PRE-FEASIBILITY REPORT FOR CAPACITY EXPANSION OF INTEGRATED IRON & STEEL PLANT TO 1.5 MTPA AT BELHA, DISTRICT BILASPUR, CHHATTISGARH

Transcription

1 PRE-FEASIBILITY REPORT FOR CAPACITY EXPANSION OF INTEGRATED IRON & STEEL PLANT TO 1.5 MTPA AT BELHA, DISTRICT BILASPUR, CHHATTISGARH TO NOVA IRON & STEEL LIMITED NOVEMBER 2014 M. N. DASTUR & COMPANY (P) LTD CONSULTING ENGINEERS KOLKATA

2 TABLE OF CONTENTS 1 INTRODUCTION Page Background Authorisation Structure of the report Acknowledgement PLANT LOCATION AND LAYOUT Location of proposed site Features Infrastructural facilities Transport linkages Water Power RAW MATERIALS Major raw materials Iron ore fines Coal Limestone Dolomite Quartzite Pyroxenite Iron ore pellet Coke MAJOR PLANT FACILITIES Raw materials handling and storage system Requirement of raw materials Unloading and storage facility Base-mix preparation system Despatch of raw materials to the consuming units Charge-mix feed to the DR kiln Product handling system Facilities associated with the raw material handling systems Coal washery Design basis/consideration i

3 TABLE OF CONTENTS (Continued) 4 MAJOR PLANT FACILITIES (cont d) Page Direct reduction (DR) plant Design basis Product quality Raw materials Major facilities Sinter plant Production programme Design basis Raw materials Consumption of input materials Sinter quality Major facilities Blast furnace Production programme Design basis Analysis of raw materials Coal for PCI application Input materials quantity Hot metal quality (typical) Facilities in blast furnace Steelmelt shop-1 (SMS-1) Design basis Requirement of raw materials and supplies Equipment and facilities for steelmelt shop Steelmelt shop-2 (SMS-2) Design basis Requirement of raw materials and supplies Equipment and facilities for steelmelt shop Calcining plant Wire rod mill (WRM) Design basis Major equipment Medium merchant mill (MMM) Design basis Major equipment Light merchant mill (LMM) Design basis Major equipment ii

4 TABLE OF CONTENTS (Continued) 4 MAJOR PLANT FACILITIES (cont d) Page Captive power plant Technical profile of the captive power plant Top recovery turbines (TRT) Air separation plant (ASP) Oxygen Nitrogen Argon Facilities proposed Plant materials flowsheet UTILITY AND SERVICE FACILITIES Power distribution system and electrics Plant power requirements Characteristics of plant loads Source of power Power distribution philosophy Instrumentation and automation systems Structure of proposed automation system Instrumentation and level-1 automation Process automation (level-2) system Supervisory control and data acquisition system (SCADA) Manufacturing execution (level-3) system IT infrastructure Plant communication system Plant telephone system Loudspeaker intercommunication (LSIC) system Closed circuit television (CCTV) system Wireless communication system Plant optical fiber cable (OFC) backbone Fire detection and alarm system Water system Water requirement Source of water Plant water system Waste water and effluent treatment management Distribution pipework iii

5 TABLE OF CONTENTS (Continued) 5 UTILITY AND SERVICE FACILITIES (cont d) Page Utility system Fuel system Availability of by-product gases for power generation LPG/propane manifold Process steam Plant and instrument air system Air pollution, ventilation and air conditioning Chilled water plants Overhead yard pipework Central utility monitoring and control Auxiliary facilities Laboratories Repair shops and stores Ancillary facilities Drainage and sewerage system Roads ENVIRONMENTAL POLLUTION CONTROL MEASURES Review of pollution potential Proposed mitigation measures Air pollution mitigation measures Water pollution control measures Zero Discharge Concept Work Zone Pollution control measures Solid waste generation and utilisation Plant safety Plant greenbelt and landscaping Design targets for APC and WPC measures Environmental Monitoring IMPLEMENTATION SCHEDULE Implementation schedule iv

6 TABLE OF CONTENTS (Continued) 8 CAPITAL COST ESTIMATE Page Capital cost estimate Plant cost Interest during construction TABLES Table 3-1 Major raw materials Table 4-1 Annual consumption of various raw materials and mode of receipt Table 4-2 Requirement of wagon tippler Table 4-3 Base-mix and trimming materials Table 4-4 Specific consumption of raw materials for the DR plant Table 4-5 Design basis of sinter plant Table 4-6 Typical analyses of raw materials for sinter production Table 4-7 Consumption of input materials Table 4-8 Design basis of blast furnaces Table 4-9 Typical raw materials analysis (dry basis) Table 4-10 Input material quantities Table 4-11 Requirement of major raw materials and supplies Table 4-12 Requirement of major raw materials and supplies Table 4-13 Estimated power generation capability Table 4-14 Technical profile of CPP Table 5-1 Make-up water requirement Table 5-2 Major water systems Table 5-3 Generation of by-product gas Table 5-4 Surplus by-product gas availability FIGURES Fig. 2-1 Location map of existing plant Fig. 7-1 Implementation schedule DRAWINGS Dwg Dwg Dwg Plant general layout Plant materials flowsheet Schematic water flow diagram v

7 SUMMARY 1. Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron plant of capacity 500 tons per day (TPD) adopting coal based rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state. NISL is now contemplating expansion of the above mentioned sponge iron plant to 1.5 million tons per annum (MTPA) integrated steel plant along with a 260 MW power plant. The area of the existing plant is acres out of which the existing facilities occupy only 30 acres and the rest of the land is vacant. In addition to the above, BPSL has purchased acres of land. Accordingly, total land area available for the project will be acres. 2. After expansion, the plant would produce saleable products consisting of wire rods, billets, beams, channels, rounds, squares, angles and flats, as listed below: Rounds.. 675,000 Beams.. 245,000 Squares.. 50,000 Channels.. 280,000 Angles.. 200,000 Flats.. 100,000 Apart from above finished products, about 514,700 tons per annum pig iron would be used for sale

8 Summary (Cont d) 3. Based on the BF-DRI-EAF-IF process route following major plant facilities have been envisaged for the proposed expansion plan. Sinter plant.. 1 x 248 sqm Blast furnace.. 1 X 1008 cum.. 1 X 550 cum DR Kiln.. 4 X 500 tpd Calcining Plant.. 2 x 600 tpd Steelmaking.. IF - 3 x 15 ton LF 1 X 15 ton EAF 2 X 90 ton LF 2 x 90 ton VD - 1 x 90 ton Casting and Rolling.. Light Merchant Mill.. Medium Merchant Mill.. Wire rod mill Captive Power Plant.. 2 x 130 MW (CPP-1).. 2 x 7.5 MW (CPP-2) 4. Nova Iron and Steel Limited (NISL) is located at Belha tehsil of Bilaspur district in the State of Chhattisgarh, between latitudes 22 53'N to 22 55' N and longitudes 82 00' E to 82 05' E and 268 m above mean sea level (MSL). The site is approximately 40 km from Bilaspur town. The site is located on the eastern side of national highway NH-130 and connected with the bypass road from NH-130. The bypass road is connecting NH-130 and village Belha at the northern side of proposed plant. The NH-130 is about 9 km away from the site. The nearest railway station is Dagori, situated about 6 km. on the north-east side of the plant. 5. Requirement of some of the major raw materials considered for the production viz. anthracite coal and PCI coal would be met through import. Iron ore fines, coke, non-coking coal, iron ore pellet, BF & SMS grade limestone, dolomite, quartzite - 2 -

9 Summary (Cont d) and pyroxenite would be procured from indigenous sources. Wagon tipplers/truck tipplers are envisaged for unloading of the raw materials and mechanised systems are considered for storage and distribution of various raw materials. 6. Requirement of fuel, power and other utilities viz. plant and instrument grade compressed air, steam, industrial gases (oxygen, nitrogen & argon), chilled water would be fulfilled through installation of new facilities. Blast furnace gas would be available as by-product gas inside the plant for various process needs and heating applications of the plant, besides being a source of power generation. Total make-up water requirement for the plant after full implementation would be about 2,040 cu m per hour, which would be drawn from the Sheonath river. The requirement of power for the expansion would be 1,288 Million KWh, which would be met partly through captive power generation from coal & gas fired captive power plant and from TRT of blast furnace. 7. In view of the aforementioned plant facilities, there would be pollution load, for which adequate mitigation measures would be adopted to keep the pollution load within the stipulated norms. 8. It is envisaged that the project would be completed within 36 months from the Go-Ahead date. 9. The estimate of capital cost includes plant cost, preoperative expense, working capital margin and interest during construction. The plant cost comprises the costs of plant & equipment (as erected) together with the cost of pollution - 3 -

10 Summary (Cont d) control, design, engineering, consultancy & administration during construction and contingency. The capital cost is estimated to be Rs. 10,834 crore approximately. About 7-9 per cent of the total plant cost has been kept for environment management measures

11 1 INTRODUCTION BACKGROUND Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron plant of capacity 500 tons per day (TPD) adopting coal based rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state. NISL is now contemplating expansion of the above mentioned sponge iron plant to 1.5 million tons per year (MTPA) integrated steel plant along with a 260 MW power plant. M/s Bhushan Power & Steel Limited (BPSL) has taken over NISL in BPSL is a leading manufacturer of flats, rounds and long products including value added products with billets, HR coils, pig iron, CR coils, GP/GC, precision tubes, black pipe/gi Pipe, cable tapes, tor steel, wire rod and special alloy steel. BPSL has successfully commissioned a greenfield steel and power plant in Odisha with hot rolled coil making facility - first in private sector in the state of Odisha. BPSL is selling its value added range of products in secondary steel sector through a large distribution network in India (comprising more than 35 sales offices) and abroad. The area of the existing plant is acres out of which the existing facilities occupy only 30 acres and the rest of the land is vacant. In addition to the above, BPSL has purchased acres of land. Accordingly, total land area available for the project will be acres. 1 1

12 1 Introduction (cont d) AUTHORISATION NISL, vide its letter No. NISL/WO/BSP/RKG/RNY/14-15/166 dated commissioned M. N. Dastur & Company (P) Ltd. (CONSULTING ENGINEERS), Kolkata, for preparation of an Environmental Impact Assessment (EIA) study for its 1.5 MTPA integrated steel plant. According to the Ministry of Environment and Forests (MoEF) regulations, this (PFR) has been prepared as an appendage to the EIA study for the proposed project. This PFR, along with Form I, needs to be submitted to MoEF for obtaining prior environmental clearance for the project. STRUCTURE OF THE REPORT The is presented in eight chapters. Following this introduction, the project concept and site conditions are discussed in Chapter 2. Chapter 3 describes annual requirements of major raw materials and their availability for the project. Major plant facilities envisaged for the project including plant layout are discussed in Chapter 4. Chapter 5 describes various utility services, like power system, instrumentation, automation and plant communication systems, water and utility systems and auxiliary facilities, like laboratories, workshops, and stores, etc. Environmental pollution control measures proposed are indicated in Chapter 6. Chapter 7 describes plant construction schedule and volume of construction. The capital cost estimate is indicated in Chapter 8. ACKNOWLEDGEMENT CONSULTING ENGINEERS gratefully acknowledge the co-operation and assistance extended by the officials of NISL and BPSL during the site visit and the preparation of the Pre-Feasibility Report. 1 2

13 . P re Fe asi bility Repor t 2 PLANT LOCATION AND LAYOUT This chapter presents the location of proposed plant site, its features and briefly reviews the infrastructure facilities available at site. LOCATION OF PROPOSED SITE Total land area available for the project will be acres. The location map of the existing plant is shown in Fig. 2-1 on the next page. The plant general layout of the proposed plant is given in Drawing No The site is approximately 40 km from Bilaspur town. The site is located on the eastern side of national highway NH-130 and connected with the bypass road from NH-130. The bypass road is connecting NH-130 and village Belha at the northern side of proposed plant. The NH-130 is about 9 km away from the site. The nearest railway station is Dagori, situated about 6 km. on the north-east side of the plant. River Sheonath is flowing by the southern boundary of the proposed site. It is a perennial river. It is envisaged that the requirement of water will be fulfilled from this river for expansion project. 2-1

14 NOVA IRON & STEEL LTD. Integrated Steel Plant in Chhattisgarh Pre Feasibility Report M. N. DASTUR & COMPANY (P) LTD 2 Plant location and layout (cont d) 2-2

15 . P re Fe asi bility Repor t 2 Plant location and layout (cont d) FEATURES The acquired additional area for plant comprises predominantly barren/single crop agricultural land. The village Dagori is located at the northern side of the proposed plant. The finished ground level of the existing plant is RL m. The land at its northern side is higher than the existing plant which varies from RL m to RL m. Land is fairly plain with small undulations for developing a good layout. The soil predominantly consists of moorum, clay, slit and sand. There are a few rocks outcrops within plant site. INFRASTRUCTURAL FACILITIES Transport linkages Rail: The nearest railway station, Dagori, located in Bilaspur Raigarh railway line, is situated about 6 km away from the plant site. Dagori railway station is located in between Belha and Nipania Railway Stations. Major raw materials will be transported by rail. Anthracite coal will be imported through Paradip port and then will be transported by rail to the plant site. Suitable rail link has been envisaged from the proposed railway siding at Dagori station to the plant site for receipt of raw materials, as well as for despatch of finished products. Road: Nearest national highway NH-130 is about 9 km away from plant approach. There is a bypass road connecting NH-130 and village Belha at the northern side of proposed plant. The condition of approach road from the existing plant to the bypass road needs to be improved under expansion project. 2-3

16 . P re Fe asi bility Repor t 2 Plant location and layout (cont d) Port: Paradip port is situated about 640 km from proposed site. Imported raw materials will be handled through Paradip port. Suitable interaction with the port authorities will be necessary to finalise this arrangement. Water To meet the make-up water requirement, it is necessary to have a reliable water source. The main source of make-up water is river Sheonath which is about 100 m from the existing southern boundary of the plant. The river is a perennial source of water. The river Sheonath has been considered as a probable source of water. To ensure an uninterrupted supply of water, a reservoir of 14 days storage capacity has been considered within the plant premises. However, suitable study on impounding arrangements in the form of a pick-up weir at the river source and intake facilities will have to be assessed at an appropriate time to meet the plant water requirements. Power The nearest 220 kv sub-station is located at 20 km away from the proposed plant site. The plant power requirement will be met from the captive power plant as well as from the grid. 2-4

17 3 RAW MATERIALS This Chapter discusses the annual requirement of major raw materials, reviews their availability, quality and probable sources of supply. MAJOR RAW MATERIALS The major raw materials required for the proposed project are iron ore fines, coal, limestone, dolomite, etc. Estimated gross requirement of raw materials to be procured annually on net and dry basis are given in Table 3-1 in the next page. Iron ore fines Iron ore in the form of fines will be required for use in sinter plant. The entire requirement of iron ore fines will be met from the mines located in Madamnar region, Narayanpur district of Chhattisgarh. The procurement size of iron ore fines and their likely chemical analysis are as follows: Size Fe SiO 2 Al 2O 3 LOI mm % % % %

18 3 Raw materials (cont d) Consuming unit Sinter plant DR plant Blast furnace Coal washery TABLE 3-1 MAJOR RAW MATERIALS Raw materials Indicative source Net & dry Gross requirement procurement tons/year tons/year (1) Iron ore fines Narayanpur, 1,653,511 1,834,000 Chhatisgarh Limestone fines Keonjhar, Odisha 218, ,910 (2) Dolomite fines Baradwar, Chhattisgarh 17,230 - (3) Pyroxenite Local 69,056 74,180 Anthracite coal Australia 34,569 37,200 Non-Coking Jharsuguda, 592, ,400 (4) coal Odisha Dolomite Baradwar, 18,480 19,300 Chhattisgarh Injection coal Jharsuguda, Odisha 254, ,800 Pellet Local 991,320 1,120,900 Quartzite Local 21,964 23,340 PCI coal Australia 175, ,750 Coke Local 696, ,700 Pellet Local 480, ,000 Non-Coking coal Jharsuguda, Odisha Power plant Thermal coal Jharsuguda, Odisha 1,500,000 1,663, , ,020 Calcining plant Limestone Keonjhar, Odisha 606, ,170 Dolomite Baradwar, 114, ,640 Chhattisgarh Notes: (1) Includes moisture, handling and screening losses as applicable. (2) Excludes about 91,220 tons of limestone fines generated in calcining plant, which is to be utilized in sinter plant. (3) Excludes about 17,230 tons of dolomite fines generated in calcining plant, which is to be utilized in sinter plant. (4) Excludes about 385,050 tons of washed coal produced in coal washery, which will be used as a non-coking coal in DRI plant. Coal Anthracite: Anthracite coal will be used in sinter plant. As such coal is not available in India, the same will be met through imports from Australia. Pulverized coal injection: Coal with low volatile matter and ash content will be used for pulverized coal injection (PCI) in blast furnace. As such coal is not readily available in India, requirement of the same is planned to be met through imports from Australia. 3-2

19 3 Raw materials (cont d) Non-coking coal: Raw non-coking coal will be sent to coal washery and the entire washed coal will be used in the DR plant. To meet the balance requirement of coal in the DR plant, suitable grade of non-coking coal will be procured from collieries of IB Valley region, Jharsuguda, Odisha. The middling from coal washery and char from DR plant will be used in the thermal power plant. The balance requirement of suitable grade thermal coal will be procured from collieries of IB Valley region, Jharsuguda, Odisha. Limestone BF grade limestone will be used in the sinter plant and SMS grade limestone will be used in the calcining plant. It is envisaged that, the total requirement of limestone for use in sinter plant and calcining plant will be procured from Banspani region within a size range of (+) 40 to (-) 80 mm. A typical chemical composition of limestone considered for this report is tabulated below: SiO 2 Al 2O 3 CaO MgO LOI % % % % % Dolomite It is envisaged that the entire requirement of dolomite for use in sinter plant, DR plant and calcining plant will be met from Baradwar region in Chhattisgarh. Size of the dolomite to be procured will be in the range of (+) 40 to (-) 80 mm. The typical analysis of Baradwar dolomite considered is as follows: SiO 2 Al 2O 3 CaO MgO LOI % % % % %

20 3 Raw materials (cont d) Quartzite Quartzite will be used in the blast furnace. It is envisaged that the entire requirement of quartzite will be procured from local sources in the size of (+)10 to (-)40 mm. A typical chemical analysis of quartzite considered for this report is as follows: Pyroxenite SiO 2 Al 2O 3 % % Pyroxenite will be used in the sinter plant. It is envisaged that the entire requirement of pyroxenite will be procured from local sources. A typical chemical analysis of pyroxenite considered for this report is as follows: SiO 2 Al 2O 3 CaO MgO % % % % Iron ore pellet It is envisaged that, the entire requirement of pellet for use in blast furnace and DR plant will be procured from local sources. Coke It is envisaged that, the entire requirement of coke for use in blast furnace will be procured from local sources. 3-4

21 4 MAJOR PLANT FACILITIES The major production facilities of the steel plant will comprise coal washery, direct reduction plant, sinter plant, blast furnaces, steelmelt shops and long product mills. The plant will also have captive air separation plant on Build-Own-Operate (BOO) basis to meet the plant oxygen requirement. Power generation units are also envisaged utilising surplus blast furnace gas and in-plant char and middlings. Additionally, boiler coal will be used in the power plant. This chapter describes the major facilities envisaged for the project. RAW MATERIAL HANDLING AND STORAGE SYSTEM Requirement of raw materials The annual consumption of various raw materials and mode of receipt is indicated in Table 4-1 in the next page. Unloading and storage facility All rail-bound materials viz. pellet, iron ore fines, non-coking coal for power plant and coke will come in an open top BOXN wagon. These materials will be unloaded by crescent type rotary wagon tippler. Materials unloaded by wagon tippler will be drawn by apron feeder/belt feeder located below the wagon tippler hoppers and fed to the conveyor system for its onward transmission to the storage yard. The tippling rate of wagon tippler will be 25 tips per hour and the same will be designed as per Research Designs and Standards Organisation (RDSO) stipulated norm G-33, May Handling of DFC wagons is not envisaged in this Report. 4 1

22 4 Major plant facilities (cont d) Sl. No. TABLE 4-1 ANNUAL CONSUMPTION OF VARIOUS RAW MATERIALS AND MODE OF RECEIPT Material A. For Sinter Plant Receipt size Gross (1) annual quantity Gross daily (2) quantity mm ton ton Mode of receipt Iron Ore Fines (IOF) (-)10 1,834,000 5,558 Rail Limestone , Road Pyroxenite , Road Anthracite (-)20 37, Road B. For Blast Furnace Iron Ore Pellet ,000 1,552 Rail Quartzite , Road PCI Coal (-)50 190, Road Coke ,600 2,211 Rail C. For DR Plant Iron Ore Pellet ,120,900 3,397 Rail Non-coking coal ,200 1,552 Road Dolomite (-)8 19, Road D. For Coal Washery Raw coal (-)600 1,663,700 5,455 Road E. For Calcining Plant Limestone ,200 2,079 Road Dolomite , Road F. For Power Plant Boiler coal ,000 2,375 Rail G. For SMS-1 Ferro-alloy - 2,400 7 Road H. For SMS-2 Ferro-alloy - 25, Road Direct reduced iron - 235, Road Note: (1) Above figures are derived based on the following losses: - 2 per cent handling loss - 5 per cent screening loss per cent moisture loss (2) Above figures are derived based on the following operating day/year: days for Sinter plant days for BF days for DR plant days for Coal washery days for Calcining plant days for Power plant days for SMS days for SMS-2 4 2

23 4 Major plant facilities (cont d) The number of rakes to be handled per day and requirement of wagon tippler are given in Table 4-2. TABLE 4-2 REQUIREMENT OF WAGON TIPPLER Material Daily quantity ton No. of rakes (1) No. of rakes (2) at peak load Iron Ore Fines 5, Pellet 4, Coke 2, Boiler coal for power plant 2, Note: (1) A rake load of 2,100 ton for coke and 3,800 ton for other materials has been considered. (2) Bunching factor of 1.33 for indigenous and 1.5 for imported materials have been considered for finding out peak load. Based on number of rakes to be handled per day at peak load and keeping in view the contamination of materials for process requirement, two (2) nos. C type rotary wagon tipplers have been envisaged. Road-bound materials will be unloaded in the ground hopper in the storage yard and the same will be stored in the respective storage yard by stacker/reclaimer. (-)600 mm raw coal required for coal washery will be brought to the site by 130-ton dumper and the same will be stored in the storage yard. Unloading of all roadbound materials will be done by external agency. Purchased coal for DR plant having size of 5-20 mm will be unloaded in the ground hopper and will be stored in an overhead bunker and then fed to the day-bin of DR plant through conveyor system. 4 3

24 4 Major plant facilities (cont d) Materials unloaded by wagon tippler will be stored in the respective storage pile with the help of stacker/reclaimer with by-pass facility. Open storage piles system has been considered for all material except PCI which will be kept under the covered storage. PCI coal delivered by road will be unloaded to a separate ground hopper. PCI will be stored in the covered store by using travelling tripper. A storage capacity of seven (7) days for indigenous materials and fifteen (15) days storage for imported materials has been considered. Base-mix preparation system A base-mix yard has been envisaged to get good quality of sinter. Base-mix and trimming materials required to be despatched to the sinter plant and their respective quantities are indicated in Table 4-3 below: TABLE 4-3 BASE-MIX AND TRIMMING MATERIALS Constituents of base-mix: Estimated daily gross quantities tons Iron ore fines.. 5,558 Limestone (purchased) Limestone fines from LCP Dolomite fines from DCP.. 52 Pyroxenite Coke breeze/anthracite Trimming materials: Total.. 6,635 Limestone (purchased).. 83 Limestone fines from LCP.. 55 Pyroxenite.. 45 Coke breeze/anthracite.. 76 Total

25 4 Major plant facilities (cont d) base-mix. Twin boom stacker has been considered for stacking of Seven (7) days storage with 2 nos. of pile of base-mix have been considered, one (1) under stacking mode and the other on reclaim mode. Despatch of raw materials to the consuming units Despatch of coke, pellet, sinter and quartzite to BF: Material (one at a time) will be reclaimed by stacker/ reclaimer in reclaim mode and dispatched to the bins at blast furnace stock house through series of conveyors. Sinter received from sinter plant will be fed to the BF stock house through conveyor system. Despatch of PCI to BF: PCI from covered shed will be reclaimed by pay loader and fed to the yard hopper. Materials from yard hopper will be withdrawn by vibrating feeder located below and fed to the hammer mill for sizing of (-)10 mm. This (-)10 mm material will be then fed to the bunker for its onward pulverization suiting the requirement for injection system to BF. Despatch of base-mix to sinter plant: Base-mix will be reclaimed by barrel reclaimer and fed to the bunkers at the proportioning bin of sinter plant for its onward transmission to the sinter machine after final adjustment of chemistry of the sintermix. Transfer car has been considered to transfer barrel reclaimer from one bay to the other. Despatch of limestone to LCP: Limestone will be reclaimed by stacker/reclaimer in reclaim mode and fed to screening station through conveyor system. 4 5

26 4 Major plant facilities (cont d) (-)40 mm size fraction separated out will be dumped to the ground mm will be fed to the respective bins at LCP area. Despatch of lime and DRI to SMS: Lime received from LCP will be stored in a bin having storage capacity of 600 ton. Lime is then fed to the bins at SMS building through conveyor system. DRI will be fed to the bins at SMS by conveyor system. Additional DRI purchased for SMS will be transported to SMS by conveyors. Despatch of raw coal to washery: Raw coal (- 600 mm) stored at storage yard by dumper (by external agency) will be reclaimed by pay-loader and fed into the dumper (35-ton). Dumper will dump the coal into the hopper. Material drawn by apron feeder located below the hopper will be fed into the primary sizer to crush down (-) 120 mm. Secondary sizer will be used to crush down further upto (-)20 mm. (-)20 mm size will be stored in bunker through series of conveyors. Six (6) nos. bunkers, each having 1,000-ton capacity, have been envisaged to store 6,000 ton of coal, which is the daily requirement for the coal washery. Material drawn by belt feeder will be then transported to top of de-sliming screen. Despatch of middling char and boiler coal to power plant: Middlings (0.5 to 6 mm) stored at ground will be reclaimed by pay-loader and fed into the conveyor system for its onward transportation to the bins at Power Plant. Char generated in the DR plant will be transported to the stock yard and stored beside boiler coal stock pile. It will be 4 6

27 4 Major plant facilities (cont d) transported to the power plant from the yard by means of conveyor system. Boiler coal will be reclaimed by stacker/reclaimer on reclaim mode and fed to the crushing unit to size down into (-) 25 mm with the help of hammer mill. Then, (-) 25 mm boiler coal is fed to the bins at power plant through conveyor system. Necessary grinding arrangement of coal will be kept in the power plant, to suit the feed requirement of boiler. Despatch of raw materials to DR Plant: The following raw materials will be despatched to the DR Plant: Despatch of pellet: Pellet will be reclaimed by stacker /reclaimer in reclaim mode and after screening, (+) 5 mm to (-) 18 mm size will be stored in the day-bin. (-)5 mm iron ore of pellet separated out after screening, will be stored in the ground and disposed off from time to time (by external agency). Non-coking coal: Coal generated in the coal washery will be stored on ground in coal washery plant. The size fractions of coal will be mm and (-) 5 mm to 0.5 mm. Different size of coal will be reclaimed by pay-loader and stored in the respective bins at day-bin building. A mixture of two (2) fractions of coal will be used for injection system. Dolomite: Dolomite will be reclaimed by pay loader and fed to the yard hopper for onward transmission to the day-bin. Charge-mix feed to the DR kiln Raw materials namely pellet, coal and dolomite will be drawn from the respective storage bunkers of day-bins as required by weigh feeders in pre-determined proportion and conveyed to the kiln inlet buildings as co-current feed. Product handling system Cold DRI will be discharged at C and screened to separate out magnetic and non-magnetic materials. 4 7

28 4 Major plant facilities (cont d) An emergency bypass system will also be provided for intermediate storing and handling of cooler discharge material in the event of temporary break down of finish product screening and separation system. Electromagnet belt scale and mechanical hoist will be provided in the system as required for DRI conveyor also. Adequate facilities will be provided for dust extraction and suppression system to minimize the dust level. Facilities associated with the raw material handling system The following facilities have also been provided: - Belt weighing facilities - Belt charging facilities - Maintenance facilities - Air-conditioning and ventilation facilities - Dust suppression facilities COAL WASHERY A coal washery of 1.5 million tons per annum (mtpy) throughput capacity will be installed. The washed coal will be consumed in DR plant. The plant will be operated at rated capacity of 250 tons per hour (tph). In order to achieve the raw coal throughput rate of 250 tph, the washery will be designed with single stream process. Heavy media cyclone process will be used for optimizing the yield. The products are clean coal and middling. Tailings generated from disc filter will be dumped via conveyors to the designated area of washery. The clean coal will be sent to DR plant. Due to higher requirement of washed coal in DR plant, NISL will purchase clean washed coal from different sources for continuous feeding to DR 4 8

29 4 Major plant facilities (cont d) plant. The middlings will be used in power plant for power generation. Design basis/consideration Capacity: The main washery plant will have a throughput capacity of 1.5 mtpy. The coal washing plant will be designed for throughput rate of 250 tph based on 6000 effective working hours per year. However, 20% design margin will be considered for selection of the plant equipment. The washing plant will be designed for washing crushed raw coal of size -20 mm. Coal feed: Raw coal (0-20 mm) will be brought from coal handling plant via conveyor and fed into a desliming screen with throughput capacity of 250 tph. below: The raw coal is expected to have characteristics as given Top size of raw coal mm Raw coal ash.. 52 to 55% Angle of repose.. 35 to 40 degrees HGI of raw coal.. 40 to 60 Size of coal to be fed to the washery.. (-) 20 mm Desired product characteristics: The washery will be designed to produce clean coal with an ash content of 32-35% on dry basis for feeding to DR plant. Two types of washed clean coal is generated from washery circuit one is washed fines ( mm) and the other one is clean coal coarse (-20+5 mm). Middling have a size fraction of -6mm to 0.5 mm. Middling with ash content about % (on dry basis) will be used in power plant. 4 9

30 4 Major plant facilities (cont d) DIRECT REDUCTION (DR) PLANT Design basis The DR plant will have four numbers of 500 tpd rotary kilns, out of which one 500 tpd kiln is already present and three new 500 tpd kilns will be installed at the plant site. Each DR kiln will be based on rated production of about 500 tons of direct reduced iron (DRI) per day. The annual production from all four number of kilns will be about 660,000 tons of DRI based on 330 days operation using iron ore pellets. Commercially established coal based rotary kiln process will be adopted for the DR plant. Product quality It is expected that the DRI produced will contain about 88 per cent of Fe (total), around 0.15 per cent carbon and the degree of metallization will be about 88.5 per cent. Raw materials The rotary kiln charge will consist of iron ore pellets, non coking coal and dolomite. The specific consumption of various raw materials are indicated in Table 4-4. TABLE 4-4 SPECIFIC CONSUMPTION OF RAW MATERIALS FOR THE DR PLANT Raw materials Specific consumption (1) Kg/ton DRI Iron ore pellets.. 1,502 Non-coking coal.. 1,283 Dolomite.. 28 NOTE: (1) Net and dry basis. Major facilities major units: The facilities within the DR plant will comprise the following - Raw materials feeding system - Rotary kiln 4 10

31 4 Major plant facilities (cont d) - Rotary cooler - Product (DRI) handling system - Waste gas system SINTER PLANT Production programme One sinter machine of about 248 sq m will be installed to produce mtpy charge sinter, which will be adequate for 80 per cent sinter feed in BF-1 & BF-2. Design basis The design basis considered for sinter plant is given in Table 4-5 in the next page. TABLE DESIGN BASIS OF SINTER PLANT Product sinter, tons/year.. 2,256,700 Charge sinter, tons/year.. 1,918,200 Screening at BF stock house, %.. 15 Operating days/year Daily product sinter, tons/day.. 6,840 No. of strand.. 1 Approx. suction area, sq m Product sinter size, mm Temperature of sinter at cooler discharge, o C Raw materials The typical analyses of input raw materials (dry basis) for sinter production are given in Table 4-6 in the next page. TABLE 4-6 TYPICAL ANALYSES OF RAW MATERIALS FOR SINTER PRODUCTION Fe SiO2 Al2O3 CaO _MgO LOI % % % % % % Iron ore fines Limestone Coke breeze Flue dust Mill scale Lime Dolomite

32 4 Major plant facilities (cont d) Pyroxenite Consumption of input materials The annual input material consumption for production of mtpy charge sinter is given in Table 4-7 in the next page. Sinter quality The expected chemical analysis of sinter production from sinter plant is as follows: Fe FeO SiO2 Al2O3 CaO MgO CaO/SiO2 % % % % % % ratio follows: Physical and metallurgical properties of sinter will be as ISO tumbler index (+6.3 mm).. 76% (min) Reducibility index.. 65% (min) RDI (-3.15 mm).. 28% (max) Sinter size range mm Sinter mean size.. 18 mm TABLE 4-7 CONSUMPTION OF INPUT MATERIALS Annual Materials consumptions (1) tons/year Iron ore fines.. 1,653,500 Limestone.. 218,700 Dolomite.. 17,300 Calcined lime.. 35,500 Pyroxenite.. 69,100 Flue dust.. 17,300 Mill scale.. 40,800 Coke breeze and anthracite.. 124,700 NOTE: (1) Quantities are approximate net input for 4 12

33 4 Major plant facilities (cont d) sinter plant on dry basis. Major facilities The sinter plant will comprise: - Proportioning section - Mixing and nodulizing section - Sinter machine section - Sinter cooler section - Sinter stabilizing section - Sinter storage and despatch - Waste gas cleaning section - Plant dedusting system - Cranes, hoists and elevator - Plant electrics - Instrumentation and Level-1 automation system - Plant communication system - Utility system - Air-conditioning and ventilation system - Fire fighting system BLAST FURNACE Production programme Two (2) blast furnaces (BF-1 and BF-2) of useful volume (U.V.) of about 1008 cu m and 550 cu m respectively will be installed to produce mtpy of basic grade hot metal in a year. Design basis The design basis of blast furnaces is given in Table 4-8. TABLE 4-8 DESIGN BASIS OF BLAST FURNACES Item Blast furnaces Hot metal production, mtpy Daily production capacity, thm/day (avg).. 4,184 No. of furnaces.. 2 Useful volume, cu m (approx) and 550 Productivity, t/(useful volume)/day (approx.) Operating days Burden: Sinter, %.. 80 Pellet, %.. 20 Top gas pressure, kg/sq cm (g) O2 enrichment, %.. 3 to 4 Coke rate (including nut), Kg/thm Coal rate, Kg/thm (1008 cu m BF) 2.75 (550 cu m BF) (1008 cu m BF) 1.2 (550 cu m BF) 4 13

34 4 Major plant facilities (cont d) Slag rate, Kg/thm Coke ash, % Hot blast temperature, 0 C Si in metal, % Analysis of raw materials The major raw materials for blast furnaces comprise sinter, pellet, additives and coke. Pulverised coal will be injected through tuyeres as auxiliary fuel in furnaces. The typical analysis of raw materials envisaged is given in Table 4-9. TABLE 4-9 TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS) Fe SiO2 Al2O3 CaO MgO % % % % % Sinter Pellet Quartzite Ash basis Moisture CSR CRI % % % % Coke (min) Coal for PCI application Ash, % (dry basis) : Fixed carbon, % : Input materials quantity The annual input materials required for the envisaged hot metal production of 1,464,300 mtpy from blast furnaces are given in Table

35 4 Major plant facilities (cont d) TABLE 4-10 INPUT MATERIAL QUANTITIES Material Annual Consumption tons/year (1) Fluxed sinter (charge).. 1,918,200 Pellet.. 480,300 Quartzite.. 21,950 Charge coke (hard+nut).. 606,200 Injection coal.. 175,700 NOTE: (1) All quantities are approximate net input to blast furnaces on dry basis. Hot metal quality (typical) The expected hot metal quality is as follows: Si S P % % % (max) 0.15 (max) Facilities in blast furnace The blast furnaces will comprise of the following facilities: - Stock house and charging system - Blast furnace proper - Cast house and cast house equipment - Hot blast stoves - Gas cleaning system - Slag granulation plant and dry slag pit - Blowers - Pig casting machine and hot metal ladle repair shop - Coal dust injection system - Electrics, instrumentation and automation - Plant communication system - Utility system - Water system - Top gas recovery turbine - Cranes and hoists - Fire fighting system - Air-conditioning and ventilation system 4 15

36 4 Major plant facilities (cont d) STEELMELT SHOP 1 (SMS-1) Design basis Steelmelt shop 1 (SMS-1) will be designed with IF route with installation of induction furnace (IF), ladle furnace (LF) and continuous casing machine (CCM) for production of about 130,300 tons per year of billets. Balance requirement of billets for mills will be met with production from SMS-2. Induction furnace (IF): (3) nos. 15 ton/7.2 MVA capacity Ifs are envisaged in the project. The estimated quantity of liquid steel from the IFs works out to be around 133,700 tpy as per detailed on the next page. Consent to establish is already available for the manufacturing of 30,000 tpy. No of furnaces.. 3 Capacity of IF.. 15T/7.2 MVA Net operating days Charge mix.. 70% DRI 20% Pig Iron 10% return scrap Tap to Tap time, mins Average number of heats possible from one (1) IF Average number of heats/day from 3 IFs Average number of heats/day considered from 3 IFs (1) Liquid steel, tons / year.. 133,700 NOTE: (1) Although 30 heats/day can be produced from 3 IFs (each IF will be capable to produce 10 heats/day), taking combined availability of logistics, furnaces, caster and other variables into account, consideration of 27 heats/day from three (3) furnaces to be cast for 330 days will be rational. 4 16

37 4 Major plant facilities (cont d) Ladle furnace (LF): It is proposed to provide one no. matching capacity LF i.e 15 tons equipped with arc heating, inert gas stirring and alloy addition facilities to treat the heats tapped from IF. All the 27 heats produced from IFs will be conveniently treated at one LF with an average treatment cycle time varying between minutes per heat depending on the extent of treatment required. Continuous casting machine: It is proposed to install one (1) no. 2-strand billet continuous casting (CC) unit in order to cast the envisaged liquid steel production. A casting time of mins will be adopted to match with the three IFs being operated in staggered way of 46 mins considering each IF tap-to-tap time of 140 mins, thus making one heat available in every 46 minutes for casting sequence. One (1) no. 2-strand billet caster will be able to cast the entire quantity of 133,700 tpy of liquid steel on the basis of casting 27 heats/day. Assuming a yield of 97.5 % from liquid steel to cast billets, the annual quantity of billets will be 130,300 tpy. Annual production from SMS-1: of SMS-1 will be as below: The annual production Liquid steel, tpy.. 133,700 Semis (Billets), tpy.. 130,300 Requirement of raw materials and supplies The requirement of the raw materials and major supplies for annual production of 130,300 tons of billets is presented in the Table

38 4 Major plant facilities (cont d) TABLE REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES Raw materials and supplies Annual consumption, tons/year DRI.. 112,700 Pig.. 32,200 Scrap (return).. 16,100 Ferro alloys.. 2,000 Burnt lime.. 2,700 Fluorspar Electrode.. 60 Pet coke Oxygen, N cu m/yr x 10 6 N 2/Ar, N cu m/yr x 10 6 Propane/LPG, N cu m/yr x 10 6 Equipment and facilities for steelmelt shop-1 The major equipment and facilities proposed to be installed in the steelmelt shop-1 are briefed below: Induction Furnace (IF): Three (3) nos. 15 ton capacity IFs consisting of two (2) crucibles each are envisaged for melting DRI, pig iron and return scrap. Major technical parameters are given as follows: No. of units.. Three (3) No of crucibles.. Two (2)/furnace Capacity.. 15 tons Transformer rating MVA IF and LF gas cleaning system: A common system for collection and cleaning of fumes from IFs and LF is proposed to be provided. Fume collecting hood dedicated for two crucibles of each IF will be provided. This will be of swinging type and is operated on 4 18

39 4 Major plant facilities (cont d) the crucible which is under operation. Fumes from each IF will be joined in one common duct. Fume from LF will also be collected through a water cooled hood, sleeve and ductwork. The ducts carrying fumes from the LF and the duct carrying fume from IFs will join in the mixing chamber, from where the gases will be led to the bag house, by means of ID fans. Clean gases having less than 50 mg per N cu m dust content will be exhausted through a stack. Ladle furnace (LF): The relevant parameters of the LF are as follows: No. of units.. One (1) Nominal capacity.. 15 tons Heating rate deg C/min Transformer rating MVA Type of unit.. Lift/lower roof type This unit will also be utilized to hold the heats for an extended period of time, should it be necessary for any reason, such as, sequencing of casting in CC machine, hold up in CC machine, etc. All the required features including both top and bottom rinsing, multi-strand wire feeding, automatic temperature measurement and sampling facilities will be provided. Billet casting machine (CCM): The salient features of the CCM are indicated below: No. of machines.. One (1) No. of strands.. Two (2) Type of machine Mould Casting practice Ladle capacity, ton.. 15 Billet Size.. Conventional billet caster, radial bow type.. Tubular mould.. open/closed sq mm & 150 sq mm 4 19

40 4 Major plant facilities (cont d) The continuous casting machine will be inclusive of ladle turret, ladle shroud manipulator, tundish preparation facilities, mould and segment assembly, testing and storage facilities, etc. Necessary automatic control system for casting speed, primary/secondary cooling water system and billet transfer system up to the end of cooling bed will also be provided. Provision of emergency water supply to caster in case of power failure will be provided. Shop auxiliary and maintenance facility: Suitable shop auxiliary equipment will also be considered. Facilities for debricking/relining/drying of refractory for ladles & tundishes, slide gate nozzle and porous plug setting, tundish nozzle setting, mould preparation, testing and assembly will be provided. STEELMELT SHOP 2 (SMS-2) Design basis Steel melt shop-2 (SMS-2) will be designed with installation of electric arc furnace (EAF), ladle furnace (LF), vacuum degasser (VD) and continuous casting machine (CCM) for production of about 1,460,200 tons per year of billets/blooms. The EAF has been designed considering use of DRI, hot metal and scrap as metallics. A hot metal pretreatment facility (hot metal desulphurization plant) is also envisaged in the shop. The billet quantity per year of 1,460,200 tpy is considered with optimum number of heats produced from two (2) EAFs that can be cast through two (2) nos. 4-strand billet cum bloom caster. The total quantity of semis produced from both SMS-1 and SMS-2 meets the mill production requirement. Electric arc furnace (EAF): In order to achieve the required production of billets, it is proposed to install two (2) nos. 4 20

41 4 Major plant facilities (cont d) 90ton/70 MVA capacity EAFs. The estimated quantity of liquid steel from the EAFs works out to be around 1,497,600 tpy as per the basis detailed below. No of furnaces.. 2 Capacity of EAF.. 90 tons/70mva Number of operating days Charge mix.. 52% hot metal 45% DRI 3% return scrap Tap-to-Tap time, mins.. 55 Average number of heats/day/eaf.. 26 No of heats from 2 EAFs.. 52 Liquid steel, tons/year.. 1,497,600 Ladle furnace (LF): It is proposed to provide two nos matching capacity LFs i.e 90 tons equipped with arc heating, inert gas stirring and alloy addition facilities to treat the heats tapped from EAF. All the 26 heats produced per day per EAF can be conveniently treated at one LF with an average treatment cycle time varying between 40 to 50 minutes per heat depending on the extent of treatment required. Hence, two (2) nos LFs will suffice the shop requirement. Vacuum degassing (VD): While the LFs will be adequate to produce almost all the steel grades, certain special grades requiring low gas levels need to be degassed to obtain the required quality. These heats after LF treatment will be transferred with adequate superheat to VD unit for degassing. Minor additions may be required at VD unit as well. It is proposed to install one no. of VD unit, in case if all the heats are required to be processed through VD. Normally, the refining cycle time will be minutes. 4 21

42 4 Major plant facilities (cont d) Continuous casting machine: It is proposed to install two (2) nos. 4-strand billet cum bloom continuous casting units in order to cast the envisaged liquid steel production. The product sizes of the billet caster include 130 mm to 200 mm square billets. The speed will be adjusted for different billet sections according to steel grades and facilitating sequence casting operation. A casting time of mins is adopted to match with EAF tap-to-tap time of 55 mins. Two (2) nos. 4-strand billet cum bloom caster will be able to cast the entire quantity of 1,497,600 tpy of liquid steel on the basis of casting 26 heats/day/caster. Assuming a yield of 97.5 % from liquid steel to cast billets, the annual quantity of billets will be 1,460,200 tpy. Annual production from SMS-2: The annual production of SMS-2 will be as below. Liquid steel, tpy.. 1,497,600 Semis (Billets/Blooms).. 1,460,200 Requirement of raw materials and supplies The requirement of the raw materials and major supplies for annual production of 1,460,200 tons of billets is presented in the below Table TABLE REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES Raw materials and supplies Annual consumption tons/year Hot metal (after HMDP).. 905,500 DRI.. 782,800 Return Scrap.. 53,000 Ferro alloys.. 40,000 Additives.. 7,500 Burnt lime.. 97,400 Burnt dolo.. 22,500 Fluorspar.. 3,700 Pet coke.. 4,500 Steam.. 8,

43 4 Major plant facilities (cont d) Electrode.. 3,600 Oxygen, N cu m /yr x 10 6 Ar/N 2, N cu m/yr x 10 6 Propane/LPG, N cu m/yr x 10 6 Equipment and facilities for steelmelt shop-2 The major equipment and facilities proposed to be installed in the steelmelt shop-2 are described below: Hot metal desulphurization plant: The sulphur content in hot metal will be percent (max). In order to meet the requirement of low sulphur content in steel, desulphurisation of hot metal will be installed prior to feeding the hot metal into EAF. Hot metal will be desulphurised by deep injection of a combination of desulphurising reagent (calcium carbide and magnesium) in charging ladle by injection lances. Provision for mono-injection (CaC 2) and co-injection (CaC 2 +Mg) as well as deslagging will be provided. Electric arc furnace (EAF): The salient features of the EAF are indicated below: Number of furnaces.. Two, EBT type Furnace capacity.. 90 tons Furnace transformer.. 70 MVA Metallic charge, approx.. 52% Hot metal, 45% DRI + 3% return scrap Method of charging.. Continuous charging of DRI/flux, and charging of hot metal by charging crane or via a launder Hot metal will be charged to EAF by means of hot metal ladle held with shop EOT cranes either by opening the furnace roof or via a hot metal launder through the slag door. Water cooled side panels and water cooled roof have been envisaged. 4 23

44 4 Major plant facilities (cont d) EAF and LF gas cleaning system: A common system for collection and cleaning of fumes from EAF and LF and dust from the raw material handling system of the steelmelt shop is proposed to be provided. Fumes and dust will be evacuated directly from EAF roof through water cooled elbow, movable sleeve, combustion chamber, water cooled ducting, forced air cooler and mixing chamber to the bag house. The secondary fumes arising during hot metal charging, deslagging, tapping, etc. and those escaping from the annular spaces around electrodes will be collected through a canopy hood located in the building roof above crane level. The fume from LF will also be collected through a water cooled hood, sleeve and ductwork. The ducts carrying fumes from the LFs and from the roof canopy, as well as ducts carrying dust from the dust extraction points of the raw material handling system will join the mixing chamber, from where the gases will be led to the bag house, by means of ID fans. Clean gases having less than 50 mg per N cu m dust content will be exhausted through a stack. Ladle furnace (LF): The relevant parameters of the LF are as follows: No. of units.. One (1) Nominal capacity.. 90 tons Heating rate deg C/min Transformer rating.. 14 MVA Type of unit.. Lift/lower roof type This unit can also be utilized to hold the heats for an extended period of time, should it be necessary for any reason, 4 24

45 4 Major plant facilities (cont d) such as, sequencing of casting in CC machine, hold up in CC machine, etc. All the required features including both top and bottom rinsing, multi-strand wire feeding, automatic temperature measurement and sampling facilities will be provided. Vacuum degassing (VD) unit: VD unit will primarily be used for ladle degassing to reduce the entrapped as well as the dissolved gases in steel such as hydrogen, nitrogen and oxygen to desired levels, and chemical homogenization. The salient features of the VD unit are given below: No. of units.. One Ladle capacity, tons.. 90 Type of unit.. Stationary vacuum vessel with cover lift and travel car Vacuum system.. Multi-stage stream ejector with boosters and condenser units Billet cum bloom casting machine (CCM): The salient features of the CCM are indicated below: No. of machines.. Two (2) No. of strands.. Four (4) Type of machine.. Conventional billet cum bloom caster, radial bow type Mould.. Tubular mould Casting practice.. open/closed Ladle capacity, ton.. 90 Billet Size: sq mm to 200 sq mm The continuous casting machine will be inclusive of ladle turret, ladle shroud manipulator, tundish preparation facilities, mould and segment assembly, testing and storage facilities, etc. 4 25

46 4 Major plant facilities (cont d) Necessary automatic control system for casting speed, primary/secondary cooling water system and billet transfer system up to the end of cooling bed will also be provided. Provision of emergency water supply to caster in case of power failure will be provided. Raw material handling and conveying: Facility for DRI conveying from DR plant to SMS storage bunker and further conveying and charging to EAF will be considered. Lime will be either conveyed from lime plant or brought by transport vehicle and stored in storage bunkers for further charging to EAF. Ferro alloys will be brought by transport vehicle from stores and stored in storage bunkers for further charging to EAF & LF. Facility for storage and charging of lime and ferro alloy will be provided. Shop auxiliary and maintenance facility: Suitable shop auxiliary equipment will be provided. Facilities for debricking/ relining/drying of refractory for ladles & tundishes, slide gate nozzle and porous plug setting, tundish nozzle setting, mould preparation, testing and assembly will be provided. CALCINING PLANT The production of calcined lime & burnt dolomite has been considered based on the following requirements: Calcined product Net requirement for steel melt shop Net requirement for other plant/sale tpa tpa tpa Calcined lime 100, ,900 Burnt dolomite 22,500 22,500 In view of the above, total net production of calcined lime and burnt dolomite is estimated as around 250,900 tpa and 45,000 tpa respectively. In case of future expansion, the calcined materials for other plant/sale will be used to meet the in-plant requirement 4 26

47 4 Major plant facilities (cont d) first and then the excess calcined products, if any, will be sent to the Odisha plant or sold out in market. The calcined product will be screened before dispatch to the steel melt shop or other plant and the undersize fraction of calcined products will be used in sinter plant. Considering handling and screening losses as well as fluctuation in the specific consumptions of calcined lime and burnt dolomite, the daily peak production requirement is estimated as 984 tons for calcined lime and 176 tons for burnt dolomite based on 330 days working annually. The installation of a separate dolomite kiln for the above requirement will make non uniform kiln size in comparison with other plants. Hence, it is proposed to install two (2) Nos. each of 600 tpd capacity vertical shaft kilns for the production of calcined lime and burnt dolomite in separate campaign. The high grade limestone and dolomite in the size range of mm is proposed to be used. The annual net requirement of limestone and dolomite in the size range of mm has been estimated at about 606,880 tons and 114,660 tons respectively. The calcining plant will comprise raw materials storage and handling, kilns with kiln feed building, calcined product handling and storage facilities. Various utilities, such as fuel, electric power, water, compressed air, etc., will be made available to the plant. The plant will be provided with kiln waste gas cleaning system and dedusting system for raw material and product handling facilities. WIRE ROD MILL (WRM) It is proposed to install a wire rod mill of 500,000 tpy capacity under the 1.5 mtpy expansion plan. 4 27

48 4 Major plant facilities (cont d) Design basis Product-mix: The finished product will be produced in following sizes: Rounds Coil weight (max.) mm.. 2 ton The grades of steel for wire rods considered are low & medium carbon steel, spring steel, welding rod, tyre bead, cold heading quality (CHQ) steel, ball bearing steel. The size-wise and grade-wise product-mix for the proposed single strand 0.5 mtpy capacity wire rod mill (WRM) is given in the next page. Product-mix, size in mm Description Total tpy tpy tpy tpy tpy Low carbon 45,000 35,000 25,000 25, ,000 Medium carbon 30,000 30,000 30,000 30, ,000 Spring steel 15,000 15,000 25,000 15,000 70,000 Tyre cord 35, ,000 Welding rod 40,000 30, ,000 Ball bearing 15,000 10,000 10,000-35,000 Cold head quality ,000-40,000 Total 180, , ,000 70, ,000 Billet requirements: It is proposed to use 150 mm sq (with a provision for 160 mm sq) and 12 m long billets which would give a coil weight of about tons. However, the wire rod mills will be capable of rolling 130 & 160 sq mm. 4 28

49 4 Major plant facilities (cont d) Yield: Material losses in the production of wire rods arise due to scale, shear, cropping, trimming, cobbles, etc. In a modern mill, average yield is 97 per cent. Hence an yield of average 97% has been considered. Thus total billet requirement will be 515,500 ton for a annual production of 500,000 tpy wire rods. Reheating furnace capacity: A 150 tph walking beam type furnace has been selected for the wire rod mill. Major equipment Continuous cast (CC) billets from the Steel Melt Shop will be transferred through roller table of caster bay or cross transfer (cold billet) to storage bay of this shop. The mill will comprise of the following major facilities: - Billet charging and discharging equipment - Walking hearth type reheating furnace (150 tph) - Descaler - Roughing train - Intermediate train - Prefinishing blocks - Finishing blocks - Post Finishing blocks (optional) - Water boxes before & after finishing blocks - Shears - Pinch rolls - Laying head - Air cooling conveyor - Reform station - C-hook conveyor - Coil compacting, trimming and strapping machine - Weighing device - Unloading stations The mill will be provided with its own roll/rings and guide shop, express laboratory, recirculating water treatment facilities, etc. 4 29

50 4 Major plant facilities (cont d) MEDIUM MERCHANT MILL (MMM) A medium merchant mill (MMM) of 650,000 tons per year capacity will be installed. It will roll continuous cast (CC) billets received from the steel melt shop. The CC billets will be stored, inspected and conditioned in the continuous cast billet storage aisles, and then transferred and stocked in the finished billet storage aisles. Design basis Product-mix: Low, medium and construction grade steel of following sizes will be rolled in this mill: Size mm Quantity tons/year below: Beams (ISMB, ISJB, ISLB) ,000 Channels (ISMC, ISJC, ISLC) ,000 Rounds ,000 Squares ,000 Angles ,000 Flats x 12,15 75,000 Total.. 650,000 Billet requirements: The billet size and requirement is given Billet size mm sq, 12 m long, Yield.. 95% Billets required.. 684,200 tons Mill characteristics: MMM will be designed to roll at a maximum speed of 16 meters per second. The mill stands are divided into three groups roughing, intermediate, finishing groups. The finishing group will have convertible stands for rolling beams. 4 30

51 4 Major plant facilities (cont d) Reheating furnace capacity: A walking beam type furnace of 180 tph has been selected for MMM. Major equipment Continuous cast (CC) billets from the Steel Melt Shop will be transferred through roller table of caster bay or cross transfer (cold billet) to storage bay of this shop. The mill will comprise of the following major facilities: - Billet charging and discharging equipment - Walking hearth type reheating furnace (180 tph) - Descaler - Roughing train - Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers and fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - weighing and collecting station LIGHT MERCHANT MILL (LMM) A light merchant mill (LMM) of design capacity 400,000 tons per year capacity will be installed. However, the plant will produce 371,300 tons of finished product. It will roll continuous cast (CC) billets received from the steel melt shop. The CC billets will be stored, inspected and conditioned in the continuous cast billet storage aisles, and then transferred and stocked in the finished billet storage aisles. 4 31

52 4 Major plant facilities (cont d) Design basis Product-mix: Low, medium and construction grade steel of following sizes will be rolled in this mill: Size mm Quantity tons/year Rebars & Rounds ,000 Squares ,000 Channels ,000 Angles ,000 Beams ,000 Flats.. 25x5-75 x 12,15 25,000 Total.. 400,000 given below: Billet requirements: The billet sizes and requirement is Billet size & 150 mm sq, 12 m long Yield.. 95% Billets required.. 390,800 tons Mill characteristics: LMM will be designed to roll at a maximum speed of 22 meters per second for rolling of rebars and round of size 10 to 40 mm. Reheating furnace capacity: A walking beam type furnace of 100 tph has been selected for LMM. Major equipment Continuous cast (CC) billets from the Steel Melt Shop will be transferred through roller table of caster bay or cross transfer (cold billet) to storage bay of this shop. The mill will comprise of the following major facilities: - Billet charging and discharging equipment - Walking hearth type reheating furnace (100 tph) - Descaler - Roughing train 4 32

53 4 Major plant facilities (cont d) - Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers and fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - Weighing and collecting station CAPTIVE POWER PLANT The following captive power plants have been envisaged to generate the electrical power in the plant: - 2 x 130 MW power plant (CPP-1) - 2 x 7.5 MW in-plant gas based power plant (CPP-2). This plant will also generate 20 MW mechanical power for BF blowers. The power demand of the steel plant facilities are indicated in Chapter 5. The installed capacity, average power and energy generation, etc. are given in Table 4-13 in the next page. TABLE 4-13 ESTIMATED POWER GENERATION CAPABILITY Sl. No. Description CPP-1 CPP-2 TRT 1. Installed capacity, MW 2 x130 2 x Average electrical power generated, MW 3. Send out power, average, MW Send out energy, MU, yearly 1, Technical profile of the captive power plant Table The technical profile of the CPP-1 and CPP-2 are indicated in 4 33

54 4 Major plant facilities (cont d) TABLE 4-14 TECHNICAL PROFILE OF CPP Sl. No. Description CPP-1 CPP-2 1. Nos. and size of boilers 4 Nos. coal fired boilers (AFBC) of 250 TPH each and 4 Nos. Waste heat recovery boilers of 50 TPH 2 Nos. by-product gas fired boilers 80 TPH each 2. Nos. and size of turbines 2 Nos. x 130 MW 2 Nos. x 7.5 MW TOP RECOVERY TURBINES (TRT) The TRT has been envisaged to recover energy from the top gas of blast furnace and convert to power. Around 4.5 MW of power will be available from top recover turbine of blast furnace. AIR SEPARATION PLANT (ASP) The industrial gases viz. oxygen, nitrogen and argon are envisaged to be received through pipeline supply at Battery Limit from the ASP. Oxygen Oxygen (99.5% purity) will be required in EAF, cutting operation in caster, scrap and for other general purpose usage. Low purity oxygen will be required in blast furnace for enrichment purpose. Nitrogen Nitrogen (99.9% purity) will be required for gas line purging process purpose and general purpose (e.g. instrumentation, etc.) applications in blast furnace, sinter plant, EAF, casters and rolling mills, etc. 4 34

55 4 Major plant facilities (cont d) Argon Argon (99.995% purity) will be required in Vacuum Degasser (VD) in SMS-2. Facilities proposed An ASP of capacity 600 TPD will be required to meet the above demand of oxygen, nitrogen and argon. The ASP will be installed in Build-Own-Operate (BOO) basis. Besides, the oxygen plant will have adequate liquid generation and storage capacity so as to supply 72 hours of oxygen, nitrogen and argon in the event of stoppage of operation of the ASP. Oxygen will be available at pressure levels of 40 kscg and 8 kscg from the ASP. Nitrogen will be available at pressure of 20 kscg. Argon will be available at the pressure of kscg. Buffer vessels and pressure reducing stations for oxygen, nitrogen and argon will be provided to cater to the various peak requirements of the process. PLANT MATERIALS FLOWSHEET The plant materials flowsheet for the proposed steel plant is given in Drawing No

56 5 UTILITY AND SERVICE FACILITIES This Chapter presents electric power distribution system, water system, various utility systems and auxiliary facilities of the proposed project. POWER DISTRIBUTION SYSTEM AND ELECTRICS This section presents the estimated power requirements, characteristics of plant loads, source of power and power distribution philosophy for the proposed steel plant at Bilaspur, Chhattisgarh. Plant power requirements The estimated power requirements for the proposed plant are indicated below: Annual Energy Consumption, million kwh.. 1, min. maximum demand: in MW in MVA (0.9p.f.) min. peak demand, MVA Note: The power balance reveals that around 62 MVA power will be exported from the plant to the grid considering all proposed captive power generations. Characteristics of plant loads The major consumers of power for the proposed plant will impose a more or less steady load on the power system. The electric arc furnaces (EAF), ladle furnaces (LF) and main drives of Mills will be fluctuating power consumers and will impose flicker and harmonics in the power system. 5 1

57 5 Utility and service facilities (cont d) In order to mitigate the effect of flicker adequately rated static var compensation (SVC) equipment will be provided. In order to mitigate the effect of harmonics, reactive power compensation equipment with power factor improvement capacitor banks arranged in harmonic filter circuits will be provided. The plant overall power factor will be maintained in the range of 0.9. Source of power The power requirement of the proposed plant will generally be met from the following captive power plant sources: (i) Two (2) captive power plants, each having capacity of 130 MW, with coal fired boilers. (ii) Two (2) captive power plants, each having capacity of 7.5 MW, from by-product gas. This plant will also generate 20 MW mechanical power which will be sent to blast furnace blower. (iii) One (1) captive power plant of capacity 4.5 MW with top pressure recovery turbine (TRT) of blast furnaces. Further, it is given to understand that there will be connectivity over 220 kv over head lines with the nearby 220 kv grid substation located approximately 20 km away from the plant. Power distribution philosophy A new 220 kv Main Receiving & Step down Substation (MRSS) will be established in the proposed area for the expansion project. The transmission line from grid substation will be terminated at the incoming line gantries of MRSS. The switchyard at MRSS will be laid out with double busbar arrangement with one incomer, one outgoing and one bus-coupler bays. The space for future expansion will be kept in the MRSS. 5 2

58 5 Utility and service facilities (cont d) The power distribution system will be so developed that the electrical power generated from 2 X 130 MW CPP, 2 X 7.5 MW CPP and 1 X 4.5 MW TRT will be utilized for feeding plant loads. The excess generation will be evacuated to grid. The start-up power for CPPs will be arranged from 220 kv MRSS over suitable power distribution arrangement. The power will be stepped-down to 33 kv for feeding bulk power. The EAFs, LFs and Induction Furnaces will be fed from from 33 kv dirty bus and other steady loads like existing DR plant, sinter plant, BFs, continuous casting machines and rolling mill loads will be fed from 33 kv clean bus. The power will be further stepped-down to 6.6 kv at respective plant units for feeding HT motors and 6.6 kv/ V load centre substation transformers. The LT consumers will be fed from respective 415 V switchboards of load centre substations. INSTRUMENTATION AND AUTOMATION SYSTEMS This section describes the automation systems proposed in general for various individual process plant units as well as on overall organization basis for the project. The automation systems are envisaged to enable NISL to achieve higher productivity with better quality in a planned and well-co-ordinated manner using state-of-the-art equipment and facilities. Structure of proposed automation system The automation systems proposed have been structured application-wise into four hierarchical levels as follows: Level 1 - Instrumentation and Basic Automation Level 2 - Supervisory Computer and Process Automation Level 3 - Manufacturing Execution (Level 3) System (MES) 5 3

59 5 Utility and service facilities (cont d) The salient features of Level 1, Level 2, Level 3 automation systems as well as the SCADA systems, Communication and FDA systems are presented in the following: Instrumentation and level-1 automation The various plant units will each be provided with dedicated DCS/PLC based Level 1 automation systems and necessary instrumentation, which will perform all the functions for controlling, regulating, data acquisition, alarms and interlocks including material tracking, drive control and other process specific technological control system (TCS) functions, wherever required. The system will have necessary hardware and software features to ensure plant safety as well as ease in operation and maintenance. As far as possible, it is proposed to adopt common type of hardware and software. The system will be suitably interfaced with higher level (level 2) process computer system, wherever required. The instrumentation and Level 1 automation system will be configured around an Open System Architecture for implementing smooth interoperability among different systems as well as maximum unit availability, using an integrated, functionally distributed Programmable Logic Controller (PLC)/Distributed Control System (DCS) based system. The digital control system will mainly comprise required No. of intelligent HMI s and Process Stations / PLCs interconnected over the data communication bus system. The HMI s will consist of Personal Computers along with TFT-LED monitors, keyboard, alarm, event and report printers. HMI s will also include engineering and programming terminals. Laptop type programming terminal will be provided for programming of PLCs and drives. 5 4

60 5 Utility and service facilities (cont d) The Process Stations / PLCs will be of the latest state-of-art technology suitably connected to the bus system. The data communication bus as well as CPU, communication processors and power supply unit in PLCs will be in redundant configuration. Package PLCs will be conceived where ever essential and will be suitably interfaced with the corresponding main PLC, etc. Remote input/output units connecting inputs/outputs in different plant areas with the PLC system will be envisaged. I/O bus will be fiber optic if required based on distance between PLC and Remote I/O units. Parallel redundant type UPS will be envisaged for power supply to Automation, Instrumentation, Communication and FDA system equipment with battery back-up for a duration of minimum 30 mins. The design of control system and related equipment will adhere to the principle of Fail Safe Operation at all system levels. The software for the Level-1 automation and instrumentation system will be simple, user friendly and have the provision of on-line editing and programme development without interrupting the process lines and the same will support on-line diagnostic features. All field sensors and instruments will be of latest state-ofthe-art design. All transmitters will be Smart type conforming to HART/FF protocol. Field bus (Profibus/FF) technique will be adopted wherever found suitable. 5 5

61 5 Utility and service facilities (cont d) Process automation (level-2) system The proposed steel plant will be equipped with state-of-the art supervisory computer and process automation system (Level 2) for improved quality, process optimisation management, product tracking and reporting functions. The systems will be configured based on client-server architecture and will have provision for future expansion and upgradation, when needed. The production units such as blast furnace, hot metal desulphurization station, electric arc furnace, ladle furnace, vacuum degasser, continuous billet casting machines, wire rod mill, medium merchant mill, light merchant mill as well as the reheating furnaces will have dedicated Level 2 systems to achieve higher productivity with better quality in a planned and coordinated manner. All necessary control functions including process models as well as supervisory functions like PDI handling, product tracking, data archival, reporting, etc. will be considered for optimized operation of the units. Also, following automation systems may be considered for better tracking & utilization of process units for optimized operation: - Laboratory Management System - Yard Management System - SMS area Ladle tracking System Supervisory control and data acquisition system (SCADA) A supervisory control and data acquisition system will be implemented at specific places for monitoring & control (if required) of production, distribution and consumption of the different utilities and water systems as well as for the electric power system. 5 6

62 5 Utility and service facilities (cont d) The SCADA system will be installed in a central location in the plant and will be based on Client/Server architecture with server and HMI clients and necessary Remote Terminal Units (RTU) located at various strategic points. Manufacturing execution (level-3) system A production planning and control system, more commonly known as Manufacturing Execution System, at the next higher level of the automation hierarchy is proposed on overall plant basis. The system will be used for execution of various production automation related functions like Provision for order entry, Technical dressing of commercial order, Production planning, Detailed production scheduling, Resource allocation, Production progress control & monitoring, Quality data collection and assessment, Data acquisition and archival, KPI monitoring, etc. The system will be designed considering servers housed in a central location in the plant and clients distributed in various areas and departments. IT infrastructure Data communication network will be proposed for providing intranet/internet facility for all kind of business related data with required servers and application software. The network will include switches and related cabling within the plant area. The proposed network will have 3-tier star topology based architecture. Access switches will be at the lowest level and connected to the corresponding zonal switches. Zonal switches will be connected to the centralized core switches at the top level. The proposed network will also have the facility to further integrate/ interface with the future expansion. 5 7

63 5 Utility and service facilities (cont d) PLANT COMMUNICATION SYSTEM Following communication facilities are envisaged for reliable and quick communication amongst various units of the plant: Plant telephone system Plant telephone system as envisaged will comprise of required nos. of exchanges/gateways located at strategic nodes of the plant along with associated cable network, for providing telephone facilities all over the plant. These exchanges/gateways will be interconnected over Plant OFC backbone to work together as an integrated virtual single telephone exchange. Loudspeaker intercommunication (LSIC) system Independent loudspeaker intercommunication (LSIC) system is envisaged in respective plant unit to ensure quick communication facility amongst various sections inside the respective plant unit. Each LSIC system will provide announcement and point to point calling facility. Closed circuit television (CCTV) system Independent closed circuit television (CCTV) system is envisaged in respective plant unit for viewing and monitoring critical operating areas from control rooms. Each CCTV system will be IP based and will comprise of cameras, PC based monitors and other equipment. Wireless communication system VHF Wireless Communication system is envisaged for communication between cranes or moving machine operators and control room/supervisory personnel on shop floor as well as amongst operation & maintenance personnel. 5 8

64 5 Utility and service facilities (cont d) Plant optical fiber cable (OFC) backbone An optical fiber cable (OFC) backbone is envisaged inside the plant covering a number of strategic nodes at different plant units. This OFC backbone will be used for integration of various systems (e.g. plant telephone system, SCADA, fire detection and alarm system, etc.) FIRE DETECTION AND ALARM SYSTEM Intelligent addressable microprocessor based fire detection and alarm (FDA) system is envisaged in each plant unit in order to have an early detection and location details in case of possible fire outbreak in the plant premises. All the FDA systems will be monitored from central fire station of the Plant. WATER SYSTEM Water is primarily required in the steel plant for equipment cooling. In addition, it is also used for process use, for collecting and conveying of scales, control of dust and debris; for drinking and sanitation; for fire-fighting and for other miscellaneous purposes. Water requirement It is estimated that the total make-up water requirement for the proposed plant will be 2,040 m³/hr out of which 20 m³/hr will be soft water, 60 m³/hr will be DM water and 20 m³/hr will be used for drinking and sanitation purpose. Total make up water requirement of 2,040 m³/hr is considered based on water cooled condenser of the power plants and wet handling type gas cleaning plant (GCP) for blast furnace. Out of the estimated make-up water requirement of 2,040 m³/hr, about 905 m³/hr make-up water is required for proposed expansion to 1.5 mtpy integrated steel plant and balance 1,135 m³/hr make-up water is required for the power plants. 5 9

65 5 Utility and service facilities (cont d) Estimated shop-wise break-up of the make-up water requirement is given in Table 5-1. TABLE 5-1 MAKE-UP WATER REQUIREMENT Sl. No. Consumers Make-up water requirement Cu m per hour 1. Raw Material Handling System Coal washery Lime calcining plant 7 4. Oxygen plant Sinter Plant Blast Furnace including pig 219 casting machine & slag granulation plant 7. DR plant Steel Melt Shop (SMS-1) 49 consisting of induction furnace, ladle furnace, billet caster 9. Steel Melt Shop (SMS-2) 329 consisting of electric arc furnace, ladle furnace, vacuum degassing unit, billet cum bloom caster 10. Wire rod mill Medium section mill Light section mill BF TRT power plant Surplus BF gas based power 168 plant 15. Coal based power plant DM Plant Softening Plant Drinking & Sanitation Fire water Miscellaneous Requirement 30 Total 2596 Recovery from treated effluent from the system and reused 556 Grand Total 2040 Note: Blow down/waste effluent from the various water systems will be collected in blow down sump and common effluent plant and the same will be treated and reused for various consumers. 5 10

66 5 Utility and service facilities (cont d) Source of water The water source for the proposed steel plant is from river Sheonath. The proposed plant is located about 100 m away from the river. An existing intake pump house had already been constructed and rising main of 250 mm was laid from the intake pump house to the plant for supplying water to the existing plant comprising one (1) no. 500 TPD DR plant. It is understood from NISL that the existing intake pump house is not capable to handle additional water requirement. So, a separate intake pump house will be installed to meet the water requirement for proposed expansion project. It is also understood from NISL that at present, withdrawal of about 560 m³/hr water on a continuous basis is allowed from river Sheonath. Out of the 560 m³/hr water available, 250 m³/hr water has to be delivered by the existing intake pump house to one (1) no. existing 500 TPD DR plant. So, remaining 310 m³/hr make-up water can be drawn by the new intake pump house and delivered to the proposed plant facilities. NISL will arrange to provide additional 1,730 m³/hr by obtaining permission from the State Water Resource Department to meet the requirement of proposed plant. Plant water system A raw water reservoir, of 14 days storage capacity, will be provided within the plant boundary. The requisite quantity of water will be continuously withdrawn from the reservoir to be treated in the Raw Water Treatment Plant to makeup water quality. This grade of water will be supplied as make-up to the various re-circulating water systems. In addition to this, a portion of this water will be further treated to produce soft water, to be supplied as make-up to various close-loop systems, and drinking water for the plant personnel. 5 11

67 5 Utility and service facilities (cont d) In order to conserve water to the maximum possible extent, independent recirculating system with cooling towers, pump houses and treatment units, wherever required, have been proposed for the units envisaged for this project. Make-up water of desired quality will be supplied to each individual recirculating system. In certain contaminated circuits make-up water will be fed from blowdown of non-contaminated circuit to conserve water consumption. The plant water system comprises make-up water system, recirculating water systems, drinking water system and water based fire-fighting system, emergency water supply system for the vital units of the plant, waste water, effluent and sewage generated in the plant will also be reused after treatment. Adequate arrangement will be made for rain water harvesting by collecting the rain water in the plant. The schematic water flow diagram for the proposed plant is given in Drawing No The different plant water systems considered in this section, their respective consumers and broad facilities provided for each system indicated in Table 5-2 in the next page which reflects a conceptual water supply scheme for plant water systems. 5 12

68 5 Utility and service facilities (cont d) TABLE 5-2 MAJOR WATER SYSTEMS Sl. No. System Main consumer/source Main facilities 1. Make-up water system 2. Drinking water system 3. Water based fire fighting system 4. Soft water system 5. Coal washery recirculating system 6. Lime calcining plant recirculating system. 7. Oxygen Plant recirculating system. 8. Sinter Plant recirculating system 9. Blast Furnace recirculating system 10. Slag Granulation Plant water system Cold wells of various recirculating systems, consumptive and oncethrough water systems, Softening Plant, DM Plant, etc. Plant Personnel and laboratory. Yard/shop hydrant. Various close-loop cooling systems, Byproduct plant. Contaminated open cooling circuit. Open-loop indirect cooling systems. Open-loop indirect cooling system Open-loop indirect cooling systems. Various close-loop and open-loop indirect cooling systems, contaminated Gas Cleaning Plant water system Contaminated open cooling circuit. Make-up water storage tank, pumphouse with pumpsets and accessories, raw water treatment plant, distribution pipework. Pumpsets, filters, chlorination unit, overhead tank, pipework. Motor driven and diesel engine driven pumpsets, storage reservoir of required capacity, ring main, yard and shop hydrant system. Softening plant with regeneration system, supply pumps and pipework. Pumphouses, pumps and associated equipment, settling tank, etc. Pumphouses, pumps and associated equipment, cooling towers. Pumphouse, pumps and associated equipment and cooling tower. Pumphouses, pumps and associated equipment, cooling towers. Pumphouses, pumps and associated equipment, cooling towers, heat exchangers, waste water treatment plant. Pumphouses, pumps and associated equipment, settling tank, etc. 11. Pig Casting Machine recirculating system Contaminated open cooling circuit. Settling tank, sump and pumpsets. 5 13

69 5 Utility and service facilities (cont d) TABLE 5-2 MAJOR WATER SYSTEMS (cont d) Sl. No. System Main consumer/source Main facilities 12. DR plant recirculating system 13. SMS-1 consisting of induction furnace, ladle furnace, caster recirculating system 14. SMS-2 consisting of electric arc furnace, ladle furnace, vacuum degassing unit, caster recirculating system 15. Wire Rod Mill recirculating system. 16. Medium Section Mill recirculating system. 17. Light Section Mill recirculating system. 18. BF TRT power plant 19. Surplus BF gas based power plant 20. Coal based captive power plant 21. Effluent Water Treatment system Open-loop indirect cooling systems. Various close-loop and open-loop indirect cooling systems. Various close-loop and open-loop indirect cooling systems. Various close-loop and open-loop indirect cooling system and contaminated direct cooling system Various close-loop and open-loop indirect cooling system and contaminated direct cooling system Various close-loop and open-loop indirect cooling system and contaminated direct cooling system Condenser cooling and other open-loop indirect cooling systems, DM water Plant. Condenser cooling and other open-loop indirect cooling systems, DM water Plant. Condenser cooling and other open-loop indirect cooling systems, DM water Plant. Waste effluent generated from various shops Pumphouses, pumps and associated equipment, cooling towers, settling tank. Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant. Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant. Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters. Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters. Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters. Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc. Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc. Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc. Effluent water treatment plant. 5 14

70 5 Utility and service facilities (cont d) Waste water and effluent treatment management Waste water generated from the different areas of the plant will be treated to the desired extent in suitable treatment facilities and recycled back to the process, to attain zero discharge, facilitating adequate reuse of water in the respective recirculating systems and economizing on the make-up water requirement. Sewage generated from toilet blocks, etc., will be collected by means of suitable sewer system for treatment in package type Sewage Treatment Plant (STP) and the treated sewage will be transported to Effluent Treatment Plant (ETP). The blow down from the indirect cooling water will be collected in a blow down sump. The water accumulated in the blow down sump will be reused as make up to low end users such as pig casting machine, slag granulation plant contaminated open cooling circuit, raw material handling system and make-up to fire water reservoir. Balance waste effluent generated from the various units will be treated in ETP and the treated effluent will be used as make up in make-up water system. Distribution pipework Mild steel or pipes of suitable material of construction are considered for various units of plant water system. All the pipelines except fire water line, drinking water line & treated waste water line will be routed over ground in the yard. Fire water line, drinking water line & treated waste water line will be routed in buried condition with necessary corrosion protection. However, for railway crossing, pipe tunnel has to be considered. Shop internal pipes with protection-painting will be routed through the building structure. The pipe-work will comprise all necessary pipes, valves, fittings and hydrant complete with all other accessories as required as per relevant standards. 5 15

71 5 Utility and service facilities (cont d) UTILITY SYSTEM Fuel system The by-product BF gas generated i.e. blast furnace gas will be mixed with LPG/propane and utilised as fuel for various heating applications of the steel plant. Balance available gas will be utilised in power plant for steam and power generation. The major consumers of fuel gas in the steel plant are for blast furnace stove heating, sinter plant, heating equipment in the steel melt shop, furnaces in the mills, lime calcining plant and the boilers. Small quantities of fuel would also be required for the repair shops, etc. By-product gas generation: The generation of by-product gas is given in Table 5-3. TABLE GENERATION OF BY-PRODUCT GAS By-product gas Volume Energy N cu m/hr 10 9 kcal/yr BF gas.. 268,000 1,823 Availability of by-product gases for power generation Surplus by-product gases, which will be available after meeting the plant demands, will be as given in Table 5-4. TABLE 5-4 SURPLUS BY-PRODUCT GAS AVAILABILITY (N cu m/hr) By-product gas Quantity N cu m/hr BF gas.. 120,

72 5 Utility and service facilities (cont d) LPG/propane manifold In addition to being used as a fuel, LPG/propane will be required for cutting operation of the caster. To meet the requirement of LPG/propane, one (1) no. LPG/propane manifold system with distribution piping of suitable capacity is envisaged. Process steam Process steam required for the plant will be made available through controlled extraction of the condensing turbine of the by-product gas fired power plant. Steam network of around 13 kscg and temperature of C has been envisaged within the plant for process steam. Plant and instrument air system Plant grade compressed air for general service purpose usage like pneumatic conveying, bag filter pulsing and dry instrument grade compressed air for the operation of pneumatic devices for instruments and controls, pneumatic tools, etc., will be required in each of the production shops and other ancillaries. Requirement of plant grade compressed air and balance requirement for dry instrument grade compressed air will be met from one centralised compressed air station of suitable capacity of centrifugal compressor, along with required nos. air receivers of requisite capacities. The pressure of the available compressed air will be around 7-8 kscg. Suitable nos. of refrigerated air dryers along with required nos. air receivers of requisite capacities have been envisaged to meet the balance oil-free dry instrument grade compressed air requirement. The pressure of the available dry instrument grade compressed air will be around 5-7 kscg. 5 17

73 5 Utility and service facilities (cont d) Air pollution, ventilation and air conditioning Air pollution control systems: The scheme proposed for prevention of air pollution is as follows: - Collection of fumes from deslagging station and argon rinsing station and discharging them to the atmosphere through stacks after cleaning. - Removal of dust generated during various operations by local exhaust systems. Ventilation systems: The ventilation systems proposed to achieve desired conditions in different areas are as follows: - Switchgear rooms, cable tunnel, cable basement, oil and hydraulic cellars: Mechanical ventilation system using fan-filter units for supply and exhaust fans. - Compressor Building, transformer rooms: mechanical ventilation system using exhaust fans. - Production building: natural ventilation by roof monitors as necessary. Natural ventilation arrangement will be adopted in most of the production buildings. Air conditioning systems: The air-conditioning systems are proposed to be designed to maintain the following condition in the spaces serviced: - 25 ± 2 0C dry bulb temperature and 55 ± 5 percent relative humidity for control rooms, control pulpits, computer rooms, PLC rooms, laboratory, etc. - To meet the above requirement, chilled water based air conditioning are envisaged throughout the plant. Chilled water plants Vapour compression type chilled water plant of adequate capacity are envisaged to satisfy the air conditioning and ventilation needs of various units. Chilled water inlet and outlet 5 18

74 5 Utility and service facilities (cont d) temperature will be maintained at 16 0 C and 7 0 C respectively. Ring mains for both supply and return pipelines will be suitably provided around the shops. Overhead yard pipework The Steel plant will have a piping network for distribution of the air separation plant products, various utility services, steam, water, etc. The yard portion of the pipework for all services (except water) will be laid on towers and trestles with a clear height of 7 m above finished ground level (FGL). Shop internal pipework will generally be routed in multiple rows through building columns taking support from buildings and girders. Central utility monitoring and control A centralised control room for utilities and water services will be located at the Energy Management Centre (EMC) in Fuel Management building for overall monitoring of critical parameters of utility systems provided for the new facilities. AUXILIARY FACILITIES Laboratories To meet the analytical and testing needs of the proposed plant, suitable laboratory facilities will be considered at different locations in the plant. Repair shops and stores Repair and maintenance shops are important units of any integrated steel plants not only for the manufacturing spares and replaceable items but also for catering to the capital and running maintenance requirement of the various units of plant. It has been envisaged that total repair and maintenance work of the steel plant including manufacturing operational spares 5 19

75 5 Utility and service facilities (cont d) will be outsourced to the competent agencies. NISL will provide the following infrastructural facilities: - Shop with EOT cranes/hoists - Open yard, wherever necessary. - Shop lighting arrangement without light fittings - Electric power at one point near the equipment/machine tools for operation - Portable and industrial water at one point - Industrial grade compressed air at one point - Metering facilities for the utility services Facilities for repair shops and stores: It is envisaged that the following repair shops and stores will cater to the need of maintenance services and repair activities: - Central repair shop, - Electrical repair shop, - Mobile equipment repair shop - General store - Refractory store - Alloy store - Oil and lubrication store ANCILLARY FACILITIES Necessary ancillary facilities, such as administrative building, canteen, car park, cycle and scooter stands, first-aid station, etc., will be provided based on the manpower requirement for the plant. Drainage and sewerage system Open type drain has been envisaged for the plant storm water drainage. The drains will be laid generally by the side of the roads. Storm water run-off, collected through arterial and trunk drain, will be discharged to the existing river Sheonath. 5 20

76 5 Utility and service facilities (cont d) Sanitary faecal sewage will be collected from the ablution blocks through pipeline and the same will be connected to a sewage treatment plant. The effluent from sewage treatment plant will be utilized for the development and maintenance of greenery. Roads Adequate plant road system will be provided considering the types of vehicles and the traffic volume. The road system will be designed to minimize cross movement of vehicles. Adequate vehicle parking facilities and road weighbridges will be provided. 5 21

77 6 - ENVIRONMENTAL POLLUTION MITIGATION MEASURES The proposed project involving the expansion of Integrated steel plant of NISL to 1.5 MTPA crude steel production, comprises of coal washery, sintering, iron making, steelmaking, casting and rolling etc. have been discussed in the previous chapters. This production would generate wastes in different forms, the recipient of which would be air, water and land environment causing pollution of these environmental elements. This Chapter accordingly outlines the various mitigation measures in compliance with the prevailing Environment Protection Acts & Rules and amendments thereof taking into consideration of the proposed production facilities envisaged for the project. Review of Pollution Potential The production from new production units; namely, Sinter Plant, Coal Washery, Blast furnace, DR Kiln, Lime Calcining Plant, SMS and the mills. The off gases would be utilized for in-plant use and power generation. Also power would be generated from BF top gas heat recovery turbine. Hence, the project would generate particulate dusts, Volatile organic compounds (VOCs), Dioxins, Furans, oxides of sulphur and nitrogen and carbon dioxide to the air environment. Likewise, there would be generation of waste water due to enhanced capacities, contaminated with total suspended solids (TSS), B.O.D, C.O.D, oil and grease etc. which are of major concern from environment perspective. 6-1

78 6 - Environmental Pollution Control Measures (cont d) The land environment may get disturbed due to generation of the solid wastes like BF slag, SMS slag, mill scales etc which may call for other secondary environmental problems. Proposed Mitigation Measures In view of the aforementioned plant facilities, there would be pollution load, for which adequate mitigation measures as described below have been considered: Air Pollution Control (APC) Measures Material Handling Area: There would be fugitive dust emission from the handling and stockpiling of the added raw material, which would be controlled by Dry Fog (DF) system. The raw material handling section is provided with dust suppression (DS) by water sprinkling at open stockyard. All conveyors would be of covered types and leak proof to prevent any emission of dusts during transport of raw materials and products. All closed zone working areas such as raw materials handling zone, conveyor transfer points, dust generation points at screen is provided with multiple dust extraction (DE) systems/dry fogging (DF) at several emission points to control the fugitive dust emissions. DE system shall consist of suction load followed by bay filter, ducts, extraction fans and stack of adequate height. Coal Washery: In coal washery, the primary air pollution control measure would dust suppression system (DS). During conveying the coal, dust emissions from junction house and discharge points would be mitigated by Dust Extraction (DE) systems. Other areas would be facilitated with water sprinklers to minimize suspended dust levels. Sinter Plant: In Sinter Plant, the principal air pollution control system is dust extraction (DE) or fume extraction (FE) 6-2

79 6 - Environmental Pollution Control Measures (cont d) systems and ESPs with stacks of appropriate heights. Stretching of the capacity of sinter plant would add to the present pollution level, requiring augmentation of present APC equipments. Blast Furnace: In addition to cleaning of BF gas in gas cleaning plant (GCP), which is a process requirement, dust and fumes emission in stock house and cast house areas would be controlled by dust and fume extraction (DE & FE) systems respectively in all the operating BFs. DR Plant: The exhaust gas from the kiln would be contaminated with dust particulates, SO 2, NO x and carbon. At the kiln inlet, a dust settling chamber (DSC) would be provided for allowing the dust to settle before entering the After Burning Chamber (ABC). The ABC would be provide with additional combustion air fans for proper burning of the combustibles contained in the kiln off-gas. The dust collected at the DSC would be emitted from time to time through a wet scraper, located at the bottom of the DSC and dispatched to the dumping yard. The DR Kiln off gas would pass through the Post Combustion Chamber to burn out CO in the flue gas before it is taken to the Waste Heat Recovery Boiler (WHRB) for generation of power. Calcining Plant: The emissions arising due the fuel burning in lime calcining plant is taken through a bag filter to separate out the lime fines. The kilns would be provided with separate DE systems, complete with bag filters and stack of adequate height. EAF and IF: The primary emissions would be extracted by fume extraction (FE) system. Fumes would be indirectly cooled and cleaned through a bag filter for separation of particulates and the clean gas would be vented into the atmosphere through a tall stack of adequate height. The secondary emissions would be controlled through canopy hood extraction, integrated with the main system to 6-3

80 6 - Environmental Pollution Control Measures (cont d) clean the fugitive emissions during charging and tapping operations. The gas cleaning system would be complete with water cooled duct, fume & gas cooler, bag house, ID fan and stack of adequate height. LF: The primary emissions extracted from the LF area collected by fume extraction (FE) devices. Dust laden fumes are indirectly cooled and cleaned through a bag filter for separation of particulates and the clean gas is vented into the atmosphere through a tall stack of adequate height. Mills: The reheating furnaces are incorporated with low NOx burner and controlled combustion would take place. The flue gas, which is fairly clean, is vented through a stack of adequate height. These pollution control measures would be carried on and additional APC measures would be adopted as per requirement. Water Pollution Control (WPC) Measures: The source water for the plant would be the Sheonath river which is situated adjacent to the plant. The wastewater from various units would be treated in the Common Effluent Treatment Plant (CETP) to make it suitable for recycling to the plants direct make up water circuit. Three different types of process effluent streams would be generated from the steel plant complex. For Type-I effluent streams, mostly physico-chemical treatment schemes like oil separation, settling, clarification, ph adjustment etc, would be employed. Type-II effluent, CT blow downs would be taken to the treated waste water storage reservoir for recycling purpose after treatment in the CETP. 6-4

81 6 - Environmental Pollution Control Measures (cont d) Type-III effluent, which is plant sanitary wastewater, would be separately treated in a sewage treatment plant before the same is also routed to the treated effluent storage reservoir. Zero Discharge Concept In order to have a near zero discharge of the proposed plant, the CT blow down along with all other primary treated wastewater streams with high TDS levels may be further subjected to Reverse Osmosis (RO) treatment to reduce the TDS levels and the residual oil & grease, BOD and COD levels, so that this treated waste water as RO permeate can be added to the plants make up water circuit. Work Zone Pollution Control Measures The work zone pollution would be mostly fugitive dust, heat and noise. The fugitive dust emission would be controlled by DS and DE system as described earlier. All the process vessels would be lined with adequately thick refractory bricks to contain the surface heat emission and in some cases they would be indirectly cooled by water. In addition to this, there would be provision for adequate ventilation of the closed zone work environment. Noise arising from the mechanical machineries like crushers, screens, compressors, blowers, pumps etc can not be ruled out. Such noise-prone equipment would be installed in a separate housing so as to enhance the noise attenuation. Isolation of the operational staff from the high noise prone zone would be adopted by providing noise proof control room so that they are not exposed to the noise level exceeding the allowable limit. 6-5

82 6 - Environmental Pollution Control Measures (cont d) Solid Waste Generation and Utilization There would be generation of solid by-products like BF slag, EAF slag, LF slag, IF Slag, mill scales, caster scrap, refractory debris, flue dusts, coal washery rejects etc from the proposed project. It is estimated that the proposed expansion would generated nearly 2.1 MTPA solid wastes comprising mainly of BF & EAF, IF & LF slags, dusts, etc. TABLE SOLID WASTE GENERATION 1.5 MTPA STAGE Sl. No. Solid By-product Expected generation at 1.5 MTPA crude steel stage, TPA 1. BF slag 453, EAF slag 265, IF slag 13, LF slag 19, Dust, mill scales and 58,100 sludges 6. Coal Tailings 451, CPP Ash 993,693 BF slag would be required to be granulated before it is sold off. The flue dusts, mill scales and scraps would be recycled to the Sinter plant and SMS. EAF and IF slag would be processed for metal recovery and also partly recycled in Sinter Plant, EAF and IF. The non metallic part would be used for various construction purposes. Coal middlings/reject from the washery would be reused in the power plant. CPP ash would be disposed in an earmarked area. Plant Safety Plant safety measures would be an integral part of the environment protection plan of the proposed plant. Workers safety would be of highest degree of concern as required by the Factories act-1948 and OSHAS so as to avoid any personal injury or untoward incident. In-built safety measures of the plant 6-6

83 6 - Environmental Pollution Control Measures (cont d) and machinery would be made adequate in order to avoid hazardous events causing damage to the life and property. Plant Greenbelt and Landscaping As per the recent regulatory requirement, 33% of the plant area has to be reserved for peripheral greenbelt, gardening and tree plantations. This would not only prevent the fugitive dust emissions but also improve the plant peripheral appearance from aesthetics view point. This would be considered while planning for the expansion facilities. Design Targets for Environmental Protection The proposed mitigation measures would be adopted the following design targets: I. Stack emissions Particulate matter : 50 mg/n cu m SO 2 emission : 500 mg/n cu m NOx emission : 500 mg/n cu m II. Wastewater discharge Temperature : Ambient ph : 5.5 to 9 Total Suspended Solids : < 100 mg/l BOD 3 (27 0 C) : < 30 mg/l COD : < 250 mg/l Oil and grease : < 10 mg/l Iron (as Fe) : < 3 mg/l III. Workzone Environment Exposure to Dusts : 3 mg/cu m (max) in a closed environment 500 mcg/cu m (max) in an open environment within 20 to 30 m aerial coverage Exposure to Noise : L eq 85 db(a) for a continuous period of 8 hours exposure 6-7

84 6 - Environmental Pollution Control Measures (cont d) Environmental Monitoring While design and engineering of the plant, the principal pollution sources like BF, EAF, IF, DR Kilns and captive power plant stacks would be provided with on-line monitoring device for routine monitoring of pollutants like TSP, SO 2 and NOx. In addition, conformance to the ambient air and waste water discharge standards would also be monitored. 6-8

85 7 IMPLEMENTATION SCHEDULE This chapter deals with the construction aspects of project-overall construction schedule and construction facilities for implementation of the project are also presented in this chapter. IMPLEMENTATION SCHEDULE The preliminary overall implementation schedule for the project, indicating the time required to complete the major activities like engineering, construction, procurement of equipment, erection, testing/trial run and commissioning and hook up of the various plant facilities is shown in the form of a bar chart in Fig. 7-1 on the following pages. It is envisaged that the project will be completed within a period of 36 months from Go-Ahead date. The schedule has been developed on the basis of the estimated quantum of work, expected delivery and installation periods of plant and equipment and the need to commission the plant facilities in the shortest possible time. Scheduled commissioning of the plant can only be achieved if construction, delivery and erection periods, as shown in the bar chart, can be met by respective suppliers and contractors. Completion time of major Plant units: Coal washery.. 24 months DR plant.. 30 months Sinter plant.. 30 months Calcining plant.. 25 months Blast furnace.. 30 months SMS months SMS months Rolling mills.. 36 months Captive power plant.. 25 months 7-1

86 7 Implementation schedule (cont d) 7-2

87 7 Implementation schedule (cont d) 7-3

88 7 Implementation schedule (cont d) 7-4