This is because elimination of some element from the molten steel is difficult in an induction furnace melting In the case where these are present in high quantities, a secondary metallurgical unit (Ladle Refining Furnace etc) is required to refine the metal up to a desired extent The only exception is phosphorus, when present in the molten metal cannot be eliminated even with the help of a secondary refining unit and thus procurement of the appropriate kind of raw material is of utmost importance in Induction Furnace melting practice The charge should be compact It should consist of good quality sponge iron mixed with clean turnings, pig iron and a moderate amount of heavy melting of commercial grade scrap This is to provide the initial conditions of a high flux path through the charge for facilitating generation of heat and commencement of melting The process for manufacturing steel in IF may be broadly divided into the following stages: i) Melting the charge mix and ii) Ladle teeming practice for Casting Induction Furnaces are Steel Framed and rugged in construction It consists of a Coil, which works like Primary Coil of a Transformer The Coil is lined with Refractory Material Charge to be melted is put inside the lined Coil The Charge acts like Secondary Coil of the Transformer The furnace is switched on, current starts flowing at a high rate and a comparatively low voltage through the induction coils of the furnace, producing an induced magnetic field inside the central space of the coils where the crucible is located As the magnetic fluxes pass through the scrap and complete the circuit, they generate induce eddy current in the scrap This induced eddy current, as it flows through the highly resistive bath of scrap, generates tremendous heat and melting starts Melting rate depends primarily on the density of magnetic fluxes and compactness of the charge The magnetic fluxes can be controlled by varying input of power to the furnace, especially the current and frequency Pre-feasibility Report 21

23 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO In a medium frequency furnace, the frequency range normally varies between K cycles per second Heat is developed mainly in the outer rim of the metal in the charge but is carried quickly to the center by conduction A metal pool is quickly formed at the bottom causing the charge to sink At this point remaining charge mix is added gradually The eddy current, which is generated in the charge, imparts a motor effect on the liquid steel, which is thereby stirred and mixed and heated more homogeneously This stirring effect is inversely proportional to the frequency of the furnace Furnace frequency is selected in accordance with the purpose for which the furnace will be utilized The melting continues till all the charge is melted and the bath develops a convex surface However, as the convex surface is not favorable to slag treatment, the power input is then decreased to flatten the convexity and to reduce the circulation rate when refining under a reducing slag The reduced flow of the liquid metal accelerates the purification reactions by constantly bringing new metal into close contact with the slag Before the actual reduction of steel is done, the liquid steel which might contain some trapped oxygen is first treated with some suitable deoxidizer When no purification is attempted, the chief metallurgical advantages of the process attributable to the stirring action are uniformity of the product, control over the super heat temperature and the opportunity afforded by the conditions of the melt to control de-oxidation through proper addition of deoxidizer At the end slag is skimmed off and necessary alloying elements are added When these additives have melted and diffused through the bath, the power input may be increased to bring the temperature of metal to the point required for pouring The current is then turned off and the furnace is tilted for pouring into a ladle After pouring of metal, slag adhering to the wall of the crucible is scrapped out and the furnace is prepared for next charging cycle As the furnace is equipped with a tight cover over the crucible, very little oxidation occurs during melting Such a cover also serves to prevent cooling by radiation from the surface of the molten metal Hence, the use of slag covering for preventing heat loss and protecting the metal is unnecessary Another advantage of the induction furnace is that there is hardly any melting loss compared with Arc Furnace Ladle Preparation Adequate number of bottom pouring and refractory lined ladles will be provided for tapping of liquid steel from Induction Furnaces After teeming of liquid steel from ladles into CCM, ladles are cleaned by removing skull and refractory lining is patched up as required The ladle is then preheated, as and when necessary, in oil fired ladle pre-heaters to a maximum temperature of about 1000 C Preheating of ladle is done to reduce the thermal shock to the brick lining while pouring hot liquid steel and to reduce the chilling effect Further, preheating will also remove any moisture from the refractory lining thus preventing explosion due to Pre-feasibility Report 22

24 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO generation of steam when liquid steel is poured Slide gate mechanism is adopted for bottom pouring of liquid steel from the ladle A refractory plate with a hole is made to slide on the nozzle surface for closing and opening of the flow of liquid steel Hydraulic mechanism is provided for sliding operation of the refractory plate The ladle is prepared after each heat by patching of its refractory lining and changing the slide gate These ladles are lined with basic or neutral refractory Since the slide gate can be changed from outside, this can be undertaken in a very hot condition of the ladle, if needed View of a Typical Induction Furnace 53 CONTINUOUS CASTING MACHINE SPSL is presently operating one 6/11 m Twin Strand Continuous Casting machine The CCM is having in-built capacity to produce 1,05,000 TPA MS grade Billets of 100x100mm and 125x125 mm size As such no additional CCM is envisaged in the expansion phase The molten steel from the ladle is bottom poured into the Tundish of the Continuous Casting Machine to produce billets The process of casting is continuous Liquid steel is continuously poured into a bottomless mould of CCM at the same rate as a continuous steel casting is extracted Before casting Pre-feasibility Report 23

25 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO begins, a dummy bar is inserted to close the bottom of the mould A ladle with hot molten steel is lifted above the casting machine and the slide gate is opened for pouring / teeming As the steel s outer surface solidifies in the mould, the dummy bar is slowly withdrawn through the machine, pulling the steel with it Water is sprayed along the machine to cool / solidify the steel into billets At the end of the machine, the steel Billet is cut to the required length by gas torches and transported hot to the hot rolling mill for further processing A Reheating Furnace will also be installed for heating cold billets prior to rolling Schematic Flow Diagram of CCM is shown below 1: Ladle 7: Turning zone A: Liquid metal 2: Stopper 8: Shroud B: Solidified metal 3: Tundish 9: Bath level C: Slag 4: Shroud 10: Meniscus D: Water-cooled copper plates 5: Mold 11: Withdrawal unit E: Refractory material 6: Roll support 12: Billets Pre-feasibility Report 24

26 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 54 ROLLING MILL SPSL has planned to set up a Rolling Mill of 1,00,000 TPA capacity for production of TMT Bars, Rods, Strips and Structural as finished product Rolling of TMT product is a process of converting feed stock (billets) to desired finished section in hot condition by way of passing the material between sets of grooved rolls (put in pairs) and providing suitable draft at various stages The whole rolling operation has to be conducted at a particular temperature range and within a limited time span The stages of rolling operation are comprised of heating of feed stock to roll-able temperature (in case of cold billets), rolling the feed stock in different mill stands, cropping the hot bar during process of rolling between mill stands as necessary and subsequently finishing same in the form of hot rolled deformed bar in straight length The hot bar coming out of last pass will be then conveyed through TMT Line and collected in a cooling bed after shearing The bars at almost ambient temperature are sheared to commercial length, stored and kept ready for dispatch Rod Mill with TMT Facilities To produce 8 to 16 mm dia hot rolled deformed bar in straight length and converting the same to TMT bar, it is proposed to use 12 M long 100 mm sq & 125 mm sq Billets as feed stock The semi continuous mills are equipped with cross-country primary & intermediate mills followed by continuous finishing mills Stock Preparation Billets shall be checked for any surface defect Any defective cold billet should not be charged to reheating furnace The billets will be then stacked on charging grid of the furnace Billet Reheating It is envisaged to normally feed hot Billets to Rolling Mill as it will be located near CCM In case cold billets are to be rolled, same will be heated prior to rolling An Oil-fired Re-Heating Furnace has been envisaged for this purpose Heat from Waste Gases coming out of Reheating Furnace will be used for preheating air required for Oil Burners Heat Exchangers will be installed for this purpose Subsequently waste gases will be let out to atmosphere through a Chimney Pre-feasibility Report 25

27 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Cold billets are charged from one end to oil fired reheating furnace by suitably rated pusher After heated and soaked to desired rolling temperature level at about 1200 C, hot billets are side discharged at the other end Temperature is maintained at 650 C in Heating Zone and at 1250 C in Soaking Zone Thermo Couples are provided to measure temperature in various zones of the Re-Heating Furnace In order to avoid de-carburisation on heating, the ingots are heated slowly and uniformly up to 800 C and then rapidly to 1200 C At this temperature, ingots are soaked properly for maintaining almost uniform temperature across the crosssection for better deformation during rolling After soaking, billets are discharged to a delivery table and from where with the help of roller table the billets are conveyed to the roughing mill stand Rolling A Y-table is connected at entry side and a drop wall arrangement at exit side of the first 400 mm Roughing Mill stand Hot billets directly from CCM or cold billets after heating in the reheating furnace is first conveyed over Y-table and enters to top pass of Roughing Mill Stand-I The bar coming out shall turn 90 over drop wall and fall on delivery roller table and enter the bottom pass The bar will be conveyed out of bottom of Y-table through flap and allowed to travel over Y-table for top pass Such to and fro rolling in top and bottom passes in the first stand shall be carried out till a definite square section shall be obtained in 6th pass The bar will be then fed to 7th pass at top to get an oval pass and then will be allowed to feed to bottom pass of Roughing Mill Stand-II over a repeater for formation of a square In Roughing Mill Stand-III an inter-stand repeater has been provided and as such the square thus formed shall be fed to top pass of same stand for formation of an oval The oval bar will then be allowed to pass through one pass in each 280 mm Intermediate Mill comprising four stands Repeaters are provided on either side of mill stands for material transfer The oval bar coming out of second stand of Intermediate Mill shall be conveyed to pass through two 260 mm stands of First Continuous Finishing Mill and with a repeater the bar will pass through to 260 mm stands of Second Continuous Finishing Mill form where 8 mm dia Hot rolled ribbed bars shall be produced The higher sizes of the deformed bar shall be finished from last stand of First Continuous Finishing Mill The roughing mill speed shall be 125 rpm The roughing mill stands shall be driven by a 1000 HP AC motor through pinion stand & gear box The four (4) stands of intermediate mill shall be driven by a 800 HP motor through pinion stand & gear box A speed increaser drives the first continuous finishing mill while a 600 HP AC motor drives each stand of second continuous mill Depending upon the requirement, the speed in these stands can be adjusted during process Pre-feasibility Report 26

28 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Thermo Mechanical Treatment (TMT) It is a metallurgical process that combines mechanical process with thermal process where low carbon bars are quenched in a controlled manner to produce high strength bar The quenching converts bar s surface layer to martensite and causes it to shrink The shrinkage pressurizes the core, helping to form the correct crystal structures The core remains hot and its micro structure is austenitic A microprocessor controls the water flow to the quench box, to manage the desired temperature difference through the cross-section of the bars As the bar cools, heat flows from the bar's centre to its surface so that the bar's heat and pressure correctly tempers an intermediate ring of martensite and bainite Finally, the slow cooling in the cooling bed automatically tempers the austenitic core to ferrite and pearlite These bars therefore exhibit a variation in microstructure in their cross section, having strong, tough, tempered martensite in the surface layer of the bar, an intermediate layer of martensite and bainite, and a refined, tough and ductile ferrite and pearlite core This is the desired micro structure for high quality construction rebar TMT bars resist corrosion better than cold, twisted and deformed (CTD) bars Production of TMT Bar will cover Fe: 415/500/550/600 grades A Crank type Flying Shear cuts the bars to suit cooling length For production of 8 & 10 mm deformed bar, the finishing speed is about 147 m/s & 100 m/s respectively However, it is always necessary to reduce its speed to the acceptable limit of cooling bed The cut piece from flying shear shall be allowed to pass through a pinch roll and a tail end speed breaker The breaker engages and rebases for a brief period depending upon bar speed and bar length The breaker can take two bars at a time and engage/disengage of breaking of these bars can be taken up independently After releasing, the breaking bar will smoothly enter into the cooling bed In cooling bed the cut pieces are stored for a pre-determined period of time for further surface cooling to ambient temperature However, here the heat from the core of the bar will flow to the surface causing tempering With the ambient cooling in cooling bed the hardened zone is tempered by temperature homogenization in the cross-section and the austenitic core is transformed to fine grained ferrite-pearlite The bar is then conveyed to a roller table to shear to cut to commercial length The cut pieces are then stored and kept ready for dispatch Changes in micro structure of TMT Bars at different stages of processing are shown below Pre-feasibility Report 27

29 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Rolling Mill Process Flow Sheet for Production of TMT Bars & Rods is shown below Pre-feasibility Report 28

30 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO 55 SINTER PLANT Sinter Plant is an excellent scavenger in a Steel Plant It uses all raw material fines and dusts generated in the plant (during handling and operation) and convert same into agglomerate that can be reused in steel making / Ferro Alloys production It is proposed to install one 35 TPD Pot Type Sinter Machine under Expansion Phase of the Mini Steel Plant Fines, generated during handling of Iron Ore Lumps and Pellets and other Raw Materials and Dust and sludge from Process and waste gases captured in cyclones, bag filters and Electro Static Precipitators will be utilised as feed-mix in Sinter Plant in effective manner Scales generated in CCM and Rolling Mill will also be utilised thereby solving disposal and environmental problems of Solid Wastes The Agglomerate Sinter produced will be used in the Charge Mix of SAF Iron ore lump / pellet fines, mill scale as well as dust and sludge ESP will be thoroughly mixed with water and fuel (coke breeze and coal fines) in a rotary mixer and placed in a pot having perforations at the bottom Upward and downward suctions are employed for drying, preheating and sintering and also preheating of air Sinter Cakes formed are then removed from Pots, broken and sent to SAF as feed Adequate Dedusting facilities (cyclones, bag filters) will be installed before the waste flue gases are let out to atmosphere through a Stack 56 SUBMERGED ARC FURNACE (SAF) Ferro alloys are intermediate products used in steel making as deoxidizers and as a specified addition to give particular properties to the steel Ferro Alloy Industry is an essential and vital industry producing basic alloys, which are required for the growth of the steel industry With Increase in domestic steel production, requirement of Ferro Alloys also increases Ferro Alloy industry in India is making inroads into exports market as well Demand for medium Carbon Si-Mn and low Carbon Si-Mn has gone up due to usage of these Ferro-alloys in stainless steel making Silico Manganese is an alloy containing high amount of manganese and silicon It finds extensive applications as deoxidizer and an alloying element Under Product Diversification, SPSL proposes to manufacture 6,480 TPA Silico Manganese (Si Mn) by installing a 45 MVA Submerged Arc Furnace (SAF) in the Mini Steel Plant at Dewandighi Production of Ferro Alloys is highly energy intensive process Si-Mn will be produced by carbothermic reduction of oxidic raw materials in SAF The same type of furnaces is used for Fe-Mn Pre-feasibility Report 29

31 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO and Fe Si alloys Operation of the Si-Mn process is often more difficult than the Fe-Mn process because higher process temperature is needed Raw materials required for production of Si-Mn in SAF are Mn Ore, Mn slag from Fe-Mn operation, Iron Scrap, Quartzite, dolomite and Pearl Coke Low volatile coal is also used as a source of carbon for reduction Sinter produced utilizing Iron ore fines, scales and dust in Mini Steel Plant will also be used as Raw material Raw materials from Storage Yards are brought to a Ground Hopper It is then conveyed to Raw Material Storage Bins Mix Material after weighing, batching and blending is taken to Charging Hoppers above SAF furnace The mix is then gravity-fed through a feed chute The principle of a conventional SAF is electric resistance heating Electric energy is converted into heat & reduction energy by using the resistance (R) of the molten slag and reinforced by the electrical resistance of an arc between the slag and carbon electrodes During the initial period of melting, the applied power is kept low to prevent damage to furnace walls and the roof from radiation, while allowing the electrodes to bore into the mixture of raw materials As soon as the arcs have become shielded by the surrounding raw material mixture, the power is increased to complete melting As the charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the reductants, being heavy, gradually settles at the bottom At regular intervals the furnace is tapped The tap-hole is opened by oxygen lancing pipe and after tapping is completed, it is closed by clay plugs The liquid Ferroalloy is collected and cast in dressed beds After solidification the cakes are broken manually to required lump size Unlike in EAF, the electrodes of SAF penetrate the raw material The lower ends of the electrodes are maintained at about 09 to 15 meters (3 to 5 feet) below the charge surface Normally the slag penetrates into this coke bed, but not as far as to be in contact with the tip of the electrode Reaction gases from the smelting zone, mainly CO gas, pass upwards through the descending raw materials partly preheating them giving off its sensible heat and partly causing solid state reduction of the higher iron oxides However, the thickness of the zone where materials are heated to reaction temperature is so small that the gases do not have sufficient retention time to give an extensive reduction % pre-reduction is normal in cold charge operation Without considering the power factor on the electric grid, the Ohmic resistance on the hearth and the allowable amperage in the electrodes are the determining parameters for the load in a furnace However, the effect of a low power factor can easily be compensated by installation of capacitor banks to correct the power factor on the grid Pre-feasibility Report 30

32 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO The quality of the raw material has the biggest impact on the process The physical properties determine whether the SAF can run in the (i) conventional resistance mode using the electrical resistance of slag, or (ii) shielded arc mode using the electrical resistance of the slag and arc or using the electrical resistance of the feed mix High-carbon Silico-Manganese is made in 45 MVA SAF operating at a voltage of Volt The charge for making high-carbon Silico-Manganese is composed of manganese ore, Quartz and coke Silico Manganese will contain 60-70% Mn and 14-18%Si, 004% S and o25-030% P In the Ferro Silicon process, the important reactions are: SiO2 + C = SiO + CO SiO + 2C = SiC + CO 2SiO2 + SiC = 3SiO + CO SiO + SiC = 2Si + CO The following processes take place when making high-carbon Silico Manganese: (a) Removal of volatiles and moisture from the charge and heating of the charge (b) Reduction of iron and manganese ores with simultaneous formation of metal carbides (c) Melting of the elements reduced with the formation of molten metal (d) Formation and melting of slag and (e) Reduction of Manganese and silicon from the slag Features of SAF SAF comprises a circular shaped furnace shell with separate tap holes for slag and metal The furnace is lined with fire bricks, silicon carbide bricks and carbon tamping paste Furnace Shell is water cooled by a special sidewall cooling system The shell bottom is cooled by forced air ventilation The electrodes are consumed by the furnace bath The self-baking electrodes with casings are periodically extended by new pieces The electrode is semi automatically slipped into the bath with the furnace at full electric load and with no interruptions of the furnace operation The electrode column assemblies contain all facilities to hold, slip, and regulate the penetration into the bath All electrode operations are performed hydraulically The electric power is supplied from the furnace transformer via high current water cooled flexible bus tubes at the electrodes and the contact clamps to the electrodes The major normal features of AC based furnaces are as follows Pre-feasibility Report 31

33 Proposed expansion of existing Steel Plant at Palitpur Road, Village & PO Low maintenance electrode columns for various electrode types Fail safe, robust designed electrode holding and slipping device Robust furnace design does not allow bulging/movement Hollow electrode charging system Gas tight water cooled roof design provides high quality CO rich gas Application of energy recovery system possible Presently more than 99% of Ferro Alloys production is carried out in AC Submerged Arc Furnaces View of a Typical Submerged Arc Furnace Adequate Pollution Control Facilities like Smoke Hood, Spark Arrestor, Forced Draft Cooler/Heat Exchangers, Cooling Towers, Cyclone, Bag Filter, ID Fan and Chimney will be installed To recover metallic Iron (scrap) from slag generated in Induction Furnaces and SAF, a Slag Processing Unit is be installed, capacity of same will be augmented as required under expansion Pre-feasibility Report 32