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JAI BALAJI INDUSTRIES LIMITED ( Unit – I )
PRE-FEASIBILITY REPORT
for Proposed expansion of existing Steel Plant by installation
of Sponge Iron Plant with 5x100 TPD DRI Kilns, 4x15 T
Induction Furnaces, 50 TPH Coal Washery, Iron Ore
Beneficiation & Palletization Plant & 22 MW capacity
Captive Power Plant along with the product mix change of
existing 2x7 MVA Submerged Arc furnaces
at G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar,
District – Burdwan, West Bengal
September – 2018
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion program of steel complex. 1 - 1
CHAPTER - 1
INTRODUCTION
1.1 BRIEF WRITE UP ABOUT THE GROUP :
Kolkata based Jai Balaji Group is among the top ten steel producers of the
country, having turnover around Rs. 2,500 Crores. The group is engaged in the
production of Sponge Iron, Pig Iron, Steel Billets, Alloy Steel, Rounds, TMT
Bars, along with facilities like Coal Washery, Coke Ovens and Captive Power
Plants Pellet Plant and Sinter Plant.
Jai Balaji Group is a well known steel manufacturing group in the secondary
sector in eastern India. The group has a chain of value-added products which
include Sponge Iron, Pig Iron, Reinforcement Steel TMT Bars, Alloy and Mild
Steel Billets, Wire Rods and Carbon, Alloy and Mild Steel Heavy Rounds. The
group draws its strength from an old tradition of reliable customer service and
quality products.
The group comprises of Jai Balaji Industries Limited ( JBIL ), Jai Balaji Jyoti
Steels Limited, Nilachal Iron & Power Limited, Jai Salasar Balaji Steels Limited
and Chandi Steel Industries Limited.
1.2 BRIEF WRITE UP ABOUT THE COMPANY :
M/s jai Balaji Industries Ltd. (JBIL) previously M/s Jai Balaji Sponge Ltd.
(JBSL), was initially incorporated in West Bengal as a private limited company
on 1st July 1999.
The Board of Directors of the company at their meeting held on 28th August,
2006 approved the merger of Shri Ramrupai Balaji Steels Limited, another
flagship company of the Jai Balaji group with M/s Jai Balaji Sponge Limited
with effect from 1st April, 2006. Subsequently after the merger, the name of the
company was changed to M/s Jai Balaji Industries Limited from M/s Jai Balaji
Sponge Limited.
1.3 FUTURE PLANS FOR SPONGE IRON, ITS FORWARD AND BACKWARD
INTEGRATION
Jai Balaji Industries Limited (JBIL) has an operating steel iron plant at
Mangalpur Industrial Complex, P.O.-Baktarnagar, Raniganj, District – Paschim
Bardhaman of West Bengal. Encouraged by the good results of the already
operating plants and anticipating future market, the company has decided further
expansion of its existing plant at Mangalpur Industrial Complex, details of which
is given in the next page.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion program of steel complex. 1 - 2
Sl.
No
Facilities Existing Capacity
(Having NOC)
Proposal Ultimate Capacity
1. DRI Plant 7 X 50 TPD
or 1,05,000 TPA
5 X 100 TPD
or 1,50,000 TPA
850 TPD or
2,55,000 TPA
2. Coal Washery 2,16,000 TPA (50 TPH) 2,16,000 TPA (50 TPH) 4,32,,000 TPA
3. Iron ore
Beneficiation
Plant
- 6,00,000 TPA
6,00,000 TPA
4. Iron ore Pellet
Plant
6,00,000 TPA 6,00,000 TPA
5 Steel Melting Shop
(Induction Furnace)
2,37,600 TPA (4 X 15 MT)
2,37,600 TPA (4 X 15 MT)
6. Ferro – Alloys Plant
2 X 7 MVA Ferro-Manganese –
15,576 TPA Silico Manganese –
14,580 TPA Total 30,156 TPA
]
Change of Product-Mix (Ferro-Chrome
inclusion)
Keeping the plant configuration unchanged
Either Ferro Manganese - 30,156 TPA (capacity optimized)
or Silico Manganese- 29,.160 TPA (capacity optimized)
or Ferro Chrome – 24,000 TPA (capacity optimized)
Total Ferro-Alloys production will never cross 30,156 TPA
7. Captive Power Plant
18.3 MW
22 MW (10 MW WHRB + 12
MW AFBC )
40.3 MW
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion program of steel complex. 1 - 3
1.4 PLANT LOCATION
The existing plant of the company is located at Mangalpur Industrial Complex of
Raniganj (Lat 25° 52' N, Long- 87° 52 ' E) district – Burdwan of West Bengal
(shown in Fig 1.1). The location is in close proximity to various collieries
belongs to Raniganj Coalfield. The plant is situated on the NH-2 with a distance
of 200 Km. from Kokata.
Fig 1.1(Location of the Plant )
1.5 PLANT LAYOUT The layout showing location of each of the existing and proposed facilities is shown in
Plate 1.2.
Location of the Plant
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
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1.6 PLANT MATERIAL FLOW SHEET
Integrated flow sheet of proposed expansion facilities is shown in Fig 1.3
1.7 AREA REQUIREMENT
The total area required for proposed expansion 85.5 acres land, which is already acquired
by the company.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-1
CHAPTER - 2
MARKET FOR DIRECT REDUCTION (DR) PRODUCTS
Direct Reduced Iron (DRI) has found its use in almost all smelting/ melting systems,
including blast furnaces, submerged arc furnaces, open hearths, basic oxygen furnaces,
induction furnaces (IF), electric arc furnaces (EAF) and cupolas (Fig 2.1). Of these, the major
usage of DRI is undoubtedly in the production of steel through EAF or IF route. Accordingly
the demand of DR products is closely related to the growth of the secondary steel sector. Any
projections about the demand of DRI/HBI should, therefore, be attempted in the overall
scenario of electric steel production projected for the country and the interplay of different
techno-economic considerations that determine the relative percentages of different metallics
in the production of electric steel. A brief review of these aspects is presented in following
paragraphs.
2.1 DEMAND OF STEEL IN INDIA
2.1.1 Past consumption trend
Recorded past consumption trend of steel in India for the period 1987-88 to
2002-03 is presented in Table 2.1 below:
TABLE 2.1
PAST TREND OF FINISHED STEEL CONSUMPTION (ACTUAL
DEMAND) IN INDIA -FOR THE PERIOD 1987-88 TO 2002-03
Year Consumption (‘000 T)
1987-88 12,806
1988-89 14,130
1989-90 14,118
1990-91 14,370
1991-92 14,830
1992-93 15,000
1993-94 15,320
1994-95 18,660
1995-96 21,650
1996-97 22,130
1997-98 22,630
1998-99 23,400*
1999-2000 26.710*
2000-01 29.270*
2001-02 31.630*
2002-03 33.000*
Source: 1. Steel Scenario - Statistical Yearbook 2001.
2. JPC statistics on Iron & Steel, March 2002.
3. SAIL statistics for Iron & Steel Industry in India, 2000.
* Website of Ministry of Steel updated on 04.02.2005
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TEFR for expansion of Steel Complex. 2-2
FIG 2.1 : CONSUMERS OF SPONGE IRON (DRI) or HOT BRIQUTTED IRON (HBI)
DRI/HBI
Blast Furnaces
Submerged Arc Furnaces
Open Hearths Basic Oxygen furnaces
Induction Furnaces
(IF)
Electric Arc Furnaces
(EAF)
Cupolas
Major Users
Smelting/melting systems
Other Users
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-3
It will be seen from Table 2.1 above that there is almost a steady growth (6.5%) in steel
consumption in last 15 years.
2.1.2 Future steel demand
Projections of the steel demand in India for varying time horizons up to 2011-12 have
been made by several agencies from time to time. In order to have a long term
perspective to facilitate planning, a Sub-Group on Steel and Ferro Alloys was constituted
for the steel sector under the aegis of the Planning Commission. The sub-Group
deliberated upon all aspects including supply-demand projections for finished steel
during the period 2001-02 to 2011-12. Considering a GDP growth rate of 6.5% as
realistic during 10th plan, the Sub-Group has projected the demand of finished carbon
steel in the country to rise as given in Table 2.2.
TABLE 2.2
PROJECTIONS OF FINISHED STEEL DEMAND IN INDIA (MT)
Year Forecast of demand for Finished
Steel
2001-02 28.24
2002-03 30.01
2003-04 31.91
2004-05 33.92
2005-06 36.05
2006-07 38.22
2007-08 40.74
2008-09 43.30
2009-10 46.03
2010-11 48.93
2011-12 52.01
Source : Web site of Ministry of Steel
2.2 STEEL PRODUCTION
The production of crude steel in India for the period 1987-88 to 2001-02 and the
corresponding ratios of crude steel production to finished steel consumption are presented
in Table 2.3.
TABLE 2.3
TOTAL CRUDE STEEL PRODUCTION TRENDS AND DEMAND
SATISFACTION RATIO IN INDIA FOR THE PERIOD 1987-88 TO 2002-03
(MT)
Year Total crude
steel
production
Finished steel
Consumption
(Ref. Table 2.1)
Demand satisfaction ratio (crude
steel production/ finished steel
consumption)
1987-88 12.510 12.81 0.98
1988-89 13.500 14.13 0.96
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-4
Year Total crude
steel
production
Finished steel
Consumption
(Ref. Table 2.1)
Demand satisfaction ratio (crude
steel production/ finished steel
consumption)
1989-90 13.370 14.12 0.95
1990-91 15.840 14.37 1.10
1991-92 16.760 14.83 1.13
1992-93 17.460 15.00 1.16
1993-94 17.300 15.32 1.13
1994-95 19.450 18.66 1.04
1995-96 22.430 21.65 1.04
1996-97 23.357 22.13 1.06
1997-98 24.759 22.63 1.09
1998-99 23.120 23.40 0.99
1999-2000 26.90 26.71 1.01
2000-01 27.29 29.27 0.93
2001-02 28.814 31.63 0.91
2002-03 30.50 33.00 0.92
A perusal of above table shows that crude steel production levels recorded an average
annual growth rate of around 7 per cent up to 1997-98 and then declined slightly in the
subsequent years. It may further be noted that the demand satisfaction ratio in India has
normally varied between 0.92 to 1.16, reflecting the high dependence of the Indian steel
industry on indigenous production.
In this context it may be noted that the demand satisfaction ratio basically depends on
two factors: namely, yield from crude steel to finished steel and net exports. With
increase in yield, the demand satisfaction ratio should decrease and with increase in net
exports, the ratio should increase. While yield from crude to finished steel is likely to
increase marginally in future; given the past trends, net exports should however exhibit a
marked increase. Accordingly, the demand satisfaction ratio should increase. However,
on a conservative basis, the crude steel production levels in the terminal years have been
estimated assuming a demand satisfaction ratio of 1.10 and are indicated in Table 2.4.
TABLE 2.4
ESTIMATED FUTURE CRUDE STEEL PRODUCTION AND
FINISHED STEEL DEMAND IN INDIA
Year Finished steel demand
(MT)
Crude steel production
demand (MT)
2006-07 38.22* 42.04**
2011-12 52.01* 57.21**
Note : * Figures adopted from Table 2.2
** Figures obtained by multiplying the finished steel demand by
assumed demand satisfaction ratio of 1.10
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TEFR for expansion of Steel Complex. 2-5
2.3 PRODUCTION OF ELECTRIC STEEL
The past production of steel produced in India through the EAF and IF route is indicated
in Table 2.5 below along with the share of this route in total crude steel production.
TABLE 2.5
ELECTRIC CRUDE STEEL PRODUCTION AND SHARE IN INDIA
FOR THE PERIOD 1987-88 TO 2000-01
Year Production of crude
steel by EAF/ IF
route ‘000 T
Total crude steel
production ‘000 T
(Refer Table 2.3)
Share of EAF/ IF
route in crude steel
production %
(1) (2) (3) (4) = (2) (3)
1987-1988 2,745 12,505 22
1988-1989 2,706 13,496 20
1989-1990 2,777 13,370 21
1990-1991 4,668 15,838 29
1991-1992 4,196 16,758 25
1992-1993 4,176 17,456 24
1993-1994 3,700 17,296 21
1994-1995 4,573 19,466 23
1995-1996 6,720 22,431 30
1996-1997 7,330 23,357 31
1997-1998 8,470 24,759 34
1998-1999 7,534 23,119 33
1999-2000 9,368 26,900 35
2000-2001 9,703 27,290 36
2001-2002 11,000 28,814 38
2002-2003 30,500
A perusal of the above table shows that crude -steel production by the secondary steel
sector increased from levels of around 2.8 MT in 1987-88 to 11.0 MT in 2001-02,
representing an average annual growth rate of around 10.5 per cent. This trend can be
seen in Fig 2.2. The share of the EAF/IF route also exhibited a corresponding increase
from levels of around 20% in the last decade to around 38% (Refer Table 2.5).
Keeping in view past trends in the growth of electric steel production and the increasing
importance of the secondary steel sector in the domestic steel industry, the share of the
EAF/ IF route is expected to exhibit a steady growth in future. The future expected shares
of the EAF/ IF route in crude steel production and corresponding production of electric
steel are indicated in Table 2.6.
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TEFR for expansion of Steel Complex. 2-6
TABLE 2.6
ESTIMATED FUTURE SHARE AND PRODUCTION OF CRUDE
STEEL (MT) THROUGH EAF/ IF ROUTE IN INDIA
Year Crude steel
production
Production of crude steel through EAF/ IF
route (assumed 40%)
2006-07 42.04 16.82
2011-12 57.21 22.88
2.4 METALLICS SCENARIO
2.4.1 Metallics requirement
The corresponding metallics requirement to support current and future levels of electric
steel production are given in Table 2.7, assuming a metallics requirement of 1.1
tonne/tonne of crude steel.
TABLE 2.7
CRUDE STEEL PRODUCTION (EAF/IF ROUTE) V/S SOLID
METALLICS REQUIREMENT
Year Crude steel production
through EAF/IF route (MT)
Solid metallics requirement
(MT) (@ 1.1 % of crude steel)
2006-07 16.82 18.50
2011-12 22.88 25.17
This metallics requirement has to be met either through scrap or DRI/HBI.
FIG 2.2 : CRUDE STEEL PRODUCTION THROUGH EAF/IF ROUTE
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
1987-8
8
1988-8
9
1989-9
0
1990-9
1
1991-9
2
1992-9
3
1993-9
4
1994-9
5
1995-9
6
1996-9
7
1997-9
8
1998-9
5
1999-2
000
2000-0
1
2001-0
2
2002-0
3
year
Pro
du
cti
on
Production of crude steel by EAF/IF route Crude steel production
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TEFR for expansion of Steel Complex. 2-7
2.4.2 Scrap scenario
Steel scrap is available indigenously from two sources
(i) process scraps produced by steel plants and
(ii) obsolete capital scrap obtained from scrapped iron and steel products like ships,
automobiles, etc.
The other major source of melting scrap is through imports.
The availability of melting scrap in India since 1987-1988 is given in Table 2.8 and
the same is shown in line graph (Fig 2.3).
TABLE 2.8
AVAILABILITY OF STEEL MELTING SCRAP IN INDIA
(EXCLUDING INTEGRATED STEEL PLANTS), ‘000 TONNES
Year Indigenous scrap availability Imports Total
1987-1988 2,200 1,860 4,060
1988-1989 2,880 2,120 5,000
1989-1990 2,231 2,269 4,500
1990-1991 1,978 2,822 4,800
1991-1992 3,992 1,268 5,260
1992-1993 2,827 2,573 5,400
1993-1994 4,446 754 5,200
1994-1995 4,004 1,416 5,422
1995-1996 4,886 974 5,860
1996-1997 4,500 1,165 5,665
1997-1998 4,500 831 5,331
1998-1999 5,600 880 6,480
1999-2000 5,300 823 6,123
2000-2001 5,100 1,512 6,612
Source : 1. Steel scenario statistical yearbook 2001
2. JPC Bulletin on Iron & Steel , March 2002
3. SAIL statistics for Iron & Steel Industry in India, 2000
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It will be observed from the above that availability of melting scrap in India has been
around 5.4 MT in the past.
The internal generation of scrap by integrated steel plants is gradually decreasing due to
adoption of concast technology and modern rolling techniques and the same is not
expected to be available to other plants which use scrap as raw material. Recovery rates
of obsolete scrap in India have also not exhibited significant growth over the past few
years and the domestic scrap collection/ processing sector is not well organised. Further
availability of good quality capital scrap is also decreasing worldwide.
Keeping in view the above factors, researchers and planners do not expect indigenous
availability of scrap to exceed 5.0 to 5.5 MT per year over the next few years. Further,
with increase in the production of EF steel and gradual decrease in the quality of traded
scrap, it is difficult to envisage more than 2.0 to 2.5 MT being imported to India on
regular basis in the near future.
Based on the above, future estimated availability of scrap is indicated in Table 2.9.
FIG 2.3 AVAILABILITY OF STEEL MELTING SCRAP IN INDIA
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
1987-8
8
1988-8
9
1989-9
0
1990-9
1
1991-9
2
1992-9
3
1993-9
4
1994-9
5
1995-9
6
1996-9
7
1997-9
8
1998-9
9
1999-2
000
2000-2
001
YEARS
Pro
duction (
Mill
ion T
onnes)
Indigenous scrap availability Imports Total availability
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-9
TABLE 2.9
FUTURE AVAILABILITY OF SCRAP FOR MELTING PURPOSES
BASED ON PAST RECORD (REFER TABLE 2.8) (MT) (REFER TABLE
2.13)
Year Indigenous
availability
Imports Total availability
2006-07 5.0 2.0 7.0
2011-12 5.0 2.5 7.5
2.5 SPONGE IRON (DRI/HBI) AVAILABILITY
Sponge iron is produced through two alternative routes. Through a coal based
route, sponge iron is produced in the form of lumps or granules. It is called Direct
Reduced Iron (DRI). DRI can be produced by smaller capacity plants with lower
investments. However it has the disadvantage of slightly lower yields as compared to a
gas based DRI. Through a gas based route, sponge iron is produced in the form of
briquettes (small cubes of 9cm x 6cm x 3cm) and is called Hot Briquetted Iron (HBI).
HBI has the advantages of higher yields, however, it can be produced only through large
scale plants with large investments and substantial feedstock requirements.
India is the largest sponge iron producer in the world. The installed capacity of
sponge iron increased from about 1.52 MT in 1991 to about 6.60 MT in 2001.The
installed capacities in India are as given in Table 2.10.
TABLE 2.10
ANNUAL INSTALLED CAPACITY OF SPONGE IRON IN INDIA (‘000
T)
Sl. No. Name of Plant Process Installed capacity
1. Gas Based
i) Essar steel Midrex 2,200
ii) Ispat industries Midrex 1,200
iii) Vikram ispat HYL III 900
Total gas based 4,300
2. Coal Based
i) JSPL Jindal 720
ii) PIL SL/RN 300
iii) Tata sponge TDR 240
iv) Goldstar Codir 220
v) Monet ispat Jindal 200
vi) BSIL SL/RN 150
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
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Sl. No. Name of Plant Process Installed capacity
vii) NISL SL/RN 150
viii) Llyods Metals Accar/OSIL 150
ix) Sunflag Codir 150
x) Sree Metaliks Popuri 150
xi) OSIL OSIL 100
xii) Ispat Godawri 100
xiii) Shyam Sel Ltd. Indigenous 100
xiv) Adhunk Corporation Ltd. Popuri 72
xv) Rexon strips Jindal 60
xvi) SIIL SL/RN 60
xvii) Bellary Steel SOO: 60
xviii) HEG SIIL 60
xix) KMCL SIIL 60
xx) Raipur Alloys SIIL 60
xxi) Deepak Steel & Power Ltd. Popuri 84*
xxii) Vandana Global SL/RN 50
xxiii) MSP Sponge SL/RN 45
xxiv) Tamil Nadu Sponge SIIL 30
xxv) Kusum Pwermet SIIL 30
xxvi) Suryaa Sponge Popuri 24
xxvii) Scan Sponge Popuri 24
xxviii) Ashirwad Steel SL/RN 24
xxix) Rungta Mines Ltd. Popuri 150*
Total coal based 3,593
Grand total 7,893
* Updated January, 2005
The production of coal-based DRI plants in the recent past (as available from
Sponge Iron Manufacturer’s Association – SIMA) has been as follows:
Year MT
1999-2000 : 1.88
2000-01 : 2.02
2001-02 : 2.48
The production of Sponge Iron from 1992-93 to 2002-03 is indicated in the
Table 2.11 below and the same is shown in Fig 2.4 by line graph.
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TABLE 2.11
SPONGE IRON PRODUCTION TREND
PERIOD GAS BASED COAL BASED TOTAL (MT)
1992-1993 0.9 0.46 1.36
1993-1994 1.5 0.8 2.3
1994-1995 2.1 1.2 3.3
1995-1996 2.9 1.2 4.1
1996-1997 3.3 1.7 5.0
1997-1998 3.6 1.7 5.3
1998-1999 3.5 1.8 5.3
1999-2000 3.4 1.9 5.3
2000-2001 3.4 2.0 5.4
2001-2002 3.1 2.5 5.6
2002-2003 - - 6.91
2003-04 - - 8.08
From the above table it is seen that the sponge iron production increased from
1.36 MTPA in 1992-93 to 8.08 MTPA in 2003-04 which represents a consistent growth
in production of sponge Iron.
2.5.1 Metallics shortfall
The metallics shortfall which may be expected in the next decade has been
computed by subtracting the expected scrap and DRI availability from the total metallics
requirement for crude steel production through EAF/IF route and is given in Table 2.12.
TABLE 2.12
FUTURE METALLICS SHORTFALL FOR CRUDE STEEL
PRODUCTION THROUGH EAF/IF ROUTE (MTPA)
2006-07 2011-12
Total metallics requirement (Refer Table 2.8) 18.50 25.17
Scrap availability 7.00 7.50
DRI/HBI availability 6.00 6.00
Solid metallics shortfall 5.50 11.67
It will be seen from the above that as per projections by the sub-group, metallics
shortfall to the tune of 5.50 MTPA may be expected by 2006-2007 and it is expected to
further increase to 11.67 MTPA by the year 2011-12. This metallics shortfall is to be met
either through scrap imports or creation of additional DRI/HBI capacity.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-12
With regard to probabilities of increased scrap imports, the same would depend on its
availability and relative price structure. As already indicated earlier, availability of good
quality scrap is steadily decreasing. Moreover, even under current market conditions,
landed price of scrap at end-user sites in India continues to be more expensive than
landed price of DRI. Possible reasons for this could include high freight rates, inland
transportation rates, heavy dependence on changes in custom tariff by GOI and high third
party commissions charged by scrap traders.
With regard to the creation of additional DRI/HBI capacity in India, it should be
mentioned that prospects of installation of new gas-based DR plants are very remote
keeping in view the natural gas allocation policy followed by the Government.
Accordingly, any new DRI capacities to be created would necessarily have to be based on
coal-based route. The prices of indegenous coal and iron ore are more or less stable and
therefore DRI manufacturing prices will remain competitive against the imported scrap
hence the viability of DRI industry in India.
2.6 CONCLUSION
i. Total crude steel production in India increased from 12.51 MT in 1987-88
to 30.50 MT in 2002-03 with annual growth of about 7% upto 1997-98
after which it reduced to about 4%
ii. The total finished steel consumption in India increased from 12.81 MT in
1987-88 to 33.00 MT in 2002-03 at an average growth rate of 6.5%.
FIG. 2.4 SPONGE IRON PRODUCTION TREND
0
1
2
3
4
5
6
7
8
9
1992-
1993
1993-
1994
1994-
1995
1995-
1996
1996-
1997
1997-
1998
1998-
1999
1999-
2000
2000-
2001
2001-
2002
2002-
2003
2003-
2004
Years
Pro
du
cti
on
(M
illi
on
Tto
nn
es)
Gas based Coal based Total
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TEFR for expansion of Steel Complex. 2-13
iii. The demand satisfaction ratio (crude steel production ÷ finished steel
consumption) varied from 0.91 to 1.16 for 1987-88 and 2002-03
respectively.
iv. A sub-Group on steel and Ferro Alloys was constituted under the aegis of
Planning Commision (2001-02) which projected the demand for finished
steel as 38.22 MT and 52.01 MT in 2006-07 and 2011-2012 respectively.
v. The future crude steel production in India is substantiated from finished
steel projection and has been projected assuming a conservative figure of
1.10 for demand satisfaction ratio hence these come to 42.04 and 57.21
MT for the years 2006-07 and 2011-12 respectively
vi. The share of crude electric steel (EAF & IF) in total crude steel in India
varied between 22% (2.75 MT) and 38% (11.0 MT) from 1987-88 and
2001-02 respectively. The projected electric crude steel at 40% and 46%
share corresponding to the years 2006-07 and 2011-12 respectively will be
16.82 and 22.88 MT respectively.
vii. Metallics requirement are projected @ 1.1 metallic/te of crude steel
produced hence they become 18.50 and 25.17 MT for the years 2006-07
and 2011-12 respectively.
viii. The total scrap (indigenous and imported ex-integrated steel plants)
availability has been 4.06 MT to 6.61 MT in 1987-88 and 2000-01
respectively in which imported share on an average has been about 27%.
The projected availability of total scrap is 7.0 and 7.5 MT for 2006-07 and
2011-12 with 57% and 31.25% share of imported scrap.
ix. Sponge iron production increased from 1.36 MT in 1992-93 to 8.08 MT in
2003-04. The future projected DRI/HBI availability is assumed as 6.0 MT
for calculating the solid metallic shortfall.
x. Solid metallics shortfall as calculated by subtracting available scrap and
DRI/HBI from total metallics requirement comes to 5.50 and 11.67 MT
for the year 2006-07 and 2011-12 respectively.
The summarised data in Table 2.13 shows the past and future status of all the
related parameters.
TABLE 2.13
SUMMARISED DATA OF PAST AND FUTURE LEADING TO
IDENTIFICATION OF DEMAND OF METALLICS
Sl.No Particulars 1987-88 1992-93 2000-01 2002-03 2006-07 2011-12
1 (a) Total crude steel production in
India by all routes, MT
12.51 30.50
(b) Growth rate 7%
2 (a) Total finished steel consumption
in India, MT
12.81 33.00
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for expansion of Steel Complex. 2-14
Sl.No Particulars 1987-88 1992-93 2000-01 2002-03 2006-07 2011-12
(b) Growth rate 6.5%
3. Demand satisfaction ratio (DSR) =
crude steel production ÷ finished
steel consumption
0.98 0.92
4. Future projection of finished steel
based on Sub-Group on Steel and
Ferro Alloys 2001-02
38.22 52.01
5. Future projection of crude steel
production calculated from future
projection of finished steel by
multiplying by DSR as 1.10
42.04 57.21
6. Past and future projected crude
steel share through Electric (EAF
and IF) route, MT
2.75 9.70 16.82 22.88
Percentage of total (Ref Sl.1a) 22% 37% 40% 40%
7. Future total metallics requirement
by EAF/IF, MT@ 1.1 times that
of crude (Ref Sl. 6)
- - 18.50 25.17
8. Present scrap available in India
(ex integrated steel plants), MT
a) Indigenous Average 73%
b) Imported Average 27%
Total 4.06 6.61
9. Future scrap availability, MT
a) Indigenous 5 5
b) Imported 2.0 2.5
Total 7.0 7.5
10. Past sponge Iron (DRI/HBI)
production MT
- 1.36 - 6.91
11. Future projected DRI/HBI
availability, MT
6.0 6.0
12. Solid metallics shortfall (Total
solid metallics requirement-scrap-
DRI/HBI), mil te
- - - - 5.50 11.67
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 3-1
CHAPTER - 3
RAW MATERIALS
Proposed expansion programme of the company is planned on the basis of
optimum waste recycling policy, which is reflected in this chapter.
3.1 RAW MATERIAL REQUIREMENTS
Based on prevailing operating data for different steel complex the annual
rawmaterials requirement is estimated as in Table 3.1:
TABLE 3.1
ESTIMATED ANNUAL QUANTITY OF RAW MATERIALS FOR THE
PROPOSED UNITS AS WELL AS EXISTING UNITS
SL. NO. PRIME RAW
MATERIALS
ANNUAL REQUIREMENT ( IN TPA ) SOURCE
EXISTING PROPOSED ULTIMATE COAL WASHERY
1. ROM COAL 1,92,000 1,92,000 3,84,000 RANIGANJ
COALFIELDS
IRON ORE BENEFICIATION PLANT 1. IRON ORE FINES ( -20
MM. )
- 8,20,000 8,20,000 BARBIL
IRON ORE PELLET PLANT 1. IRON ORE FINES - 6,00,000 6,00,000 IN-HOUSE
DRI PLANT 1. IRON ORE LUMP 2,20,000 - 5,32,500 BARBIL 2. IRON ORE PELLET - 4,00,000 4,00,000 IN HOUSE
PELLET
PLANT 3. WASHED COAL 1,08,000 1,08,000 3,16,000 IN HOUSE
COAL
WASEHRY 4. NON-COKING COAL 24,000 1,04,000 1,28,000 RANIGANJ
COALFIELDS 5.. DOLOMITE 1,620 2,325 3,945 MINES IN
BHUTAN
CAPTIVE POWER PLANT 1. MIDDLINGS/REJECTS 84,000 84,000 1,68,000 IN HOUSE
COAL
WASEHRY
2. DOLOCHAR 40,000 60,000 1,00,000 IN HOUSE
DRI PLANT
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TEFR for Steel Complex Expansion. 3-2
OTHER RAW MATERIALS WILL BE PROCURED FROM THE MARKET.
3.2 RAW MATERIAL STORAGE
The number of days stock of raw materials in terms of consumption in various units of
plant as have been envisaged are given in Table 3.2
TABLE 3.2
STORAGE DETAILS OF RAW MATERIALS
Materials No. of days stock
Power plant
Char 10
Middlings 10
SL. NO. PRIME RAW
MATERIALS
ANNUAL REQUIREMENT ( IN TPA ) SOURCE
EXISTING PROPOSED ULTIMATE INDICTION FURNACE
1. DIRECT REDUCED
IRON
- 1,55,000 1,55,000 IN HOUSE DRI
PLANT
2. IRON SCRAP - 65,000 65,000 MARKET
FERRO-ALLOYS FERRO-MANGANESE
1. MANGANESE ORE 35,825 69,360 69,360 IN HOUSE
PELLET
PLANT 2. COKE 8,175 15,828 15,828 IN HOUSE 3. DOLOMITE 3892 7,536 7,536 MINES IN
BHUTAN SILICO-MANGANESE
1. MANGANESE ORE 25,512 51,024 51,024
2. QUARTZ 2,190 4,380 4,380 MINES IN
BHUTAN 3. COKE 9,480 18,960 18,960 IN HOUSE
COKE
OVEN
4. DOLOMITE 2,190 4,380 4,380 MINES IN
BHUTAN
5. FE-MN SLAG 7,296 14,592 14,592 MINES IN
BHUTAN FERRO-CHROME
BRIQUETTE - 48,000 48,000 IN-HOUSE
CHROME ORE - 9,600 9,600 MINES IN
ORISSA
COKE - 12,960 12,960 IN-HOUSE
QUARTZ - 4,800 4,800 BHUTAN
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TEFR for Steel Complex Expansion. 3-3
Materials No. of days stock
DR plant
Coal 15
Iron ore pellet 15
Dolomite 20
Iron Ore Beneficiation Plant
Iron ore Fines 20
3.3 BRIEF OF THE RAW MATERIALS
Non-Coking Coal -
Non-coking washed coal will be used as reductant and heat producing material in the DR
Plant. Non- coking coal with low ash and moisture contents and moderately high volatile
matter is generally used for sponge iron production.
JBIL envisages their required non-coking coal mostly from its own Coal washery and
and the balance from the mines in Raniganj Coalfield area.
Iron Ore fines -
The entire requirement of iron ore fines for pellet making would be procured from mine
owners namely Essel Mining & Rungta Mines for uninterrupted basis for which tie up
arrangement has already been concluded.
Dolomite -
It is suggested to procure the entire requirement from Bhutan. There are several private
owned dolomite mines in that area, trading dolomite mostly to Indian iron and steel
industry. The chemical analysis of the dolomite from this region used in iron and steel
industry is presented below:
CaO MgO Al203 Fe2O3 LOI
% % % % %
30 20.0 1.9 0.64 43.9
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TEFR for Steel Complex Expansion. 4-1
CHAPTER - 4
MATERIAL HANDLING SYSTEM
As already discussed, the existing and proposed activities are as follows :
I. Existing setup:
(i) 7 x 50 TPD Kiln for DRI - 1,05,000 TPA.
(ii) 2 x 7 T Submerged Arc Furnace – 30,156 TPA (Ferro-Alloys).
(iii) Captive Power Plant – 18.3 MW.
(iv) Coal Washery – 2,16,000 TPA
II. Proposed facilities and their capacities
Facility Proposed Capacity 100%
Coal Washery
DRI Plant
2,16,000 TPA
1,50,000 TPA
Iron Ore Beneficiation Plant
Pellet Plant
Steel Melt Shop
( 4 X 15 T Induction Furnace )
6,00,000TPA
6,00,000 TPA
2,37,000 TPA.
Captive Power Plant 22 MW
(10 MW WHRB + 12 MW AFBC)
Raw material quantities
The bulk raw material which will be handled through the material handling
system consists of Iron ore fines, non-coking coal, Dolo char, washery middlings
and dolomite etc. The quantities have been given in Table 3.1.
Process of raw materials
A coal washery is being installed at plant, from where sized & washed coal will
be available for directly feeding the kilns. Crushers and screens will be provided
for coal and dolomite to provide required size to the existing kilns and the
ancillary units.
Receipt of raw materials
Run of mines Coal, Iron ore fines are envisaged to be received by rail/road and
Dolomite/limestone of the required size shall come by road.
0.03T
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Truck unloading, handling and feeding
Rear dump-trucks/Rail carrying coal, Iron ore fines, dolomite etc. will enter the
plant via weighbridges. Front end loaders will load the materials into 10 T
dumper which will feed the hopper of a crusher which, in turn, feed the same into
a belt conveyor which delivers the materials in to the respective areas. The trucks
carrying washed coals will unload into a hopper which in turn feed the same into
a belt conveyor which will deliver the coal in a day bin. The dolomite/limestone
will be stored either in an open or a covered shed. Dolomite shall be fed to the
day bin through belt conveyors.
Sampling and weighing
A sampler will be provided at the drive end of the dispatch conveyor I in the
junction house for manual collection of samples of prepared material.
Belt scales will be provided on the conveyors transporting the incoming materials
to the storage yard as well as on the reclaimed materials from the storage yard
upto process plant. Belt scales will also be provided on the product line to
ascertain the quantities of product.
Miscellaneous facilities
Provision will be made for installing dust extraction facilities in various
hoppers/buildings. Electrical and mechanical hoisting equipment facilities will be
provided for maintenance of the equipment installed in these houses and
buildings. Belt replacements facilities will also be provided for convenience in
replacement of conveyor belts.
Electrical equipment
The equipment of the raw materials handling system will be centrally controlled
from a master control desk located in the control room. The electrical control
system will be categorised as per intended operation requirements. The system
will be sequentially controlled with provision for local manual operation, and for
monitoring of equipment faults.
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5 - MAJOR PLANT FACILITIES
5.1 RECEIPT, UNLOADING STORAGE AND HANDLING OF RAW
MATERIALS
This section describes receipt, unloading, storage & handling and despatch of raw
materials for different consuming units of the proposed plant.
The estimated gross quantity of raw materials to be handled and their mode of
receipt are tabulated in Table 3.1.
Materials received by rail/road will be stored in the respective open storage yard
(by Contractor). Materials received by rail/road will be unloaded manually by
contractor labour equipped with modern machines and will be stacked to the
respective pile in the yard.
5.2 DIRECT REDUCTION (DR) PLANT
JBIL has its operating plant of DRI of capacity 1,05,000 TPA and which has been
planned to increase by 1,50,000 TPA.
PHASE CAPCITY
Present 1,05,000 TPA
Proposed 1,50,000 TPA
Ultimate 2,55,000 TPA
5.2.1 Design basis
The Sponge Iron plant will be designed on the basis of production of about
1,50,000 TPA of Direct Reduced Iron (DRI) from five kilns of 100 TPD
each.The annual production of DRI will be based on 300 days of operation.
Accordingly, commercially established coal-based rotary kiln process will be
adopted for the DR plant.
5.2.2 Product quality
It is expected that the DRI produced will contain about 92 per cent of Fe (Total),
around 0.2-0.3 per cent carbon and the degree of metallisation will be 90 per cent
average.
5.2.3 Raw materials
The rotary kiln charge will consist of iron ore pellet, washed non-coking coal and
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TEFR for Steel Complex Expansion. 5-2
dolomite. The quality of raw materials have already been discussed in Chapter 4.
The specific consumption of various raw materials are indicated in Table 5.2.
TABLE 5.3
SPECIFIC CONSUMPTION OF RAW MATERIALS
FOR THE DRI PLANT
Raw materials Specific consumption
Kg/ton DRI
Iron ore pellet 1,500
Clean coal &
Injection coal 1,200
Dolomite 15
5.2.4 Major facilities
The facilities within the DR plant will comprise the following major units:
- Rotary kiln.
- Rotary cooler.
- Waste gas system.
5.2.5 Rotary kiln:
The dimensions of the rotary kilns would depend on the process parameters
selected, the technology adopted and quality of raw materials. The kilns will be
lined with refractory/castables. The rotary kiln will have a main drive for normal
operation. The main drive system of the kiln will be powered by means of a
thyristor controlled DC drive so that the speed of the kiln can be varied as desired
by operating conditions.
An auxiliary drive will also be provided for slow speed rotation during
emergency/process requirement.
Air required for proper burning of combustibles inside the kiln and maintaining
the desired temperature profile, will be introduced through air tubes provided at
certain intervals along the length of the kiln. These air tubes will be connected to
individual shell mounted air fans for supply of air. Apart from the air tubes, air is
also supplied through a central burner fan provided at the kiln discharge end.
Combustion air supplied by the shell air fans and central burner fan will be
regulated through a set of butterfly valves in accordance with the process
requirement
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Besides the heat supplied by coal, additional heat may also be required to be
supplied by auxiliary fuel, especially during start-up of the kiln and in an
emergency. A central oil burner will be provided at the discharge end of the
rotary kiln for this purpose.
5.2.6 Rotary cooler:
The product discharged from the rotary kiln will be indirectly cooled in rotary
cooler by spraying water on the shell of the cooler. The cooler will only be
partially lined with refractory/castables. Both main and auxiliary drives will be
provided for the cooler.
5.2.7 Waste gas system:
At the kiln inlet, a dust settling chamber (DSC) will be provided for allowing the
dust to settle before passing through the After Burning Chamber (ABC). The
ABC will be supplied with additional air by fans for burning the combustibles
contained in the kiln off-gas. It is envisaged that the waste gas from the ABC will
be used to generate steam in a waste heat recovery boiler (WHRB), to be
installed in the captive power plant
5.2.8 Electrical System:
One 11 KV switchboard will be established at DRI plant electrical room to feed
the electrical loads including variable frequency drives for kiln rotation over
11/0.433-0.25 kV load centre substation. Power to 11 kV switchboard will be fed
from CPP through underground cable . feeders. HT motor for ID fan drive will be
fed from high voltage load centre (HVLC) with the 11/6.6 kV transformer to be
established within the plant.
All sequencing, interlocking and control functions of electrical drives including
instrumentation and process automation shall generally be in compliance with the
requirements described under plant electrical system in this chapter.
5.2.9 Production Process
The process for the production of sponge iron consists of the reduction of iron ore
pellets with solid carbonaceous material (coal/coke/lignite) in a rotary kiln at
high temperature, cooling to room temperature in the rotary cooler with indirect
water cooling system, screening and magnetic separation of the product. Sponge
iron being magnetic gets attracted and separated from the non-magnetic char.
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In the process for the production of sponge iron, the raw materials (iron ore, feed
coal and lime stone /dolomite) are fed to the rotary kiln through feed tube in a
pre-determined ratio by electronic weighing equipment. Due to inclination and
rotary motion of the kiln the material moves from the feed 'end of the kiln to the
discharge end in approximately 5.5 hrs. (Tendency time). The fine coal is blown
counter currently from the discharge end of the kiln to maintain the required
temperature and the carbon concentration in the bed. The kiln has seven shells air
fans mounted on the top which blow air in the respective zones to maintain the
required temperature profile. The material and the hot gasses move in the counter
current direction and as a result iron ore gets pre-heated and gradually reduced by
the time it reaches the discharge end.
The kiln is divided into two zones namely pre-heating zone and reduction zone.
The pre-heating zone is normally 30% of the total length of the kiln and the rest
is taken as the reduction zone. The material gets heated to the reduction
temperature in the pre-heating zone up to 200°C, the iron ore, coal and limestone
gets dried and all the moisture is vapourised. Upto 800° C, the iron ore gets
roasted and any carbonates in it get calcinated. In the coal, the volatile matter
starts getting released. The limestone also gets calcinated and becomes active.
The iron ore, which is in the form of hematite, gets reduced to magnetite. After
this the materials enter to the reduction zone where the magnetite is reduced to
wustite and then to metallic iron.
Coal contains sulphur. During decomposition of the coal, sulphur is released in
the form of Iron sulphide.
The iron sulphide (FeS) has deleterious effect in the steel making and is to be
removed. So limestone is used to prevent the sulphur pick up by the sponge iron.
All the above reactions are possible only in the presence of CO. The generation
of the CO is most important reaction, which is called the Boudard reaction.
This reaction is highly endothermic which is also reversible. The conditions
favourable for the forward reaction i.e. the generation of CO is:
The higher temperature favours the production of CO.
The concentration of the reactants has. to high so that the forward reaction
occurs.
Low pressure favours the CO generation.
The oxygen required for the burning of these combustibles is supplied from the
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air tubes placed along the length of the kiln. By controlled combustion, the
temperature in the various zones is maintained so that the reduction is proper and
to sufficient degree.
The reduction of iron ore is topo-chemical i.e. the reduction proceeds from the
surface to the core. The iron ore on partial reduction has all the different stages of
the reduction.
The hot material after the reduction is complete is then transferred to the rotary
cooler via the transfer chute. The rotary cooler is 1.5 Mts. in diameter and 15
Mts. Long made up of Mild Steel shell. It is also inclined at 2.5° approximately
and rotates at variable speed from 0.2- 1.2 rpm .It is driven by an AC variable
speed motor. The water is sprayed on the top of the shell, which cools the
material inside the cooler indirectly. The heat from the material is extracted by
the shell. In order to increase the surface area for the heat extraction fins are
welded inside. Complete shell is covered by thin layer of water. The heat is
transferred from the shell to the water by convection. By this the material gets
cooled to 80oC and is discharged on the belt conveyor by the double pendulum
valve. The double pendulum valve acts as the seal for the prevention of the
atmospheric air into the kiln cooler system. The total kiln cooler system is kept
under positive pressure about 0.3-0.5 mbar. This prevents the atmospheric air
from getting into the system. The kiln has to be always operated on positive
pressure, as any leakage into the system will cause the re-oxidation of the sponge
iron there by causing the drop in the quality of the product.
The material after the discharge from the cooler is dropped on to the cooler
discharge conveyor. A diversion chute is provided at the head end of this
conveyor for diversion of the material in case of break down in the production
separation. The material is then sent to the product separation system. In product
separation system consisting of double deck screen, the material is screened to 0-
3mm and 3-20mm size fractions. The oversize i.e. +20 mm obtained is small
quantity so it is taken on the floor or diverted to the sponge iron bin. The 0-3mm
size fraction is called the fines are fed to a drum type magnetic separator where
the magnetic sponge iron fines and the non-magnetic dolochar separated and fed
to the respective bins through the chutes and conveyor. The coarser fraction is
similarly separated by another magnetic separator and fed so respective bins. This
magnetic fraction is called the sponge iron lumps and the non- magnetic as char
which is the unburned coal. This char can be recycled depending on the quality
obtained after processing.
The gasses, which flow in the counter current direction of the material, go to the
dust-settling chamber where the heavier particles settle down. These particles are
continuously removed by the wet scrapper system. The gasses then pass to the
after burner chamber where the residual carbon or CO is burned by the excess air
available. The gasses are at high temperature and have lot of heat energy, which
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can be utilised for the power generation through the waste heat recovery boiler.
The hot gasses after the heat recovery boiler gets cooled to 200°C. The gasses are
then scrubbed and let of to the atmosphere at BO°C through the chimney.
Alternatively the hot gasses are quenched and scrubbed to clean all the dust in it.
And then they are let off to the atmosphere through the stack.
The chemical reactions taking place in the reduction zone is represented by the
following equation:
FexOy + CO FexOy-1 + CO2
The carbon dioxide formed is converted to carbon monoxide by means of the
carbon in the reductant in accordance with the boudourd reaction:
C + CO2 2CO
Burning of small amount of carbon and excess carbon monoxide by means of
outside air supplied through tubes to provide heat for the process reactions can be
shown by the following equations:
CO + 1/2 O2 CO20
It is to be noted that a reducing and oxidising atmosphere prevail side by side in
the rotary kiln. Within the material charge it is reducing atmosphere accompanied
with endothermic reaction while in the free board above are the oxidising
conditions with the exothermic reactions.
The separation of the two atmospheres is ensured by the pressure generated by
CO emerging from the charge into the kiln free board. This avoids re-oxidation of
the reduced particles at the charge surface.
5.3 IRON ORE BENEFICIATION PLANT
In order to produce about 6,00,000 TPA pellet grade iron ore concentrate at full
development stage, it is proposed to set up a 0.6 MTPA iron ore beneficiation
plant to beneficiate low-grade iron ore fines (-10 mm) from different mines.
PHASE CAPCITY
Present -
Proposed 6,00,000 TPA
Ultimate 6,00,000 TPA
These low grade iron ore fines, after beneficiation, shall become suitable for
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TEFR for Steel Complex Expansion. 5-7
production of pellets. Iron ore will be ground to a size of (-) 150 micron in
grinding mill which shall then be beneficiated to upgrade it to (+) 65% Fe.
The iron ore fines (-10 mm) from different mines will be brought to the raw
material and material handling plant for open stockpiling. The stockpiled material
will be reclaimed and conveyed to the beneficiation plant. The material will be
processed in beneficiation plant utilizing grinding mill, hydro cyclone and wet
high intensity magnetic separator (WHIMS)/ High intensity magnetic separator
and, if required, by flotation to obtain the concentrate having 65% Fe. The
concentrate product will be transported to the pellet plant in the form of slurry.
The tail fraction, generated from the beneficiation plant, will be pumped to the
tailing pond.
5.3.1 The Process
The major process units involved to upgrade the ROM iron ore to 65% Fe content
as final product are grinding mill; wet high intensity magnetic separation
(WHIMS)/ High gradient magnetic separation HGMS unit; hydro cyclone;
thickener for tails; thickener for concentrate; process water storage tank and fresh
water storage tank.
The sub-grade, low and medium grade iron ore generated in different mines will
be transported to stock pile. The stockpile will be reclaimed and conveyed to
grinding mill. A hanging magnet and metal detector have been planned on belt
conveyor to remove foreign magnetic materials. A belt weighing scale has been
planned on conveyor to monitor and control the quantity of material.
The beneficiation plant covers grinding circuit with closed circuit operation,
hydro cyclones for de sliming and classification operation, wet high intensity
magnetic separator (WHIMS) / high intensity magnetic separation (HIMS) for
separation of magnetic and nonmagnetic material and thickener to re pulp the
tails slurry before sending to tailing pond. The material from stockpile will be fed
to the ball mill to grind the crushed product to (-) 150 micron or a size decided
after test results. The grinding mill operation will be made under close circuit by
using cluster of hydro cyclone. The underflow of hydro cyclone will be re
circulated to the mill by pump and the overflow material will be pumped to
WHIMS/HGMS. The magnetic fraction will be concentrate and nonmagnetic
fraction will be either tails or may be further upgraded by second stage magnetic
separation or flotation depending on ore characterization tests. The magnetic
fraction of WHIMS will be finally re grinded to (-) 325 mesh and collected as a
product in concentrate thickener and underflow of concentrate thickener will be
pumped to pellet plant whereas non magnetic fraction will be rejected and
pumped to a tailing thickener. The overflow water of thickeners will be pumped
to process water tank for re use of water in the plant. The underflow material of
tailing thickener will be pumped to the tailing pond. Water recovery will be done
from tailing dam and from pellet plant.
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TEFR for Steel Complex Expansion. 5-8
The Process would not be generating any Hazardous Waste, as there is no
Hazardous Chemical involved in the process. Disposable solid waste consisting
of impurities of naturally available iron ore would be used for filling of the
abandoned mines in the vicinity. Solid disposable waste is also ideally suitable
for brick making and would be delivered to local brick makers. Thus solid waste
generated will not be having any negative impact on the environment.
5.4 PELLET PLANT
It is proposed to put up a Pelletising Plant of capacity 6,00,000 TPA so as to
beneficiate the ore and produce pellets to use it as raw material for iron making.
In the pellet making process, use iron ore fines which will be further ground and
mixed with additives like Bentonite and coke breeze / non-coking coal.
PHASE CAPCITY
Present -
Proposed 6,00,000 TPA
Ultimate 6,00,000 TPA
The pellet plant will operate with haematite iron ore concentrate (- 325 mesh).
Iron ore concentrate will be received in the plant in the form of slurry, which will
be filtered to form a cake. The cake will have less than 9.0% moisture level.
The raw materials required for the proposed pellet plant are haematite ore
concentrate cake (- 325 mesh, 80% minimum) and ground additives like
bentonite, limestone and coke breeze / non-coking coal. Iron ore concentrate and
additives are mixed in an EIRICH mixer. The green ball formation is done using
disc pelletiser. Heat hardening of green pellets is done in indurating machine
(pre-heating, drying, heating, firing and finally cooling) using LDO as fuel.
Beneficiated iron ore concentrate (-325 mesh, 80% minimum) in the form of
slurry will be received at the proposed pellet plant site. The bentonite
requirement of the proposed plant will be met through purchase.
The expected chemical composition of pellets is as follows:
Fe(t) : 65%
SiO2 + Al2O3 : 2%
CaO + MgO : 0.5%
FeO : <0.5%
5.4.1 The Process
Iron ore slurry is received in the thickener. Slurry is thickened in the thickener
and transported to the filtration unit. Filtered cake from the filtration unit is stored
in the storage bins.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-9
Proportioned quantities of filter cake from concentrate storage bins and ground
additives like limestone, bentonite and coke breeze / non-coking coal are fed to
mixer for thorough mixing with moisture.
The mixed material is conveyed to the bins above individual balling disc for
subsequent balling to green balls in the balling discs. These green balls/ pellets
are screened for narrow size range (9 - 16 mm) in a double deck roller screen
with oversize and undersize material being returned to mixed material bins. The
right size (9-16 mm) green balls are fed on to the traveling grate indurating
machine over a bed of hearth layer and side layer of fired pellets and pass
through drying, preheating, induration and cooling zone. The cooled product
pellets are then taken away to stockpile through a series of belt conveyors after
separation of hearth and side layers in the hearth layer separation bin.
Major technological units of the pellet plant will include slurry storage and
filtration unit; additives (limestone, coke breeze / non-coking coal and bentonite)
grinding; concentrate and ground additives storage bins; mixing of filter cake and
additives; balling; induration; pellets segregation and hearth layer separation and
finished pellet stockpiles.
Major services facilities like material handling, water supply system, compressed
air, ventilation and air-conditioning, process gas & plant dedusting, building
structures, civil works and industrial safety, electrics, instrumentation and
automation, central control room etc. have been envisaged for the proposed pellet
plant.
Emergency stockpiles of finished pellets have been envisaged within pellet plant
for uninterrupted supply of pellets to the Blast Furnace. The pellets can be
reclaimed from the stockpiles and discharged to product conveyor leading to the
blast furnace.
All junction houses and transfer points are dust generating sources. To control the
dust two numbers of ambient dust catching system will be installed in the pellet
plant. The dust content after dust catcher shall not be more than 50 mg/Nm3.
Finally dust will be controlled by the ESP before discharge through stack.
The process flow diagram of the proposed pellet plant is presented in Figure
5.4.1.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-10
`
Fig. 5.4.1: Process Flow of Pellet Plant
5.5 CAPTIVE POWER PLANT
PHASE CAPCITY
Present 18.3 MW
Proposed 22 MW
Ultimate 40.3 MW
Product Pellet Storing Bin
Water
Blower
Iron Ore Concentrate Bentonite
Proportioning
Mixing
Disc Pelletier
Double Layer Roller Screen
Distributor
Traveling gate
Rotary Kiln
Circular Cooler
Combustion
Fan
Chimney
Exhaust Fan
Dedusting
Producer Gas
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-11
The proposed power plant will generate power to meet the demand of the various
facilities envisaged in this report and further to the projects which are under
construction.
Present operation units are being power supplied by existing Captive Power Plant
of 18.3 MW. Proposed projects like Steel Melt Shop, Pellet Plant and Coal
Washery will require around 42.5 MW power for operation. A suitable power
generation facility has been planned based on heat recovery steam generators by
recuperating sensible as well latent heat of waste gases emanating from DR kilns
along with a Thermal Power Plant (TPP) based on middlings to be generated in
the coal washery and Dolo-char generated in the DRI Kilns located in the plant.
Circulating Fluidized-Bed Combustion (CFBC) boiler for this purpose shall also
utilise the char to be generated to the maximum extent. The basic configuration
of thermal cycle and other relevant technical details are furnished in the
subsequent paragraphs. Capacity of the proposed Captive Power Plant is so
designed to cater power for the proposed projects as well as to projects which are
under construction.
5.5.1 Steam cycle for captive power Plant
The steam cycle define the transformation of the heat energy to the mechanical
energy at the turbine shaft, through the various thermodynamic processes that is
capable of producing the net heat flow or work when placed between the energy
cource and energy sink. The heat energy is derived from burning of fuels or
using heat energy already available in the hot waste gases. The cycle needs a
working fluid and steam is viewed as the most favored working fluid mainly
because of its unique combination of high thermal capacity, high critical
temperature, wide availability at cheaper cost and non toxic nature. Higher
thermal capacity of the working fluid generally results in the smaller equipment
for the given power output or heat transfer.
All the steam based power plants operate under the Rankine cycle. Simplistically
the cycle is described as the combination of the various processes like the
isentropic compression of water in the boiler feed water pumps, reversible heat
addition to the working fluid through the liquid, two phase and super heat states,
isentropic expansion of the working medium in the turbine and the constant
pressure heat middlingion to the atmosphere through the condenser and the
cooling water system. The cycle to be adopted for this project will be a modified
Rankine cycle with the addition of a Regenerative feed water heating. To
improve the efficiency of the cycle the feed water from the condenser is heated
with the steam extracted from the turbine.
5.5.2 Description of the captive power plant scheme and Plant operating Parameters
The proposed enhancement scheme for the JBIL,Unit-I , Raniganj plant, consist
of 1No. Waste Heat Recovery Boilers (WHRB) of 50 TPH capacity with steam
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-12
outlet parameters of 91 Ksc(a), 515 Deg C and 1 No. Atmospheric Fluidized Bed
Combustion of 91 Ksc( a) , 515 Deg C and one 22 MW double extraction cum
condensing turbo generators.. The proposed waste heat recovery boiler is capable
of operating round the year with waste gases generated from the DRI Kilns in the
plant.
The fluidized combustion boiler will be capable of operating round the year with
Coal, Dolo Char & Washery Middlings, which is available as waste in the DRI
Plants and the coal.
The feed water management programme shall ensure the supply of good quality
make up water to the system. In the proposed extension of power cycle most of
the steam will be supplied to the turbine , about 98%, will come back as the
condensate from surface condenser and through the feed water heating system.
Middlings. The make up required will be approximately 3% of the steam
generated in the boiler, which includes all the losses in the system and blow
down in the boiler. The complete make up required for the plant operation will be
treated water. Reverse Osmosis (RO) water treatment plant of adequate
augmented capacity will be provided. The make up cycle will be added in the
condensate storage tank and the quantity of makeup will be controlled by
dearator level control system.
The boiler being proposed will be with the steam parameters of 91 Ksc(a) and
515 +5 0C at the boiler outlet. The AFBC boiler will be designed with coal Char
and coal as fuels. The inlet feed water temperature for the waste heat boiler will
be 115 Deg. C with feed water heated in the dearator. The inlet feed water
temperature for the CFBC boilers will be 150 Deg C, with the feed water heated
in a dearator and HP heater.
5.5.3 Fuel Balance
The CPP is based on one waste heat recovery boilers and one AFBC Boiler.
For the waste heat boilers, no fuel is required as the heat available in the waste
gases generated from the sponge iron plant are used.
The 50 TPH AFBC boiler will be operated with coal char, washery middlings,
“D” grade coal. With the available coal char it is possible to generate a steam
capacity of 12 TPH . For the balance steam requirement of 38 TPH , 50 TPD of
washrey middling will be used along with coal.
5.5.4 Power Balance
The total power generation in the plant will be 22,000KW.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-13
The following gives the detailed break up of the auxiliary power consumption in
the captive power plant.
Boiler Auxiliaries : 950 KW
Turbogenerator auxiliaries : 100 KW
Cooling Tower : 525 KW
Fuel and Ash Handling System : 175 KW
Other pumps (DM, Raw, make-up water): 50 KW
Air compresors : 50 KW
Water Treatment Plant : 35 KW
Ac & Ventilation : 50 KW
Lighting
Transformer and other losses : 100 KW
Total For Power plant : 2,035 KW
The power requirement of the in house enduse plants will be met by CPP by
operating parallel with grid. Also the power requirement ( inclusive of losses) of
auxiliaries of the CPP at 2,035 KW will be met from the generated power
through Three No’s of 3.0 MVA capacity step down distribution transformer.
There will not be any export to the grid.
5.4.5 Plant and Equipment Design Criteria.
General
The proposed captive power generation facilities at JBIL, Unit-1, Ranigunj will
be operated on a continuous basis, throughout the year (300 days). These
facilities will be located at JBIL, Unit-1, Ranigunj in the state of West Bengal.
These power generation facilities will be designed for year round operation. All
the plant and equipment of the power plant will be designed for a minimum of
7200 hrs of operation in a year.
Design Criteria for Captive Power Plant (CPP)
The CPP proposed will generate a gross output of 22,000 kW at the generator
terminals. After meeting with the internal power requirement of CPP auxiliaries,
the power will be fed to the enduse plants and their auxiliaries, by operating the 1
x 22 MW turbogenerators in parallel with the grid. In order to maintain full production on the kilns, during periods when the turbine
is out of service, the turbine is provided with an associated desuperheating and
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-14
dump condensing facility to handle the steam produced. This will also take care
of the high load fluctuation in induction furnaces. The surface condensers shall
be designed considering this additional dumping steam.
The 22 MW CPP will be with one turbogenerator, receiving steam from two (2)
different boilers. One of the boilers will be waste heat recovery boiler generating
the steam from heat recovered from the waste gases leaving the rotary kiln of the
sponge iron plant. The AFBC boiler will be using the coal char from the sponge
iron plant, and washery middlings. The system is designed such that all the
boilers operate in parallel supplying the total steam required to the 1 no. of 22
MW turbogenerators.
The electrical loads of the induction furnaces introduces a lot of harmonics into
the system. The one no. of 22 MW Generators and system design shall be made
to take care of system harmonics. The generator has been oversized to take care
of the heating effects due to the harmonic loads. A detailed study is to be
undertaken during the contract execution stage to finalize the actual sizing required
for the generator.
All the plant and systems shall be designed to achieve the best possible efficiency
under the specified operating conditions. The Captive power cycle shall be
designed with one two LP heaters (Deaerator) and two HP heaters. The steam
requirements of the deaerators and the HP heaters shall be met from the
extraction from the turbines.
The complete plant instrumentation and control system for CPP shall be based on
DCS, covering the total functioning requirements of measuring, monitoring,
alarming and controlling, logging, sequence interlocks and equipment protection
etc.
The Plant layout shall make optimum use of the land and facilities to Minimize
the cost of installation. The optimum arrangement of the Equipment shall be
determined by the considerations of functional requirement, economy of piping
and electrical cables, economy of equipment supports, installation and
maintenance access requirements, ventilation requirements and equipment
generated noise and vibrations.
Plant & Machinery design criteria
This section of the report gives the basic criteria for the design of the plant .The
design parameters like the size, layout, ratings, quantities, materials of
construction, type of equipment etc., described in this report approximate.
Necessary changes could occur as the detailed engineering of the plant
progresses and such changes are permitted as long as the detailed engineering of
the plant achieves the intent of this report.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-15
Ambient Conditions
Plant Elevation above Mean Sea Level (MSL) : 126.0 meters
Temperatures :
• Maximum Temperature : 40.0 Deg.C
• Minimum Temperature : 16.3 Deg.C
• Plant Design Temperature (Dry Bulb) :30.0 Deg.C
• Plant Design Wet Bulb Temperature :23.0 Deg.C
• Plant ,Design Temperature for Electrical :50.0 Deg.C
Equipment
Relative Humidity :
• Maximum : 86%
• Minimum : 27%
• Plant Design Relative Humidity : 60%
5.5.6 Composition of waste gases from the rotary kilns.
The waste heat recovery boilers at the back end of the rotary kilns will recover the waste
heat from the hot gases generated from the DRI Kilns. The following is the analysis of
waste gas, leaving the after burning chamber (ABC) at the back end of the kiln. These
composition shall be taken for the design and guarantee performance of the waste heat
recovery boilers.
Gas composition (% by Volume)
➢ Carbon di oxide :20%
➢ Moisture : 16%
➢ Nitrogen : 63 %
➢ Oxygen : 1 %
➢ Sulphur di oxide : Nil
➢ Dust content (gm / N.Cu.m) : 30
Gas Temperature leaving the ABC : 950 Deg.C.
5.5.7 Properties for the Coal char, Washery middlings, "D" grade coal
The design and guarantee fuel for the FBC boiler will be Coal char, Washery middlings.
The following will be the analysis:
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-16
Coal Char composition (% by weight) :
Ultimate Analysis:
Carbon(%) : 25.8
Hydrogen(%) : 1.5
Nitrogen(%) : 0.7
Sulphur ( %) : 0.3
Oxygen(%) : 4.2
ASH (%) : 64.4
Moisture (%) : 3.1
Gross Calorific Value (Kcal / Kg) : 1300
Washery middlings composition (% by weight)
Ultimate Analysis:
Carbon(%) : 24.53
Hydrogen(%) : 01.59
Oxygen(%) : 03.16
Moisture (%) : 10.00
Nitrogen(%) : 00.72
Sulphur ( %) : 0.00
ASH (%) : 60
Gross Calorific Value (Kcal / Kg) : 2700
5.5.8 Raw Water
The raw water supply will be from LocalAuthority. This raw water will be used as a
make up for the losses in theboiler blow down, servics water for the CPP etc.
5.5.10 Boiler Feed Water
The boilers shall be capable of operating with the following feed water
quality requirements.
pH : 8.8 - 9.2
Oxygen : 0.007 ppm (max.)
Hardness : Nil
Total Iron : 0.01 ppm (max.)
Total Copper : 0.01 ppin (max.)
Total Silica : 0.02 ppm (max.)
Hydrazine residual : 0.01 -0.02 ppn1
Specific Electrical Conductivity at : 0.5 pslcm
25°C measured after Cation
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-17
exchanger in the H + form and
after COz removal (max)
Total C02 : Nil
Oil : Not allowed
5.5.11 Steam Purity
All boilers shall be capable of supplying uninterrupted steam at the
MCR rating with the following steam purity levels.
Total Dissolved Solids : 0.1 ppm (max)
Silica : 0.02 ppm (max)
Performance Guarantee Tests for waste heat recovery boilers
▪ Maximum Continuous Rating (MCR) of the waste heat boiler, with
the feed water temperature of 115°C and superheater outlet
parameters of 91 Ksc(a) and 515°C.
▪ Auxiliary Power Consumption under MCR operating conditions.
▪ Steam purity for all operating loads.
▪ Dust Concentration in the flue gases leaving the ESP
Performance Guarantee Tests for the FBC boiler
▪ Maximum Continuous Rating (MCR) of the AFBC boiler, with the
feed water temperature of 150°C and superheater outlet parameters
of 91 Ksc(a) and 515°C.
▪ Boiler Efficiency at MCR on GCV basis while firing 70 % coal char
+ 30 % washery middlings
▪ Auxiliary Power Consumption under MCR operating conditions.
▪ Steam purity for all operating loads.
▪ Dust Concentration in the flue gas leaving the ESP.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-18
5.5.12 Turbogenerator & Auxiliaries
The turbo generators shall be a double extraction cum condensing machine. The first
extraction shall be uncontrolled at 8 Ksc(a) and the second extraction shall be
uncontrolled at 2.5 Ksc(a). The following shall be the salient design parameters. The
speed of the turbine shall be less than 8000 RPM.
Number of Turbogenerators : One (1 x 22 MW)
Steam flow at the turbine stop valve : 50,000 (max.) (at each turbine)
at boiler MCR (KgIHr)
Steam pressure at the turbine stop : 84
valve (Ksc(a))
Steam temperature at the turbine : 515
stop Valve (Deg.C)
Extraction Steam Requirements
First Extraction (HP) Parameters:
Type : Uncontrolled
Steam Pressure (Ksc(a)) : 8.0
Quantity Requirements
Normal (Kg / Hr) : 4365 (from each turbine)
Temperature of Extraction steam
required at the terminal point (Deg.C): 190
Second Extraction (LP) Parameters:
Type : Uncontrolled
Steam Pressure (Ksc(a)) : 2.5
Performance Guarantee Tests
The performance test shall be conducted for the following parameters as per ASME PTC
6 and DIN 1943:
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-19
Power Output at Generator Terminals with the inlet steam Parameters of 84 Ksc(a) and
515°C, specified power factor and cooling water temperature of 32°C. The extraction
shall be at the indicated Normal flow conditions.
• Auxiliary Power Consumption under Guarantee conditions.
• specific Steam Consumption and heat rate.
• maximum temperature rise in the generator windings.
5.5.13 Auxiliary Plant and Equipment
Fuel handling
For the waste heat boilers no fuel is required, but only the gases from the rotary kiln is to
be routed to the boilers through refractory lined ducts. The fuel for the FBC boiler is Coal
char, washery middlings. Coal char & washery middlings will be mixed and loaded in
the ground hopper manually or by front end loaders. Mixed fuel will thenconveyed to the
crusher / screen house through a belt conveyor (CC-1).
After passing through the crusher, the crushed fuel will be screened. The fuel of less than
6 mm size will be conveyed to boiler front bunker through belt conveyor (CC-2). Higher
size fuels will be recycled to the conveyor (CC-1) through conveyor (CC-3). Allowable
inclination for the belt conveyor is 18" (max.). The belt speed shall be approximately 1.0
metres / second. The fuel handling system shall be designed for a capacity of 60 TPH.
The fuel handling system is selected for 12 hours operation in a day.
5.5.14 Ash handling
Waste Heat Recovery Boilers
The ash handling system envisaged is of dense phase pneumatic ash handling type. It is to
be noted that there is no ash generation in the waste heat boilers. The dust already
available in the waste gases is passing through the waste heat boilers.
The ash will be dry and powdery in nature and occasionally with hot solids.
The ash from Superheater / Evaporator zone / Economiser zone will be dry and powdery
in nature and occasionally with hot solids. The temperature will be around 200°C.
The ash from ESP will be dry and powdery in nature and occasionally with hot solids.
The temperature of ash will be around 170°C.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-20
AFBC Boiler
Since furnace & boiler bank ash will be at high temperature (600°C to 950°C), the same
shall be cooled with the help of ash coolers using air before taking into dense phase ash
handling system. The ash from furnace and bank ash will be dry and powdery in nature
and occasionally with hot solids.
The ash from Economiser will be dry and powdery in nature and occasionally with hot
solids. The temperature will be around 350°C maximum. The fly ash from the Air Heater
Hopper will be dry and powdery in nature and occasionally with hot solids. The
temperature of the ash will be around 250°C maximum.
The fly ash from ESP will be dry and powdery in nature and occasionally with hot solids.
The temperature of ash will be around 150°C maximum.
The ash from the discharge points of waste heat boilers will be collected by means of
pipes with the help of compressed air into the ash storage silo provided for WHRBs. The
ash from the discharge points of AFBC boilers will be collected by means of pipes with
the help of compressed air into the another ash storage silo provided for AFBC boilers.
There will be one (1) ash silos WHRB and one (1) ash silo of capacity for the AFBC
boiiers.
The storage silos are selected considering 12 hour storage capacity. From the ash silo the
ash will be disposed off by trucks/trailers.
5.5.15 Pumps
The head / flow characteristics of pumps will be such that the head continuously rises
with decreasing capacity until a maximum head is reached at zero flow. Maximum run-
out flow should at least 130% of duty point flow.
The shut off head should be at least 1.1 times the duty point head and should not be more
than 1.2 times the duty point head. The power curve should be of non-overloading type
with the maximum power occurring at or near duty point or towards maximum run out
flow.
NPSHR curve should be a continuously rising one in the range of Operation from the
minimum in the range to the maximum flow in the range Required NPSH values shall
not exceed available values over The entire range minimum to rated flow
5.5.16 Condensate system
The condensate from the surface condenser will be used to meet the feed Water
requirement of the CPP boilers. The make up water for the cycle Will be from the water
treatment plant.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-21
Water treatment Plant based on Reverse Osmosis (RO) principle. The RO plant shall be
designed to have single stream with a capacity of 25 TPH The RO plant shall be designed
based on the raw water analysis furnished elsewhere in this section of this report.
The RO water quality at the outlet of the RO plant shall be as follows:
PH : 8.8 - 9.2
Hardness : Nil
Total Iron : 0.01 ppm (max.)
Total Copper : 0.0 1 ppm (max.)
Total Silica : 0.02 ppm (max.)
Hydrazine residual : 0.0 1-0.02 ppm
Specific Electrical Conductivity at : 0.5 s/cm
25°C measured after Cation
exchanger in the H + form and
after CO2 removal (max)
Total C02 : Nil
Oil : Not allowed
The raw water at the inlet of the RO plant will be delivered at a pressure of 3.0 Kg/
Sq.Cm. The Treated water at the outlet of the RO Plant will be delivered at a pressure of
3.0 Kg/ Sq.Cm . The RO plant will be provided with a mixed bed polishing unit to deliver
the required quality of the treated water.
All vessels shall be designed with adequate free board. Only seamless pipe shall be used
wherever rubber lining is done. All fabricated equipment shall be designed according to
IS: 2062. The regenerants like Hydrochloric Acid and Caustic Soda shall be stored
in bulk in the RO plant premises, and pumped to the RO plant for regeneration. Manual
handling of the regenerants shall be avoided to the maximal extent. Adequately sized
neutralizing pit shall be provided near the RO plant for collecting the discharges from the
RO plant and effectively neutralizing the same before pumping the waste to the power
plant's effluent treatment system.
5.5.17 Vessels & Heat Exchangers
The design shall be as per ASME Sec. VIII, HE1 and TEMA. All heat exchangers and
vessels for steam application shall be designed for full vacuum conditions. The heat
exchangers shall be provided with stai-tup vent cotu~ections. The design shall have
provision for complete drainage on both shell and tube sides. The heat exchangers shall
be provided with emergency drains, shell side safety valves, and individual bypass with
manual valves. A minimum corrosion allowance of 1.6 mm shall be provided. The tube
bundle shall be of removable type. The tube material shall be stainless steel, unless
otherwise specified in the specifications.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-22
5.5.18 Fire Protection System
For protection of the plant against fire, all yards and plants will be protected by any one
or a combination of the following systems:
• Hydrant system
• High pressure water sprinkler-system
• Foam system
• Emulsifier system (mist formation)
• Portable fire extinguishers
The system will be designed in conformity with the recommendations of the Tariff
Advisory Committee of Insurance Association of India. While designing the fire
protection systems for this power station its extreme ambient conditions need special
attention. Codes and Standards of National Fire Protection Association (NFPA), USA
will be followed, as applicable.
The crusher house and transfer houses will also be provided with hydrant headers
connected to plant header hydrant network.
Unit auxiliary transformers down to 3000KVA rating and also all coal conveyor galleries
and tunnels will have automatic HPW sprinkler protection. The coal bunker conveyor
floors, coal crusher house and transfer points and the turbine oil tanks will have
automatic HPW sprinkler protection. Suitable fire detectors, and manual call points etc.
as suited will be provided at all such locations with necessary annunciations in the fire
control station, fire water pump house and unit control room Effective measures will be
taken to tackle fire in the cable galleries. Fire barriers with self-closing fire resistant
doors will be provided wherever necessary to prevent spreading of fire. Ventilation
system of the cable galleries will be so interlocked with the fire alarm system that in the
event of a fire alarm the ventilation system in the respective area will be automatically
switched off. All cable entries/openings in cable galleries, tunnels, channels, floors,
barriers etc. will be sealed with non-inflammable/fire resistant sealing material.
Adequate number of portable and mobile chemical fire extinguishers will be provided at
suitable locations throughout the plant.
5.6 STEEL MELTING SHOP WITH BILLETS CASTER(BILLET
DIVISION)
This chapter deals with the steel melt shop (SMS). It discusses the major facilities
proposed to be provided to achieve the desired production. The annual requirement of
major raw materials for steel making is indicated in this chapter.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-23
It is proposed to install 4 (four) numbers of 15 t (each) Induction furnace having
production capacity of 2,37,600 TPA liquid steel.
PHASE CAPCITY
Present -
Proposed 2,37,600 TPA
Ultimate 2,37,600 TPA
5.6.1 Steel making process
The primary steel making unit will be 4 Nos. Induction furnaces of 15 ton capacity (tap
weight). The furnaces will be designed with a charge mix of suitable proportion of hot
metal from blast furnaces, sponge iron from rotary kilns and in plant generated scrap. In
keeping with the modern trend, the Induction furnaces will be used mainly as a fast
melting-cum-decarburisation unit. Along with melting & decarburisation, phosphorous in
the molten steel will be brought down to the desired range. The semi-finished liquid steel
will then be tapped slag free into a preheated ladle. Depending on the steel grade aimed,
the liquid steel will then be subject to secondary refining & finishing treatment in the
Ladle Furnace.
5.6.2 Process details:
The process involves the charge mix of Raw material mainly sponge iron/scrap 70%, Hot
metal from Blast furnace 30%, poured into molten bath with constant power tract through
Solid State generator converting A.C. Power into D.C. Power and again to convert the
same into A.C. Power after changing the frequency of cycle in between 250 to 500 Hz
through thryster (an electronic device). This converted A.C. power with a frequency of
250 to 500 Hz is passed through capacitor Rack to achieve the desired voltage and the
same is passed through copper Bus Bar into Molten bath having copper coal, cooled
through water circulation, transparent the heat energy into molten bath at constant voltage
and KW to melt the Iron and Steel at a temperature of 1550oC.
This method is established all over India. Sponge iron manufacturers and Medium
Frequency Melting Induction furnace equipment manufacturer/arc furnace manufacturers
have developed the process parameters by which considerable quantity of sponge iron are
used in steel making.
5.6.3 Charge Mix :
Sponge Iron is being mixed with hot liquid metal of blast furnace, which are less rusty.
Hot liquid contains higher carbon higher carbon percentage is used for sandwiching
sponge iron. Sponge iron contains less percentage of carbon and cast iron with high
percentage of carbon make the mix charge perfectly to melt. The agitation of Furnace is
so high that the sponge iron take little time to attain molten metal. The reactive slag
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-24
formed in one bath attain the same temperature that of molten metal so quickly that by
addition of sponge iron into bath, nothing is hold by slag. Sponge charging is
discontinued once the metal bath level attains the two third height of crucible.
Extra carbon either in the form of free carbon or excess carbon present in the liquid hot
metal of blast metal is charged per ton of sponge iron. This is required to ensure F.C.
recovery from FCO with the use of sponge iron, the bath will have a rising tendency
because of the presence of FCD in sponge iron. Therefore, one bath should be suitably
killed by slagging off the impurities from molten bath. The induced current circulates the
charge in a direction opposite to but parallel with the current of primary coil.This current
is induced in one outer layers of the charge but the head produced is conducted quite
rapidly to the interior. As soon as a pool of molten metal starts to form, the charge sinks
and extra metal, as required, is being added. The current induced in the molten metal
causes a rapid stirring action and helps in melting the rest of charge by washing molten
metal. Thus the uniformity of among the charge is assured and necessity of any manual
stirring is avoided.
When as the mix charge is completely melted, necessary Ferro Alloys and de-oxiders are
added. The temperature of liquid metal is allowed to rise in the Furnace till the correct
pouring temperature is achieved which is checked with the help of Immersion Pyrometer.
After that the furnace is fitted with the help of the hydraulic system. The hydraulic
control ensures a smooth but rapid stop action in any attitude. Tilt speed is infinitely
variable and maximum speed varies with the size of furnace. Maximum tilt can be done
upto 95 degree.
The hot metal is poured with the hydraulic system in the pre-heated ladle after adding
certain fluxes so that the temperature is maintained at about 16000C. Ladle is then
carried by EOT crane to the concast machine and kept above the tundish of the concast
machine. The bottom of the ladle is opened by hydraulic system and hot metal starts
pouring out into the concast machine. Through tundish, it passes through copper moulds.
Copper moulds give the particular desired shape. To initiate casting, a dummy bar is
inserted into the bottom end of the mould, while the other end of the dummy bar is held
by withdrawal/straightening rolls when the moulten steel at the correct temperature
reaches the stipulated level inside the mould, the withdrawal rolls and mould
reciprocating unit are operated. The cooling water circulation through the mould
(primary cooling) and in the secondary circuit started a few minutes before the actual
casting operation. The dummy bar is withdrawn followed by the hot solidify billet. The
cooling water circulating around the mould carries away enough heat from the liquid
steel to produce a solid outer skin of sufficient strength to safely envelope the liquid
portion at the interior that to will be solidify by the secondary cooling, which consist of
spraying of water jets on the body of the billet. Before beginning to withdrawn the
dummy bar it must be insured that the outer casing of the billet is strong enough
otherwise a rupture in the skin may occur resulting in a break out which releases the
molten metal and forces a shut down of the operations. Thus the important parameters
are temperature of liquid steel, rate of primary and secondary cooling, mould
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-25
reciprocating characteristics, which all influences the casting rate and the quality of the
casting. The solidified billet further passes through straightening machine, cut to
required length and sent to the cooling through the roll conveyer system. The total
system requires soft water for cooling of copper moulds. Sized billets are lifted by
rectangular magnets to finishing yard for inspection and storage/dispatch.
5.6.4 Steel Making facilities.
The major facilities in steel melt shop include Induction Furnace and Billet Caster. All
the liquid steel produced are continuously cast into Billet. Automation and
computerization for the process are envisaged for making the operation efficient, in time
with the modern trend, for achieving high productivity and quality to compete in the
international market.
5.6.5 Technologies in Steelmelt Shop
The state-of-the-art technologies to be adopted in steel melt shop are: Induction Furnace
for melting DRI (Sponge Iron) along with Hot Metal available from MBF instead of
charging Solid Pigs for energy saving and higher productivity.
5.6.6 Selection of Equipment
The size and number of various facilities in the steel melt shop have been selected with
the following basic considerations:~
• Utilizing maximum hot metal available from Blast Furnace.
• Attaining the required production level with minimum number of steel making
and casting facilities.
• Maximizing availability of facilities provided by state-of-the-art technologies and
practices.
5.6.7 Equipment availability:
The continuous billet caster availability is envisaged as 330 days (approx) in a year
considering scheduled / unscheduled maintenance and operational breakdowns.
Availability of the Induction Furnace and secondary metallurgical facilities has also been
considered as 330 days (approx.) in a year to match the availability of the caster.
Considering the equipment availability a nominal heat size of 2 x 15 i.e. 30 MT is
selected to meet the annual liquid steel and market requirements. The selected heat size
also matches the caster cycle time as discussed below:
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-26
HEAT CYCLE TIME
Time
Mins.
------------
Pig / Scrap Charging 10
Pig Iron/Hot metal charging 15
Blowing
Deslagging, Sampling etc. 15-20
Average Reblow 7-8
Tapping 15
Slag splashing, slag-off 15
Vessel Inspection, delays etc. 10 – 12
-----------
Total 87 - 95
-----------
However, considering converter operational downtime like tap hole repair, mouth jam
cleaning, track cleaning gunning etc. as well as the caster cycle time, the average number
of heats is considered as 12 heats per day.
5.6.8 Selection of Continuous Casting Machine:
The number of strands required to cast 100 mm sq. and 160 mm sq. billets is worked out
of two. One 2 – strand billet casting machine suitable for casting 100 mm sq. and 160
mm sq. billets has been selected.
The size of billets that are cast in the shop is 100 mm sq. and 160 mm sq. to suit the
various grades of steel to be produced in the shop. It is planned to cast both the above
sizes of billets from 30 tons heat size in about 95 minutes for Construction and Alloy
Steel.
5.6.9 Major equipment and facilities
Furnace transformer capacity
AC furnace is envisaged in this report. In case of each 15 ton (tap weight) capacity
furnace, the transformer rating will be 7.1 MVA (Continuous rated). This will ensure a
high level of effective power input which is desirable because furnace charge will
comprise of high proportion of DRI/sponge iron which will be fed into the furnace
continuously at regulated rate.
Water cooled panels (WCPS)
Although the application of high power transformer concept results in greatly improved
furnace productivity, it also gave rise to stringent demand on furnace refractories
resulting in increased refractory consumption and considerably higher refractory costs.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-27
With high power input, hot spots develop on the furnace wall directly behind the
electrodes, while cold spots occur on the furnace wall between the consumption, WCPs
in the side wall as well as in roof (WCR-Water cooled roof) have been envisaged.
Electric bottom taphole (EBT)
The EBT which is a modified design of the conventional taphole, permits rapid and
practically slag-free tapping, which is an essential requirement for efficient refining and
finishing of the steel by ladle metallurgical processes.
The salient features of IF AC) are indicated below:
Number of furnace 4
Nominal capacity 15 tons each
Type of Unit Double station type with common change.
Transformer rating 7.10 MVA
Power rating 6000 kW
Operating frequency range 300-700 Hz
Tilting System By hydraulic cylinder
IF gas cleaning system
Separate fume extraction system and gas cleaning facilities will be provided for the IF to
extract the furnace fume through fourth hole in the roof and discharge it to the
atmosphere after cleaning. The gas cleaning system will be complete with water cooled
duct, gas cooler, bag house, ID fan and sufficiently tall stack. The cleaned gas discharged
into the atmosphere will have a dust content well within the statutory limits of WBPCB
& CPCB. The dust collected in the bag house will be stored in a dust silo. Periodically
the dust will be loaded into trucks for disposal.
Secondary refining facility (ladle gurnace)
The desired secondary refining functions, which need to be performed include the
following or a suitable combination thereof :
- De-oxidation and control of chemistry
- De-sulphurisation
- Arc heating & temperature control
- Inert gas stirring for thermal & chemical homogenization as well as for
scavenging the inclusions
- Inclusion shape control
The proposed LF will be used for arc heating, de-sulphurisation, de-oxidation, inert gas
stirring, alloy & flux addition etc. This unit can 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 the cc machine, hold up in the cc machine etc. Argon/nitrogen gas will be
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-28
introduced through a porous plug fitted at the bottom of the ladle for stirring the liquid
steel during treatment.
Continuous casting machine The billet caster is installed in the continuous casting shop. The caster is equipped with
ladle car to facilitiate sequence casting and to improve the surface and internal quality of
cast billets.
The casting machine along with tundish cars, casting platform etc. Is located in the
casting aisle undish preparation facilities as well as mould testing facilities for the caster
are also located adjacent to the caster
Scale pit is located close to the caster in casting bay. Scale is removed from the scale pit
by a grab attached to the crane and disposed by truck.
The main features of the casters are as follows:
No. of machines : 2
No. of strand : 2
Type : Low hear curved type 6/11 m
Radius
Steel grades that are cast : Construction steel, carbon
Steel.
Nominal heat size : 30/40 Ton
Ladle handling : Ladle car
Type of ladle : Bottom poured with slide gate
Machine equipped to cast : Billets : 100 x 100
Section, mm : 160 x 160 & 130 x 130
Cutting device : Automatic gas cutter
Cut length, m : 6-9
Method of discharge : Roller tables for each strand
and common cooling bed
suitable for billet handling by
crane for storage.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-29
5.6.10 Annual requirement of major raw materials
The annual requirement of major raw materials estimated by taking into consideration
225720 tons per year liquid steel production and a charge mix of approximately 30% hot
metal about 70% DRI/sponge iron and about 4% scrap will be as given in Table 5.9.
TABLE 5.9
ANNUAL REQUIREMENT OF MAJOR RAW MATERIALS
Item Quantity / year
Pig iron (tons) 71,200
DRI/Sponge iron (Tons) 1,66,320
Scraps 9,504
5.6.11 Handling facilities
DRI handling
DRI will be brought from DR plant by dumper to SMS building. DRI storage bins will be
of concrete construction. The storage capacity of DRI will meet about seven days
requirement.
Ferro Alloy and additive handling
Ferro alloys and additives will be received at the LF area and kept in earmarked bins.
Automatic weighing, batching and conveying system will be provided. The ferro alloy
and additive charging system will be operated from a remote control panel.
Liquid steel handling
Liquid steel from IF will be tapped into a preheated ladle mounted on a transfer car. Each
ladle will be equipped with a slide gate system with a porous plug at the bottom for inert
gas stirring. The steel in the ladle will be tapped slag free as far as practicable. The
transfer car will transport the ladle to the LF aisle and place it under LF hood for
treatment. After LF treatment, the ladle will be moved out and the heat will be placed on
the ladle turret of the CCM.
On completion of casting, slag in the ladle will be dumped on the ground in a specified
area. The ladle will then be placed on the ladle transfer car to take it back where it will be
placed on the ladle stand for slide gate and porous plug setting and preheating.
Slag handling
It is estimated that the annual generation of slag in the IF will thus be about 40,000 tons.
In addition, about 3,500 tons of slag will be generated in LF. The total quantity of slag to
be handled in the steel melt shop will amout to 43,500 tons per year.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-30
The IF slag will be poured through the slag door on the ground and disposed to the dump
yard by heavy duty loaders and road transport.
The slag remaining in the steel ladle after casting, will be dumped on the ground in a
specified area of the LF aisle. It will then be sent to the dump yard in the similar manner.
5.6.12 Ladle preparation, roof relining and other facilities
Facilities for various ladle preparation activities such as, deskulling, debricking and
relining, ladle preheating, will be provided, along with slide gate nozzle & porous plug
setting facilities for roof preparation etc. One crane will be used for these activities.
Refractories for relining the ladle will be received in trucks and stored by the relining
pits.
About 2,37,600 tons per annum of billets shall be available from proposed steel melt
shop.
5.7. FERRO-ALLOYS PLANT - PROPOSAL OF CHANGE IN
PRODUCT –MIX:
M/s. JAI BALAJI INDUSTRIES LIMITED (Unit I) proposes for Change in number of
Products of the existing Ferro-Alloys plant, keeping the total installed capacity same as
per the existing CTO
There will be no change in pollution load, plant & machineries and plant layout on
account of the above proposal.
Proposal of M/s. JAI BALAJI INDUSTRIES LIMITED (Unit I) for Change in number of
Products of the existing Ferro-Alloys plant, at G-1, Mangalpur Industrial Estate, P.O.
Bakhtarnagar, P.S. Raniganj, District – Burdwan, undertakes:
✓ There will be no change in total quantity of Ferro-Alloys production (i.e. 2,513
Tons/Month)
✓ There will be no change in pollution load as prescribed in the obtained Consent to
Operate, Ref. Memo No. 546 WPBA/Red(Bwn)/Cont(332)/2002, dated
05.05.2017.
✓ There will be no change in plant & machineries.
✓ There will be no change in plant layout.
✓ No further investment is also required
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-31
OPTIMISATION OF PRODUCT MIX – PROPOSAL
FACILITY PRODUCT MIX & CAPACITY
EXISTING PROPOSED
FERRO
ALLOYS
Total Capacity :
2,513 Tons / Month
(CTO obtained)
Product Mix:
• Ferro Manganese - 1,298
Ton/month
• Silico Manganese- 1,215
Ton/month
Total Capacity :
2,513 Tons / Month
Keeping the total Ferro-Alloys
production Capacity 2,513 Tons /
Month unchanged; product mix
capacity will be optimized, or
combination thereof.
Product Mix:
Either
• Ferro Manganese - 2,513
Ton/month (capacity
optimized)
Or • Silico Manganese- 2,430
Ton/month (capacity
optimized)
Or
• Ferro Chrome – 2,000
Ton/month (capacity
optimized)
5.7.1 List of rawmaterials with quantity:
RAW MATERIAL QUANTITY
(Ton/month)
either, Ferro Manganese – 2,513 Ton/month
Mn Ore 5,780
Coke 1,319
Dolomite 628
or, Silico Manganese – 2,430 Ton/month
Mn Ore 4,252
Coke 1,580
Quartz 365
Dolomite 365
Fe-Mn Slag 1,216
or, Ferro Chrome - 2,000 Ton/month
Briquette 4,000
Chrome Ore 800
Coke 1,080
Quartz 400
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-32
5.7.2 Manufacturing process of each product
The Ferro alloys section will make following three types of alloys:
1. Ferro-manganese (high carbon)
2. Silico-manganese
3. Ferro-Chrome
The facilities within the ferro alloy plant comprise of the following major units:
1. Raw material handling system
2. Furnace feeding system
3. Submerged arc furnace
4. Furnace tapping and casting
5. Product handling system
6. Electrical system
7. Gas cleaning plant
Two numbers of conveyor system will be envisaged to feed the day bins for different
ferro alloy production. Day bins will be for Ferro manganese, Silico-manganese and
Ferro chrome. Vibrating feeders located below each ground hopper, which transport the
material on a vibratory screen through conveyor. In order to store the materials in
individual bunker a reversible shuttle conveyor has been provided on top of bunker.
Furnace feeding system
A conveyor has been provided to collect the seighed mixture of material from surge
hopper on ground level and dump the same in to a feed hopper. The material from this
hopper is collected by a conveyor and transported to a rotating unidirectional conveyor
mounted on the rails. By way of rotation this conveyor gets aligned with charging bins
and correction bins, which are located around the circumference of this rotation. The
charging bins extends further in the form F.A. chute, up to the furnace. Pneumatically
operated slide gates has been provided in each chute. These gates is operated from the
central control desk.
Submerged arc furnace
Two submerged arc furnaces of capacity 7 MVA each have been established. The
furnaces are equipped with charge feeding hoppers, chutes, transformer, electrodes and
gas cleaning plant.
Furnace tapping and casting
The furnaces are tapped at an interval of about two and half hours considering eight
numbers of heats per day. The tap hole is opened by tap hole drilling machine. Oxygen
lancing is resorted for piercing the solidified metal/slag in the tap hole for proper flow of
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-33
metal and slag from the furnace. Tap hole closing device has been provided for closing
the tap hole after tapping. Skimmer/ladle tapping arrangement is provided. The liquid
metal is cast in moulds or in sand bed. The slag from the furnace is collected, cooled and
disposed at suitable area allocated for slag disposal.
Product handling system
The solid cakes are broken in to smaller pieces manually in to required sizes. Suitable
adjustment of breaking can change the product sizes to suit customer’s requirement.
The products, classified according to sizes and grades of different three ferro alloys will
be stored in the dedicated storage areas. Sized product is weighed, packed and kept ready
for dispatch.
Metallurgical Reactions involved during production of Ferro-manganese & Silico-
manganese:
• 2MnO2 + C → Mn2O3 + CO
• 3 Mn2O3 + C → 2Mn3O2 + CO
• Mn3O2 + C → 3MnO + CO
• MnO + C → Mn + CO
• Fe2O3 + 3C → 2Fe + 3CO
• SiO2 + 2C → Si + 2CO
• P2O5 + 5C → 2P + 5CO
The main Metallurgical Reactions involved during production of Ferro-chrome :
• Fe2O3 + CO → 2FeO + CO2 (at 800°C)
• FeO + C → Fe + CO (at 1200°C)
• Cr2O3 + 3C → 2Cr + 3CO (at 1400°C)
• SiO2 + C → SiO + CO (at 1600°C)
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-34
5.7.3 Mass Balance for each product:
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-35
5.7.4 Water Aspects:
Water Consumption Details (KL/Day) :
Propose
Existing Water
Consumption
Water Consumption
Break up after change
in product mix
Proposed Additional Water
Consumption
INDUSTRIAL
No additional water
consumption
Process + APCM
Boiler
Cooling 300 300
Washing
Gardening
Other
Total Industrial 300 300
Domestic 2 2
5.3 Water Balance Diagram (with reuse/recycle if any):
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-36
5.7.5 Effluent Generation (KL/day) :
Purpose
Existing
Effluent
Generation
Effluent
Generation after
proposed change
in product
mix
Mode of Disposal &
Ultimate
Receiving Body
INDUSTRIAL
Dust
suppression/greenery
purpose
Process + APCM
Boiler
Cooling 100 100
Washing
Other
Total Industrial 100 100
DOMESTIC 2 2
5.7.6 Effluent Gas Emission:
Sr.
No.
Stack attached
to
Fuel
Existing Fuel
Consumption
Proposed Fuel
Consumption
Stack Height
1. Submerged Arc
Furnaces
Electricity 11.2 MW 11.2 MW 1 Stack of 30
mtrs height
5.7.7 Process Emission:
Stack
No.
Stack attached to
Stack
height in
meter
APCM
Parameter
Permissible
Limit
1 Submerged Arc
Furnace (SAF) - 1
& 2
30 Heat
Exchanger
& Bag Filter
PM – 46.58
mg/Nm3
50 mg/Nm3
5.7.8 Hazardous Waste Generation :
In the existing operation, negligible quantity of Used Oil is being generated, which will
remain within the same level after the proposed change in number products.
Stack
No.
Type of
waste
Category (as
per schedule
Generation per year (No
Change)
Permissibl
e Limit
Source of
Generation
Mode
of
Storage
Mode of
Treatment
& Disposal
Existing After change
in product
mix
- - - - - - - - -
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-37
5.7.9 Proposal for reduction / recovery / reuse / recycle / sale of waste:
Solid Waste Type Quantity Management
Ferro manganese
Slag
25,632 TPA
Ferro manganese Slag will be used as raw
material for Silicon Manganese production.
Silicon Manganese
Slag
24,780 TPA Silicon Manganese Slag will be used for low
land filling.
Ferro-chrome slag 20,400 TPA ❖ Chrome will be recovered from Ferro-
chrome slag at Chrome recovery plant.
❖ After chrome recovery, the tailing
material will be used as stone chips (8 to
25 mm) & land filling purpose (0 to 8
mm).
❖ TCLP Test shall be carried out all
around the storage area on regular basis.
5.7.10 Ferro-Chrome Slag Generation :
Arround 20,400 TPA Ferro-Chrome Slag generations is estimated per annum in case of
Ferro Chrome production reaches 24,000 Tons/Annum (optimized capacity).
Chrome concentration in the Ferro-Chrome slag obtained from Jai Balaji Industries
Limited is found 2.6 mg/Kg, therefore, Ferro-Chrome Slag obtained shall not be
characterized as Hazardous Waste.
However, Jai Balaji Industries Limited, have some specific programmes for the Ferro-
Chrome slag generated as followings:
- Recovery of Chromium (metal) from Ferro Chrome Slag.
- After Metal Recovery from slag, the balance tailing material will be used as stone
chips (8-25 mm) in civil work and land filling (0-8 mm ).
5.7.11 Chrome Recover – Process Description:
Ferro Chrome Slag of size fraction (+0 - 300 mm) will be received on Feed Hopper,
which will be discharged from the bottom opening through a Rod Gate and Reciprocating
Feeder.
Reciprocating Feeder will discharge the Slag to the Primary Jaw Crusher through Feed
Conveyor to feed it to the Primary Jaw Crusher.
Jaw crusher shall crush the slag to (-) 65 mm and discharge the crushed material to
Double Deck Sizing Screen Feed Conveyor to feed it to Double Deck Sizing Screen.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-38
+25mm material from the Surge Hopper will be fed through Rod Gate and Vibrating
Feeder to the Secondary Jaw Crusher.
Secondary Jaw Crusher will crush the slag down to -25mm.
The crushed (-) 25mm product will also be discharged to the Double Deck Sizing Screen
via Double Deck Sizing Screen Feed Conveyor .
The overflow (+8 to 25 mm) from the Bottom Deck of Double Deck Sizing Screen will
be discharged to Surge Hopper for Coarse and the underflow (+0 to 8 mm) from the
Double Deck Sizing Screen shall be discharged to Surge Hopper for Fines.
Jig will produce 3 (Three) types of Products.
i) Concentrate (Pure Metal)
ii) Middlings (Remelt)
iii) Tailings (Slag)
✓ Middling will be discharged on to the Middling Conveyor for onward ground
storage.
✓ Tailings will be discharged on to the Tailings Conveyor for onward ground
disposal.
Provision will be kept to further crush the Middling in the Secondary Jaw Crusher.
Clarified water from the tailing settling pond will be recycled back to Jig water feed
sump
5.7.12 Ferro-Chrome Slag Storage:
An area near to Ferro-Chrome Plant area have been identified for storage of Ferro-
Chrome Slag (metal recovered). The Slag Storage area will have R.C.C. flooring and a
garland drain will be constructed at this storage area.
TCLP test will be carried out all around the storage area on regular basi.
5.8 AUXILIARY FACILITIES
Repair and maintenance shop:
The plant repair and maintenance facilities will be centralised to take care of regular
maintenance work. Tool room, hydraulic and pneumatic equipment repair, welding
section, office, toilet etc will be suitably located.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-39
General store:
A single bay building will keep equipment spares, hardwares, wearing parts and
consumables.
Laboratory Facilities
Facilities will be provided for collection of various samples and carrying out necessary
analysis as required for operation of the plant.
Other Facilities
Besides the repair and maintenance shop, and general stores, other auxiliary facilities
like general administrative building, first aid station, canteen will also be provided.
5. 9 ELECTRIC POWER
This section presents the estimated power requirements for the proposed new plant, the
characteristics of plant loads, the source of power and the proposed power distribution
arrangement. The major electrical equipment as envisaged such as switchgear,
transformers, motors and controls as well as plant lighting system, instrumentation and &
automation system and plant communication system are also discussed.
ESTIMATED OVERALL PLANT POWER REQUIREMENTS OF
NEW FACILITIES.
Sl. No. Facility Required Power
1 DRI Plant ( 5 X 100 TPD ) 1.5 MW
2 Iron ore Beneficiation Plant ( 0.6 MTPA ) 4 MW
3 Pellet Plant 2.5 MW
4 Induction Furnace 32 MW
5 Coal Washery 0.5 MW
3 Ancilliary units of Captive Power Plant
(22MW )
2 MW
Total: 42.5 MW
5.9.1 Power arrangement:
JBIL ( UNIT – I ) is well planned in arrangement of power for project operation.
Presently the Captive Power Plant ( 18.3 MW ) is catering power to its operational units.
For the proposed projects additional 42.5 MW power will be required. Out of the total
44.2 MW rewuirement 22 MW power will be supplied by proposed 20 MW captive
power plant and balace 20.5 MW will be met from DVC, DPL
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-40
5.10 WATER SYSTEM
Water is predominantly required in the steel plant for equipment cooling. In addition, it is
used for process use; steam raising; for collecting and conveying of scales, control of dust
and debris; for drinking and sanitation; for fire-fighting and for other miscellaneous
purposes.
5.9.1 Water requirement
The existing plant water requirement for operational unit is 570 m3/day and additional
water requirement for the proposed expansion project is about 1175 m3/day. Thus, the
total water requirement will be 1745 cu.m/day. The break-up of water required for
proposed Units is given in Table-5.4.
TABLE – 5.4
WATER REQUIREMENT FOR EXPANSION Sl. No. Plant / Section Water (m3/day)
1 4x15 T Induction Furnaces 110
2 DRI Plant ( 5 X 100 TPD ) 65
3 Coal Washery 50
4 Iron Ore Beneficiation Plant ( 0.6 MTPA ) 540
5 Pellet Plant (0.6 MTPA) 100
6 Captive Power Plant( 20 MW ) 275
7 Domestic Water 35
NET MAKE UP REQUIREMENT 1175
It is considered that requisite amount of make up water supply shall be made available by
the supply of Asansol Durgapur Development Authority ( ADDA ).
5.9.2 Plant water system
The plant water system comprises a make-up water system, drinking water and fire-
fighting water systems, individual recirculating water systems for the proposed facilities,
effluent disposal system as well as emergency water supply system for the vital units of
the plant.
The different water systems, their respective consumers and broad facilities provided for
each system are indicated in the following Table 5.4, which reflect a conceptual water
distribution scheme.
TABLE – 5.4
MAJOR WATER SYSTEMS
Sl.
No.
System Main consumers Main facilities
1. Make-up water
system
Cold well of various recirculating
waster systems of plant, drinking
Water storage tank,
make up water pump
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TEFR for Steel Complex Expansion. 5-41
water and sanitation system, fire-
fighting water system, softening
and DM plants.
house with storage,
pumps, distribution
pipework and
chemical dosing
system
2. Drinking Water
System
Plant personnel and laboratories Drinking water
facilities including
filtration unit,
chlorinating unit,
pump, overhead tank
and distribution pipe
network and disposal
facilities including
sewage treatment
plant.
3 Fire-fighting Water based fire-water system. Fire-fighting water
fighting system
pumps, storage
reservoir of required
comprising
yard/capacity, fire
fighting water network
shop fire hydrants
covering yard and
shop comprising
distribution mains,
landing valves, hoses
nozzles etc. including
jockey pumps.
4 Demineralistation
water supply system
Closed recirculating system of
units comprising captive power
plants.
Demineralisation
plant, storage, pumps
and pipework.
5. Direct reduction
plant water system
DR Plant consumers requiring
primarily closed circuit cooling
involving ICW system etc.
Pumping instllation,
cooling tower,
pipework and
chemical dosing.
6. Captive Power Plant
recirculating system.
Captive power plant (gas based
unit and coal and char based unit)
Pumping installation
cooling tower,
chemical dosing
system, pipeworks etc.
7. Iron Ore Benficiation
Plant
Process Washing.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-42
5.9.3 Waste water and faecal sewage 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, as far as
practicable, facilitating adequate reuse of-water in the respective recirculating systems
and economizing on the make-up water requirement. Sewage generated from toilet blocks
etc shall be treated in a sewage treatment plant and the treated effluent shall be collected
in a sump, located in a low lying area, where bleeds from the several clear water
recirculating cycles shall also be collected. The water thus collected shall be used for dust
suppression at raw material handling system, landscaping etc. The excess effluent with
quality parameters conforming to norms stipulated by statutory authorities shall be
allowed to be drained out to nearby watercourse/drains.
5.9.4 Electrics, instruments and controls
The requisite instruments and controls as well as audio- visual alarms and safety
interlocks will be provided for safe and efficient operation of the water system which will
be complete with necessary sensing devices, transmitters, actuators, control valves,
instrument panel, impulse piping and other accessories. The electrical equipment required
for catering to the water system equipment are considered separately under the relevant
portion pertaining to section on electrics.
5.9.5 Drainage
Open drains are envisaged for the plant storm water drainage. The drains will be laid by
the side of the roads close to plant units. The space between the drain and the building
apron will have gentle slope towards the drain. The outfalls of plant drains will be located
at low lying areas near the plant boundary wall adjacent to natural nullahs.
5.10 UTILITY SYSTEM
This section discusses the requirements and facilities proposed for various utilities viz.,
fuel oil, Oxygen plant and instrument air. In addition, air pollution, ventilation and air
conditioning and fire protection systems envisaged have also been discussed.
5.10.1 Fuel oil system
Fuel oil is required to start-up the kiln and for emergency requirements in the Kiln, and
DG set operation.
It is envisaged that LDO will be brought in road tankers and unloaded into respective
storage tanks through unloading pumpsets. The oil storage tank has been considered for
Kiln and DG set operation. The tank will be provided with standard auxiliaries such as
conservative vent valve, flame arrestor, drain connection. Oil from these tanks shall be
transferred to the respective consumer units by 2 x 100 per cent fuel oil transfer pumps
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-43
through filters. Return oil, if any, shall be discharged back to the storage tank. The tank
farm will be provided with dyke wall and suitable fencing all around according to
statutory requirement.
5.10.2 Cutting fuel gas system
LP gas shall be used for general purpose cutting and gas welding. The requirements of LP
gas shall be met by gas cylinders. Necessary facilities including cylinder banks,
manifolds and associated pipework shall be provided near the respective consumption
points.
5.10.3 Oxygen system
Oxygen required for general purpose welding and cutting operations shall be met by
oxygen cylinder which shall be provided near the respective plant units. The cylinders
shall be provided with necessary cylinder valve and suitable manifold to a distribution
piping network upto the respective consumption points.
5.10.4 Plant and instrument air system
Compressed air will be required for general service purpose, cleaning of bag filters used
in fume/dust extraction systems for DR kilns and various furnaces, other process users
and for instrumentation.
5.10.5 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.
Natural ventilation arrangement will be adopted in most of production
buildings.
5.10.5 Air conditioning system
The air-conditioning system is proposed to be designed to maintain the following
conditions in the spaces serviced:
25 + 2oC dry bulb temperature and 55 + 5 percent relative humidity for control rooms,
control pulpits, computer rooms, PLC rooms, laboratory etc.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 5-44
To meet the above requirement, air handling units using chilled water, package type air
conditioning unit complete with compressor, condenser and ductwork are envisaged. AC
units/AHUs shall be installed in separate rooms adjacent to various conditioned spaces
served. Conditioned air from AC units to the spaces served shall be provided by
plenum/ductwork. Wall mounted window model air conditioners have also been
envisaged in some areas for the purpose of air conditioning.
5.10.6 Fire protection system
In addition to the yard fire hydrant system, the fire protection systems envisaged for the
plant are as follows:
- Internal fire hydrant for storied buildings to be tapped-off from the outdoor
fire water header.
- Fire detection and alarm system for electrical rooms, cable basements/cellars,
cable tunnels, selected oil/ hydraulic cellars.
- Portable fire extinguishers such as CO2, foam and dry chemical powder in all
areas of the plant with fire hazard.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-1
CHAPTER - 6
CONTROL MEASURES FOR ENVIRONMENTAL POLLUTION
6.1 Intruduction
The proposed expansion will follow Environment Friendly operation. The
recovery of energy in the form of electricity from DR kiln waste gas makes this
production process more attractive. However, there would be some
environmental pollution in respect of land, air and water that need to be
controlled. This chapter accordingly gives an outline of the principal types of
pollution, its sources and also highlights the proposed environmental pollution
control measures that form an integral part of the proposed project concept.
6.2 Pollution potential sources
The sources and types of pollution can be assessed from the project concept
described in the earlier chapters. It may be seen from the earlier chapters that the
major sources of pollution in the proposed plant are from the (i) Raw material
handling (ii) DRI production by using non-coking coal in rotary kiln. Apart from
these there would be Captive Power Plant to generate power using Waste heat
from DRI Kilns in Waste Heat Recovery Boilers and Dolo-char/Washery Rejects
in CFBC Boiler. Each of these production units would contribute to air, water
and land pollution of varying nature and degree. The sources of pollution from
the proposed project and type of environmental pollution likely to occur are
summarized in Table 6.1.
Table – 6.1
Sources of pollution due to proposed expansion
Proposed
production
facilities
Process operation Pollutants released Type of
environmental
pollution
Raw material
handling yard
Stockpilling, crushing,
screening, conveyor
transfer and charging
Fugitive dust
emission
Air pollution
Noise pollution
Iron ore
beneficiation Plant
Stockpiling, crushing,
screening, conveyor
transfer
Iron ore dust, waste
water containing
fine ore
Air pollution
Water pollution
Iron ore Pellet
Plant
Stockpiling, crushing,
screening, conveyor
transfer
Iron ore / Coal dust. Air pollution
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-2
Proposed
production
facilities
Process operation Pollutants released Type of
environmental
pollution
Rotary kiln Direct reduction of iron
ore at 900 °C
TSP, CO2, SO2,
NOX and thermal
heat from emissions
of combustion flue
gases at 900-1000
°C
Air pollution
Thermal pollution
Induction Furnace Production of liquid
steel at around
temperature of 1100 °C
followed by secondary
refining of steel in LF
and billet casting
Waste gas
containing
particulates
Discharge of hot
water from the
pollution cooling
circuit
IF & LF slag land
pollution
Waste water
containing iron
scales, oil and
grease discharge of
hot water.
Air pollution
Noise pollution
Water pollution
Solid Waste
Water pollution
Ferro-Alloys Plant Production of Ferro-
Alloys in Submerged
Arc Furnace at around
temperature of 1600 °C
Discharge of hot
water from the
pollution cooling
circuit
Ferro-Manganese /
Silico Manganese /
Ferro-Chrome Slag
Water Pollution
Solid Waste
Captive power
plant
Generation of power
from plant fuel gas, coal
middlings and char
TSP, SO2, NOX &
CO
Generation of ash
Air pollution
Land pollution
The air pollution will take place due to emission from stacks attached to various units in
the complex.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-3
6.3 Pollution prevention and control measures
In consideration of the above stated pollution potential of the proposed steel plant, the
following mitigation schemes are envisaged in order to control environmental pollution
within the permissible norms and keep the environment fairly clean.
6.3.1 Air environment protection
a) Raw material handling area
The raw material handling section would be provided with dust suppressing (DS) by
water sprinkling at the open stockyard and multiple dust extraction DE) systems within
the closed work zone for various dust generation points. The DE system shall consist of
bag filter units complete with ducts, extraction fans and stack of appropriate height.
b) DRI kiln
The exhaust gas from the kiln generated at a temperature of 900 to 1000 °C and
contaminated with dust particulates, sulphur dioxide, oxides of nitrogen and carbon
monoxide would be cleaned by dry gas cleaning system (ESP/bag filters). The DR kiln
off gas would pass through after burning chamber to burn out CO in the flue gas before it
is taken to the waste heat recovery boiler for generation of power. The product separation
unit would be provided with DE system to arrest the dust emission.
c) Captive power plant
The flue gas generated from combustion of char and coal middlings would be taken
through an ESP or bag filter to arrest the fine dust particulate matter. The clean gas would
be vented into the atmosphere through a tall stack of adequate height.
d) Iron ore beneficiation plant
The air and water pollution from various technological units is controlled by employing
suitable pollution control systems for source reduction of pollution and effluent is treated
before they are let out if any. All the conveyors transfer points are equipped with dust
extraction system(s) as required.
There is no effluent let out from the iron ore beneficiation plant. Water from the tailings
is also reclaimed and reused in the process.
e) Iron ore Pellet plant
All junction houses and transfer points are dust generating sources. To control the dust
two numbers of ambient dust catching system will be installed in the pellet plant. The
dust content after dust catcher shall not be more than 50 mg/Nm3. Finally dust will be
controlled by the ESP before discharge through stack.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-4
f) Steel Melting Shop
In this shop, air pollution would be primarily due to emission of dusts, CO and NOX.
The essential pollution control measures would be the arresting of dust emissions to the
atmosphere from the EAF and the LF. The IF would be provided with in-built after
combustion chamber for CO removal and dust separation from the waste gases by bag
filters.
The water required for cooling of the billets would give rise to hot fumes containing
mostly vapours of water. This would be collected by suitable FE system and taken
through a condenser to separate out the steam condensate and the spent gas would be let
out theough a roof top stack into the atmosphere.
6.3.2 Water environment protection
The waste water generated in the Iron ore beneficiation plant containing fine iron ore
would be passed to tailing pond of desired capacity. The clear water from the pond would
be re-circulated for further use.
The plant sanitary waste water including canteen effluent would be treated in a modular
type sewage treatment plant for separation of floating oil and reduction of BOD. The
treated waste water would be collected in a pond within the plant to be used for dust
suppression and the maintenance of plant green belt.
6.3.3 Work zone pollution control
As stated earlier, the work zone pollution would be mostly fugitive dust, heat and noise.
The fugitive dust emission in open area would be controlled by DS and DE system as
described earlier.
The work zone noise would be mostly fluid noise from the rotary equipment and
machinery like fans, blowers, compressors and pumps. Propose selection of low noise
prone equipment and the grouting of this equipment will be made free from vibrations.
The work zone nose exposure of the operating personnel would be avoided by remote
operation from the control rooms.
6.3.4 Solid waste disposal
The solid waste produced due to the proposed plant would be DR kiln char, treatment
plant sludge’s, fly and bottom ash, flue dust etc. coal ash would be collected and
temporarily stored in the ash disposal area for onward transporting to nearby Cement
manufacturing unit / brick manufacturing units.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-5
6.3.5 Pollution control equipment for the steel complex
The pollution control equipment are given in the following Table 6.2
Table – 6.2
POLLUTION CONTROL EQUIPMENT
FOR FUGITIVE AND STACK EMISSIONS IN STEEL COMPLEX
Probable Pollution Sources Mitigation Measures
DRI Plant
Loading / Unloading of Raw Materials and Finished
Products
Sprinklers / Fogging / Mist
Raw Material Handling System for DRI Plant Bag Filters
Product handling during discharge and intermediate
and product bins
Bag Filters
DRI Kiln off Gases ESP (Electro Static
Precipitator)
Iron ore Beneficiation Plant
Stock piles
Dust Extraction system. Material Transfer points on Conveyors
Power Plant
Unloading of Raw Material Sprinkler / Fogging / Mist
Raw Material Handling System for Power Plant Bag Filters
Boiler Flue Gases ESP
SMS
Raw material handling system for Steel Melting
Section
Bag Filters
IF & LF off Gases Fume Extraction System with
Bag Filters
PELLET PLANT
Process E.S.P & Bag Filters
The cost of pollution control equipment is given in the following table, which forms part
of main investment.
Table – 6.3
Cost of equipment/facilities for pollution control
Location/ Plant Air pollution
control equipment
to be deployed
Specification
(If possible)
Tentative cost
( Rs in crore )
Coal Washery Bag-filters 100mg/m3 0.40
Induction Furnace Bag-filters 100mg/m3 1.80
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-6
Pellet Plant Bag-filters, Silo 100mg/m3 3.20
Sponge Iron ESP, Bag-filters,
GCT
100mg/m3 20.00
Power Plant (20
MW)
ESP, Silo, Bag
filters.
100mg/m3 5.00
Iron Ore Beneficiary Dust Extraction
system
100mg/m3 3.00
Total 33.40
6.3.6 Plant safety
Plant safety measures would form an integral part of the environment protection plan of
the proposed plant. Workers safety would be of highest degree of concern so as to avoid
any form of personal injury or untoward accident. In-built safety features of the plant and
machinery would be made adequate in order to avoid hazardous events causing damage
to the life and property.
6.3.7 Green belt and landscaping
Jai Balaji Industries Limited has already earmarked 16.2 acres of land for Green Belt
Development within its existing plant at Raniganj, part of which has already been
developed.
Pertaining to the proposed expansion the Company proposes to increase area for green
belt development by 28.5 acres, which will be 33.72 % of the total proposed project area
of 85.5 acres.
• Green belt development is planned to be completed within 5 years by planting
about 500-600 saplings per acre.
• It is also proposed to build a green belt at the solid waste disposal sites.
• Plantation along the road will attenuate noise level, arrest dust and improve the
environment in surrounding.
• This would improve the plant aesthetics as well as prevent the fugitive dust
emissions
• The plant species will be selected as per CPCB guidelines.
6.3.8 Design targets for environmental protection
Stack emissions :
Particulate matter 100 mg/Nm3
SO2 emission Would be permitted within the
carrying capacity of the site
environment NOX emission
Work zone environment :
Dusts 10mg/cum (max) in a handling Closed area and 500 mg/cum (max)
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-7
and transport of raw materials and
finished product
in an open area within 20 to 30 m
aerial coverage
Thermal pollution 2.5 KW/m2 (max) for 40 sec.
Noise maximum 85 dB(A) for a period of 8 hours
exposure
Waste water discharge :
pH 6 to 9
Total suspended solids 100 mg/l
BOD 5 (20 °C) 30 mg/l
COD 250 mg/l
Oil and grease 10 mg/l
Iron (as Fe) 3 mg/l
6.4 Environmental monitoring
Routine environmental monitoring of stack emission, ambient air quality, work zone air
quality, noise level, waste water and surface water stream would be carried out. The
monitored data would be recorded and necessary corrective measures to be implemented
to avoid any con compliance of statutory regulations.
6.5 Land use planning
It is estimated the total area required for the proposed facilities is 86 Acres. The land use
planning of the same is as follows:
The built up area details combined for existing and expansion are as follows:
1. DRI PLANT (5 X 100TPD) = 20 acres
2. CPP (20MW) = 10 acres
3. IRON ORE BENEFICIATION PLANT = 6 acres
4. IRON ORE PELLET PLANT = 6 acres
5. SMS DIVISION = 4 acres
6. ASH POND = 5 acres
7. MAIN WATER STORAGE TANK = 4 acres
8. MISCELLANEOUS = 2 acres
9. GREEN BELT = 28.5 acres
TOTAL = 85.5 acres
6.6 Waste water management
A. Domestic waste water
No residential accommodation is planned within the plant premises. However, large
manpower 800 persons will require 40 cum/day of drinking/sanitary water. This will be
treated before releasing to the environment for plantation etc.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 6-8
B. Industrial waste water
The Industrial waste water will be treated and recycled.
6.7 Solid waste management
The solid wastes generated by the expansion plant will be as follows :
Particulars TPA Remarks
1. Dolo-Char from DRI Plant 60,000 Will be utilized in CFBC
Boiler for Power
generation.
2. Dust from DRI Plant through WHRB
boilers
18,000 Will be given to the
Pellet Plant.
3. Fly Ash from 10 MW Thermal power
station
40,000 Will be sold to the
Cement Plants / Brick
manufacturing
4. Bottom ash Power Plant 10,000 To be disposed in
abandoned mines
ESP Dust from Power Plant 10,000 To be disposed in
abandoned mines
5. Tailings from Iron ore beneficiation plant 2,20,000 To be disposed in
abandoned mines
IF Slag 40,000 Land Filling
LF Slag 3,500 Land Filling
Ferro-Chrome Slag 20,400 After chrome recovery,
the tailing material will
be used as stone chips (8
to 25 mm) & land filling
purpose (0 to 8 mm).
Ferro-Manganese Slag 25,632 Ferro manganese Slag
will be used as raw
material for Silicon
Manganese production.
Silico Manganese Slag 24,780 Silicon Manganese Slag
will be used for low land
filling.
ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion. 7-1
CHAPTER - 7
MANPOWER REQUIREMENTS
This chapter deals with assessment of manpower requirement for the proposed expansion.
The requirement of additional manpower for the proposed expansion, its auxiliaries and
services will be 800.
Breakup of the additional manpower requirement is given in the following Table.
Category wise break up of additional manpower
The category wise break down of additional manpower requirement if indicated in the
following Table.
CATEGORY WISE BREAK-UP OF ADDITIONAL MANPOWER
Category Number of persons
Managerial staff 10
Executive staff 40
Skilled staff 200
Non - skilled staff 500
Office staff 50
Total 800
JAI BALAJI INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion 8-1
CHAPTER - 8
CAPITAL COST ESTIMATES
This chapter presents the estimate of project cost for installation of steel complex
(expansion) with 5 X 100 TPD Kilns, 0.6 MTPA Iron Ore Beneficiation Plant,
0.6 MTPA pellet Plant, 4 X 15 T Induction Furnace and 22 MW Captive Power
Plant.
8.1 CAPITAL COST ESTIMATE
a) Plant cost
The plant cost covers the cost of all facilities as described in Chapter 5 & 6. It
includes the cost of civil and structural work and equipment as erected within the
plant boundary. It also includes the expenses for technical services, design,
engineering and administration during construction.
i) Civil and structural work
The cost of civil and structural work includes expenses towards all civil works
and structural steelworks for factory buildings of main and auxiliary services.
The cost of civil work has been based on prevailing prices of building materials
and existing rates of construction work for similar plant and equipment. The cost
of structural steel work has been estimated on the basis of current prices of steel
structurals and the prevailing rates of fabrication and erection work. The
quantities of civil structural steelwork have been estimated based on preliminary
design concepts and layouts of the major departments.
ii) Plant and machinery
The cost of equipment is based on prevailing prices with manufacturers and
vender.
Technical services, design and engineering fees and administration during
construction
A provision has been made towards technical services, design and engineering
fees, administration and interest during construction. The overall project cost
becomes Rs 332 crores as shown in the following Table 10.1.
JAI BALAJI INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.
TEFR for Steel Complex Expansion 8-2
TABLE – 8.1
TOTAL PROJECT COST
Sl.No. Particulars Rs. Crores
1 DRI Plant ( 5 X 100 TPD ) 60.00
2 Captive Power Plant ( 20MW ) 110.00
3 Iron Ore Beneficiation Plant ( 0.6 MTPA ) 12.00
4 Pellet Plant 100.00
5 Induction Furnace 40.00
4 Land & site development 10.00
TOTAL *332.00
*-Including cost of environment pollution control equipments / systems.
TABLE – 8.2
MEANS OF FINANCE
Sl.No. Particulars Rs. Crores
1 Term Loan 232.00
2 Equity / Internal Accruals 110.00
TOTAL 332.00