PRE-FEASIBILITY REPORT

Transcription

1 ANNEXURE : IX PRE-FEASIBILITY REPORT FOR ENVIRONMETAL CLEARANCE OF DHENKANALSTEEL PLANT AT VILLAGE JHARBANDH, GALPADA AND TARKABEDA DISTRICT DHENKANAL, ODISHA (EXTENT : ACRES) PRODUCTION 2.6 MTPA STEEL SEPTEMBER, 2018 Submitted by: RUNGTA MINES LIMITED RUNGTA HOUSE, CHAIBASA, JHARKHAND

2 CONTENTS Sl. No. Description Page No. 1.0 Executive summary Introduction Identification of project and project proponent Brief description of nature of the project Need for the project and its importance to the country and or region 2.4 Demand-supply gap Imports vs. indigenous production Export possibility Domestic / export markets Employment generation (direct and indirect) Project description Type of project including interlinked and interdependent projects 3.2 Location with coordinates Details of alternate sites & environmental considerations Size or magnitude of operation Project description with process details Raw material required along with estimated quantity, likely source, marketing area of final product s mode of transport of raw material and finished product 3.7 Resource optimization/recycling and reuse envisaged in the project 3.8 Availability of water its source, energy/ power requirement and source 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management /disposal 3.10 Schematic representations of the feasibility drawing which give information of EIA purpose Site analysis Connectivity Land form, land use and land ownership Topography Existing land use pattern 31 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. i

3 Sl. No. Description Page No. 4.5 Existing infrastructure Soil classification Climatic data from secondary sources Social infrastructure available Planning brief Planning concept Population projection Land use planning (break up along with green belt etc.) Assessment of infrastructure demand (physical & social) Amenities / facilities Proposed infrastructure Industrial area (processing area) Residential area (non processing area) Green belt Social infrastructure Connectivity Drinking water management (source & supply of water) Sewarage system & Industrial waste management Solid waste management Power requirement & supply / source Rehabilitation and resettlement plan Project schedule & cost estimates Project schedule Cost of the project Analysis of proposal (final recommendations) 37 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. ii

4 LIST OF TABLES Table No. Description Page No. 1 Power supply position 3 2 Detail of raw Material and their sources 28 3 Details of product/ finished product 28 4 Solid waste generation (TPA) 30 5 Break up of plot area 32 6 Need evaluation for villages in and around plant area 33 7 Expenditure for CSR initiatives undertaken by Dhenkanal steel plant 8 Solid waste utilisation and disposal plan Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. iii

5 1.0 EXECUTIVE SUMMARY Project name Project proponent Location Latitude Longitude Total Area Present Land use break up Integrated Steel Plant (Dhenkanal Steel Plant) Rungta Mines Limited Jharbandh, Galpada and Tarkabeda, District Dhenkanal, Odisha 85 17' 12" to 85 18' 45" E 20 45' 14" to 20 46' 24" N acres LAND USE IN CORE ZONE (IN ACRES) Sl. No. Name of the Village Private Land (In Acres) Government Lands (In Acres) Leasable Gochar Communal Forest Total Grand Total (In Acres) 1 Jhadabandha Tarkabeda Galapada Grand Total Possession Taken Product Rated Capacity Balance Working Days 350 Manpower Implementation Schedule Expected cost of the project Elevation Topography DRI, Power, Steel, Pig Iron, Ductile Pipe, Pellets, Coke, Cement Phase-I 1.45 MTPA Steel ; Phase-II 1.4 MTPA Steel Phase-I 1300 ; Phase-II Months Phase-I 48 Months; Phase-II 36 Months Phase-I Rs Crores Phase-II Rs Crores Approximate 90 m (Core zone) 60 to 312 m ( Buffer zone) Flat Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 1

6 Water Requirement Source of water Power Description Power Source 2950 Cum/ Hour Brahmani River Phase-I 217 MW; Phase-II 168 MW Power generated shall be utilised in its proposed Steel Plant Captive Power Plant 2.0 INTRODUCTION 2.1 Identification of project and project proponent The proposed Integrated Steel plant is one of the projects of M/s Rungta Mines Limited (RML), which is a one of the leading and the oldest mining group of the mineral rich belt of Odisha & Jharkhand. The company's vision & mission is to utilise its core values & strengths, complemented with the vast experience gained, to help it keep pace with the changing times and respond to domestic & international market forces by maintaining consistent quality & dispatch schedules, making RML synonymous with reliability. 2.2 Brief description of nature of the project The nature of the project is ferrous metallurgical industries and falls under the category of primary metallurgical industry, Thermal Power Plant, Coal Washery, Mineral Beneficiation and Coke Oven Plant which is item no. 3(a), 1(d), 2(a), 2(b) and 4(b), respectively under category A of the schedule of EIA Notification, Need for the project and its importance to the country and or region Steel: India s economic growth is contingent upon the growth of the Indian Steel Industry. Consumption of steel is taken to be an indicator of economic development. While steel continues to have a strong hold in traditional sectors such as construction, housing and ground transportation, special steels are increasingly used in engineering industries such as power generation, petrochemicals and fertilizers. Power: The DRI Kiln operation produces substantial quantity of hot gases, which can be utilised to power generation, further large quantity of waste produce char. Company will also installed AFBC based Power Plant. Also The Company will install WHRB for Blast Furnace & Coke Oven Flue Hot gases. The generated power will meet the power requirement of Beneficiation Plant, Pelletisation Plant, DRI, Blast Furnace, Sinter, Coke Oven, SMS, Caster, Finished Product Mill, Ductile Pipe Plant, Producer Gas Plant, Oxygen Plant, Lime Plant, Cement Plant, Coal Washery. Thus, power demand from the state grid will be not be there and will improve the power scenario locally as well as at state level. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 2

7 2.4 Demand-supply gap Steel: The Indian Steel industry has entered into new development stage from riding high on the resurgent economy and rising demand of Steel. Rapid rise in production has resulted in India to become 5 th largest producer of steel. It is estimated that, India s Steel consumption will continue to grow at nearly 16% rate annually, fuelled by the demand of construction project. The National Steel Policy envisaged steel production to reach 110 million tonnes by So considering the huge demand of steel, this project is important for partially fulfilling of demand. Power: Over the year electricity industry has made significant progress. It may be seen that average gap between generation and demand in India is %. Power supply position is given Table 1. TABLE 1 POWER SUPPLY POSITION Region Peak demand Peak met Deficit % Jan 15 Jan 16 Jan 15 Jan 16 Dec 14 Dec 15 All Northern Western Southern Eastern North eastern All India Source: CEA 2.5 Imports vs. indigenous production Steel : Imports from China had adversely affected the Indian Steel Market and the policy change by Govt of India is now leading to recovery of the sector. There is no proposal for import of steel. Power: There is no possibility of import and will be produced at plant site. 2.6 Export possibility Steel: First priority to meet domestic demand, should also take into account the large export possibilities. Power: There is no possibility of export of power. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 3

8 2.7 Domestic/ Export markets Sponge Iron shall be used as raw material from within house for producing steel. The steel shall sell in domestic market. Total power generated from the 385 MW will be utilised in the Beneficiation Plant, Pelletisation Plant, DRI, Blast Furnace, Sinter, Coke Oven, SMS, Caster, Finished Product Mill, Ductile Pipe Plant, Producer Gas Plant, Oxygen Plant, Lime Plant, Cement Plant, Coal Washery, etc. 2.8 Employment generation (Direct and Indirect) The manpower requirement for steel plant is 1300 people in each phase and an equal number in indirect employment. Many more persons will also get employment in the ancillary & other services connected with this project. 3.0 PROJECT DESCRIPTION 3.1 Type of project including interlinked and interdependent projects No 3.2 Location with Coordinates District & State Village Latitudes Longitudes : Dhenkanal & Odisha : Jharbandh, Galpada and Tarkabeda : to E : to N Location map showing general location, specific location and project boundary enclosed as Annexure III of Form Details of Alternate Sites & Environmental Considerations No alternatives under consideration since the project has already been granted environmental clearance as well as several other clearances are in advanced stage of processing. Majority of the land has been acquired. The proposed project will be incorporated within the acres. 3.4 Size/ Magnitude of operation Plant area: acres Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 4

9 Sl. No. Proposed Manufacturing facilities Plant Facilities No of Units Production Unit Description Unit Unit Capacity Phase-1 Phase-2 Total Capacity Annual Production/ Generation Unit Annual Capacity No of Units Production Unit Description Unit Unit Capacity Annual Production/ Generation Unit Annual Capacity Total Annual Production/ Generation C1 C2 C3 C4 C5 C6 C7 C13 C14 C15 C16 C17 C18=C7+C12+C17 1 Sponge Iron Plant DR Kilns 2 TPD 500 MTPA TPD 600 MTPA TPD 600 MTPA Pelletisation Plant 1 MTPA 1.2 MTPA MTPA 1.2 MTPA Beneficiation Plant (Based on input) 4 Coal Washery (Based on input ROM Coal) 1 MTPA 2.69 MTPA MTPA 2.69 MTPA TPH 400 MTPA TPH 235 MTPA Mini Blast Furnace 1 CUM 600 MTPA CUM 1050 MTPA Sinter Plant 1 SQM 64 MTPA SQM 110 MTPA Coke Oven Plant 6 TPA MTPA TPA MTPA Steel Melting Shop MTPA MTPA Steel Melting Via IF- Route MTPA a Induction Furnace 7 Ton 20 MTPA b Laddle Furnace 4 Ton Steel Melting via EAF- MTPA MTPA Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 5

10 Sl. No. Plant Facilities No of Units Production Unit Description Unit Unit Capacity Phase-1 Phase-2 Total Capacity Annual Production/ Generation Unit Annual Capacity No of Units Production Unit Description Unit Unit Capacity Annual Production/ Generation Unit Annual Capacity Total Annual Production/ Generation C1 C2 C3 C4 C5 C6 C7 C13 C14 C15 C16 C17 C18=C7+C12+C17 VD-AOF Route a Electric Arc Furnace 1 Ton 90 MTPA Ton 160 MTPA b Laddle Furnace 1 Ton 90 1 Ton Continuous Casting Machine a Billets/ Bloom Caster/Slab Caster 9 Finished Product Facilities 9.1 Rolling Mill (TMT/ Flat/ Round/ Wire Rod/ Structural Mill/ others) MTPA MTPA Strands 3 MTPA Strands 3 MTPA MTPA MTPA MTPA a Rolling Mill-1 4 TPA MTPA TPA 300, MTPA b Rolling Mill-2 1 TPA 200, MTPA Strip Mill/Sheet/Coil/ Wire & Bar Mill/Wire Rope 1 TPA MTPA TPA 400, MTPA Ductile Pipe Plant 1 TPA MTPA TPA 200, MTPA Producer Gas Plant Nm 3 /Annum Nm 3 /Annum Producer Gas Plant 10 Nm 3 /Hr 3000 Nm3/Annum Nm 3 /Hr 3000 Nm3/Annum Oxygen Plant MTPA MTPA Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 6

11 Sl. No. Plant Facilities No of Units Production Unit Description Unit Unit Capacity ANNEXURE : IX Contd.. Phase-1 Phase-2 Total Capacity Annual Production/ Generation Unit Annual Capacity No of Units Production Unit Description Unit Unit Capacity Annual Production/ Generation Unit Annual Capacity Total Annual Production/ Generation C1 C2 C3 C4 C5 C6 C7 C13 C14 C15 C16 C17 C18=C7+C12+C17 Oxygen Plant 1 TPD 100 Nm 3 /Annum TPD Nm 3 /Annum Lime Plant MTPA MTPA Lime Plant 1 TPD 300 TPA TPD 570 TPA Cement Plant MTPA MTPA Cement Plant alongwith Clinker Plant 1 TPD 2600 TPA TPD 2300 TPD Captive Power Plant MW MW WHRB Based CPP MW MW a WHRB (500 TPD DR Kiln) b WHRB (600 TPD DR Kiln) 2 TPH 50 MW TPH 60 MW TPH 60 MW c WHRB (MBF) 1 TPH 50 MW TPH 90 MW d WHRB (Coke Oven) 1 TPH 60 MW TPH 100 MW AFBC/CFBC based CPP MW MW a AFBC/CFBC 2 TPH 125 MW b AFBC/CFBC 2 TPH 250 MW TPH 250 MW Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 7

12 3.5 Project description with process details Sponge Iron Plant (DR Plant) Production Facilities: Phase-I Phase-II Quantity Unit Capacity Days Hours Total Capacity TPA 2 TPD ,000 2 TPD ,000 2 TPD ,000 Total 850,000 Capacity after up-gradation: Phase-I Phase-II DRI Plant Unit Capacity Up-gradation Total Capacity 2 X 500 TPD TPA 340, , ,000 2 X 600 TPD TPA 408, , ,000 2 X 600 TPD TPA 408, , ,000 Total TPA 1,156, ,000 1,547,000 Iron Ore (lumps or pellets) is reduced by heating with solid carbonaceous material, such as coal, in a Rotary Kiln to temperature of about 1000 C. After reduction, products are cooled in a drum type rotary cooler and then separated into Sponge Iron and Char by magnetic separation. Main Raw Materials- iron ore, coal and dolomite are fed to the ground hoppers with the help of pay loaders and tippers and are carried away by belt conveyors to the crusher house. Screened and crushed raw material, calibrated by weigh feeders is fed into the kiln. The main reduction process occurs in a rotary kiln. The iron ore is reduced by carbon monoxide generated by burning coal. The material is discharged in the Rotary Cooler at a temperature of about 700ºC, which is cooled up to 90ºC. The product of kiln is taken to a sealed rotary cooler where the product is cooled by indirect water spray. The hot water is collected and passed through the cooling tower. The evaporation loss is made up with make-up water Raw Material Handling System Main Raw Materials Iron Ore, Coal & Dolomite shall be fed to the ground hoppers with the help of Pay loaders and Tippers and carried by belt conveyors to the Crusher House. Screened and Crushed Material will be carried out by belt conveyers to the stock house, having 5 days bins. The Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 8

13 main raw material handling system consists of iron ore crusher, vibrating screen and conveyor belts for preparation of raw material as mentioned above Raw Material Feed System The stored Raw Material are calibrated by Weigh Feeders separately for Iron Ore, Feed coal, Lump Coal, Injection Coal and Dolomite and fed to the Kiln through a Rotary Airlock Feeder. The feed mix will be fed through feed tube, which shall be sealed for leakage of gases with a sealing air fan, which creates a positive pressure to avoid the gas escape. The Injection Coal system injects coal at the discharge end of rotary kiln to avoid Coal starvation with 1 bar pressure at which leakages are not possible. There is a burner system, which shall be used for initial heating up of the kiln to 400 C. Calibrated quantity of combustion air is also fed through the same opening Main Processing System - Kiln The main reduction process occurs in a Rotary Kiln made by boiler quality Plate. The Drive unit consists of 2 nos. main drive gearbox and 1 no. auxiliary gearbox. The kiln is supported by four nos. tyres and 08 nos. support rollers, one girth gear and two pinions. Calibrated quantity of air is fed to the kiln by shell air fans mounted on the kiln shell. The iron ore is reduced by the carbon monoxide generated by burning coal. The product of Kiln is taken to a Sealed Rotary Cooler where the product is cooled by indirect water spray, which is discharged to a conveyor at about 90 C. The cooler discharge is also sealed with a collecting hopper. There are 4 nos. slip seals at Kiln Inlet, Kiln Outlet, Cooler Inlet & Cooler Outlet that shall be made up of Ni hard steel. The seals are also lubricated to avoid false air entry into the kiln and gas leakage from the kiln. At inlet side of the Kiln, a back flow chute is made which is sealed with a Double Pendulum Flap Gate Valve Cooling System The material is discharged in the Rotary Cooler at a temperature of about 700ºC, which is cooled up to 90 o C. The Drive Unit consists of one Main gearbox and one Auxiliary gearbox. The cooler is supported by Two Tyres and four support rollers. This will be cooled by indirect circulating cooling water system, the hot water shall collected and passed through the cooling tower. The evaporation loss is made up with makeup water Product Separation System The Cooler Discharge material consists of Sponge Iron lumps, fines and ash of coal (char), and is taken to a vibratory screen and two nos. magnetic separators by belt conveyor. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 9

14 The Magnetic and Non Magnetic material are separated here and stored in fully closed hoppers. The Product House consists of silo for sponge iron lumps, sponge iron fines and char. The char shall be used as fuel in the proposed Power Plant Flue Gas Cleaning and Pollution Control The flue gas coming out from the Rotary Kiln is passes through a Dust Settling Chamber, in which the heavier dust is settled down. The bottom of the dust settling chamber is immersed in the wet scrapper water which is working as the sealing to avoid the gas leakage and false air entry. The gas next passes through the After Burning Chamber (ABC) in which the carbon monoxide and un-burnt carbon are burnt completely. The flue gas is taken to the Waste Heat Recovery Boiler (WHRB), where the recoverable heat is utilized for generation of high pressure steam. The flue gas is next passed through an electro static precipitator (ESP), where the gas is cleaned up to maximum level. The clean gas passes to the atmosphere through the Chimney with the emission level of less than 100 mg/nm 3. The boiler bottom hoppers and E.S.P hoppers are provided with a dense phase ash handling system. The dust collected from these hoppers is sent to an ash silo by pneumatic conveying system. Finally the stored dust in the ash silo is taken to the solid waste disposal site for storage and final disposal to brick manufacturing plants/ cement plants Requirement of Raw Materials The main raw materials for sponge iron production are iron ore, coal, and dolomite. RAW Material for DRI Plant Phase-I Raw Material Requirement (1,001,000.00) Raw Material Inputs Specific Consumption T/T of Production /Generation Quantity (TPA) % Charge Mix Iron Ore 1.5 1,501, % Coal , % Dolomite , % Total 2,342, % Phase-II Raw Material Requirement (530,400 TPA) Raw Material Inputs Specific Consumption T/T of Production /Generation Quantity (TPA) % Charge Mix Iron Ore , % Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 10

15 Raw Material Inputs Specific Consumption T/T of Production /Generation Quantity (TPA) ANNEXURE : IX Contd.. % Charge Mix Coal , % Dolomite , % Total 1,277, % Total Raw Material Requirement DRI Plant (1,196,800 TPA) Raw Material Specific Consumption Unit Required Own Source From Outside Purchase Iron Ore 1.5 TPA 2,320,500. 2,293,000 27,500 Coal 0.8 TPA Dolomite 0.04 TPA 1,237,600 1,237,600 - Total Production / Generation from DRI Plant Product Unit Phase-I Production Phase-II Production Total Production DRI TPA 1,001, ,000 1,547,000 Char (18% of DRI Production) Coal Fines (12% of Coal requirement) Steel Melting Shop (SMS) TPA 180,180 98, ,460 TPA 96,096 52, ,512 A brief description of the manufacturing process is as follows Induction Furnace (IF) Induction furnace works on the principle of Induction melting of scrap/ sponge iron with the help of electric power. An alternating electromagnetic field induces eddy current in the metal so that the electrical energy converts into heat, whose quantity depends on the resistivity of the charge. Induction furnaces operate on current of commercial frequencies (50Hz) or on current of higher frequencies from 500 to 2000 Hz. These furnaces are beneficial in steel making for low melting loss. An induction furnace constitutes a single larger primary coil made of watercooled copper tube. The working voltage is impressed across the terminals of the coil. The furnace has a rammed lining. The ramming material silica mass contains should more than 96% silica and minimum of Al 2 O 3 & Fe 2 O 3. Before ramming the material, a steel template is kept inside the furnace and the material is rammed between the template and the insulated coil of the Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 11

16 induction heater. To minimize the consumption of electric power and cut down the melting period, the crucible wall must be as thin as possible. The inside of crucible lining is in contact with liquid metal while it s outside surface contacts the water-cooled induction Charging In order to control the air pollution in the induction furnace, dust extraction system will be installed. It consists of suction hood, cyclone, wet scrubber etc. Suction hood mounts on the head of furnace; the flue gases will be sucked through the hood. The blower sucks the flue gases through hood along with pipe, which connected to the cyclone and wet scrubber. The wet scrubber cools the hot gases of furnace through water spray. The nozzles spray water uniformly and perform the fog. The cyclone and scrubber separates the solid particles, dust and it falls down in the bottom of the water tank. The cool and fresh air will be exhausting through the Air Vent, in which the dust concentration will be less than 100 mg/nm Ladle Refining Furnace (LRF) The LF installation will be single station system with provision for arc heating, inert gas stirring, and addition of ferroalloys and additives. The LF will be complete with the transformer, Ladle stirring System, Aluminium wire feeder, Carbon injecting device, additives storage and addition system, Sampling and temperature measuring device. A fume extraction and cleaning system consisting of bag filters, ID fan and chimney with the related duct work will be provided. Production Capacity Quantity Unit Capacity Days Hours Heats Total Capacity TPA IF 7 Ton ,000 LRF 4 Ton 20 Total 539,000 Raw Material Requirement for SMS Via IF route Raw Material Unit Required Own Source From Outside Purchase DRI (From DR Plant ) Pig Iron (From MBF ) TPA 539, ,000 - TPA 87,880 87,880 - Scrap TPA 29,293-29,293 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 12

17 Continuous Casting Machine (CCM) Semi-Finished Product Caster IF Rote: The Caster is complete with ladle stand, mould assembly, Strand guide segments and supports withdrawal and straightening system, mould cooling system, Cut- off equipment incl. length measuring device, marking machine etc. Production Capacity Quantity Strands Days Hours Total Capacity TPA ,220 Raw Material Requirement Raw Material Unit Required Own Source From Outside Purchase Hot Metal (From Induction Furnace) TPA 539, , Electric Arc Furnace (EAF) In the electric steel making process, the necessary heat is generated by electrical power. This precludes the possibility of impurities being introduced into the melt. The industrial facilities employed for converting electrical energy into heat mainly take the form of electric arc furnaces and induction furnaces. More than 90% of electric steel is produced in the electric arc furnace with the arc providing a concentrated source of heat. In the case of the AC furnace, there are three graphite electrodes striking three arcs. Each conducts the electric current through the metallic charge to the next electrode in accordance with the supply phase sequence. In the case of the alternative DC furnace developed to commercialization over the last few years, one graphite electrode, the cathode, conducts the electrical power via the arc through the metallic charge to the bottom anode. Temperatures of up to 3500oC are created in such arcs for melting the metallic charge. The electric arc furnace (EAF) is thus particularly well suited to the production of the full range of alloy steel grades. In the case of the basic oxygen steel making processes, on the other hand, the danger arises that the expensive alloying elements will be absorbed at least in part by the slag. Owing to their high energy consumption and limited const-efficiency, for many years electric arc furnaces were only used for the production of high grade steels. The situation changed with the increase in tapping weights (heat volume) and a significant reduction in the cost of energy, electrodes, refractory materials and investment. Today, electric arc furnaces combined with scrap metallurgy and a secondary metallurgy processes are used for production of widely varying grades of steel, and in particular the tonnage qualities. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 13

18 The main components of the electric arc furnace are the furnace shell with its tapping protrusion and work/slag opening, the removable roof with the electrodes, and the tilting device. The furnace shell is refractory-lined. EAF tapping weights start at just a few tones and can in some cases reach figures of 200 ton. The work/slag opening and tapping protrusion are arranged opposite each other. The complete furnace is inclined with the aid of the tilting device for tapping purposes. Normally, the furnace is charged with its roof removed. When scrap is added, a charging bucket travels over the furnace, its bottom opens and the scrap is discharged into the furnace, so filling it in just a few minutes. During the melting process, a control system advances the slowly burning consumable electrodes so that they gradually slip in a downward direction. The requisite electrical power cannot simply be taken from public grid. High voltage must be converted into low voltage and high amperage by means of a transformer. The most important parameter for the efficiency of an electric arc furnace is the specific apparent power of the transformer related to 1 tonne of charge. Values range from 300 KVA/T to 750 KVA/T (KVA/T= kilovolt ampere per tonne). In be as much as 1,000 KVA/T The Melting Process The melting process performed in an electric arc furnace essentially comprise the following stages. Charging Melting Tapping The charging operation involves not only the input of scrap or direct reduced iron but also addition of ores, fluxes (lime, fluorspar, reducing agents, carbon) and alloying elements in the form of Ferro-alloys. The refining process begins with ignition of the arc. Once melting has been completed, further scrap may be added. The additional injection of oxygen or other fuel gas mixtures accelerates the melting phase. The duration of the melt-down period is determined by the maximum amount of electrical power that can be transferred and the thermal load capacity of the lining. The most advance furnaces with high specific apparent power ratings (=UHP or ultrahigh power furnaces) are able to achieve melt-down times of approx. 40 to 60 minutes and thus tap-to=-tap times of less than one hour. During the refining period, iron oxides contained in the slag react with the carbon of the bath. This gives rise to gaseous carbon monoxide which causes the heat to boil and flushes impurities such as phosphorous, hydrogen, nitrogen and non-metallic compounds out of the melt. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 14

19 These impurities escape as gases or are absorbed in the slag. Sulphur is not completely eliminated in this process Current Status Of The Electric Arc Furnace Process : The advantages of the electric arc furnace include its ability to produce any steel grade completely irrespective of the charge (scrap, direct reduced iron, pig iron or any mixture of these). It is particularly suitable for the production of high-grade alloyed steels. It can be readily automated, it offers a high level of electrical efficiency and requires only a low capital out-lay. Higher installed electrical power (UHP furnaces) Acceleration of the melting phase through the addition of pure oxygen or through the use of gas/oxygen burners Scrap preheating with the aid of process heat from the electric arc furnace Improved tapping (bottom tapping technique) Water cooling of the wall, roof and electrodes Operations with foamed slag and residual slag held over for the next heat Automated addition of alloying elements Automated sampling Improved process control Interlinking of electric arc furnace and ladle furnace (secondary metallurgy) As the installed electrical power increased and the melting process accelerated, a solution had to be found to the problem of handling the increased heat dissipation requirement. Operations with foamed slag to protect the walls from the radiation emanating from the electric arc, the installation of water-cooled furnace panels and the application of the eccentric bottom tapping technique have contributed to solving this problem. With the eccentric bottom tapping arrangement the furnace only has to be tilted by approx. 12, as a result, both the furnace volume and the area covered by water cooled panels can be increased. With bottom tapping, it must be ensured that the slag is drawn off separately and / or largely retained in the furnace. The DC electric arc furnace has recently been developed to commercialization. The furnace operates with just one graphite electrode in Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 15

20 the roof operating as the cathode, and a bottom anode in the hearth. Aside from the more favorable conditions, which prevail during the melting of scrap, this also gives rise to a somewhat lower level of consumption in terms of electrical power input, electrode loss and refractory material wear. As the graphite electrode can be more heavily utilized (power levels up to 120 ka) the resultant increase in energy input leads to shorter melting times and thus a higher level of productivity. The temperature distribution around the furnace as a whole is more even and the melt exhibits a greater degree of homogeneity thanks to the electro-dynamic stirring effect that occurs between the cathode and anode. In order to achieve favorable contract conditions with the bottom anode as quickly as possible at the beginning of the scrap melting phase, the DC furnace is operated with a molten pool (hot heel) of 10 to 20% of the heat weight. This type of plant is DC electric arc furnace with arrangement of components thus suitable more for the production of tonnage steels than of special or stainless steels with often changing chemical compositions. The investment costs overall are higher than the capital outlay required for an AC furnace. As the system per duration (main pollution) caused by the DC source is smaller than with the AC furnace, this furnace type, particularly in the form of large-volume furnaces with heat weights up to 200 T, is often preferred in those geographical locations where the electrical power supply networks are less robust (Asia, certain areas of the USA). The integration of the electric arc furnace and the downstream ladle or secondary metallurgy facilities offers the following benefits: Transfer of all metallurgical operations to the upstream melting stage transfer of all non-melt-related work to the ladle for post-treatment with or without vacuum (ladle furnace) Incorporation of the electric arc furnace, secondary metallurgy facilities and the continuous casting machine within a single production line can give rise to significant savings. The EAF and continuous caster are decoupled with the secondary metallurgical stage performing a buffer function in which the temperature of the heat, the melt analysis (alloy content, desulphurization) and cleanness separation of oxidic in a) Liquid Steel; b) Slag; c) Water-Cooled Coil; d) Crucible Lining; e) Pouring Channel; f) Thermal Insulation; g) Refractory Lining or bricks Selection through a coreless induction furnace Collusions are adjusted to the final values required. Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 16

21 The use of powerful computers for static and/or dynamic process control enhances the cost-effectiveness with which today s electric steel works operate. High efficiency dust removal facilities have further promoted the acceptance of this technology. As mentioned above, owing to these developments, the electric arc furnace is now no longer used exclusively for the production of alloy steels of high cleanness. Recently a special genus of EAF plant has come into being as a components of so-called mini mills designed for the production of basic steel grades Heating Practice After tapping the ladle is transferred to the ladle furnace station on a ladle car where slag builders are added. Inert gas (Argon or nitrogen) bubbling is performed during all operations in ladle and during car transportation. The first heating period will last until the slag is fused, the steel analysis is uniform and the steel temperature is high enough to enable good sampling. While waiting for the sample analysis, heating is continued and main alloying additions are given as soon as the laboratory analysis is received. The temperature is increased to the aim temperature before casting. The main operations in the secondary treatment station are as follows: a) Tapping from the melting unit b) Transport to the ladle furnace station on a ladle car & positioning c) Temperature measurement and sampling d) Slag builder addition e) Slag melting, homogenization f) Temperature measurement and sampling g) Temperature and composition correction (alloy & flux addition depending on steel grade) h) Wire feeding, if any i) Final temperature and sampling and necessary adjustment j) Timing to meet the schedule of casting Production Capacity Quantity Unit Capacity Days Hours Heats Total Capacity TPA Phase-I EAF 1 Ton ,000 LRF 1 Ton Phase-II EAF 1 Ton ,232,000 LRF 1 Ton Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 17

22 Raw Material Requirement for SMS Via EAF route Raw Material Unit Requirement Own (Phase-I) (Phase-II) Total Source DRI (From DR Plant) Hot Metal (From MBF) From Outside Purchase TPA 462, ,000 1,008,000 1,008,000 - TPA 330, ,428 1,141,429 1,063,206 78, Semi-Finished Product Via EAF Route Continuous Casting Machine (CCM) Semi-Finished Product Caster EAF Rote: The Caster is complete with ladle stand, mould assembly, Strand guide segments and supports withdrawal and straightening system, mould cooling system, Cut- off equipment incl. length measuring device, marking machine etc. Production Capacity Quantity Strands Days Hours Total Capacity TPA Phase-I ,140 Phase-II ,207,360 Total 1,886,500 Raw Material Requirement Phase-I Raw Material Unit Required Source Hot Metal (From EAF Furnace) Phase-II Hot Metal (From EAF Furnace) Mini Blast Furnace TPA 693,000 Own Plant TPA 1,232,000 Own Plant Total 1,925,000 The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions. The air is blown through tuyers in the bottom portion and liquid iron is tapped from the tap hole. The blast furnace complex will consist of two blast furnaces Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 18

23 and two pig casting machines along with the requisite support facilities, namely the stock house, coal injection system, cast house, gas cleaning plant, de-dusting facilities, slag granulation facilities, etc. The blast furnace flue gas is passed through Gas Cleaning Plant. A part of the clean gas is utilized for stove of blast furnace and balance clean gas is used as a fuel in the boiler. Production Facility Quantity Unit Capacity Days Hours Ton/ Cum Total Capacity TPA Phase-I 1 CUM ,000 Phase-II 1 CUM ,250 Total 1,559,250 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Unit Required Own Source Iron Ore TPA 701, Own Plant Sinter TPA 1,637, Own Plant Coke TPA 951, Own Plant Coal Dust TPA 77, Talchir Coal field Dolomite TPA 218, Local Market Quartz TPA 81, Local Market WHRB Power Generation Unit Manufacturing of Sponge Iron in Rotary Kiln generates Flue Gases at C from each Kiln. Also, Blast Furnace & Coke Oven generates hot flue gases during the process. As the flue gases contain substantial sensible heat, it is proposed to utilize the heat for power generation through waste heat recovery boilers. Power Generation Facilities for Phase-I Facilities Connected With WHRB 2 Nos. X 50 TPH WHRB 2 Nos. X 60 TPH 2 X 500 TPD DR Kilns 2 X 600 TPD DR Kilns Each unit Waste gases generation quantity (Nm3/Hr) Power Generation (In MW) 120, , WHRB 1 Nos. X 50 TPH MBF 135, WHRB 1 Nos. X 60 TPH Coke Oven 159, Total 67 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 19

24 Power Generation Facilities for Phase-II Facilities Connected With Each unit Waste gases generation quantity (Nm3/Hr) WHRB 2 Nos. X 60 TPH 2 X 600 TPD DR Kilns ANNEXURE : IX Contd.. Power Generation (In MW) 145, WHRB 1 Nos. X 90 TPH MBF 243, WHRB 1 Nos. X 100 TPH Coke Oven 260, Total 68 The waste heat recovery boilers consist of radiation chambers to evaporate steam at 34 kg/cm 2 pressure. The steam is carried to super heater system where the temperature is maintained at 430 C. The boiler has an economizer, which utilizes the heat of outgoing gases to raise the temperature of feed water from 100 to 200 C. The steam is used to rotate the turbine and to generate power. The condensed steam is collected and recycled to the boilers as boiler feed water. A DM water plant is provided for preparation of de-mineralized water for make-up to the steam-condensate cycle. The flue gases are passed through ESPs, where the dust concentration is brought down to below 50 mg/m FBC based Power Plant It is proposed to install 150 MW (Phase-I) & 100 MW Power Plant (Phase-II) with 2X125 TPH & 2X250 TPH FBB capacity in Phase-I & 2X250 TPH FBB in Phase-II capacity, based on Char, Coal, Coal Fines & Middlings firing. The boiler will be of natural circulation, balanced draft, single drum type and will be equipped with fluidized bed firing system. The boiler will be provided with Electrostatic Precipitator to maintain particulate concentration in flue gas at chimney outlet below 50 mg/nm 3. Power Generation Facilities for Phase-I Facilities Quantity Fuel Capacity (in TPH) Phase I AFBC / CFBC 2 Char, Coal Fines, Middlings & Coal AFBC / CFBC 2 Char, Coal Fines, Middlings & Coal Phase II AFBC / CFBC 2 Char, Coal Fines, Middlings & Coal Power Generation (In MW) Total 250 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 20

25 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Specific Consumption Unit Required Own Source Char Generation from DR TPA 278,460 Own Plant Plant 18% 2000 KCal/Kg) Middlings 42.5% in CW TPA 1,759,908 Own Plant 2200 KCal/Kg) Coal Fines from DR Plant TPA 148,512 Own Plant 12% KCal/Kg) Coal KCal/Kg) TPA 843,355 Talchir Coal field Coal Washery The ROM coal needs crushing and washing to reduce the ash content before it can be used in DRI Plant. Therefore a Coal Washery is provided, which will consist of a coal crusher, screening station and washing equipment. Production / Generation Facilities Quantity Unit Capacity Days Hours Unit Total Capacity Phase-I 1 TPH TPA 2,616,480 Phase-II 1 TPH TPA 1,524,480 Total TPA 4,140,960 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Unit Required Source Phase-I ROM Coal TPA 2,616,480 Domestic/Imported/E auction Phase-II ROM Coal TPA 1,524,480 Domestic/Imported/E auction Total Requirement TPA 4,140,960 Total Production / Generation Product Unit Phase-I Phase-II Total Production Production Production Washed Coal (50%) TPA 1,308, ,240 2,070,480 Middlings (42.5%) TPA 1,112, ,904 1,759,908 Reject (7.5%) TPA 196, , ,572 Total TPA 2,616,480 1,524,480 4,140, Coke Oven Plant Raw coal is crushed in a crusher into powdered form and charged in the oven for the purpose of carbonisation. In the process, the volatile matter in the raw coal gets released in the form of gas and is burnt in the oven as well as in the flues and after the completion of the carbonization process, within Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 21

26 the duration of 36 to 38 hours, the raw coal get converted in the form of coke. The coke is then pushed out from the oven and quenched by water. Production / Generation Facilities Quantity Unit Capacity Days Hours Unit Total Capacity Phase-I 6 TPA TPA 420,000 Phase-II 15 TPA TPA 1,050,000 Total TPA 1,470,000 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Unit Required Source Phase-I Coking Coal TPA 634,200 Domestic/Imported/E auction Phase-II Coking Coal TPA 1,585,500 Domestic/Imported/E auction Total Requirement TPA 2,219, Beneficiation Plant, Pelletisation Plant and Sinter Plant Normally iron ores with Fe content above 65% are desirable to achieve better productivity either in blast furnace or direct reduction. Due to non availability of quality iron ore, the run-off-mine (ROM) needed to be beneficiated to lower the impurities to improve the strength of sinter and pellet quality. Hydro-cyclone is proposed for the up-gradation of iron ore as well as for de-sliming of slime particles present in the feed. Beneficiation Plant shall be of 4.2 MTPA while the Pellitisation plant shall be of 2.4 MTPA. Mixture constituting of Ore Fines, Limestone, Bentonite, Coal and slurry ore fed into disc pelletisers. Pellets then go through drying, preheating, recuperation, induration and looking before use. A Sinter Plant of MTPA in Phase-I & MTPA in Phase-II will install to match the requirement of Sinter in Blast Furnace. Sintering is an agglomeration process of Iron Ore Fines/Blue Dust, Coke Breeze and Fluxes. The sinter generated will meet 70% of the charge mix of Blast Furnace. Production / Generation Facilities Quantity Unit Capacity Days Hours Total Capacity Phase-I 1 TPD ,200,000 Phase-II 1 TPD ,200,000 Total 2,400,000 Capacity after up-gradation: Pelletization Unit Capacity Upgradation Total Plant Capacity Phase-I 4000 TPD TPA 1,200, ,000 1,474,000 Phase-II 4000 TPD TPA 1,200, ,000 1,474,000 Total TPA 2,400, ,000 2,948,000 Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 22

27 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Unit Required Source ANNEXURE : IX Contd.. Iron Ore Fines TPA 3,233, Own Mines Dolomite (Flux) TPA 41, Local Market Bentonite TPA 44, Gujarat Coke Breeze TPA 50, Domestic/Imported/ E auction Coal >= 5500 Kcal /kg TPA 98, Domestic/Imported/ E auction Beneficiation Plant Production / Generation Facilities Quantity Unit Capacity Days Hours Total Capacity Phase-I 1 MTPA ,694, Phase-II 1 MTPA ,694, Total MTPA 5,389, Raw Material Requirement for Phase-I Raw Material Unit Required Source Low Grade Iron Ore Fines (0 to 5 mm) TPA 8,983, Own Mines Flocculent TPA Local Market Sinter Plant Production Facility Quantity Unit Capacity Days Hours Ton/ SQM Total Capacity TPA Phase-I 1 SQM ,520 Phase-II 1 SQM ,051,050 Total 1,662,570 Total Raw Material Requirement for Phase-I & Phase-II Raw Material Unit Required Own Source Iron Ore Fines TPA 1,579, Own mines Coke Fines TPA 108, Domestic/Imported/ E auction Lime Stone TPA 249, Local Market Dolomite TPA 83, Local market Lime and Dolo Plant Lime stone and dolomite of size mm will be received from mines and stored in raw material storage yard. From there these material will be conveyed to raw materials storage bunker (capacity 650 ton). The limestone and dolomite from storage bunkers will be fed to a screen by belt conveyor Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 23

28 and under size limestone and dolomite of size 0-25 mm will be screened out and stored in another bunker 9 capacity 300 ton) which is meant to store the undersize limestone and dolomite will be stored onward disposal to outside agencies. Screened material of size mm will be fed to shaft kilns by means of skip hoist through a weigh hopper. The sequence for feeding limestone / dolomite from raw materials storage bunker to screen and from screen to weight hopper is same of all the kilns. Limestone and dolomite will be calcined at temperature of deg C. The Lime & dolomite from the kiln will be discharged to two different conveyors, which area placed below the kiln. The lime will then be screened by single deck screen to separate out 0-10 mm size and mm size of lime and stored in separate bunkers. The sized lime mm will be stored in 2 separate bunkers (each capacity 160 ton). The undersized lime 0-10 mm will be stored in another bunkers (capacity 130 ton). The calcined dolomite will then be single deck screen to separate out 0-10 mm sizes and will be stored in 2 separate bunkers (capacity 160 ton). The undersized dolomite 0-10 mm will be stored in another bunker (capacity 130 ton). Lime and dolomite size mm will be conveyed to SMS through belt conveyor. Undersize lime and dolomite of size 0-10 mm will then be transported to other consumers. Capacity of lime & dolo Plant shall be 300 TPD. Air pollution control measures are given below: 1. Raw waste gas dust before bag filter gm/nm 3 2. Bag filter out put dust mg/nm 3 3. Stack height - 50 m Oxygen Plant (100 TPD ) An air separation unit of 100 TPD for EAF-1 & EAF-2 capacities has been envisaged to meet the requirement of oxygen, nitrogen and argon of the steel plant. Oxygen will be consumed in steel melting shop for oxygen blowing in EAF. In the continuous casting plant to meet the cutting needs and also to meet the general purpose requirement of various shops of the steel plant. The average demand of the oxygen with 99.6 % purity is estimated to be about 68.6 MNm 3 /year. Argon will be required for rinsing in ladles and also to maintain inert atmosphere in the mould/ tundish in the continuous casting plant and for stirring in the ladle during secondary refining. Argon will also be required for laboratory purpose. Nitrogen will be required for purging of fuel pipelines and equipments, etc. Oxygen, nitrogen and argon will be produced by air separation process based on low pressure cryogenic cycle and double column rectification system. List of equipment pertaining to oxygen plant is indicated below: Pre-feasibility Report for Extension of validity of EC for Integrated Steel Plant of M/s Rungta Mines Ltd. 24