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TECHNO-ECONOMIC FEASIBILITY REPORTFor

3.5 MILLION TON PER YEAR INTEGRATED STEEL PLANT ATVILLAGE HALVARTHI, KOPPAL in KARNATAKA

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Nagpur - India

February, 2017

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INDEX

ChapterNo.

Subject Pages

VOLUME-1

1 Introduction 62 Executive summary 443 Market Analysis- Demand and Supply 224 General lay out and transportation 125 Raw Material Handling and Storage Facilities. 36 Coke Oven battery & By-product Plants 117 Sintering Plants and Auxiliaries 9

7A Iron Ore Fine Beneficiation unit 108 Blast Furnace and Auxiliaries 229 Steel making and continuous casting plants 42

VOLUME-2

10 Hot Rolling Mills 3211 Cold Rolling & Processing Complex 3212 Captive Power Plants and Turbo-blower stations. 1113 Cryogenic Oxygen plants 214 Pollution Control & Environment Management 2115 Power Distribution 816 Instrumentation & Automation 417 Water Supply facilities 818 Steam and Compressed Air Facilities 719 Fuel Oil storage & Distribution system and

Interplant pipe lines4

20 Industrial Safety and Fire Protection Facilities 321 Air Conditioning, Ventilation & De-dusting systems 222 Repair Shops 323 Quality Control & laboratory facilities 724 Construction planning and implementation

schedule.6

25 Estimate of man power 426 Capital Estimate and Economics 8



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List of Tables

Table No. Title Chapter PageVOLUME-1

1.1 Units envisaged in the Integrated Steel Plant 1 2-4

3.1.1 Consumption pattern of total alloy & special steels in India 3 1

3.1.2 Consumption pattern of stainless steels in India 3 2

3.2 Common grades of carbon and alloy constructional steels 3 5-6

3.3 Growth of export of auto components 3 8

3.4 Used based indices of Industrial production 3 9

3.5 Projected year wise demand for alloy and special steels 3 10

3.6 Capacities of Major Alloy/Special Steel producers and dataon current production

3 12-13

3.7 Suggested product mix for AISL from the phase-1 plant 3 13

3.8 Production, import, export and real consumption of finishedsteel (Alloy and Non alloy) in India

3 15

3.9 Strategy to push steel Demand growth 3 16

3.10 Forecast of finished steel demand(2013-14/2025-26/2032-33)

3 16

3.11 Forecast of crude steel production(2013-14/2025-26/2032-33)

3 17

3.12 Capacity projection of mild/carbon steel production2016-17; 2020-21;2025-26;2032-33

3 17

3.13 Product wise steel demand forecast2016-17; 2020-21;2025-26;2032-33

3 18

3.14 Crude steel capacity in India 3 19

3.15 Hot rolling capacity to date (including expansion) 3 20

3.16 Projected cold rolled coil demand2016-17; 2020-21;2025-26;2032-33

3 21

4.1 Computation of land requirement in blocks for the steel plant 4 1-3

4.2 External transport by Rail 4 7-8

4.3 External transport by road 4 9-10

4.4 Internal movement by rail/road 4 10

4.5 Railway transport facilities 4 11

4.6 Road transport facilities 4 11

4.7 Lay out indices 4 11-12

5.1 Storage capacity envisaged for various raw materials 5 1-2

5.2 Material handling equipment 5 2-3

6.1 Coke Oven batteries – main technological indices 6 1-2

6.2 List of oven machines at each phase of the project 6 6

List of Tables (Contd.)



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Table No. Title Chapter Page6.3 Typical technical parameters of a coke dry quenching

system6 7

6.4 Annual production of by-products 6 8

6.5 Typical Analysis of coke oven gas at various stages 6 9

6.6 Requirement of chemicals at the by-product plant 6 10

6.7 Requirement of utilities at the by-product plant 6 10

7.1 Technological Parameters of the sintering Plants 7 2-3

7.2 Sintering – Specification envisaged for the product and theinput raw materials

7 3

7.3 Details of the storage and proportioning bins 7 4

7.4 Technical parameters of the Sintering machine 7 6

7.A-1 Parameters of the Sinter fine beneficiation process 7A 3

7.A-2 Major Equipment envisaged at the sinter fine beneficiation unit. 7A 4

7 A-3 Inputs and outputs of the fine ore magnetic separation unit 7A 5-6

7 A-4 Major Equipment envisaged at the tailing beneficiation unit. 7A 7

7 A-5 Consumptions and yields in the fine ore magnetic separationunit

7A 9

8.1 Blast Furnace Iron making- main technological parameters 8 2

8.2 Blast Furnace input material consumption 8 3

8.3 Stock house bunker configuration and storage capacities forBF-1 and BF-2 complexes

8 6

9.1 Steel Melting Shop No. 1 (EOF Shop) parameters 9 2-3

9.2 Parameters of the ladle Furnace (LRF) 9 3-4

9.3 Parameters of the Vacuum degassing Furnace 9 4-5

9.4 Technological Features of Bloom casting machine 9 10-11

9.5 Technological Features of Billet casting machine 9 11-12

9.6 Steel Melting Shop No. 1 (EOF shop) Input materialparameters

9 14-15

9.7 Steel melting shop No. 1 (EOF Shop) Utility requirement 9 15

9.8 Details of EOF Layout and handling cranes 9 15-16

9.9 Steel Melting Shop No. 2 (BOF Shop) Parameters 9 19

9.10 Steel Melting Shop No. 2 (BOF Shop) input raw material andutility requirement

9 20

9.11 Steel Melting Shop No. 2 (BOF Shop) generation of by-products and wastes

9 20-21

9.12 Converter wear zone conditions and refractory envisaged 9 24-26

9.13 Technological features of the envisaged slab caster 9 33-34




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Table No. Title Chapter PageVOLUME-2

10.1 Product mix of Phase-1 facilities 10 1

10.2 Major Parameters of the Bar and Rod Mill 10 2

10.3 Major Facilities in Bar & Rod Mill 10 3-5

10.4 Bar & Rod Mill Building details with Crane handling facilities 10 8

10.5 Major parameters of the Billet & Bar Mill 10 9-10

10.6 Major Facilities in Billet & Bar Mill 10 10-12

10.7 Billet & bar mill complex building details with Crane handlingfacilities

10 13

10.8 Major Technological parameters of the Hot Strip Mill 10 14-15

10.9 Furnace characteristics of Hot Strip Mill 10 16

10.10 Quality of Products envisaged from the Hot strip mill 10 17

10.11 Mill Characteristics – Hot Strip Mill 10 18-19

10.12 List of Major Equipment – Hot Strip Mill 10 19-22

11.1 Comparison of properties between hot rolled and cold rolledsteel.

11 1

11.2 Product mix in the cold rolling mill complex 11 5

11.3 Technological parameters of the continuous galvanizing line 11 8-9

11.4 Technical characteristics of the Tandem Cold Rollin Mill 11 9-10

11.5 Technical Characteristics of a DCR skin pass mill 11 14

11.6 Technical Characteristics of the Galvanizing line 11 20

11.7 Technical Characteristics of the Colour coating line 11 26

11.8 Utility requirement in the CRMC 11 26-27

11.9 Details of the buildings and handling cranes in the CRMC 11 27-28

12.1 Capacity calculations of the turbine and the steam generatorsets.

12 8-9

13.1 Requirement of oxygen at two phases 13 1

13.2 Production parameters of the oxygen plants 13 2

14.1 Ambient air quality standards 14 1-2

14.2A Utilization of By-product gases in Phase -1 (End of Chapter) 14 13-14

14.2B Utilization of By-product gases in Phase -2(End of Chapter) 14 14-15

14.3A Details of stacks envisaged in Phase-1(End of Chapter) 14 16-18

14.3B Details of stacks envisaged in Phase-2(End of Chapter) 14 19-20

14.4 Measures for treatment of waste water 14 4-6

14.5 Solid waste Generation and Management 14 7-1117.1A Recirculation and make up water requirement at Phase-1 17 1-2

17.1B Recirculation and make up water requirement at Phase-2 17 2-3

18.1 Requirement of steam and cold blast 18 1




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Table No. Title Chapter Page18.1A High pressure steam balance – Super heated steam 90 bar

at 535 Deg. C18 2

18.1B High pressure steam balance – Super heated steam 60 barat 485 Deg. C

18 2

18.1C Process steam balance – 6-16 bar 18 3

18.2 A Requirement of compressed air – Phase-1 18 4

18.2 B Requirement of compressed air – Phase-2 18 7

23.1 Area laboratories and sections with basic functions 23 4-7

24.1 Construction quantities (Tentative) for the steel plant at bothphases

24 1

24.2 Summary schedule of principal activities of the plantconstruction

24 2-3

24.3 Assumptions for the indicated construction schedule 24 5-6

25.1 Man power estimate for the integrated steel plant of AISL 25 1-3

26.1 Product mix at Phase-1 26 1

26.2 Product mix at Phase-2 26 2

26.3 Capital cost estimate of Phase-1 facilities 26 3

26.4 Capital cost estimate of Phase-2 facilities 26 4

26.5 Summary of production cost at full capacity utilization –Phase-1 & 2

26 5

26.6 Summarized 10 year profitability projections- Phase-1 & 2 26 8



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List of Figures

Figure No. Title Chapter Page6.1 Schematic representation of a coke dry quenching

system6 11

9.1 Schematic representation of an EOF furnace 9 89.2 Schematic overview of the energy optimizing

Furnace9 9

9.3 Sectional elevation of converter vessel 9 239.4 Sectional elevation of converter vessel showing

zones of lining9 24

9.5 3D view of a typical ladle furnace installation 9 319.6 A schematic representation of a single vessel RH

degasser.9 32

11.1 Material Flow in the Cold Rolling mill Complex 11 411.2 Schematic representation of box annealing

process11 13

11.3 Hot dip galvanizing process –schematics 11 1611.4 Schematic arrangements of Colour coating

structure11 23

11.5 Schematic representation of a Colour coating line 11 2511.6 Principal units of a Colour coating line 11 2616.1 Concept of level-2 control in major processes 16 523.1 Structure of Quality Control Facilities 23 3


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List of Annexure

AnnexureNo.

Title Chapter Sheets

Volume-11.1 Annual Steel Production in million metric tons in Major steel

producing Countries during the last 7 years1 1

1.2 Plot of steel intensity of consumption vs. annual averageGDP

1 1

3.1 Details of non-stainless alloy and special steels 3 104.1 Break up of land utilization proposed 4 9

Volume-224.1 A list of major structural and civil buildings 24 824.2 Major typical quantities involved in the construction of the

steel plant24 7

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List of Drawings

Drawing No. Title Sheets Size Chapter Colour

ENVIRO/AISL/FR/02/01(R-1) Material Flow Chart for the steel Plant 4 A3 2 B&W

AISL/DRG/Location map Location of the AISL site in the toposheets

1 A3 4 Colour

AISL/MSPL Land details Land details and land use in and aroundthe AISL site

1 A3 4 Colour

ENVIRO/AISL/FR/GL/01(R-2) General layout of the AISL proposed site 1 A0 4 Colour

ENVIRO/AISL/FR/06/01(R-1) Lay out of each of the two twin cokeoven complexes

1 A3 6 B&W

ENVIRO/AISL/FR/07/01(R-1) Lay out of the Sintering Plant No. 1Complex

1 A3 7 Colour

ENVIRO/AISL/FR/07/02(R-1) Lay out of the Sintering Plant No. 2Complex

1 A3 7 Colour

ENVIRO/AISL/FR/07A/01(R-1) Process flow of sinter fine beneficiationPlant with magnetic separation

3 A3 7A B&W

ENVIRO/AISL/FR/07A/02(R-1) Lay out of the Beneficiation Plant 1 A3 7A B&W

ENVIRO/AISL/FR/08/01(R-1) Lay out of the Blast Furnace No. 1Complex

1 A3 8 B&W

ENVIRO/AISL/FR/08/02(R-1) Lay out of the Blast Furnace No. 2Complex

1 A3 8 B&W

ENVIRO/AISL/FR/09/01(R-1) Lay out of the EOF shop along with thecasters.

1 A3 9 Colour

ENVIRO/AISL/FR/09/02(R-1) Lay out of the BOF shop. 1 A3 9 Colour

ENVIRO/AISL/FR/10/01(R-1) Lay out of the Hot rolling Mills at Phase-1

1 A3 10 Colour

ENVIRO/AISL/FR/10/02(R-1) Lay out of the Hot Strip Mills at Phase-2 1 A3 10 B&W

ENVIRO/AISL/FR/11/01(R-1) Lay out of the Cold Rolling Mill Complexat Phase-2

1 A3 11 B&W

ENVIRO/AISL/FR/14/01(R-1) Utilization of by-product gases 2 A3 14 B&W

ENVIRO/AISL/ FR/15/01(R-1) Single Line diagram of powerdistribution at Phase-1

3 A3 15 B&W

ENVIRO/AISL/ FR/15/02(R-1) Single Line diagram of powerdistribution at Phase-2

2 A3 15 B&W

ENVIRO/AISL/ FR/17/01(R-1) Combined water requirement of theplant at 3.5 million ton level (Phase1 +2)

1 A3 17 B&W

ENVIRO/AISL/24/FR/01(R-1) Construction schedule of the 3.5 millionton steel plant

2 A3 24 B&W

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Chapter-1.0: Introduction

1.1 Indian Steel Scene

1.1.1 India is currently the 4th largest producer of steel after China, Japan and USA.

(Annexure-1.1) After liberation of economy during early 90s the rapid growth in sectors

like infra structure, real estate and automobiles has put India solidly in the world steel

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direct investment is expected to boost the steel intensive sectors. Government of India

has mooted a perspective plan of domestic steel capacity of 300 million tons in 2025 and

intends to make India the second largest producer of steel after China.

1.1.2 As per a recent WSA-IMF study, the plot of steel intensity of consumption vs. annual

average GDP shows a rough linear relation. (Annexure-1.2). As the curve given in the

annexure shows India is well in the linear portion and there is a certainty that the growth

of steel consumption intensity will rise linearly with the growth in the GDP.

1.1.3 Indian steel companies have made massive investments in recent times and the

capacity is now coming to stream. It is estimated that the present expansion and new

capacity additions will take capacity of Indian steel industry to over 140 million tons

shortly (2016-17). But with a maximum projected capacity utilization of 80-85% this is

only adequate possibly to meet the immediate demand of steel.

1.1.4 Steel demand in India is now showing signs of rebounding after the slowdown of the last

three years. Some cyclicality is certainly at play but definite steps of the Government like

control of inflation; interest rate cut is helping for GDP and industrial production to

recover.

1.1.5 As discussed in Chapter-3, the compounded rate of steel consumption is likely to be in

the range of 8-9% after 2016. New capacities are therefore required at new sites since

the existing plants are either having constraints of available space or the area will

become environmentally unviable with large concentration of production capacity.

1.1.6 While talking about steel, one need remember that about 10% of the steel consumed is

in the alloy and special steel grades used in industrial and domestic (Stainless steel)

sectors. The strict distinction between mild steel producers and alloy and special steel

producers has now become obsolete with the introduction of ladle treatment facilities

with oxygen based processes. It is therefore very likely that new steel plant will cater to

both types of steel for a better flexibility in catering to the demand of steel and market

trend of steel prices.

1.1.7 Traditionally, Indian steel industry was concentrated in the eastern side where both iron

ore and coal (Coking as well as non-coking) are mostly available. But iron ore is also

widely distributed and is available in Karnataka and Goa. Coals both coking and non-

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coking are increasingly being imported. Ocean vessels and river barges are being used

for transportation of raw materials and finished products. All these factors have made

western part of India the recent destination of steel industry.

1.2 AARRESS Iron & Steel Limited (MSPL Group)

1.2.1 MSPL Limited is a flagship company of the Baldota Group of Companies and is one of

the largest iron ore mining companies and has the largest installed capacity of green

energy in the country.

1.2.2 AARRESS Iron & Steel Limited is a new company promoted by MSPL group to install an

integrated steel plant including a captive power plant at Hospet. The process had started

in 2007 itself when the purchase of land at Halavarthi, district Koppal, Karnataka had

began. Today the company is in possession of about 900 acres of land another 900

acres are in the process of acquisition/purchase. The company intends to install a 3.5

million ton steel plant in two phases. The first phase will be with a capacity of 1 million

tons of crude steel finishing to long products catering to the alloy and special steel

market of India and abroad. The second phase will produce 2.5 million of crude steel

with a separate set of facilities for rolling to hot rolled coils with down ward facilities of

cold rolling, coil processing and coating facilities. To improve the flexibility of the plant

with respect of iron ore, facilities of iron ore beneficiation will be provided either in phase-

1 or 2 depending on the position of raw material availability in Karnataka in the next few

years. The beneficiated ore will go to the sinter plant for sinter grade fraction and to the

existing pellet plant (MSPL-a group company) for pellet feed fraction. The pellet input to

the blast furnaces will be mostly from the MSPL pellet plant available in the plant side.

1.2.3 The list of facilities envisaged is given below and is elaborated in the next chapters:

Table-1.1: Units envisaged in the integrated Steel Plant

Sl.

No.Plant Units Phase-I Phase-II

Final Plant

Configuration

1 Ore Beneficiation

Plant

- 448 TPH/3.36

MTPA throughput

448TPH/3.36 MTPA

throughput

2 Sinter Plants 1x144 m2

1.6 MTPA

1x360 m2

3.85 MTPA

(1x144)+(1x360) m2

5.45 MTPA gross

sinter

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3 Coke Ovens 0.996 MTPA

Gross coke

18 Hrs Coking

time

2x69 Ovens 5 m

tall Recovery

Type

1.064 MTPA

Gross Coke

16.9 Hrs Coking

time

2x69 Ovens 5.0

m tall Recovery

type

2.12 MTPA gross

coke in 4 Coke Ovens

batteries

4x69 ovens 5 m tall

Recovery type with

16.9 Hrs coking time.

4 Blast Furnaces 1x1680m3 BF

1.176 MTPA

Gross Hot metal

1x3813 m3 BF

2.67 MTPA Gross

Hot metal

1x1680m3 +1x3813

m3 BF

3.846 MTPA gross

hot metal

BF slag 0.329 MTPA 0.748 MTPA 1.077 MTPA

5 SMS

a)

EOF (Energy

Optimizing

Furnace)/BOF

(Basic Oxygen

Furnace)

2x50 t EOF

1.0 MTPA Liquid

steel

2x150t BOF

2.7 MTPA Liquid

steel

(2x50)t EOF+ 2x150 t

BOF

b) LF (Ladle

Furnace)

2x50 t 2x150 t 2x50 t +2x150 t

c) VD / RH

Degasser

2x50 t VD 1x180 t RH

Degasser

2x50 t VD +1x180 t

RH Degasser

f) Billet Caster/

Bloom Caster

2x3 Billet Caster

+1x2 Bloom

caster

- 2x3 Billet Caster +1x2

Bloom caster

h) Slab Caster - (2x1) Strand slab

caster.

(2x1) Strand slab

caster

6 Billet and Bar Mill 0.25 MTPA - 0.25 MTPA

7 Bar & Rod Mill 0.60 MTPA - 0.60 MTPA

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8 Hot Strip Mill - 2.577 MTPA slab

input

2.577 MTPA slab

input

9 Cold Rolling Mill

with continuous

Pickling line

- 1.00 MTPA Hot

coil input

1.00 MTPA Hot coil

input

10 Hot Dip

Galvanizing

/Galvalume Unit

- 0.4 MTPA CR

input

0.40 MTPA CR input

11 Colour Coating

Unit

- 0.2 MTPA

Galvanizing input

0.20 MTPA

Galvanizing input

12 Oxygen Plant (1x700) TPD 1 x 900 tpd (1x700)+(1x900) TPD

13 Lime Plant (Out

sourced)

(2x300)TPD 1 x 600 TPD units (2x300)+(1x600) TPD

14 Dolo Plant (Out

sourced)

1x300 TPD - 1x300) TPD

15 Captive Power

Plant

1x70 MW CFBC

Based boiler + 6

MW TRT

2x100 MW CPP

based on

coal/Waste gases

+ 12 MW TRT+ 7

MW WHRB

295 MW CPP from

WHRB, coal/Waste

gases TPP

16 Material handling

Plant for both

phase

Matching Matching Matching

1.3 As a partial fulfillment of the Terms of Reference (TOR) for the Environment Impact

Assessment of the project, a Techno-Economic Feasibility Report is required. M/S

AARRESS Iron & Steel Limited has assigned this work to the Pollution & Ecology

Control Services (PECS), Nagpur. The Feasibility report has the following chapters:

Chapter-1: Introduction

Chapter-2: Executive Summary

Chapter-3: Demand nAvailability Analysis and Product mix

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Chapter-4: Site details, General layout and Infrastructure

Chapter-5: Raw material receipt, storage and handling.

Chapter-6: Coke Ovens and By-product Plants.

Chapter-7: Sinter Plants.

Chapter-7A: Fine Ore beneficiation plant with magnetic beneficiation of tailings.

Chapter-8: Blast furnaces and auxiliaries.

Chapter-9: Steel Making and Continuous casting units.

Chapter-10: Hot Rolling Mills.

Chapter-11: Cold rolling and processing Complex.

Chapter-12: Captive Power Plants and Turbo-Blower Stations.

Chapter-13: Cryogenic Oxygen Plants.

Chapter-14: Pollution Control Measures

Chapter-15: Power Demand & Distribution.

Chapter-16: Instrumentation, Automation & Telecommunications.

Chapter-17: Water requirement & supply facilities.

Chapter-18: Steam and Compressed air facilities

Chapter-19: Fuel Oil Storage & in plant Pipe lines.

Chapter-20: Industrial Safety

Chapter-21: Air Conditioning & Ventilation systems

Chapter-22: Repair Facilities

Chapter-23: Laboratory Facilities

Chapter-24: Construction Planning & Schedule

Chapter-25: Man Power required

Chapter-26: Capital Cost and Economics.

Details are also given in the Annexures and feasibility drawings.

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1.4 Acknowledgement

The Pollution & Ecology Control Services (PECS) thanks the management of M/S

AARESS Iron and Steel Company for assigning the job of preparation of the techno-

Economic Feasibility Report and would like to place on record the valuable assistance

and co-operation rendered by the MSPL group in the preparation of this report.

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Chapter 2: Executive Summary

2.1 AARESS Iron & Steel Limited is a MSPL Group company and intends to establish 3.5

MTPA integrated steel plant at Village Halavarthi, District Koppal (Karnataka)

2.1.1 MSPL Limited is a flagship company of the Baldota Group of Companies and is one of

the largest iron ore mining companies and has the largest installed capacity of green

energy in the country.

2.1.2 AARESS Iron & Steel Limited is a new company promoted by MSPL group to install an

integrated steel plant including a captive power plant at Koppal in Karnataka. The

process had started in 2007 itself when the purchase of land at Halavarthi, district

Koppal, Karnataka had began. Today the company is in possession of about 900 acres

of land another 900 acres are in the process of acquisition/purchase. The company

intends to install a 3.5 MTPA Integrated Steel Plant in two phases. The first phase will be

with a capacity of 1 million tons of crude steel finishing to long products catering to the

alloy and special steel market of India and abroad. The second phase will produce 2.5

MTPA of crude steel with a separate set of facilities for hot rolled coils with down ward

facilities of cold rolling, coil processing and coating facilities. To improve the flexibility of

the plant with respect of fine iron ore, facilities of beneficiation fine ore will be provided

either in phase-1 or 2 depending on the position of raw material availability in Karnataka

in the next few years.

2.1.3 As a partial fulfillment of the Terms of Reference (TOR) for the Environment Impact

Assessment of the project, a Techno-Economic Feasibility Report is required. M/S

AARESS Iron & Steel Limited has assigned this work to the Pollution & Ecology

Control Services, Nagpur. This report is for the total 3.5 MTPA steel plant complex to

be set up in two phases.

2.2 A summary of Facilities Envisaged in the Steel Plant

The list of facilities as envisaged in this Feasibility Report is given below and is

elaborated in the main chapters of the report:

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Sl.

No.Plant Units Phase-I Phase-II

Final Plant

Configuration

1 Ore Beneficiation

Plant

- 448 TPH/3.36

MTPA throughput

448TPH/3.36 MTPA

throughput

2 Sinter Plants 1x144 m2

1.6 MTPA

1x360 m2

3.85 MTPA

(1x144)+(1x360) m2

5.45 MTPA gross

sinter

3 Coke Ovens 0.996 MTPA

Gross coke

18 Hrs Coking

time

2x69 Ovens 5 m

tall Recovery

Type

1.064 MTPA

Gross Coke

16.9 Hrs Coking

time

2x69 Ovens 5.0

m tall Recovery

type

2.12 MTPA gross

coke in 4 Coke Ovens

batteries

4x69 ovens 5 m tall

Recovery type with

16.9 Hrs coking time.

4 Blast Furnaces 1x1680m3 BF

1.176 MTPA

Gross Hot metal

1x3813 m3 BF

2.67 MTPA Gross

Hot metal

1x1680m3 +1x3813

m3 BF

3.846 MTPA gross

hot metal

BF slag 0.329 MTPA 0.748 MTPA 1.077 MTPA

5 SMS

a)

EOF (Energy

Optimizing

Furnace)/BOF

(Basic Oxygen

Furnace)

2x50 t EOF

1.0 MTPA Liquid

steel

2x150t BOF

2.7 MTPA Liquid

steel

(2x50)t EOF+ 2x150 t

BOF

b) LF (Ladle

Furnace)

2x50 t 2x150 t 2x50 t +2x150 t

c) VD / RH

Degasser

2x50 t VD 1x180 t RH

Degasser

2x50 t VD +1x180 t

RH Degasser

f) Billet Caster/

Bloom Caster

2x3 Billet Caster

+1x2 Bloom

caster

- 2x3 Billet Caster +1x2

Bloom caster

h) Slab Caster - (2x1) Strand slab

caster.

(2x1) Strand slab

caster

6 Billet and Bar Mill 0.25 MTPA - 0.25 MTPA

7 Bar & Rod Mill 0.60 MTPA - 0.60 MTPA

8 Hot Strip Mill - 2.577 MTPA slab

input

2.577 MTPA slab

input

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9 Cold Rolling Mill

with continuous

Pickling line

- 1.00 MTPA Hot

coil input

1.00 MTPA Hot coil

input

10 Hot Dip

Galvanizing

/Galvalume Unit

- 0.4 MTPA CR

input

0.40 MTPA CR input

11 Colour Coating

Unit

- 0.2 MTPA

Galvanizing input

0.20 MTPA

Galvanizing input

12 Oxygen Plant (1x700) TPD 1 x 900 tpd (1x700)+(1x900) TPD

13 Lime Plant (Out

sourced)

(2x300)TPD 1 x 600 TPD units (2x300)+(1x600) TPD

14 Dolo Plant (Out

sourced)

1x300 TPD - 1x300) TPD

15 Captive Power

Plant

1x70 MW CFBC

Based boiler + 6

MW TRT

2x100 MW CPP

based on

coal/Waste gases

+ 12 MW TRT+ 7

MW WHRB

295 MW CPP from

WHRB, coal/Waste

gases TPP

16 Material handling

Plant for both

phase

Matching Matching Matching

2.3 Demand Availability Projection and envisaged product mix

2.3.0 In Chapter-3, the demand availability projections and product mix has been separately

treated for alloy and special steels in Phase-1 and carbon steel for phase-2.

2.3.1 Alloy & Special Steels

After analyzing of the past demand availability data, likely growth in the consuming

sectors etc. it has been concluded that the demand of different categories of non-

stainless steel alloy and special steels will increase from 5.3 million tons in 2014-15 to

9.08 million tons by the year 2021-22 (a period of 7 years) and to 15.56 million tons by

2028-29. The growth rate projected for these categories will be higher than the average

6.5% growth envisaged for the steel demand as a whole. The rate of growth of

consumption of alloy and special steels in India are higher than the average total steel

consumption growth rates in recent times due to progressive sophistication of steel use.

The present capacity of production of alloy and special steels (including possible

expansions) is about 6 million tons. Thus, it gives a good justification for setting up alloy

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and special steel facilities at AISL, within a few years time. The product mix envisaged

for Phase-1 stage will be:

Sl. Type of Product Grades Size range(mm)

Annual production(Metric tons)

1 Bar MillWire rod in coils DQ, BBQ, CHQ, BQ,

FCS, Spring steel5.5-16 200,000

Bars in straight length ACS, CCS, BQ, SpringSteel

16-69 400,000

Sub Total (a) 600,0002 Billet Mill

Round bars ACS, CCS, BQ, SpringSteel

60-200 150,000

Squares (RCS) ACS, CCS 60-200 50,000Flats ACS, CCS, BQ, Spring

Steel60-140 50,000

Sub Total (b) 250,000Grand Total 850,000

2.3.2 Carbon Steel

While projecting the future demand of carbon steel, a median GDP growth rate of 7%

along with a steel demand growth rate elasticity of 1.1 with GDP growth has been

envisaged. This gives a domestic capacity requirement for meeting the demand

assuming 85% of domestic capacity requirement and imports equal to steel exports. :

Million tons

Steel Capacity required Equivalent HR coil capacityrequired

2016-17 108 38.002020-21 136 52.322025-26 192 78.53.

It was shown in Chapter-3 that the present available capacity after considering 7 million

expansion (from present 6 million ton ) at RINL, 3 million ton capacity under installation

for NMDC and 3 million ton phase-2 of Tata steel, Angul will be about 105 million ton

hardly leaving any gap up to 2016-17. The overall steel capacity gap will result only after

2020. Again looking at the available primary hot strip mill capacity after considering the

likely expansion is 45.32 million also matching requirement up to 2020-21. So it is

prudent to plan for capacity expansion of AISL in carbon steel only at phase-2. The

suggested product mix at phase-2 is:

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The tentative annual product mix at full rated capacity will be:

(1) Hot rolled coils for sale: 990,000 t

(2) Hot rolled cut Plates/sheets: 485,000 t

(3) Cold rolled coils and sheets: 567,000 t

(4) Galvanized coils and sheets (saleable): 180,000 t

(5) Colour coated coils and sheets: 190,000 t

-----------------

Total saleable steel products at Phase-2: 2,412,000 t

------------------

2.3.0 GENERAL LAYOUT AND TRANSPORTATION

2.3.1 Plant Location and land required

2.3.1.1 The steel plant is proposed to be located on NH-63 near Koppal and about 26 km from

Hospet in Bellary district of Karnataka. It is adjoining the village- Halavarthy. The land

profile is undulating and contours vary from lower value of 517.8 to 540.0 m. The area

falls in the Survey of India topo sheet No. 57A/3. About 418 ha of land (approximately

1935 m x 2164 m have already been acquired by the company for the purpose of the

project this is sufficient for phase-1 project of 1 million ton alloy and special steel plant.

For accommodating phase -2 units completely, the process of acquiring additional land

is in progress. It is anticipated that a total 650 ha of land would be finally available for

meeting the entire need of the 3.5 million ton project.

2.3.1.2 The land requirement of the project is summarized below:

Sl. Description Unit Phase-1 Phase1 +21 Total area envisaged He 418 6752 Steel plant including CPP He 189.3 322.673 MSPL Pellet Plant (Existing) He 15 154 Green belt He 129.17 219.055 Water pond area He 10.4 23.66 Road area He 29 38.637 Area for rail track, conveyors

etcHe 31.9 56.02

8 Total built up area He 256.2 432.329 Built up area out of total area % 63.44 64.04

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2.3.1.3 The proposed general lay out of the steel plant for both the phases is given in the

drawing ENV/AISL/FR/GL/001(R-2) enclosed. The general layout is developed keeping

the Phase-1 facilities within the already acquired site. Some of the phase-2 units also

have been located within the present acquired site. Additional area would be required for

accommodating phase-2 units. The additional area has been indicated in the general lay

out drawing which corresponds to the area already applied for necessary permissions to

procure/buy. The additional land beyond what has been already procured lies on the

east of the site in possession along the National highway in continuation of the present

site towards Hospet town. A small patch of land is also planned to be procured to the

south of the present site mainly to locate the village road and green belt towards

southern side of the plant.

2.3.2 Yard Facilities

Adjacent to the raw material storage yard, the plant railway yard has been planned. This

2 km long yard is planned on side of units consuming bulk raw materials roughly at the

centre of the total 3.5 million site running from north to south. Initially, it will cater to

phase-1 and then would be extended to cater to phase-2. A rail mobile weigh bridge and

Railway yard office has been located between the two yards to control the movement of

the incoming and outgoing wagons. One loco repair shop has been envisaged for the

railway yard. The railway yard will be connected to the present Ginigera railway station

(on the Bellary s Hubli line) which is 17 Km from Hospet. Ginigera station facilities and

yards are being expanded by Railways as a part of doubling of Hospet-Hubli line for

ease of connectivity with Bellary-Hospet area with Goa port.

A road fly over on NH 63 has been considered for NH-63 to facilitate the crossing of the

plant railway line connecting to the Ginigera Railway station. A road passing along with

the siding will facilitate movement of goods to the envisaged truck terminal on the north

of the NH between the railway lines. Construction of the road fly over on NH 63 would

require the involvement of NHAI and the state PWD agencies. This process is

understood to have already started.

2.3.3 Road facilities

2.3.3.1 Roads

) 7.0 m wide (2 lane) road with side shoulders of 2 m width and side drain (11 m ROW) is

proposed around the main plant units and for the raw material storage yard.

) 2 x 7 m (Four lane) roads with drains and shoulders of 4 m as above and raised median

strip of 1.5 m wide (21 m ROW) is proposed from NH up to the Raw material storage

yard.

) The area will also have some minor roads ssingle lane (7 m ROW)

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) Trees will be planted on both sides of main roads and in the median of the two main

arterial roads.

) The paved areas /hard standing have been planned for storage areas and approaches

to the individual shops/units.

2.3.4 Incoming and outgoing Movements

The total external railway traffic at phase-1 will be approximately 6.132 million tons

including 4.618 million tons of incoming and 1.514 million tons of outgoing freight. After

completion of both phase-1 and 2 the total external transport will be 18.295 million

including 13.54 million tons of receipt and 4.755 million tons of dispatch. The non-coking

coal for captive power plants is included in these figures. The details of the various

inputs and output materials are given in Chapter-4 shown in Table 4.2.

The total external road movement traffic at Phase-1 and 2 is given in the Table 4.3 at

Chapter 4. The road incoming movement at phase-1 and 2 is estimated at 353,947 t and

890,610 t respectively, while the outgoing road movements would be 609,640 t and

1578,800 t respectively for phase-1 and 2.

2.3.5 Internal Movement within the Plant

The internal transportation of in process materials are mostly by inter-unit conveyors and

some by road. Hot metal will be transported by Rail in special ladle cars or torpedo

ladles. The other materials will be transported in dumpers/trucks. The broad projection of

this movement is given in the Table 4.4 in Chapter 4.The main materials moving

internally by road will be hot rolled coils from Hot strip mill to the CRM complex and part

of the saleable products at Phase-2 (mills to the dispatch yards); Plant scrap ; SMS slag

and muck.

2.3.6 Transport equipment:

Rail transport equipment proposed to be acquired by the plant is envisages to be as

follows:

(1) 700 HP Diesel Loco 2+2 (Phase-1 & 2)

(2) Internal wagons BOX/BOXN 58 tons: 40 (Phase-2)

(3) Rail weigh bridge 100 t capacity 1

The road transport will be basically done through contractual agencies. Few trucks,

Tractor trailers, dozers/JCB and forklifts are envisaged as detailed in chapter-4 for

emergency requirement.

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2.4. Raw Material Handling & Storage Facilities

The proposed raw material handling plant is located south of the water reservoir and will

be used in both phase-1 and phase-2. It will cover receipt, unloading, storage and supply

of various raw materials to all the units. In order to meet the raw material requirement for

the proposed steel plant, the raw material handling facilities shall be planned to cater to

the present requirement of the 1 million ton stage and will be so conceived to enable

scaling of facilities to cater to the requirement of the 2.5 million stage of phase-2.

The raw materials of the various units will be received by railway wagons or by trucks.

For unloading of raw materials two number of wagon tipplers are envisaged at the

wagon tippler complex. Two numbers of boom type stacker cum re-claimer are

envisaged at phase -1. One will be basically for ore and the other for coal and lime

stone/dolomite. At phase-2, all the beds will be expanded and would utilize the available

area. A second set of two stackers cum re-claimers will be installed to meet the

increased material handling load. Shovels also will be used at phase-2 for reclaiming

lime stone and dolomite. The tentative capacity envisaged for each of the stacker cum

re-claimer will be: For iron ore and lime stone: stacking 1100 tph and reclaiming 800 tph.

For coal: stacking: 900 tph and reclaiming 500 tph. The storage capacities of each of the

raw materials have been detailed at Table No. 5.1 of Chapter-5. The locations of the

different beds are indicated in the General layout drawing. The list of equipment

envisaged at both the phases is given in Table 5.2.

2.5. Major Technological units:

The material flow charts for the major technological units starting from raw materials to

finished products for both the phases are given in AISL/FR/Material Flow R-1 (sheets 1

through 4). The brief description of the major units and the main technological indices

are given in the sections below:

2.5.1 Coke Oven Batteries:

Top charging by-product recovery type Coke Oven Batteries have been envisaged for

both the phases of the steel plant for supply of coke for the blast furnaces. 2 nos. of 5 m

tall batteries at phase-1 and 2 nos. of same size batteries have been envisaged at

phase-2 for uniformity of design & operation and battery machines. The batteries will be

by-product recovery type, twin flue under-jet, regenerative design with fire clay and silica

construction. Dry Quenching of coke with an emergency provision of wet quenching will

be provided for each battery pair at each phase. The following are the main features of

each of the four coke oven batteries.

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1. By-Product type Battery size: Two Batteries, 69 ovens each s 5 m tall battery at

each phase.

2. Battery dimensions (Typical) 15.04 m x 0.410 m x 5 m

3. Oven useful dimensions 14.3 m x 0.410 (0.39/0.43)m x 4.7 m

4. Useful Chamber volume 27.3 m3

5. Coking time 18 hrs. at phase-1. In phase -2 all the four batteries will operate at

16.9 h coking period.

6. No. of pushing per day per battery: 92 in phase-1 and 98 in phase-2.

7. Dry Coal throughput per day/Battery 1883.7 t (Phase-1); 2000.6 (Phase-1 & 2)

Analysis of blended coking coal: Moisture: 8% (max); Ash: 10-14%; VM: 23-24%;

S: 0.58% (max): FCI: .5-4.5: LTGK: F to G; Fluidity:300-4000 ddpm; Reflectance:

1.12(Min)

8. Dry Coal throughput per year/Battery: 6 87,550 t (Phase-1) 732,391t (Phase-1&2)

9. Gross coke yield from imported coking coal blend 72.4% (Phase-1); 72.7%

(Phase-2)

10. Gross coke per year /battery 4, 97,787 t (Phase-1) 5, 32,448 t (Phase-1&2)

11 BF coke (+25 mm) yield from coal input 63.8% (Phase-1) 63.8%

(Phase-2)

Coke Quality envisaged: Ash: 16-18%; CSR: 65 (Min); CRI: 21 (max)

12 BF Coke per year /battery 4, 38,657 t (Phase-1) 4, 67,265 t (Phase-1 & 2)

13 By-Products generation:

(a) Coke Oven gas: 25,150 Nm3/Hr per Battery in Phase-1; 26,778 Nm3/Hr per

Battery in Phase-2

(b) The annual generation of other by-products is given below:

Sl. Item Unit At Phase-1 At Phase-2Per battery For the twin

BatteryPer battery For the twin

Battery1 Ammonium

Sulphatet/yr 7,563 15,124 8055 32,220

2 Crude tar t/yr 21,314 42,628 22,774 91,0963 Sulphur Cake t/yr 820 1640 873 3492

The details of the coke oven battery complexes are given in the Chapter-6 of this report.

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2.5.2 Sintering Plant and Auxiliaries

2.5.2.1 The Blast furnaces of the steel plant in both the phases will use about 77% of iron

bearing materials as iron ore sinter. The rest will be lump ore in phase-1 and large

quantity of the lump ore will be replaced by acid pellets at phase-2 with the

commissioning of the new pellet plant proposed as a part of the steel plant complex.

It is proposed to install one sinter plant at each phase to take care of the input

requirement of the blast furnace installed and the size/ capacity of the sinter plant has

been envisaged to match the blast furnace requirement.

2.5.2.2 Technical Characteristics of the sintering plants

The following are the main characteristics of the sintering plants proposed at Phase-1

and Phase-2.

Wp1#

Rs1#

Teveqixiv## Tlewi04>#+WT04,# Tlewi05>#+WT05,#

4# Wmrxiv#qeglmri#x}ti## H{mklx#Pps}h#x}ti#

{mxl#gmvgypev#gsspiv##

H{mklx#Pps}h#x}ti#

{mxl#gmvgypev#gsspiv#

5# Wmrxivmrk#qeglmri#kvexi#evie## 477#q5# 693#q5#

6# Tvshygxmzmx}# 417#x2q52Lv# 4168#x2q52Lv#

7# Rs1#sj#he}w#{svomrk#tiv#}iev## 663# 663#

8# Rs1#sj#lsyvw2he}#{svomrk## 57# 57#

9# Kvsww#Wmrxiv#tvshygxmsr#tiv#}iev## 4/8=9/333#x# 6/<83/333x#

;# Mkrmxmsr#irivk}#jvsq#qm|ih#kew## 48/333#Ogep2x#sj#

wmrxiv##

48/333#Ogep2x#sj#

wmrxiv##

<# Yrhiv#kvexi#wygxmsr# 4983#qq#[G# 4983#qq#[G#

=# Limklx#sj#xli#wmrxiv#fih## ;33#qq# ;33#qq#

43# Gsspiv#Gmvgypev#{mxl#liex#

vigsziv}#w}wxiq##

% # % #

44# Qe|mqyq#Hywx#mr#i|leywx#kew#

ksmrk#xs#wxegow#exxeglih#xs#IWTw#

erh#fek#jmpxivw1#

73#qk2RQ6# 73#qk2RQ6#

45# Xiqtivexyvi#sj#gsspih#wmrxiv## @#433#Hikvii#G# @#433#Hikvii#G#

46# Wmrxiv#vixyvrih#jvsq#FJ# 43(#qe|# 43(#qe|#

47# Emv#tsppyxmsr#qiewyvih#xs#fi#

xeoir##

728#jmiph#IWT#jsv#xli#

qemr#wmrxiv#qeglmri#

?#7#jmiph#IWT#jsv#

i|xvegxmrk#hywx#jvsq#

jykmxmzi#iqmwwmsrw#mr#

xli#wmrxivmrk#evie#

erh#witevexi#fek#

728#jmiph#IWT#jsv#xli#

qemr#wmrxiv#qeglmri?#

5#Rsw1##7#jmiph#IWT#jsv#


jykmxmzi#iqmwwmsrw#mr#

xli#wmrxivmrk#evie#erh#

witevexi#fek#jmpxiv#

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jmpxiv#w}wxiqw##jsv#


mwspexih#hywx}#eview1###

w}wxiqw#jsv#


mwspexih#hywx}#eview1###

2.5.2.3 Technical Parameters of the sintering machines

Wp1#Rs1# Mxiq# Wtigmjmgexmsr##

# # Tlewi04# Tlewi05#

4# Wmrxivmrk#evie#+q5,# 477# 693#

5# Teppix#{mhxl#+q,# 6q# 7#q##

6# Wmhi#{epp#limklx#+qq,# ;33# +qe|1# fih# limklx#

983#qq,#

;63# +qe|1# fih# limklx#

;33#qq,#

7# Wtiih# sj# xli# qeglmri#

+q2qmr,#

318#xs#41;# 418#xs#913#

8# Mkrmxmsr# Jyvregi# pirkxl#

+q,#

6q# 8q# mrgpyhmrk# i|xirhih#

lssh##

9# Fyvrivw## 5#vs{w#sj#vssj#qsyrxih#

fyvrivw#

Ew# tiv# wipigxih# q2g#

hiwmkr1#

;# Jyip## Qm|ih# kew# +5333#

Ogep2Rq6,#

Qm|ih# kew# +5333#

Ogep2Rq6,#

<# Yrhiv#kvexi#wygxmsr#+qq,# 4733# 4983#

2.5.2.4 Pollution Control arrangements at the Sintering plant

' 4/5 Field ESP to de-dusting of the main sintering plant waste gas to the off gas chimney

s 80 m installed for each machine at each phase.

' 4 Field ESP for de-dusting of all transfer points/# tvstsvxmsrmrk# fymphmrk/# wmrxivmrk#

fymphmrk/# gmvgypev# gsspiv# erh# wgviir# vssq# tsmrxw# {livi# hywx# mw# kirivexih# erh# evi#

gszivih#{mxl#hywx#gsppigxmsr#lsshw#xs#83#q#glmqri}#jsv#iegl#yrmx#sj#wmrxivmrk1#

' Yrmxw# psgexih# ex# jyvxliv# tsmrxw# pmoi# JJG#yrmx# erh#JW# yrmx# erh# yrhivkvsyrh#lsttivw# xs#

lezi#witevexi#hywx#i|xvegxmsr#w}wxiqw#gsqtvmwmrk#sj#fek#jmpxivw/#i|leywx# jer#erh#63#q#

glmqri}w#{mxl#exxeglih#hywx#lyqmhmjmivw1

' Xli#glmqri}#syxpix#{ewxi#kewiw#{mpp#lezi#piww#xler#73#qk2Rq6#sj#hywx#gsrxirx1

' Epp# gsppigxih#hywx# jvsq#lsttivw#fips{# xli# IWTw#erh# fek# jmpxivw#{mpp#fi#qsmwxirih# erh#

viywih#mr#xli#wmrxivmrk#tvsgiww1#

' [exiv#{mpp#fi#vig}gpih#ejxiv#tewwmrk#xlvsykl#wixxpmrk#erh#smp#viqszep1#

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2.5.3 Iron Ore Fine Beneficiation Plant

(1) It has been decided subsequent to preparation of the PFR for the project to skip

the new pellet plant of 1.2 million ton capacity in the final FR. The total lump ore/pellet

requirement of the plant after completion of both the phases at 3.5 million ton stage will

be about 1.5 million tons. The capacity of the pellet plant already installed in the project

site through a group company is 1.2 million ton per annum which can be increased

marginally also. In view of this, the entire lump ore required by the plant at both stages

can be more or less met through acid pellet input from this sister unit. However, the

quality of fines (in terms of Fe %) is generally poor in Karnataka. It will be imperative

therefore to use low grade fines at least partly as input iron ore for sintering process after

beneficiation. At the same time, the cost and space required to process the discards in

iron ore beneficiation unit (materials with less than 40% Fe) are constraints to increase

the capacity of beneficiation operation.

(2) As a compromise, it is envisaged that for the fine ore feed of the plant at both the

phases 50% of the input fines will of grades lower than 60% which will be beneficiated

and blended with better grade fines (around 64% Fe) to obtain an average Fe% in the

sinter feed fine ore at 62.1% as envisaged in the chapter describing the sinter plants. .

(3) The annual fine ore requirements (net and dry) for the sinter plants at planned

production levels at rated capacity for both the phases are given below:

Phase-1: 1,292,760 t

Phase-2: 2,949,748 t

Total 4,242,508 t

It was also noted that the group operates two mines in the Hospet sector: Viom: High

grade deposit (Fe: +65%) output around 1.6 million tons per year and Iyli: a

comparatively poorer grade deposit (Fe- 56-60%) 0.5 million tons production per year.

But the present rule of selling iron ore in Karnataka through open auction, does not

guarantee the AISL plant to receive ore supply from captive group sources. Further, the

reserves in both the deposits are limited and cannot cater to the need of the plant for a

very long period. So even for phase-1 facilities, AISL plant will have to procure iron ore

from the neighborhood and include poorer ores also to keep the landed cost of ore at

economic levels.

(4) It is therefore envisaged that the fines to be used would be a blend of direct use

fines and beneficiated low grade fines. A 50:50 ratio is envisaged. The reduction in the

beneficiated fines in the total ore fines will also reduce the extent of rejects. The rejects

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(with Fe <40%) as per environmental requirement need to dewatered, relocated to

assigned dumps and treated for green cover.

(5) It is therefore envisaged to procure about 2.3 million ton fines with +64% Fe and

3.361 million ton fines of Fe% in the range of 55-56%. The lower grade ore to be

beneficiated to yield maximum of sinter grade fines (2.2 million tons) and a small

quantity will be further beneficiated through magnetic separation to yield pellet grade

beneficiated fine ore which can be converted to pellets at the pellet plant run by the

group company. It may be seen that the scheme proposed is flexible enough to

beneficiate the Iyli ore to sinter grade and pellet grade feeds if required.

It may be seen from above that the capacity of the beneficiation process after phase-1

and Phase-2 has been envisaged as 3.361 million ton of fine ore throughput. The input

will be Fine iron ore (-) 10 mm with Fe% ranging between 55-56%. This ore will be

primarily upgraded to sinter grade fines of about 60% Fe and the small quantity of the

tailings of the primary beneficiation process will be upgraded to +64% Fe pellet feed

concentrate in the secondary magnetic concentration plant with or without ball mill

grinding. It is envisaged that the both the beneficiation plants would operate 312.5 days

in a year and 24 hours a day giving 7500 operating hours in a year.

A. Inputs and Outputs (In terms of dry ore) after phase-1 and 2 facilities.

Item Annual tons Tons per hour % FeInput Ore(-)10 mm low grade ore 3361,000 448.1 56.5Output ore+ 8 mm fraction to lump stock 336,000 44.8 56.5Beneficiated fines 2,252,250 300.3 60.12Tailings for furtherbeneficiation

772,500 103 49.88

It is envisaged that the sinter fine beneficiation unit will be able to upgrade fine ore from

an average analysis of Fe 56.5 to 60% with about 23% as tailings with less than 50%

(49.88% Fe has been tentatively calculated) Fe. Such material however cannot be

discarded now as per current mining regulations and the net quantity of discards needs

to be limited to keep disposal costs of discards at a reasonably low level.

So treating these discards with Wet High Intensity magnetic Separation (WHIMS)

process is envisaged. The product of such separation would be essentially fine grained

and can be employed as pellet making feed only. For up gradation of 49.88% Fe fine ore

to a minimum 64% Fe material for pellet plant feed proper liberation of the Fe bearing

mineral will be needed. In the absence of any test report of the material to be actually

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used, it is difficult to say whether it would be possible to upgrade to this extent without

grinding. However, recent tests with slimes derived from the tailing ponds of fine

washing plants of several iron ore mines have shown that generally it is possible to

upgrade the slimes without any further grinding. Even then it is desirable to provide

flexibility in the magnetic beneficiation unit. So in this report two circuits of beneficiation

have been envisaged. The first circuit uses the slimes without any further grinding. The

steps are de-sliming with hydro cyclones, followed by magnetic separation in two

WHIMS machines. The concentrate as well as tailings are thickened in separate

thickeners and the thickened products are dewatered to 10% maximum moisture in two

separate filter presses. In the second circuit, the slimes are first ground in a ball mill and

then de-slimed in hydro cyclone followed by two stage concentration with WHIMS. The

flow sheets of the two circuits with details of the process flow are given in drawings:

Enviro/AISL/FR/7A/01(R-1) sheets 2 and 3.

The concentrate after de-watering in a press filter will be converted to pellets. The

tailings which would contain less than 40% Fe will also be dewatered in press filters and

temporarily dumped in the assigned area inside the plant. But for environmental

reasons, these would have to be subsequently shifted to mine site to fill in abandoned

mine areas.

Chapter 7A details the facilities envisaged and the parameters of the two units.

2.5.4 The Blast Furnace Complexes

2.5.4.1 The Blast furnace complexes in the two phases will comprise of:

Phase-1: Blast furnace of 1680 m3 useful volume along with auxiliaries.


In phase-1 the blast furnace will operate with sinter, lump ore or partially pellets, coke,

coal dust, fluxes and other additives. In phase-2, depending on the commissioning of the

pellet plant (1.2 million ton capacity), the lump ore will be mostly replaced with pellets.

2.5.4.2 Technological Parameters of the Blast Furnaces

The technological parameters envisaged in the two blast furnaces as envisaged in the

two phases are summarized in the table below:

Wp1#Rs1# Teveqixiv## Tlewi04# Tlewi05#

# Fpewx#Jyvregiw#Irzmwekih## # #

4# Ywijyp#zspyqi#+q6,# 49<3# 6<47#

5# Tvshygxmzmx}#irzmwekih#+x2q62he},# 513# 513#

#


#


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######################

6# Tvshygxmsr#tiv#he}#+xsrw,# 6693# ;95<#

7# Rs1#stivexmrk#he}w#tiv#}iev## 683# 683#

8# Kvsww#Lsx#qixep#tvshygxmsr#tiv#}iev#

+xsrw,#

4/4;9/333# 5/99=/<33#

9# Gsoi#vexi#hv}#ex#fipx2womt#+Ok2XLQ,# 753# 753#

;# Wgviirmrk#psww#jvsq#FJ#gsoi#xs#womt#

gsoi#+(,#

43# 43#

<# GHM#vexi#+Ok2XLQ,# 483# 488#

=# Wpek#vexi#+Ok2XLQ,?#hv}#kverypexih# 5<3# 5<3#

43# Kvsww#kverypexih#wpek#+43(#qsmwxyvi,#

Ok2XLQ#

63<# 63<#

44# Wpek#fewmgmx}## 31=9# 31=9#

45# Xst#tviwwyvi#+Exqswtlivi,# 418# 513#

46# Lsx#fpewx#xiqtivexyvi##Hik1#G# 4533#qe|mqyq#

+stivexmrk#43830

4433#Hik1#G,#

4583#qe|mqyq#

+stivexmrk#4433#0

4483#Hik1#G,#

47# Fpewx#lyqmhmx}#+kq2Rq6,# 73078# 78083#

48# Fpewx#zspyqi#Rq62XLQ# 4363# 4363#

49# Fpewx#jyvregi#kew#kirivexmsr#

+Rq62XLQ,#

49<3# 49<3#

4;# GZ#sj#FJ#kew## <43# <33#

4<# Wxsziw## 6# 7#

4=# Wxszi#x}ti## Zivxmgep/#giveqmg#

zivxmgep#fyvrivw/#

wmpmge#hsqi1##

Zivxmgep/#giveqmg#

zivxmgep#fyvrivw/#

wmpmge#hsqi1##

53# Woypp#erh#pehpi#psww#jvsq#kvsww#xs#rix#

lsx#qixep##

518(# 518(#

54# TGQ#}miph#jvsq#rix#Lsx#qixep## =5(# =5(#

55# XVX#vexmrk# 9#Q[# 45#Q[#

#

2.5.4.3 The specific and quantitative consumption of major raw materials in the two blast

furnaces are given below:

Wp1#

Rs1#

Teveqixiv# Tlewi04>#FJ04# Tlewi05>#FJ05# Xsxep#

viuymviqirx#ex#

Tlewi05#+x2}v,#

4# Mvsr#Svi#Pyqt2Tippixw#+Ok2XLQ,# 6=3#+78</973,# 6=3+4/374/555,# 4/7==/<95#

5# Womt#Wmrxiv+Ok2XLQ,# 45=3+4/849/533,# 45<=+6/774/6;5,# 8/34;/8;5#

6# Womt2Fipx#Gsoi#+Ok2XLQ,# 753+7=6/=53,# 753+4/454/649,# 4/948/569#

7# GHM#Gsep#+Ok2XLQ,# 483+4;9/733,# 483+733/7;3,# 8;9/<;3#

8# Pmqi#wxsri#+Ve{,#+Ok2XLQ,# <8+==/=93,# <8+559/=66,# 659/<=6#

9# Hspsqmxi#+Ve{,#+Ok2XLQ,# ;3+<5/653,# ;3+4<9/<<9,# 59=/539#

#


#


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######################

;# Qr#Svi#+Ok2XLQ,# 9+;/389,# 9+49/34<,# 56/3;7#

<# Uyevx~mxi#+Ok2XLQ,# 57+5</557,# 57+9/738,# 67/95=#

The details of technological characteristics of the input raw materials and the products

from the blast furnace complex Viz. Hot metal (Liquid iron); granulated slag and blast

furnace gas as plant fuel are given in Chapter No. 8.

Both the blast furnaces will have coal dust injection systems with oxygen enrichment of

blast to support higher coal injection rates and top recovery turbines to recover the

energy of the high pressure top gases before scrubbing and reducing to near

atmospheric pressure.

2.5.4.4 Environment control measures envisaged in the Blast Furnace Complexes

(a) Air Pollution Control

Blast furnace off gas is a valuable fuel. It is removed of its dust load first at the dust

catchers which is basically a cyclone separator to precipitate bigger dust particles. The

gas is further washed at the gas cleaning units as described in the sections dealt before.

The cleaned blast furnace gas (with dust content less than 5 mg/Nm3) is fit to be a fuel

for use in gas burners and is used in stove heating and as a general plant fuel for

reheating of as mixed gas after mixing with coke oven gas and Converter gas (after

phase-2). The off gases of furnaces using these gases burnt with air do not require any

further dust separation units.

The Blast furnace hot metal and slag runners are planned to be covered with retractable

covers as now internationally practiced. The cast house and the area around tuyeres

would have de-dusting hoods to suck the ambient air and to clean those in ESPs or bag

filter houses. Both are possible and used and would depend on the final economics. The

other dusty areas of the blast furnace like the stock house, junction houses etc. will have

suction hoods leading to Bag filters and 40 m height chimneys. Closed dusty areas

which are wide and are difficult to cover with hoods will be kept dust free by employing

dry fog process. In some open areas simple spray de-dusting can keep dust away.

Each of the slag granulation boxes will have a stainless steel 40 m chimney to let out the

granulation stream.

The solid dust recovered from the blast furnace complexes (called flue dust) are

collected and used as source of iron and fluxes in the sintering machine charge mix.

These are sent to the dedicated areas of the sintering plant.

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(b) Water pollution control

(1) The blast furnace and stove cooling water is clean water involved in indirect cooling. This

water is cooled in cooling towers and re-circulated.

(2) The gas cleaning plant water is laden with dust. The dirty water is first clarified in circular

clarifiers and then passed through oil removal unit before re-use.

(3) The granulated slag comes out of the granulation boxes in the form of water slurry. This

slurry is de-watered in rotary filters. The filtrate water is filtered again and cooled and re-

used with addition of makeup water.

The solid recovered from gas cleaning plant water treatment also contains iron oxide and

used in sintering plants and later in the pelletizing plant as charge mix.

(c) Other solid wastes

(1) Most of the scrap, jams and iron muck are sent to the steel melting units for re-melting.

(2) All blast furnace slag is granulated, de-watered and used in cement plants along with

conventional cement clinkers to be ground for making Blast furnace slag cement.

(3) Refractory wastes: Major arising of refractory wastes is at the time of blast furnace or

stove relining and capital repairs. Otherwise major refractory waste arising is from the

ladle repair shop from de-bricking of ladles. Some bricks are re-used, some ground to

mortar and those mixed with slag or muck are dumped for filling.

2.5.5 Steel Making Facilities

For phase-1 facility, Energy Optimizing Furnace (EOF) process of steel making has

been selected along with bloom and billet continuous casting. In phase-2, the steel

making process of choice is Basic Oxygen Converter Furnace (BOF) process with

continuous casting of slabs.

2.5.5.1 Facilities envisaged at Phase-1are:

' 2 Nos. of 50/55 ton Energy Optimizing Furnaces (EOF)

' 1300 t inactive mixer or 300 t torpedo ladles (2 Nos.)

' Ladle refining furnace of 55 tons capacity

' Vacuum degassing unit of 55 ton capacity.

' Bloom caster (1 No.)

' Billet caster (2 Nos.)

2.5.5.1.1 The parameters of the EOF shop are envisaged as

#


#

#534;#TIGW##epp#vmklxw#viwivzih#################### Teki#4<#sj#77##

Gletxiv05#

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Wp1#

Rs1#

Teveqixiv# Tlewi04# Viqevow#

4# Rsqmrep#liex#wm~i## 83#x#+88#x#qe|,# #

5# Xet#xs#xet#xmqi## 78#qmryxiw## #

6# Liexw#tiv#he}#jvsq#fsxl#xli#

ISJw##

93#+#97#qe|,# #

7# Stivexmrk#he}w#tiv#}iev## 6530673## 48049#he}w#hs{r#xmqi#tiv#}iev1#

8# Erryep#tvshygxmsr##sj#pmuymh#

wxiip#jvsq#xli#wlst#

=93/33304/353/333#

x#

Ez1#4/333/333#x#

9# Eziveki#}miph#sj#pmuymh#wxiip#jvsq#

qixeppmg#mrtyxw1#

<61<(# #

2.5.5.1.2 The other facilities in the EOF shop will include:

(a) Hot metal handling system including the mixer, the open top ladles/torpedo ladles

and the de-sulphurization station.

(b) Scrap storage and handling yard

(c) Flux and Ferro-alloy handling system including the overhead bulk material

bunkers and Ferro-alloy bunkers.

(d) Steel handling in steel ladles placed on self propelled transfer cars for passing to

the LRFs and VD and then to the Continuous casting bay.

(e) Slag handling by dumping on the ground, cooling of slag and removal with

dozers.

(f) Gas cooling and cleaning.

2.5.5.1.3 The specific consumption of incoming materials in the EOF furnace is given

below:

Wp1#Rs1# Teveqixiv## Wtigmjmg#Gsrwyqtxmsr##

4# # #

# Lsx#Qixep#+Ok2XPW,# <57#

# Wxiip#2GM#wgvet#+Ok2XPW,# 4<8#

# HVM2Wtsrki#mvsr#+Ok2XPW,# 4<8#

# Gepgmrih#pmqi#+Ok2XPW,# <3#

# Gepgmrih#Hspsqmxi#+Ok2XPW,# 58#

# S|}kir#+Rq62XPW,# ;3#

# Tixvspiyq#gsoi#+Ok2XPW,# 5#

# Hi0s|mherx#Jivvs0epps}w#+Ok2XPW,# 43#

# Epyqmryq#+Ok2XPW,# 4#

#


#

#534;#TIGW##epp#vmklxw#viwivzih#################### Teki#4=#sj#77##

Gletxiv05#

######################

# Ge0wmpmgmhi#+Ok2XPW,# 315#

# Epps}mrk#ipiqirxw#+Ok2XPW,# 43#

# Vijvegxsv}#+Ok2XPW,# 53#

2.5.5.1.2 The details of the caster to be installed in Phase-1 with the EOF shop are as follows:

Sl.No

Item Unit Bloom caster Parameters Billet caster Parameters

1 Heat size T 55 55

2 Type of CCM - Radial with curved mould Radial with curved mould

3 Designed section size sq. mm 200 x 200 to 350 x 350 150 x 150 E 250 x 250

4 Basic radius of the machine M 12 9

5 Straightening method Multi radius Multi radius

6 Average section to be cast mm xmm

300 x300 160 x 160

7 Casting speed for averagesection

m/min 0.6 2.5

8 Casting time Min 45 45

9 Casting practice Sequence casting Sequence casting

10 Heats in a sequence Nos. 4 05/06/16

11 Machine preparation time Min 45 45

12 No. of strands 2 4 for each machine

13 Ladle turret Lift able type Lift able type

14 Tundish Equipped with slide gate Equipped with slide gate

15 Mould type and length Copper plate assembledmould , 900 mm

Copper plate assembledmould , 900 mm

16 Strand guide Curved, secondary coolingsegment.

Curved, secondarycooling segment.

17 Withdrawal and straighteningunit

DC drive, Hydraulicallyoperated.

DC drive, Hydraulicallyoperated.

18 Gas cutting unit Automatic oxy acetylenecutting torches

Automatic oxy acetylenecutting torches

19 Dummy bar Flexible type with bottomfeeding arrangement

Flexible type with bottomfeeding arrangement

20 Run out roll table AC individual driven rollers. AC individual drivenrollers.

21 Marking unit Automatic. Automatic.

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22 Bloom cutting length M 7 9/12/16

23 Yield of cast bloom from liquidsteel

% 96 (average) 96 (average)

24 Caster working days Days 320 320

2.5.5.2 Steel making and casting facilities envisaged in Phase-2 are:

(1) The BOF shop comprising of

) 2 x 1300 t in-active mixers with provision of desulphurization of hot metal.

) Scrap storage and handling system including baling press for processing light scraps.

) 2 x 150 tons BOF converters with bulk material feeding arrangement to over head

charging bins, lance handling system, Ferro-alloy addition bins with chutes.

) BOF gas collection, cleaning, cooling, recovery system including BOF gas holder.

) 2 x 150 t ladle Furnaces for temperature adjustment, desulphurization and trimming

addition for chemistry adjustment.

) 1x 150 ton RH vacuum degassing unit of steel.

The qualities of steel envisaged to be produced in the BOF shop will include: (1) Mild Steel

(2) Low carbon steels (3) Medium carbon steels (4) Deep drawing quality steels (5) Carbon

constructional steels (6) Boiler grade steels (7) Galvanizing quality steels (8) Tin plate

quality steels. The grades are listed in Chapter 9.

(2) The basic parameters of the BOF shop is given below:

Wp1#

Rs1#

Teveqixiv## Tlewi05#

4# Qm|ivw## 5#|#4633#

5# Xsvtihs#pehpiw## ]iw##

6# Gsrzivxiv#w## 5#|#483#x##

Fsxl#stivexmrk#xskixliv##

7# Rsqmrep##liex#wm~i## 483#x##

8# Xet#xs#xet#xmqi## 7<#qmryxiw##

9# Liexw#tiv#he}#jvsq#xli#wlst## 63##

;# Stivexmrk#he}w#tiv#}iev## 633#

<# Tvshygxmsr#sj#pmuymh#wxiip## 5/;33/333#

=# Gewxivw#>## 5#rsw1#wpef#gewxivw##

4983#qq#{mhi##

43# Gsrwyqtxmsr#sj#qixeppmg#

qexivmepw##

445;#ok2XPw#

44# Pmrmrk#pmji#{mxl#wpek#wtpewlmrk## 43/333#liexw#

#


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45# Wpek#vexi## 453#ok2XPw#

46# FSJ#kew#vexi## 448##Rq62XPw#

47# FSJ#kew#Gepsvmjmg#zepyi## 5333#Ogep2Rq6#

48# ]miph#sj#gewx#wpef#jvsq#Pmuymh#

wxiip##

=8(#

# Wtigmjmg#Gsrwyqtxmsr#sj#mrtyxw## #

4# Lsx#Qixep#+Ok2XPw,# =98#

5# Wgvet#+Ok2XPw,# ;5#

6# HVM2LFM+Ok2XPw,# =3#

7# Fyvrx#Pmqi2Hsps+Ok2XPw,# <3#

8# S|}kir#+Rq62XPw,# 88#

9# Rmxvskir#+Rq62XPw,# 63#

;# Evksr#+Rq62XPw,# 415#

<# Gsqtviwwih#emv#+Rq62XPw,# 53#

=# Qeoi#yt#{exiv#+q62XPW,# 31<#

43# Ts{iv#+O[L2XPW,# 93#

44# Wxieq#+Ok2XPW,# =8#

45# Ehhmxmsr#sj#Ji0epps}w#jsv#hi0

s|mhexmsr#+Ok2XPW,#

43#

46# FSJ#kew#ywih#mr#xli#wlst#

+Rq62XPW,#

518#

47# Qeoi#yt#{exiv#+q62XPW,# 31<##

48# Gsrwyqtxmsr#sj#

hiwyptlyvm~exmsr##gsqtsyrh#

+Ok2XLQ,#tvsgiwwih#

Tewwmzexih#Qekriwmyq#ts{hiv##

Pmqi#Ts{hiv#

#

#

#

#

319#

813#

(3) The details of the slab casters are given below:

Sl. No. Parameter Value1 No. of casters 22 Heat size (liquid steel) 150 t3 Caster type Multipoint liquid core bending with straight

Mould.

4 No. of strands 1 x 1

5 Machine radius Tentatively 10,500 mmwith multi point unbending)

6 Mould type Vertical mould

7 No. of tundish cars 2 Nos.

8 Slab width (design) 950-1650 mm

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9 Slab thickness 200-250 mm

10 Width changing On line changing facility to be provided

11 Slab length 7500 to 10,500 mm

12 Casting time of a heat 35-40 minutes

13 Machine preparation time (re-stranding) 50 minutes

14 Yield (Liquid to slab) 98.5% (design)

15 Tundish practice Hot tundish

16 Liquid stream protection Refractory shroud between ladle andtundish. And SEN between tundish andmould

17 Dummy bar Flexible chain type s bottom fed

18 Mould oscillation Hydraulic mould oscillator suitable to quickchange practice

19 Mould level control Automatic mould level controller (Eddycurrent type)

20 Secondary cooling Air mist/spray cooling (as per technologyprovider.

21 Soft reduction of strand Dynamic control

22 Gas cutting machine Oxy-Propane gas based

23 Slab identification Automatic slab marking machine

24 Slab discharge Roller table

25 Process control PLC controlled

26 Sequence casting Should be 10 heats approx.

27 Flying tundish Machine should be designed for flyingtundish also

28 No. of working days for Slab Caster 320 days

2.5.5.3 Environmental control measures envisaged in the steel making processes at boththe phases of the steel plant.

2.5.5.3.1 For EOF process, the following measures are envisaged for prevention of air andwater pollution.

The air pollution control measures include:

(1) The cooling and cleaning of the EOF waste gas. This gas has no heating valueand the cooled and cleaned gas is let out through a tall chimney of about 60mheight. The gas cleaning plant is envisaged to be of wet type and comprise of (a)refractory lined down comer (b) quenching chamber (c) venturi (d) Cyclone separator(e) ID fans and Chimney. Each of the two EOF furnaces is provided a separate gascleaning and cooling system with separate chimney of 50m height. The outlet of theGCP is dirty water which is further treated.

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(2) Maintaining the shop atmosphere and prevention of fugitive dust in the air is doneby installing suction hoods in all dusty places and use of bag filters to clean the dustyair before release through medium height chimney (40-50 m)(3) The fumes of the Ladle furnaces and VOD are also collected through a duct,cooled in air cooled tubes and cleaned in bag filter houses before release throughchimneys.

Water pollution control in EOF shopThe dirty water from the waste gas cleaning plants in EOF shop is conveyed to athickener after dozing with chemicals for settling. The clear water from the thickeneris cooled in cooling tower and pumped back to the system. The collected mud has60-70% Iron and is used in sintering plant and later in the pellet plant.

The cooling water for the furnace parts are clean water which are cooled in coolingtowers and re-circulated.

2.5.5.3.2 BOF shop

The BOF waste gas has valuable heat value and is re-used after cleaning andcooling of the gas. For this project a dry type of gas cooling and cleaning system hasbeen envisaged. The system is described before. The cleaned BOF gas with aresidual dust content less than 5mg/Nm3 is used as plant fuel in combination withCoke Oven gas and Blast furnace gases and can be burnt with air with waste gas letoff without any pre-treatment.

The BOF shop also will have dust collecting hoods in particularly dust stressed areaslike the bulk material handling platform and transfer chutes the dust laden collectedair will be cleaned with bag filters. The areas like BOF furnace hoods and up-comerwill have evaporative cooling systems and would use DM water.

2.5.5.3.4 Pollution control measures at Continuous casting units.The main treatment is for water. The strand cooling water is dirty laden with millscale. The water for each of the bloom/billet casters and the slab casters is collectedin scale pits for the scales to settle and the clear water overflows and is pumped toan oil removing units after which the water is cooled and re-used. The scale iscollected from the pits with grab cranes and the scales are used in the sinteringplants as valuable Fe input.

The mould and machine cooling water used in the continuous casting machines areused for indirect cooling and only needs cooling at cooling towers before re-use.

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2.5.6 The hot rolling Mills

(1) It is proposed to install two hot rolling mills at Phase-1 to produce special and

alloy steel billets, bars and wire rods in the size range from 6.5 mm dia. to 200

mm dia. for meeting the requirement of various special steel consumers and

industries. At phase-2, where flat products would be the line of products, a hot

strip mill to roll cast slabs to strips in the size range of 800-1550 mm and

thickness of 1.6 to 12 mm will be installed.

(2) The major parameters of the two hot mills envisaged to be installed at Phase-1(1

million ton facility) are given below.

Sl.No.

Item Unit Bar & Rod Mill Billet & Bar Mill

1 Type of Mill Single strand continuousmill

Single strand mill

2 Capacity of the Mill t/y 600,000 250,0003 Rolling (operating ) speed

maxm/s 16 for bar dia. 16 mm

110 for 5.5 to 8.0 mmrods

4 No. of operating days in ayear (availability)

Days/year

300 300

5 Shifts/day 3 36 Hot rolling hours Hrs 6000 50007 Utilization of available hours % 83 69.58 Reheating Furnace (Single) Walking beam type 150

t/hrs nominal capacityWalking beam type 150t/hrs nominal capacity

9 Input billets/Blooms 160 x160 x 12000; 2400Kg

160-350 mm Square; 4-6 m

10 Fuel for reheating Mixed gas : CV 1900-2000 Kcal/Nm3

Mixed gas : CV 1900-2000 Kcal/Nm3

11 Annual billet required t 625,000 260,00012 Finished product size range Straight length products:

Rounds16-60 mmWire rod in coils 5.5 to16 mmBundle weight: 3000-5000 KgCoil weight: 2500 kgCoil ID: 860 mm ; CoilOD: 1250 mm

Straight lengthproducts:Rounds/RCS: 60-200mm dia/sides. Flats60-140 mm

13 Billet to product yield % 96 9614 Specific Fuel Consumption G Cal/T

of billets0.55 0.75

15 Specific Power consumption KWH/t 60 100

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(3) The technical parameters of the Hot Strip Mill envisaged to be installed at Phase-2 with

2.5 million ton facilities are given below:

Sl. No. Item Unit Parameter1 Type of Mill Six stand 4 high finishing train

with 4 high reversinguniversal roughing stands anda coil box. Two coilers;facilities of AGC; Work rollshifting and work roll bending.

2 Capacity of the Mill t/y 2500,000Based on 1050 mm x 2.8 mmcoils; rolling rate at reversingrougher s 474 tons/hr.

3 No. of operating days in a year(availability)

Days/year 300

4 Shifts/day 35 Hot rolling hours Hrs 55007 Utilization of available hours % 768 Reheating Furnace Two Walking beam type 300 t/hrs

nominal capacity each.9 Input slab size 210 mm thick; 800 to 1550

mm; 10 m max length; Weight25.5 t max. .

10 Slab Quality Mild Steel, low Alloy Steel.Medium carbon steel. (69Kg/mm2 variety)

11 Annual slab required t 2,577,32012 Rolled coil specification 1.6 to 12 mm thick

800-1550 mm wideMaximum coil weight- 25.59 tCoil ID: 76 mm; OD: 2100 mmPIW:

13 Slab to product yield % 96.714 Specific Fuel Consumption G Cal/T of

Slabs0.65

15 Specific Power consumption in themill

KWH/t 150

16 Connected load MW 30 MW (Mill proper) + 10 MWcoil processing facilities.

17 Specific consumption of rolls Kg/t of coils 0.5418 Specific consumption of guides Kg/t of coils 0.5219 Annual requirement of tying straps Tons 250020 Steam Tons/Hr 221 Compressed air (Dry) Nm3/Hr 5000

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22 Lubricating oil Kg/t of coils 0.0623 Grease Kg/t of coils 0.04524 Hydraulic Fluid Kg/t of coils 0.028

(4) Environment Control Measures in the hot rolling Mills

Air Pollution: The reheating furnaces in all the hot rolling mills will use mixed gas (Blastfurnace gas mixed with Coke gas and BOF gas (At phase-2). Since these gases are pre-cleaned before use as a fuel. The fuel gases are fully combusted inside the furnace andthe off gases do not contain any CO. Therefore, these off gas normally do not requireany treatment to remove dusts. These hot waste gases from the re-heating furnaces arepasses to heat re-cuperators to heat the combustion air and the cooled gas is let outfrom a tall chimney. The iron oxide dusts carried with the gases are usually deposited inthe outgoing gas path and at the base of the chimney.

Water pollution: The major dirty water comes from the scale breakers; mill standscooling waters, bar cooling water post rolling which are laden with mill scale. Every millwill have a scale pit to collect these waters and the heavy mill scale will settle at thebottom to be collected with grab cranes. The overflow water will pass through oil removalsystems to skim off any oil collected in the water from the mill bearings, cooled in coolingtowers and to be reused in the cooling water system after addition of makeup water.

2.5.7 Cold rolling complex

It is envisaged to install a Cold Rolling and Processing complex at the Phase-2 stage of

the steel plant for partly converting the hot rolled coils in the Hot Strip mill to cold rolled

and processed products. As described in Chapter 10, the input capacity of the complex

in terms of Hot rolled coils will be 1 million tons per year. The entire input hot rolled coils

will undergo pickling in a continuous pickling line and cold rolling in a five stand 4

high/six high tandem cold rolling mill. Out of the cold rolled coils, a part will be sent to the

galvanizing line of 400,000 t /year capacity. CGL will be coat the coils with zinc for

galvanized sheets (plane/corrugated) and the colour coating line and subsequent slitting

and cut to length lines for making colour sheets.

Since galvanizing lines take as rolled cold coils and has annealing and temper rolling

processes in built in the line, the batch annealing furnace section capacity will be

600,000 t of coils per year. The temper rolling mill will also have similar capacity. The

inspection, slitting and cut to length lines will cater to dispatch of about 600,000 t of

uncoated cold rolled coils. These will cater to the needs of smaller coating installations.

The main sections envisaged in the cold rolling mill complex are:

(1) Hot coil receipt bay to receive and store coils of the following range:

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' Coil width: 600-1600 mm;

' Thickness: 1.6 to 6 mm

' Coil ID: 760 mm

' Coil OD: 2100 mm

' Maximum Weight: 26.6 tons

(2) Continuous Hydrochloric acid Pickling Line with capacity to pickle the entire 1 million ton

hot rolled coil input

(3) Continuous 1600 mm tandem cold rolling mill with five stands (four stands four high, the

fifth 4/6 high) with a combined motor power of 22,100 KW. In this report separate

pickling and separate cold rolling mill has been envisaged. However a coupled pickling

and cold rolling configuration is possible and would be decided at the time of detailing.

(4) Strip cleaning line

Cold rolled coils meant for dispatch as cold rolled coils/sheets and required to be box

annealed in the subsequent process steps will pass through a Electrolytic Cleaning Line

(ECL) to remove the rolling oils from the strip so that these do not result black soot

patches while box annealing.

(5) Box Annealing Section

The section is envisaged to be having 40 bases; 20 furnaces and 20 cooling boxes. The

decision to go for only hydrogen annealing process or go for conventional H2 + N2

annealing atmosphere will be taken at the time of writing detailed specification

depending on the market situation.

(6) DCR skin pass Mill

The envisaged skin pass mill will be a Twin stand Double Cold Reduction (DCR) mill

stand 2 x 4-high cold rolling mill meant for giving a small cold reduction to the fully

annealed coils with the help of twin four high stands.

(7) Cold rolled products s slitting and shearing section.

(8) Hot Dip Galvanizing Line

The CRC is envisaged to process 1000,000 tons per year of input in terms of hot rolled

coils (HRC). Out of these 400,000 equivalent hot rolled coils are meant for coated

products: Galvanized and colour coated. Colour coated sheets require a thin galvanizing

pre-coat for better paint quality and resistance to corrosion in ultimate use. So it is

proposed to galvanize the entire produce of 400,000 tons of hot rolled coils to zinc/zinc

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aluminum coated coils and out of that 200,000 tons of equivalent HRC will be colour

coated in two colour coating lines.

(9) Colour coating line.

It is envisaged to install two colour coating lines in the CRC at phase-2. Each line will be

100,000 tpy capacity. Due to a large number of colour coating facilities installed recently,

it is envisaged to build up the capacity of colour coating progressively.

Product mix at full capacity of the Cold rolling mill Complex:

Cold rolled coils andsheets

Grades:O/D/DD/EDD

Widths: 1000 mm to1500 mm; Thickness:0.25 to 2.5 mm

567,000 tons/year

Galvanizedcoils/sheets(Planeor corrugated)

Widths: 800 mm to1000 mm:Thickness:0.25 mm to 2mm.

186,000 tons/year

Colour coatedsheets

Widths: 800 mm to1000 mm:Thickness:0.25 mm to 2mm.

190,000 tons/year.

Depending on market demand and progress of installation of the colour coating line, part

of the colour coated tonnage may be initially offered as galvanized product.

Environmental control measures

The environmental control measures to be adopted in the cold rolling mill complex can

be summarized as follows:

(1) Air pollution control:

The air contaminated with acid fumes sucked from the pickling line would be treated in

packed scrubbers to ensure less than 10 mg/m3 of acid in the exhaust air. The sucked

air over the cold rolling mills contains oil mist. This mist is removed from the air with an

electro-static mist eliminator to collect the oil before letting the air out. The outlet air

would have oil level less than 10 mg/Nm3. Most of the other places the air with small

size solid particles like scale or zinc dust or paint fumes will be treated in Bag filters to

ensure that the outlet air contains particulate at the stipulated norm level.

(2) Treatment of waste water:

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Waste water within cold rolling mill complex arises due to the process pickling and

cooling/lubrication during the process of cold rolling. Pickling and related processes

(rinsing, gas cleaning operations and acid regeneration) causes acidic waste water

streams. Cooling and lubricating processes in the rolling sections give rise to oil and

suspended solid loaded waste water streams. Depending on the steel grades

processed, several measures are relevant. In general use of process water in loops or

cascades and the use of coolants/lubricants in loops as far as practical would be used.

But to permit its use in loops, treatment measures are necessary and have been

envisaged. Waste water treatment is separated into processes for acidic streams and

those for oil loaded components.

For treatment of water with acids and acid recovery will be practiced as already

described in Chapter 11. The two major processes- Fluidized bed acid regeneration and

the Spray roasting acid re-generation have been described in Chapter-11.

In some situations, acid recovery from waste water may not be possible due to

breakdown or maintenance of downstream plants. In that case the acidic water will be

neutralized with milk of lime to bring the pH of water to acceptable level before re-use

inside the plant for spraying etc.

Treatment of water from rolling stands coolants/lubricants

The main components of coolants and lubricants from the cold rolling stands are water,

oil and emulsifying agents. The emulsions can contain stabilizers, antifoaming agents

rust preventive agents, biocides etc. Coolants/lubricants are to be used in cascades to

maintain their properties as long as possible. The cleaning and treatment measures to

be adopted are as follows:

' Removal solid properties: several proprietary processes are available involving magnetic

separation, gravity separation, centrifugal separation, and filtration.

' Removal of non emulsified oil by skimming

' Monitoring of composition, aeration to prevent putrefaction and cooling

Often industrial waste water treatment plants offered combine some or all of the above

steps to result reusable water.

Spent oil emulsions will be given to outside agencies for processing.

2.6 Captive Power Plants and Turbo Blower Stations

2.6.1 Captive Power Plants: To meet the power requirement of the steel plant, it is proposed to

install captive power plants of the following configuration.

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Phase-1: Coal/waste gases based CPP- 1 x 70 MW; 1 x 350 tpd at 90 bar steam

pressure and 530 0 C Circulating Fluidized Bed Combustion (CFBC) type boiler and 70

MW steam turbine with air cooled condensers.

Phase-2: Coal/waste gases based CPP- 2 x 100 MW; Coal/waste gas fired boiler- 2 x

450 tph at 150 Kg/Cm2 and 540 0 C. The boiler is currently envisaged as pulverized coal

fired but the option of going for CFBC type will be explored at the detailing stage

depending on the choice of available coals. 2 x 100 MW steam turbines with air cooled

condensers. The generation of power from these two captive power plant will be

supplemented by auxiliary generation of power from the Top gas pressure recovery

turbine(TRT) of blast furnace no 1 & 2. The nominal envisaged capacity of those two

units is 6 MW and 12 MW respectively. Further, steam will be available from the coke dry

quenching units of the coke oven complex. While at phase-1, the steam is proposed to

be used for the process but at 3.5MTPA stage (Phase-2) installation of steam turbine will

be considered for a total generation of another 7 MW.

Coal/waste gases is envisaged as the principle fuel. Heavy oil is the support firing fuel

for low loads and LDO/HSD would be fuel for start ups. However all the boilers will have

facility to use spare Blast furnace or mixed gas if surplus is available. This can happen

when some of the consuming mills are down.

2.6.2 Turbo-blowers:

Turbo-blowers will be used to supply cold air to the blast furnaces via stoves. The Turbo-

blower station for both phases is proposed to be located adjoining to the power plant.

Two turbo-blowers with output as envisaged above will be installed in each phase to

cater to the two blast furnaces envisaged one each in phase-1 and 2. Each phase will

have an exclusive boiler fired with by-product gases to supply steam to the turbines of

the TB sets. These boilers will also supply process steam at lower pressure to the

various units of the steel plant at each phase. Low pressure steam for coke ovens can

be supplied either from the CPP units or from the TB units as per convenience. The

capacities of the Turbo-blowers envisaged to be installed at each phase with the

capacities of their respective steam generating units are given below:

Item Phase-1 Phase-2Capacity of each of two Turbo-blowers envisaged for each BF.

108,385 Nm3/hr at 2.9Kg/cm2 and 110

0C

246,061 Nm3/hr at 3Kg/Cm2, 110

0 CEach Turbine capacity 9 MW (approx.) 20 MW (approx)Process steam or input steam toturbines

60 Kg/cm2, 4850

C 60 Kg/cm2, 4850

C

Process steam envisaged to bemet from the unit

50.5 tons/hr 91 tons/hr.

Extracted steam from turbines at 2 x 8 = 16 tons /Hr. 2 x 18 = 36 tons/Hr

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16 Kg/cm2Steam required from boiler viaPRDU

50.5-16= 34.5 t/Hr 55 t/Hr

Capacity of the boiler envisaged 18 X 5 + 34.5= 125 t/Hr. 40 X 5 + 55 = 255 t/Hr

2.7 Cryogenic Oxygen Plant

In order to meet the requirement of oxygen, nitrogen and argon in the various processes

and services in the steel plant it is envisaged to install an Oxygen plant (Cryogenic Air

separation and purification unit) at each phase of the project. The capacity selected is

700 TPD capacity oxygen plant at phase-1 and 900 TPD capacity at phase-2. Each plant

will be complete with all related auxiliary and service facilities.

2.8 Pollution Control and Environment Management

An Integrated steel plant employs a number of processes each of these has sources of

environment pollution. The pollutants in the form of solids, liquid and gases are

generated from different processes and need to be treated to harmless products before

discharge to nature. Adequate provision has been kept in selecting the processes, the

machinery and the lay out to keep emission pollutants after treatment within the current

acceptable limits. The measures envisaged to treat the polluting outputs from each

process are described along with each chapter in the Feasibility report. The following is

the summary of the steps envisaged.

(1) Air pollution control measures:

' Utilization of by-product gases and waste gases as fuels and also as sources of energy

before letting out to atmosphere. This is elaborated in chapter-14.

' Utilization of waste gases with sensible heat (like in CDQ) in waste heat boilers

' Use of de-dusting equipment like cyclone, bag filters and Electro-static precipitators to

de-dust waste gases before their entry to stacks.

' Use of tall stacks (as per CPCB norms) to let out the gases to atmosphere. Please see

Table 14.3 A & B in Chapter 14 for details of stacks, volume of effluent air/waste gases

and air treatment envisaged.

' Use of water spray/water fogging practice to reduce ambient air dust concentration in all

open transfer /unloading points where dust collection with suction ducts are not very

effective.

' Provision of Low NOX burners at the reheating furnaces in the rolling mills.

(2) Water pollution control

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Extensive measures have been envisaged to contain water pollution and in general the

plant will adopt a policy of Zero Discharge of water from the plant area to the adjoining

water bodies. However, some discharge/discard of water from the processes is

inevitable. These would be treated to a safe usage level and as far as possible, would be

used inside the plant. The general principle for achieving the aim of zero discharge

would be:

% Unit wise recirculation of water will be ensured, after cooling and treatment to reduce the

requirement of makeup fresh water and avoid wastage of water.

% Measures will be taken to treat water to remove suspended/colloidal matter and if acidic,

to treat with lime to make it neutral.

% For cooling water adequate cooling towers is provided.

% Oil and grease from the contaminated water will be removed by skimming and use of

traps.

% Installation of sewage treatment plants in all major units for treatment of the faecal waste

and removal as sludge after biological treatment.

Some of the specific measures for treatment of waste water as envisaged in the plant

unit wise, have been given in the table 14.4 in chapter-14.

(3) Solid waste management

The envisaged arising of solid waste at each technological process units and modes of

disposal has been given in the Table 14.5 in chapter 14. The position is summarized

below which shows those after Phase-1 & 2 facilities, 75% of the generated solid wastes

would be re-processed and utilized inside the plant or sold outside as saleable output.

Only 25% of the generated solid wastes including iron ore WHIMS beneficiation plant

tailings do not have any use at present except as land fill/dumps. These would be used

as landfills in nearby mine area.

Solid Waste Total generation at fullcapacity (tons)

Utilization andmode

Disposal aswastes

Phase-1 units Phase-2 unitsCoal/coke dust 11,854 12,653 100% utilized in coal

blend charge in thecoke oven complex

Nil

Undersize coke 26,000 59,200 100% utilized insintering plants as abed material for heatenergy

Nil

Tar sludge 240 256 To be used along withcoal charge in the cokeovens

Nil

Acid sludge from by- 100 100 - To be neutralized

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product units and disposed aslandfill.

Lime sludge fromPCM

450 To be used asneutralizing agent

Nil

Iron bearing dustsfrom dustcatchers/ESPs/Bagfilters

232,980 556,669 To be used along withthe charge mix in thesintering plants. Thedesign has provisionsto use these.

Nil

Blast Furnacegranulated slag

362,208 822,298 To be sold to cementplants for making blastfurnace slag cement

Nil

Steel making slag 150,000 324,000 Only iron bearingportion of the steel slagwould be recoveredand iron to be used insteel making. A small %of the steel slag can beused in Blast furnaceas source of lime.

90% i.e. 135,000t from phase-1facilities and291,000 t fromphase-2 facilitiescannot be reusedin the process asper the presenttechnology.These would beused as landfillseither inside theplant or in theneighborhood.

Iron oxide from acidregeneration plant ofCold rolling mills

40,000 To be sold to users likeFerro magnet industry,iron powder industryetc.

Nil

Power plant fly ash 127,360 490,758 To be sold to fly ashbrick makers andcement plants makingfly ash cements

Nil

Power plant Bottomash

31,840 122,689 Cannot be used in theprocesses adopted.

To be used asland fill:Phase-1: 31,840tPhase-2: 122,689t

Arising ofskull/scraps

94,197(114,197)*

191,315 To be used in steelmaking for re-melting.

Nil

Rejects after Twostage WHIMStreatment in the fineore beneficiationplant.

4,44,188(Dry)

To be temporarilystocked at thedesignated site in theplant and latertransported to a nearbyore mine pit for re-filling

Phase-1:Phase-2:4,44,188 t

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and greendevelopment.

Refractory wastes 10,880 26,849 Un-contaminated (80%)bricks will be sold (forconstruction) orcrushed to be used asmortar.

About 20% of thewaste brickswhich arecontaminatedwith slag/skulletc. would haveto discarded anddumped inlandfills.Phase-1: 2176 tPhase-2: 5370 t

Muck/sludge/wastes 5,050 7,750 Cannot be re-used Phase-1:5,050Phase-2:7750 t

Total arising 1,053,159 3,098,723 174,066 (16.53%) 870,968 (28.2%)

' Including the skull arising at PCM at Phase-1. But after installation of BOF shop at

phase-2, PCM load will drastically come down with combined working. .

(4) Noise pollution:

The major noise polluting areas in the steel plant are Captive power plant turbines and

generators, Blast furnace air blowing station, compressed air station, Oxygen plant

compressors, Blast Furnace area, hot rolling mills etc. In cases of rotating equipment the

noise level will be specified as per international standards at the time of procurement.

Suction side silencers will be specified in all such equipment. The isolation of working

persons from the noise level by placement of acoustic barrier will be provided. The

working personnel exposed to high noise will be provided with earmuff and their

exposure such high noise source will be limited.

2.9 Power requirements of the steel Plant

Power requirement of the steel Plant as envisaged is given below.

Item Phaset1 Phase-2 Total Plant afterboth the phasesinstalled

Maximum demand 80 MVA 286 MVA 366 MVAAverage demand 60.2 MW

(75.25MVA)163.64 MW(204.6MVA)

223.84 MW(279.85MVA)

Annual Energyconsumption

528 X 106 KWh 1434 x 106 KWh 1961.8 x 106 KWh

The power distribution details are given in chapter-15.

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2.10 Instrumentation, Automation & Controls

Adequate measurement and control facilities have been envisaged for all the shops/units

of the plant with a view to achieve safe, reliable and efficient operation of the plant and

optimum utilization of the inputs, safety of the plant machinery, operating personnel and

user friendly mansmachine interface. For all major processes level-2 fully automatic

process control has been envisaged in line with the modern practice.

2.11 Water supply and treatment facilities

The water supply for the proposed steel plant is basically for cooling of various solids,

liquid and gaseous intermediate products and also for machinery cooling. Water is also

required to make up boiler water requirement in the DM plants for steam raising. There

is also requirement of water for drinking and other washing/cleaning purposes. To

minimize the fresh water drawn from the source, cooling water re-circulation systems

have been envisaged with facilities for removal of solids and removal of entrapped oil.

Cooling towers have been provided for cooling the re-circulated water.

The blow downs from cooling towers and the neutralized effluent discharged from the

processes are proposed to be utilized for coke quenching, slag granulation, steel slag

cooling, de-dusting/defogging and other direct contact water treatments aiming at zero

discharge.

The fresh water requirement of the steel plant in two phases is estimated as

Phase-1: 1.0 million ton crude steel stage: 1305 m3/h (6.97 MGD)

Phase-2: 2.5 million crude steel facilities: 2615 m3/h (13.96 MGD)

Total Steel Plant after phase-2: 3920 m3/h (20.93 MGD)

Recirculation systems have been envisaged in the plant for reusing the major quantity of

water after treatment in various units. The intake water for the plant from the water

source after phase-2 installation of the whole plant before the water treatment plant will

be 4170 m3/Hr (22.24 MGD) considering about 6% loss of water during treatment.

The source of water has been identified as the Tungabhadra Reservoir located at a

distance of about 20 Km from the plant site, from where raw water will be pumped to the

plant storage reservoir located on the northern side of the site near the national highway.

The present available low area where the storage tank can be formed is about 23.6

hectares. It is proposed to develop the eastern part of this area for phase-1 storage of

water. The area is 10.4 hectares. The capacity of the plant reservoir assuming 80% of

the area will have actual water body with 10 m average holding capacity:

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At phase-1: 0.832 million m3 to cater to 20 days storage of phase-1 water requirement

of the plant at rated capacity production.

After phase-2: the storage capacity will be expanded to 1.89 million m3 for about 19

days requirement of the plant at 3.5 million ton rated capacity production.

It is understood that the present agreement of AISL with Karnataka State Government

regarding withdrawal of water from Tungabhadra dam stipulates a pumping @12.55 mgd

for the full year. But pumping will be allowed for 184 days (after July15th) and not be

allowed in the dry season (January to mid July). This means though 4809 million gallons

of gross water (12.55 mgd x 365 x1.05) can be withdrawn from the dam during the wet

season after allowing for 5% loss during pumping and 4580 million gallons of net water

can be received. The annual requirement of water at phase-1 as per estimate given

above will be = 6.97 x 1.06 x 365 =2696.7. Though it is less than the water withdrawal

allowed for the whole year, the water to be consumed during the non pumping period of

181 days with evaporation loss added, need to be stored. For phase-1 requirement it

amounts to = 6.97 x 1.06 x 181 x 1.03 = 1377 million gallons or 6198 million m3 (1.06 is

the factor for water treatment loss and 1.03 is for evaporation loss of water). The plant

water reservoir has been provided for only 20 days storage at phase-1 which will cater to

only supply and pumping disruptions. The bulk of the water storage is envisaged to be

done by adopting public tanks and bundhs in the area.

For the combined operation of 3.5 million ton plant, the total annual requirement of water

amounts to 8095.7 million gallons which shows that more water need to be committed by

the state Government before Phase-2 facilities can be started.

2.12 Steam facilities

The steam required in the technological units of the plant apart from the captive power

plants is given below:

Sl.No.

Service Unit Requirements

Phase-1: 1 MTPA Phase-2: 2.5 MTPA1 Process steam at 6-9 ata. t/Hr. 69.5 1012 Maximum steam required for

the turbo-blowerst/Hr. 2 x 45 2 x 100

The captive power plants will have dedicated boilers for generation of steam for the

turbines. The total steam generating facilities envisaged are:

' Captive Power Plant-1 (1 million ton phase)

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Boiler 1 No with capacity 350 tph of steam at 90 bar and 535 0 C feeding 1 No Turbo-

generator of capacity 70 MW

' Turbo-blowing station -1 (1. million ton phase)

Boiler 1 No. with capacity 125 t/Hr of steam at 60 bar and 485 0 C feeding the turbines of

the blast furnace blowers and supplying process steam from turbine extraction as well as

direct from boiler through PRDU.

) Captive Power Plant-2 (2.5 million ton phase)

Boilers 2 Nos. With combined capacity of 2 x 500 t/ Hr of steam feeding 2 x 100 MW

Turbo-generators.

) Turbo-blowing station -2 (2.5 million ton phase)

Boilers 1 No. with capacity 250 tph of steam feeding Turbo-blowers of 60 bar and 485 0

C feeding the turbines of the blast furnace No 2 blowers and supplying process steam

from turbine extraction as well as direct from boiler through PRDU.

The details are given in chapter 18.

2.13 Compressed air facilities

At Phase-1, it is envisaged to install two centralized compressed air stations.

Compressed air station No. 1 will cater to COBPP, Sinter Plant No.1 and Blast Furnace

No. 1 along with auxiliaries. Compressed air station No. 2 will cater to Steel melting shop

No. 1 along with secondary treatment and casters and the two hot rolling mills envisaged

at phase-1. The miscellaneous requirements of minor consumers also will be met from

ACP-1

Air Compressor Plant (ACP) No. 1 will have 4 Nos. (3 operating + 1 Stand by) of

centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unit will

also supply instrument quality air to the above processes


centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unit will

also supply instrument quality air to the above processes.

At Phase-2, it is envisaged to install two centralized compressed air stations and two

dedicated ACPs for Hot strip mill and cold rolling complex respectively due to their large

consumption. Compressed air station No. 3 will cater to COBPP complex -2, Sinter

Plant No.2 and Blast Furnace No. 2 along with auxiliaries. Compressed air station No. 2

will cater to Steel melting shop No. 2 along with secondary treatment and casters. ACP

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No. 5 and ACP No. 6 will be located in the Hot Strip Mill and Cold rolling Mill complex

areas respectively.

2.14 Fuel Oil Facilities

Fuel oil will be required in the Captive Power Plants as an auxiliary fuel in the coal fired

boilers to aid combustion. In all other units in both the phases of plant, generally coke

oven gas and mixed gas will be used as plant fuel. Fuel oil storages are being envisaged

at sintering plants, steel melting shops and rolling mills basically for start up and as

emergency measure to provide alternative fuel. The annual requirement of fuel oil and

LDO has been estimated as 1070 Kl and 15,097 Kl in phase-1 and 2 respectively. The

higher usage of fuel oil at phase-2 is due to usage of oil as auxiliary fuel in the pellet

plant.

The summary of facilities envisaged at both the stages is given below:

Sl. For Unit Fuel No. of tanks withAux. facilities

Capacity of tanks

1 Power Plant Furnace oil 2 Nos. Vertical 2 x 300 KlHSD/LDO 2 Nos. Horizontal 2 x 10 Kl

2 Steel Melting & Hotrolling Mills

LSHS 2 Nos. Vertical 2 x 210 Kl

3 Sinter plant -1 HSD/LDO 2 Nos. Horizontal 2 x 15 KlSinter Plant -2 HSD/LDO 2 Nos. Horizontal 2 x 15 Kl

2.15 Interplant gas pipe lines

Interplant gas pipe lines are proposed to supply gases like Blast Furnace gas, Coke

oven gas, Mixed gas, oxygen, nitrogen, argon, general compressed air and instrument

air to the various consuming points. The inter-plant gas pipe lines will be taken over

dedicated stockades.

2.16 Industrial Safety and Fire Protection Facilities

Many units and working premises of an integrated steel plant have hazardous and fire

prone environment. To protect the working personnel, equipment & machineries and raw

materials and stores from any damage or loss to ensure uninterrupted production,

adequate safety and fire fighting measures have been planned for the proposed plant at

both the phases of plant development. The envisaged facilities are described in Chapter

20.

2.17 Ventilation, Air conditioning and De-dusting facilities

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The facilities envisaged under this head will comprise of:

% Pressurized mechanical ventilation systems to be provided in all electrical premises,

turbine halls and pump houses. The system provided will ensure a positive pressure in

the room of + 3mm WC to prevent ingress of dust.

% At premises of stores, Battery rooms, toilets etc. general exhaust ventilation with wall

mounted axial fans along with cowl and bird screen has been envisaged.

% Various PLC rooms, control rooms of processes, office cabins, Laboratories etc. will be

provided with air conditioning arrangements. Package air conditioning system will be

provided in bigger rooms requiring large volume of air handling.

% Dust extraction system from the ambient air of the working floors will be basically

collected through collecting ducts with exhaust fans and cleaned with bag filters before

letting out to the atmosphere through 40/50 m self supporting chimneys. In some special

cases involving heavy dust loads and volume de-dusting with ESPs has been envisaged.

These are described in the individual technological chapters and also in Chapter-13

(Pollution Control Measures)

% Dust suppression measures. These involve water spraying in open dusty areas like yards

and use of defogging devices in close dusty areas where dust extraction through ducts is

difficult.

In general, the dust suppression system will operate with reclaimed water not fit for re-

cycling in the water system of the individual units.

2.18 Repair shops

Most of the routine type of repairs to be carried out in the steel plant will be offloaded to

the local facilities in the Hospet region or to Bangalore. The facilities envisaged are for

emergency repair services to ensure uninterrupted production. These would be set up at

phase-1 s for 1 million ton facilities with space kept for expansion during the phase-2

installations of 2.5 million facilities. These would be

' The Central repair shop

' Loco and wagon repair shop

' Utility repair shop

' Area repair shop for hot rolling mills and for the cold rolling mill complex

' Central electronics and instrumentation repair shop

' Repair posts at coke oven battery complexes 1 & 2; Blast furnaces 1 & 2; Sintering

plants 1 &2; Pelletizing Plant; Coal washing unit and the Captive power Plants

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2.19 Inspection, Quality Control and laboratory facilities

The proposed integrated steel plant of 3.5 million ton capacity at Koppal will produce

high quality low alloy and special steel long products at the phase -1 installations of

capacity 1 million ton of equivalent crude steel. At the phase-2 facilities it is envisaged to

produce Hot rolled strips/plates/sheets and cold rolled and coated strips/sheets

equivalent to 2.5 million ton crude steel produced at this stage. At phase-2 also, the

emphasis will be products with higher strengths, better formability and superior surface

finish and corrosion properties. At both the phases, quality assurance in the products will

be very important to penetrate into the existing market initially and to continue in a

supposedly fiercely competitive market surrounding. Moreover, considering the capital

cost of the equipment and facilities required at present, the Company will not be

profitable unless a large part of the product mix for sale is of value added products.

Therefore an elaborate quality assurance and control organization and facilities have

been envisaged. The details are given in Chapter 23. The basic organization will

comprise of the Central Quality Control and R&D facilities with separate laboratory

complex basically aimed at development. The area laboratories spread out in the steel

plant as given below will be used for routine quality control purposes for inspection and

giving feed back to the process technologists/operators often on line directly to the

process. The area laboratories envisaged are:

Phase-1:

% Raw material laboratory

% COBPP Laboratory

% Sinter plant-1 laboratory

% Blast furnace express laboratory

% EOF shop express laboratory

% Long rolling mills laboratory

% Captive power plant -1 & TB house laboratory

Phase-2:

% Raw material laboratory (expanded facilities)

% COBPP Laboratory (expanded facility)

% Sinter plant-2 laboratory

% Pellet Plant laboratory

% Blast furnace-2 express laboratory

% BOF shop express laboratory

% Hot strip mill Laboratory

% CRM complex laboratory

% Captive power plant -2 & TB house laboratory (expansion of phase-1 facilities)

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2.20 Construction planning

A tentative estimate of the construction/erection quantities involved in the setting up of

the 3.5 million ton steel plant is given below for giving an idea of the volume of work

involved.

Item Phase-1: 1 million tonfacilities

Phase-2:2.5 million tonfacilities

Excavation: 4,869,200 m3 10,069,250 m3

RCC: 823,766 m3 1,393,889 m3

Structures

Building 151,424 t 220,163 t

Technological 15,743 t 25,800 t

Mechanical equipment 139,000 t 192,835t

Electrical Equipment 26,387 t 36,685 t

Refractory 74,935 t 84,178 t

It is envisaged to complete the installation and commissioning of the plant equipment for

start up and production in 30 months for Phase-1 facilities.

(2) It is envisaged to complete the installation and commissioning of the plant equipment for

start up and production in 36 months for Phase-2 facilities. The additional time is

envisaged on account of larger % of imported components at phase-2 and relative

difficulty in construction due to presence of an operating plant at the site.

The time schedule is from ZERO date which in this case is the date of placement of

order for the major plant equipment. This period will cover detailed engineering, supply,

erection and commissioning of the units.

The interspacing between the two phases is not certain at the present. It will depend on

the market demand of steel flat product and prices as well as the availability of funds

from institutional sources. Generally a spacing of 2-3 years is expected between

commissioning of one phase and start of construction of the next phase. From that point

of view, the full 3.5 million ton phase of the plant could be completed in about 8 years

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time from the phase-1 zero date. This is provided the gap of 2-3 years is utilized for

placement of order for the phase-2.

The phase -2 units (2.5 million ton complex) can be installed in steps. While the primary

facilities like Coke oven s by product complex -2 (Battery Nos. 3 & 4); Sinter plant No. 2,

Blast Furnace No. 2, BOF-CC shop and Hot strip mill with Power plant No. 2 can be

completed together to get a capacity of 2.5 million tons of hot rolled coils, the Hot rolled

coil finishing facilities, the cold rolling mill complex can be installed later depending on

the market situation. The pellet plant installation and the installation of the coal washing

complex also can be at a time appropriate for these investments.

2.21 Manpower and Training

The details of the manpower envisaged are given in chapter 25. It may be seen that the

manpower required for phase -1 facility will be 1713 (including 129 managerial and

executive employees) and at Phase-2 the manpower will be 2098 (including 173

managerial and executive employees) giving manpower productivity of 583 tons per man

year and 1191 tons per man year respectively for 1 million ton and 2.5 million ton

facilities, in terms of rated crude steel production. The man power productivity at the full

implementation of the integrated steel plant (3.5 million tons) is envisaged to be 918 t

crude steel per man year very close to international performance for a fully integrated

unit producing from iron ore and having both long and flat products.

It should be mentioned here that the figures given above is only for regular employees.

The plantuk operation and maintenance will need perhaps as many men s mostly semi

skilled and unskilled for various non perennial jobs. All routine non key essential jobs like

road transport within the works, security, township services, medical and capital repair of

units are expected to be offloaded.

The training needs would be both in India and also abroad. It is desirable that the

technical training is given in units similar to what will be installed at AARESS at least for

some period, for the operating and maintenance persons to get acclimatized. Some part

of this training should be organized by the equipment suppliers in steel plants outside

India while a large part of the training will be organized in India in the existing steel

Companies.

2.22 Capital cost and economics of the Project

(1) Capital cost envisaged for installation of the steel Plant has been computed as

follows:

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Phase-1: Rs. 5,325 Crores.

Phase-2: Rs. 12,654 Crores

Total Rs. 17,979 Crores

The above estimate includes IDC and margin money. For Phase-1 it includes 5%

contingency but for phase-2 estimate as above contingency has not been provided. If

contingency of 5% is provided then the Phase-2 capital cost will go up by another Rs.

622 Crores. The item wise breakups of the Capital costs at the two phases are given in

Chapter 26. The capital cost includes basic cost towards pollution control equipment

which has been estimated as Rs 100Cr for phase-1 and Rs 320 Cr at phase-2, making a

total expense of Rs420Cr for the entire 3.5 MTPA project. This expense however,

excludes those facilities which aids environment protection but are otherwise required by

the process.

(2) Profitability of the Project

Chapter 26 gives the details of the profitability projection of the project with operation of

Phase-1 and Phase-2 separately. The assumptions of estimating the profitability are also

spelled in the chapter. A CSR expense of 5% of the capital cost of the project over 10

years has also been provided in the projection. The summarized position is given below;

Summarized 10 years cumulative profitability position of Phase-1 and Phase-2

Sl. No. Item Phase-1 Phase-2Amount(Rs. Crores)

% ofsales

Amount(Rs. Crores)

% of sales

1 Net sales realization 32,852 - 74,771 -2 Gross Profit 10,295 31.3 38069 50.93 Profit before Tax 4728.45 14.4 24629 32.94 Profit after tax 3301 10.1 1724` 23.15 Net cash surplus 2258.1 6.9 1507.24 20.2

The expenses include CSR expenses to the extent of 5% of project cost distributed over

a period of 5years.

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2.23 Conclusion

The feasibility report brings out that it is feasible to install the phase-1 of the project (1

million ton alloy and special steel long products) immediately in the area already

available with M/s AISL. The current demand trend of alloy and special steel in India

justifies setting of the 1 million ton alloy and special steel plant within another 3-4 years.

The project is found economically viable as per the present market trends of prices and

costs.

For Phase-2 of the overall 3.5 million ton plant, demand growth of carbon steel flat

product as projected justifies installation of 2.5 million ton flat product steel plant after

2020. The project as per the current prices and costs will be viable economically.

However, additional area will have to be procured by AISL and agreement of availability

of additional water over what has been already allotted by the Karnataka Government

need to be pursued. M/S AISL is already following these up with Government of

Karnataka.

The project has been envisaged keeping in mind the environmental protection of the

area surrounding the envisaged steel plant. Green belt has been planned all round the

plant area. Parks and gardens have been provided in the lay out. The units will have the

latest available processes and devices to minimize harmful emission of gases. The plant

will follow zero water discharge policy. Rain water will be conserved to the maximum

extent. Only about 25% of the solid waste generation of the plant needs to be discarded.

Bulk of it is the tailings from the fine ore beneficiation plant. This plant would find outlet

of the low grade fine ore in the adjoining mine area. The discards will be temporarily kept

within the plant area and then shifted to the nearby mine area to fill up old mine pits.

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Chapter-3: Market Analysis- Demand and Supply

3.1.1 M/S AARESS Iron & Steel Limited (AISL) had envisaged setting up the integrated steel

plant at Koppal in two phases. The first phase would be of capacity around 1 million tons

per annum of crude steel and the second phase with a crude steel capacity of 2.5 million

tons making a total of 3.5 million ton annual steelmaking capacity at the site. This

phasing would give initial optimum utilization of the available land and capital and also

time for further acquisition of land for expansion of the site and further tie up of capital.

3.1.2 In the present context of cost and pricing, 1 million ton steel capacity plant would be

viable as a standalone unit, only if value added product mix is considered. So AISL has

envisaged mainly alloy and special engineering grade steels at Phase-1. Bulk of such

steel is used as long products. So a long product mix is the product of choice in phase-1.

Alloy and special steels comprise about 10.5 % of the steel consumption in India.

Leaving stainless steel, bulk of which is in the form of flats, the non stainless alloy and

special steels currently comprise 6.5 % of the total steel consumption now. As we shall

discuss further that the overall demand of alloy and special steels are likely to be about

12% of the total steel demand with alloy and special steels having a share of 7-7.5% in

immediate future. Further, the consumption of alloy and special steels has registered a

growth higher than the overall steel growth recently. As compared to 2013-14, the net

domestic demand of alloy and special steels (including stainless) had increased by

31.7% in 2014-15. As per tentative estimates, the growth in the demand of alloy and

special steel during 2015-16 was 12.4%. This is after taking out internal use and double

counting. The corresponding growth in the total steel demand was 3.5%. This is given in

Table: 3.1.1below:

Table: 3.1.1 Consumption Pattern of total alloy and special steels in India $i*** b%

Year 2014-15 2013-14Production 9328 7637Export 685 477Import 2566 1151Variation ofstock

36 -46

ApparentConsumption

11173 8357

Doublecounting (-)

3140 2256

Net demand 8033 6101Growth % 31.7

Data: JPC

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Table 3.1.2: Consumption pattern of stainless steel in India $i*** b%

Year 2014 2013 2012 2011 2010 2009 2008

Production inequivalentcrude steel

2858 2891 2834 2163 2022 1721 1832

Note basic production data: www.worldstainless.org

3.1.3 The second phase will have the advantage of scale of operation and can consider mild

steel flats along with value added special steel flat products. Flats have been preferred

because there has been considerable expansion of long product capacity vis. a vis. flats

in the older steel plants recently, and bars, rods and light structural are produced more in

the smaller and medium capacity plants in the secondary steel sector. This expansion of

long product capacity is in view of the recent spurt in the housing and infra structure

activities in India.

3.1.4 It is true that demand of flat rolled products right now is low in India because of near

stagnation in the growth of the industrial sector in general. However this is considered

only a transient phase and long term demand projection shows robust demand growth

and considerable demand qavailability gap for flat products in India. Putting this category

of steel in the second phase gives the AISL management some time for the flat demand

to pick up to the projected demand path.

3.1.5 In this chapter we would discuss the demand availability scenario of both these

categories of steel. The demand of alloy and special steel on a macro level is connected

with the overall growth of steel demand and its linkage with growth of Gross Domestic

Product (GDP) and try to arrive at the optimum product mix for both the stages.

3.2 Demand h Availability projection of Alloy and Special steels.

3.2.1 Carbon steel is defined by the Alloy steels research committee as steels containing

carbon but containing not more than 0.5% manganese and 0.5% silicon. All other steels

are termed as alloy steels. Even if in grades of steels with manganese and silicon lower

than 0.5% individually, the steel can be sometimes termed as special if rigid specification

for S and P lower than 0.04% each or tight specifications of variability of analysis of

elements like carbon present are imposed. These steels may cater individually or in

combination to the needs of higher strength, higher formability, ease of welding and

often lower ductile to brittle transition temperature as required in the material of

construction of machine parts under different working conditions.

3.2.2 The alloying elements added result in the following effects on a case to case basis:

' Solid solution strengthening

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' Formation of hard carbides in the matrix like Cr7C3; W2C; Mo2C; VC for imparting

strength.

' Reduction in the critical cooling velocity as required for austenite to martensite

transformation. This facilitates adaptation of quenching process (like oil quench

against water quenching) for hardness and prevents distortion of dimensions while

quenching

' Dispersion of fine carbides in the matrix to slow down grain growth for better creep

properties.

' Alteration of eutectoid composition and structure in the steel matrix.

' Use of elements like CR, Al, Si, Cu etc. for formation of a passive oxide films on the

surface for resistance to corrosion and oxidation.

' Ensuring single Austenitic phase at room temperature for ease of deformation metal

working as in done by Nickel in stainless steels of 300 series.

3.2.3 Classification of Alloy and Special Steels

Primary basis for classification of alloy and special steels is by their chemical

compositions giving rise to different properties in as rolled or as heat treated conditions.

The general classifications are:

' Carbon constructional steels

' Alloy constructional steels

' Spring steels

' Ball bearing steels

' Tool and die steels

' Free cutting steels

' Heat and corrosion resistant steels

(1) Carbon Constructional Steels:

Carbon constructional steels are used for parts not subject to severe service conditions

calling for a combination of strength and wear resistance with toughness. A variety of

steel is covered in this category. Some of these are low carbon steels for carburized

parts; medium carbon forging quality steels for manufacture of machine parts and hand

tools; high carbon steels for high strength wires and other components and micro-

alloyed steels containing small amount of elements like V, Nb etc. to impart strength

without heat treatment. These micro-alloyed steels are replacing now other categories

of alloy steels. Carbon constructional steels generally do not contain any other alloying

elements other than moderate amount of manganese. Silicon is also generally restricted.

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(2) Alloy constructional steels

These steels are used for parts in which the desired combination of strength properties

can be obtained only through heat treatment which normally consists of quenching-

hardening and tempering. A combination of one or more of the elements such as:

manganese, nickel, chromium, molybdenum, vanadium, boron etc is generally used for

this purpose. These alloys strengthen the ferrite matrix and improve the harden-ability of

the steel by delaying the martensite transformation time. Usually in alloy constructional

steels the total alloy content is limited to about 2-6%. These steels are the backbone of

machinery construction and have host of applications such as transmission shafts,

gears, couplings, engine parts etc.

(3) Spring Steel

This group includes hardenable grades of carbon steel or alloy steels for manufacture of

various kinds of springs such as leaf springs, coil springs, flat and helical springs

required in transport equipment and many other machineries. Railway rolling stocks and

automotive transport equipment require largely such grades. Spring steels are of three

types depending on the elements used to impart the elasticity and fatigue resistance

after heat treatment. These are carbon spring steels; silico-manganese spring steels and

chromium-vanadium spring steels.

(4) Free cutting steels

These steels are either Sulphur, phosphorus or leads based (in some cases with

bismuth, selenium and tellurium) and are used for a large number of turned products like

screws etc for aid in machining. The distinguishing features of free cutting steels are

high machining rate and good surface finish after machining. S when added in free

cutting steels (typically 0.2-0.3%) forms manganese sulphide which stretches out during

rolling. These form short and brittle chips and reduce friction during machining thereby

facilitating high machining rate and better machined surface. Phosphorus (often in

combination with sulphur) dissolves in the ferrite matrix and promotes breaking of chips

during machining. Lead (0.2-0.5%) in steel forms free suspension like particle in the

structure In particular, reduces the friction between the tool and piece, extending the life

of the tools and also helps to form short brittle chips. , Use of bismuth and Selenium and

tellurium further accentuate these characteristics.

Free-cutting steels are usually supplied in bars or rolls without heat treatment; some of

these can however be tempered, normalized or annealed before finishing. Unlike other

special steels strength and cleanliness are not their essential features.

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(5) Ball Bearing steels

These are high carbon, high chrome bearing steels with high degree of internal

cleanliness and controlled decarburization. The main uses of such steels are

manufacture of ball and roller bearings.

(6) Tool and Die steels.

These steels can be both low carbon as well as high carbon with varying % of tungsten,

Molybdenum, Vanadium and Chromium. These have high strength combined with

toughness, wear resistance and cutting properties. The strength and wear resistance

varies with carbon content. Much of the hardness and wear resistance comes from the

formation of carbides in the structure. These steels are used for shaping of metal (both

hot and cold) in dies and tools. The high speed steel is also in this class.

(7) Heat and corrosion resistant steels

These are alloy steels with high % of elements like Chromium and Nickel

These steels are in the following main grades:

(1) Valve steel or creep resistant steels which retain the strength and resists deformation at

higher temperatures.

(2) Austenitic stainless steel with up to 50% in Chromium and Nickel and other alloys. The

18:8 stainless steel belongs to this grade.

(3) Ferritic /Martensitic steels with 12-18% Chromium with little or no nickel.

Many of these grades are available with S, P and Selenium for ease of machining but

with a small deterioration in the properties in comparison with non treated steels.

The following table gives the common grades of steel demanded by the consumers in

India. For chemical analysis and other details please see q Annexure- 3.1

Table: 3.2 Common grades in Carbon and alloy construction steels

Category GradesCarbon steels EN8D, EN9; C45; CK45; 45C8; 35C8; EN43B; Etc.Carbon manganese steels EN15; SAE 1541; EN15AMChrome steel 40Cr4 Type B7C; EN18; 41Cr4; SAE52100Manganese Moly Steel EN16Chrome Manganese steels 16MnCr5, 20MnCr5Chrome Moly steel EN19;SAE4140;SAE4135; SCM420; SCM415Nickel Chrome Moly steels SAE8620, EN353;EN354; EN24; EN36Nickel Chrome steel 16CrNi14, 15CrNi16

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Micro Alloy Steel 38MnSiVS5, 30MnVS6+t; C38+N2; 30Mn5V, 38MnS6

3.2.4 Aggregate Demand Pattern of alloy and special steels (other than stainless steel)

3.2.4 The following end users account for over 95% of the aggregate demand of Alloy and

Special steels. A general pattern of demand break up industry wise is:

0 Forging Industry including direct by auto ancillaries (48.5%)

0 Railways (4%)

0 Spring Industry (10.5%)

0 Defense applications (5%)

0 Ball and roller bearing manufacturing sector (3%)

0 Seamless pipes and tubes manufacturers (7.5%)

0 Forged hand tolls industry (3.5%)

0 Agriculture & industrial machinery (1.5%)

0 Electrical equipment manufacturers (5.0%)

0 Bright bar industry (5%)

0 Rods for fasteners (Alloy and special steel) (3%)

0 Others (3.5%)

There can be two approaches for predicting the demand of alloy and special steels. One

can be growth in demand based on the growth of the end using industries. The second

can be an indirect estimation as a % of the total steel demand in the country.

In the first case, the projection of the growth pattern of the user agencies shows that a

CAGR of about 8% can be safely assumed for non stainless alloy and special steels. For

stainless steels due to large expansion in domestic use the CAGR can be even higher.

Based on the above, the apparent consumption for different categories of non stainless

alloy and special steels is likely to increase from 5.3 million tons at 2014-15 to almost

9.08 million tons per annum by the year 2021-22 (about 7 years hence) and 15.56

million tons by 2028-29 (14 years hence) With an aggregate growth of 8 % per annum.

This growth rate is projected higher than the average 6.5% growth rate for overall steel

demand assumed later in the section since the share of alloy and special steels are

expected to rise from present values in future. This is assumed to be in keeping with the

recent increase in the share of alloy and special steels in the overall consumption of

steel and the general value addition required in steels for both domestic and industrial

sectors.

With the second approach when the alloy and special steels are estimated as a % of the

overall steel demand we shall see in the later part of the section that an overall CAGR of

6.5% (the worse scenario) of the total steel demand, comes to 115 million tons in 2020-

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21. Assuming that stainless steels and non stainless alloy and special steels will have

5% and 8% share of the total steel demand in 2020-21, the projected demand for non

SS special and alloy steel comes to 9.2 million tons which is closer to the earlier

estimate.

No doubt there is a considerable uncertainty in the demand of steel of all categories in

the long term. But short term ups and down notwithstanding, the growth in consumption

is certain in the long run for a developing country like India in line with the growth in the

GDP.

Exports are excluded from the apparent consumption but imports are included. An

imbalance of exports and imports can cause distortion in the order positions of domestic

producers. Even though demand may be growing, growth of imports over exports can

cause considerable problem for the domestic industry. This is what is currently visible in

India at the face of strong export push from China. But in the long run, such imbalances

are evened out. Imports are restricted to those items which domestic industry finds non

economical to produce either due to technology consideration or volume. So in this

projection we have assumed that the domestic demand is what domestic industry will be

required to produce. Any import tonnages would be balanced by corresponding exports.

3.2.5: Projected Growth in the consuming sectors of alloy and special steels in future

(1) Automobile sector:

The Indian auto industry is one of the largest in the world with an annual production of23.37 million vehicles in FY 2014-15, following a growth of 8.68 per cent over the lastyear. The automobile industry accounts for 7.1 per cent of the country's gross domesticproduct (GDP).The Two Wheelers segment with 81 per cent market share is the leaderof the Indian Automobile market owing to a growing middle class and a youngpopulation. Moreover, the growing interest of the companies in exploring the ruralmarkets further aided the growth of the sector. India is also a prominent auto exporterand has strong export growth expectations for the near future. In FY 2014-15,automobile exports grew by 15 per cent over the last year. In addition, several initiativesby the Government of India and the major automobile players in the Indian market areexpected to make India a leader in the Two Wheeler and Four Wheeler market in theworld by 2020. The expected growth rates in the sector in coming future have beenprojected as:

' Overall auto production: 9.6%

' Commercial vehicles: 8.5%

' Medium and heavy vehicles: 2.4%

' Passenger vehicles: 9.7%

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' Multi-utility vehicles: 19.7%

' Two wheelers: 9.7%

(Source: IEBF- September 2015 up date)

(2) Auto components

Indian auto component industry has registered a CAGR of 11% over the last six years.

Apart from supply to the domestic industry, the important trend in this sector in recent

years is the growth in exports. The export turnover now is several times of the turnover

of auto parts to the domestic industry. The auto component exports to destinations in

terms of share in the entire export basket are:

USA: 22.3%; Germany:7.51%; UK: 5.43%; Turkey: 6.43%; Italy: 4.99%; Thailand:

3.38%; Brazil:3.37%; China: 3.87%; UAE: 2.95%; France: 2.92%.

The growth in the export turnover and the values are given in the Table below:

Table: 3.3: Growth of export of auto components

Year/Item 09-10 10-11 11-12 12-13 13-14 14-15Export volume_d EJN r0//Crores

189 303 427 526 614 685

Export volumein US $Billions

4.2 6.7 8.8 9.7 10.2 11.2

Growth % 19.3 60.7 40.7 23.3 6.7 11.4CAGR: 29% (Source: Report on auto export- Internet)

No doubt the initial high growth rate of export has slowed down in recent past but an

average growth of 8-10% together with indigenous automobile industry and exports is

expected in the coming years.

(3) Index of Industrial production

The domestic demand for alloy and special steels depends mainly on the growth of the

domestic industry in an economy. Therefore an overview of the general industrial

scenario of the country will be relevant. The growth of the industries is expressed by

index of industrial production. The use based classification of industrial production has

the following four components.

% Basic goods

% Capital goods

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% Intermediate goods

% Consumer goods:

0 Consumer durables

0 Consumer non durables

It may be mentioned out of the four, Alloy and special steels are required mainly for

manufacture of capital goods, intermediate goods and consumer durables. The past

data and outlook for the future are given in the table below:

Table 3.4: Use based indices of Industrial production

A. Annual average indices (April-March)

Year BasicGoods

CapitalGoods

IntermediateGoods

TotalConsumerGoods

Consumerdurables

Consumernondurables

Generalindex

2005-06 106.1 118.1 106.6 110.7 116.2 108.6 108.62006-07 115.6 145.6 118.8 128.6 145.6 121.9 122.62007-08 125.9 216.2 127.5 151.2 193.8 134.3 141.72008-09 128.1 240.6 127.6 152.6 215.4 127.7 146.22009-10 134.1 243.0 135.3 164.3 252.0 129.5 152.92010-11 142.2 278.9 145.3 178.3 287.7 135.0 165.02011-12 150.0 267.8 144.4 186.1 295.1 142.9 170.32012-13 153.6 251.6 146.7 190.6 301.1 146.9 172.22013-14 156.9 242.6 151.3 185.3 264.2 154.0 172.02014-15 167.8 258.0 153.8 178.9 231.0 158.3 176.9Relativeweight

456.82 88.25 156.86 298 84.60 213.47 1000

B. Growth % over corresponding period of previous year

Year BasicGoods

CapitalGoods

IntermediateGoods

TotalConsumerGoods

Consumerdurables

Consumernondurables

Generalindex

2005-06 6.1 18.1 6.6 10.7 16.2 8.6 8.62006-07 8.9 23.3 11.5 16.1 25.3 12.3 12.92007-08 8.9 48.5 7.3 17.6 33.1 10.2 15.52008-09 1.7 11.3 0 0.9 11.1 -5.0 2.52009-10 4.7 1.0 6.0 7.7 17.0 1.4 5.32010-11 6.0 14.8 7.4 8.6 14.2 4.3 8.22011-12 5.5 -4.0 -0.6 4.4 2.6 5.9 2.92012-13 2.5 -6.0 1.6 2.4 2.0 2.6 1.12013-14 2.1 -3.6 3.1 -2.8 -12.2 4.8 -0.12014-15 7.0 6.4 1.7 -3.4 -12.6 2.8 2.8Relativeweight

456.82 88.25 156.86 298 84.60 213.47 1000

Source: Data from Government of India open data base- data.gov.in/user

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From the above table the average growth rates of the three uses contributing to demand

of Alloy and special steels come to:

Capital goods: 15.5%

Intermediate goods: 5.2%

Consumer durables: 12.75%

After averaging with the relative weights the average growth registered by the three

combined uses comes to 9.87%.

The above analysis shows the logic of assuming a CAGR of 8% in the case of alloy and

special steels (other than SS).

Table: 3.5 projected year wise demand for alloy and special steels.

Qd_j9 r/// I[jh_Y jedi

Sl. Category Projected net demand (production+imports-exports)2013-14 2020-21 2027-28

1 Carbon construction and alloyconstruction steels

3339 5720.4 9802.8

2 Spring steels 1033.5 1770.6 3034.23 Ball bearing steels 212 363.2 622.44 Free cutting steels 371 635.6 1089.25 Others 344.5 590.2 1011.4

Total 5300 9080 15560

3.2.7 Availability of alloy and special steels in India

It is well known that the overall capacity utilization of the sector producing alloy and

special steels is not very high and ranges between 70-80%. The reason of lower

capacity utilization is not always lack of demand but constraints of technical capability in

terms of size and quality coupled with cost which necessitates import. It is expected that

a new facility equipped with all necessary facilities will not face these problems.

The existing capacities of the Alloy and Special steel manufacturers are as follows:

a) Integrated Steel producers:

- RINL

b) Blast Furnace Operators with BOF/EOF/EAF

- VSP, Bhadravati /SAIL

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- Usha Martin, Jamshedpur

- Hospet Steel, Hospet, Karnataka

- SISCOL (JSW), Salem, Tamilnadu

- Jindal Steel & Power, Raigarh

- Adhunik Metallic, Rourkela

- Jaiswal Neco, Raipur

- Sunflag, Bhandara, MS

c) Electric Arc Furnace operators

- Aarti Steel

- Bhushan Steel

- Modern Steel

- Upper India

- Vardhaman

- Facor

- ISSAL

- Alloy Steels Plant Durgapur /SAIL

- Kalyani Carpenter

- Marmogoa Steel

- MUSCO

- Remi Metal

d) - Induction Furnace operators.

Some of the induction furnace operators with access to good scrap are also trying to

produce alloy and special steels particularly spring steels and some other steels not

requiring low S and low P.

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The Table below gives the capacities of the units producing alloy and special steel long

products which are relevant to the present context. Units producing Stainless steel

mainly or units producing special steel flats have also been excluded. It may be noted

that for many units with AOD facilities, the capacity between stainless steel and non

stainless steels are flexible and depends on market. The table below gives a broad

general idea of the current available capacity for alloy and special steels in India.

Table-3.6: Capacities of Major Alloy/Special Steel producers and data on current

production

Location/Name of the Unit Installed Capacity withexpansion done/planned (t)

Currentmaximumproduction (t)

A. Northern RegionAarti Steel, Ludhiana 125,000 127,000Bhushan Steel, Chandigarh 30,000 30,000Modern Steel, Ludhiana 50,000 49,000Star wire 24,000 15,000Upper India Steel, Ludhiana 72,000 50,000Vardhaman Special Steel, Ludhiana 80,000 84,000Sub Total 381,000 355,000B. Western RegionFACOR, Nagpur 50,000 34,000India Seamless and Alloys (ISSAL),Pune

250,000 230,000

Kalyani Carpenter, Pune 150,000 120,000Marmagoa Steel, Goa 75,000 74,000Mukund Steel, Kalwa, Mumbai 250,000 (380,000 with expansion) 195,000Mahindra Ugine, Khapoli (MS). 105,000 104,000Remi Metech, Phulwadi, Gujarat 50,000 47,000Sunflag Steel, Bhandara, MS 200,000 225,000Sub Total 1130,000 (1510,000 with expansion) 1029,000C. Eastern RegionAdhunik Metallic, Rourkela, Odisha. 250,000 Partly closed nowAlloy Steels plant Durgapur 164,000 (Including SS) 100,000Jaiswal Neco 300,000 (800,000 t after expansion)Jindal Steel & Power, Raigarh 200,000 (For alloy & Special

steels) Capacity flexible160,000

Usha Martin 200,000 (450,000 with expansion) 125,000

Sub Total 1114,000 (1564,000 with expansion) 450,000D. Southern RegionKalyani Steel, Hospet 137,000 (With expansion 230,00) 162,000SISCOL (Jindal Salem) 1000,000 (1200,000 after

expansion)Visvesvaraya Iron Steel, Bhadravati 150,000 128,000

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Sub Total 1287,000 (1487,000 after expansion) 390,000E. OthersRINL 650,000 500,000Induction furnace units 400,000 300,000Sub Total 1050,000 800,000Grand Total 4,962,000 (5,992,000 with expansion)

It may be noted that both Jindal Steel & Power (JSPL) (Raigarh) and RINL have high

flexibility to increase the proportion of special steel products in their product in case of

future demand. RINL has already commissioned round casters for seamless pipes and

can produce special steels for that purpose. JSPL employs EAF route can easily

increase the proportion of alloy steel with marginal balancing facilities. Between these

two units an additional 1 million ton can come within a short period. But considering a

likely demand of around 9 million ton of alloy and special steels (excluding stainless

steels) as projected earlier after 7 years, the existing capacity including capacity

potential for immediate expansion can accommodate a new unit of one million ton

capacity easily. This has been envisaged at AISL.

3.2.8 Suggested Product mix for Phase-1

AISL can take care of the requirements of strategic sectors like defense, Nuclear Power,

Railways in addition to automobile and auto component sectors having a lion share of

the total demand of alloy and special steels (other than stainless steel) in India. The

various grades of steel to be manufactured by AISL are: High temperature steel, nitriding

steel, ball bearing steels spring steels, carbon and alloy constructional steels and valve

steels.

The suggested product mix of AISL at stage-1 (Alloy and special steel production phase)

is given in the table below:

Table: 3.7: Suggested Product Mix for AISL for the Phase-1 plant

Sl. Type of Product Grades Size range(mm)

Annualproduction(Metric tons)

1 Bar MillWire rod in coils DQ, BBQ, CHQ, BQ, FCS,

Spring steel5.5-16 200,000

Bars in straightlength

ACS, CCS, BQ, SpringSteel

16-69 400,000

Sub Total (a) 600,0002 Billet Mill

Round bars ACS, CCS, BQ, SpringSteel

60-200 150,000

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Squares (RCS) ACS, CCS 60-200 50,000Flats ACS, CCS, BQ, Spring

Steel60-140 50,000

Sub Total (b) 250,000Grand Total 850,000

ACS: Alloy Construction Steel; CCS: Carbon Construction Steel; BQ: Bearing Quality; DQ:

Drawing Quality; CHQ: Cold heading quality; FCS: Free cutting steel; BBQ: Bright bar quality.

3.3. Demand availability projection for carbon steel and product mix for Phase-2

3.3.1 Steel demand and economic growth of India

It has been highlighted in the previous section that the domestic demand of alloy and

special steel is linked with the overall demand of steel in the country. In a developing

country where economy is inward looking and catering to mostly domestic needs the

overall steel demand growth is closely linked with the growth of the economy. We would

discuss in this section the future outlook of steel demand and derive the optimum

capacity and product of AISL in the Phase-2.

3.3.1.1 Despite the current concerns over growth, there is a strong optimism that due to the

intrinsic potential of the steel demand growth in India, the longer term opportunities for

the sector are bound to be bright.

3.3.1.2 Steel consumption significantly depends on the overall performance of the economy

(GDP). More so on investments made in fixed assets like housing, infrastructure like

Railways, Ports, airports, roads etc. Approximately in terms of value, steel accounts for

60-65% of these projects in the various forms of use. Further, steel is still the basic

material for capital goods like automobiles, machinery etc. though substitutes from

Plastic and aluminum are strong.

3.3.1.3 The Indian economy maintained steady and significant growth especially from 2003-04.

Only recently the economy has slowed down due to variety of factors including those

derived externally. Despite the recent economic slowdown, the overall expectations on

the macro-economic performance of the economy in the longer term, are generally and

widely seen to be strong. It is believed that the sub-optimal economic performance of

India is due to factors which can be resolved easily in the near future and clearly the

present Government is making efforts towards that direction. There is no reason to

assume that the current low growth syndrome will continue. Though a dramatic change

in a small span of time is not expected, but an annual GDP growth rate of 6.5 to 7% can

be expected for the next 15-20 years. It is also not impossible that in case of positive

global environment, the GDP growth rate may be in the range of 8-9% even.

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The table below gives the data on production, import, export and real consumption of

steel (alloy and non alloy) in India for the last 9 years.

Table 3.8: Production, import, export and real consumption of finished steel (Alloy and

Non alloy) in India. (Unit Million metric tons)

Year Production Import Export RealConsumption

2005-06 46.566 4.305 4.801 41.4332006-07 52.529 4.927 5.242 46.7832007-08 56.075 7.029 5.077 52.1252008-09 57.164 5.841 4.437 52.3512009-10 60.62 7.38 3.25 59.342010-11 68.62 6.66 3.64 66.422011-12 75.69 6.86 4.59 71.022012-13 81.68 7.93 5.37 73.482013-14 87.67 5.45 5.98 74.09

Note: The real steel consumption has been arrived after adjustment of stock accretion/depletion

and also double counting.

Source: Annual reports of Ministry of Steel, Government of India.

3.3.1.4 There are many studies projecting steel demand growth scenario over the next couple of

decades. In a recent study, the Boston Consulting Group (BCG) as reported by Joint

Plant Committee ERU has made the following observations:

A) As per the present pattern of growth: The real GDP of India grew @ 7.4% during the 9

year period 2002 to 2013 while steel consumption grew at the rate of 8.2%. If one

assumes that the next 12 years will see a GDP growth of 6-6.5% and a GDP elasticity

of steel at 1.1, the likely growth of steel consumption would be 7.3% per year and on

that basis, the finished steel consumption in 2025-26 is estimated to grow to 155-170

million tons.

>) >[dY^ cWha_d] EdZ_Wsi ijW][ e\ [Yedec_Y ]hemj^ m_j^ ej^[h Yekdjh_[i9 Kd Wdej^[h

scenario, the following the established trajectory of growth as seen in other countries,

the per capita steel consumption level would move from 59 kg in 2011 to 175 kg in

2025-26 and give that the Indian population would be 1.43 billion by that time, steel

consumption in 2015-26 is likely to be around 250 million tons.

C) One of the goals of India is to increase the share of manufacturing to 25% of GDP by

2025-26. If the above target is achieved, it can propel the finished steel usage from 16

kg/$ PPP in the year 2012 to 22-25 Kg/$ PPP in the year 2025-26. This would mean a

growth of steel consumption of 9-10 % and on this basis the steel consumption in

2025-26 is likely to be around 230-255 million tons. This is shown in the table below:

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Table 3.9: Strategy to push the steel demand growth

Particulars Finished SteelConsumption

How to be achieved

Steel Consumption under the basescenario

170 million tons

Addition in construction 30-35 million tons Growth pushed from 9%to 11%

Addition on infrastructure 20-30 million tons Growth pushed from 9%to 11%

Addition in steel intensive capitalgoods

10-15 million tons Growth pushed from11% to 14/15%

Additional direct steel export 10-15 million tons Boost export incentivesAdditional indirect steel export 5-10 million tonsTotal consumption 245-250 million tons.

It is necessary to point out that the above scenarios B and C are highly optimistic. Even

j^[d Cel[hdc[djsi ^_]^ b[l[b Yecc_jj[[ ed cWdk\WYjkh_d] ^Wi i[j W jWh][j e\ hW_i_d] j^[

annual level of steel manufacturing to 300 million tons by 2025-26 against earlier target

of 100 million tons in 2020 by the previous Government. Recently a report on the

infrastructure requirement for production of 300 million tons of steel by 2025 has been

made public.

One needs to consider that low per capita consumption level of steel is basically due to

low per capita GDP. The consumption of steel in the country per capita GDP is not so

low. Therefore the important point for steel consumption is the rate of growth of GDP in

the coming decades.

As per publicly available reports, the Economic Research unit of JPC, Government of

India has given the following projections for the coming years according to different

scenarios of GDP growth rates.

Table 3.10: Forecast of Finished Steel Demand (Million metric tons)

2013-14 2025-26 2032-33Finished steel demand @6.5 %GDP growth rate

74 176 273

Finished steel demand @7 % GDPgrowth rate

74 186 298

Finished steel demand @8 % GDPgrowth rate

74 208 339

Source: ERU, JPC

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Table 3.11: Forecast of Crude Steel production from forecast of Finished

Steel Demand (Million metric tons)

2013-14 2025-26 2032-33Crude steel Production @6.5 % GDPgrowth rate

81 185 287

Crude steel production @7 % GDPgrowth rate

81 196 314

Crude steel production @8 % GDPgrowth rate

81 219 357

Source: ERU, JPC

Boosting GDP growth rate considerably within a short time is not an easy task

particularly for a democratic country like India with pushes and pulls from all sides. In

many ways this depends on the global scenario. So we recommend taking the middle

figure of 7% annual compounded rate of GDP growth for the next two decades. It may

be mentioned that for steel demand to reach 300 million tons by 2025-26, the annual

GDP growth rate need to be over 8%.

The table below gives the projection of capacity required in mild steel production to meet

the demand of finished mild/carbon steel for four terminal years.

Table 3.12: Capacity Projection of crude, mild/carbon steel production(Unit million metric tons)

Terminal Year 2016-17 2020-21 2025-26 2032-33Finished steel demandprojection

92.44 124.37 180.22 281

% alloy and special steels inthe demand projection

10 11 12 12.5

Projection of carbon steelproduction reqd.

83 111 160 245

Yield assumed from finishedsaleable to crude %

92 92.5 95 95

Crude carbon steelproduction required

90.2 120 169 258

Capacity utilization assumed 85 88 88 88Capacity required 106 136 192 286

The table below gives the breakup of the product mix projection of finished carbon/mild

steel in India based on 7% growth rate of GDP and % of alloy and special steel in the

overall steel consumption as indicated in the table.

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Table 3.13: Product hwise shares of steel demand forecast (Unit Million metric

tons)

Year 2010-11 2016-17 2020-21 2025-26 2032-33Total consumption ofsteel- alloy and Nonalloy

66.42 93 125 181 281

% of alloy steel in thetotal steel consumed

8 10.5 11 12 12.5

Total consumption ofmild/carbon steel

61.1 83.23 111.25 159.28 245

Bars and Rods 24 33.12 44.62 64.32 97.51Structural 5.5 5.81 7.55 9.28 10.29Railway materials 2.0 1.08 1.11 1.28 0.98Total Long products 31.5 40.01 53.28 74.88 108.78Plates 4.705 5.828 7.215 9.44 12.01HR Coils/Skelp/Sheet(Excluding doublecounting)

12.83 17.38 22.98 32.64 47.53

CR coils/sheets(excluding doublecounting)

5.93 9.48 14.1 23.2 45.57

GP/GC 4.64 6.49 8.67 12.64 19.35Electrical Steels 0.48 0.67 0.89 1.28 1.96Tin Plates/TFS 0.37 0.58 0.78 1.12 1.96Pipes 1.53 2.16 3.11 4.8 7.59Total Flat products 30.485 42.59 57.74 85.12 135.98Flat (except thickplates/Electrical steel)equivalent HRC

26.59 38 52.32 78.53 129.19

3.3.2 Availability of mild/carbon steels in India

The capacity currently available in India including the work in progress which will come

to stream immediately is around 100 million tons as given in the table below. If we

include the upcoming 3 million steel plant of NMDC at Nagarnar, expansion of RINL to 7

million tons and the commissioning of 3 million ton phase-2 of Tata steel at Kalinga

Nagar which are sure to come to stream, the total capacity to be available in near future

as per the present position would be around 105 million tons. It may be seen from Table

3.12 that it matches more or less the capacity required in 2016-17 with 85% capacity

utilization. Some part of the capacity available also is utilized for production of special

steels (at RINL for example), still it may be inferred that in immediate future, the demand

of carbon and mild steels can be met with the capacity available and already in the pipe

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line. The gap starts from 2021-22 with a moderate GDP growth rate of 7% (steel

consumption growth rate 7.7% compounded annually) which would have to be filled up

with imports if domestic capacity does not come up. It is therefore appropriate for AISL

to plan for mild steel capacity in phase-2 which can come to stream after 2021-22.

3.3.2.1 Crude Steel Production capacity available in India at present

The Table below gives the broad breakup of the crude steel capacity in India at present

Table 3.14: Crude steel capacity in India (Million tons)

Jharkhand: 20.5

Odisha: 16.2

Chhattisgarh: 18.0

West Bengal: 7.3

Andhra Pradesh: 6.0

Karnataka 14.0

Gujarat 11.0

Maharashtra 5.3

Total 98.3

Source: Infrastructure for 300 million steel production in 2025: MECON

3.3.3 Demand of flats vs. existing capacity in terms of hot rolled coils

AISL in phase-2 intends to produce hot rolled coils and part of the coils will be sold as

coils or cut to thinner plates and sheets. For assessing the position, the demand

projections of Hot rolled coil/sheets, cold rolled coils/sheets, coated products and pipes

have been converted to equivalent tonnages of hot rolled coils since the basic materials

for all these products are hot rolled coils rolled out of hot strip mills. Please see the last

row of Table 3.13. The table below gives the capacities of the Hot strip mills

(Conventional, thin strip mills as well as stackel Mills (rolling mild steel mainly for strips).

The gaps in the different terminal years are also projected in the table. The position

clearly justifies planning for a 2.5 million ton Hot strip mill at phase-2 of the AISL project.

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Table 3.15: Hot strip rolling: Capacity vs. requirement projection

Sl. Plant/Company Type Capacity (Million tons per year) Coilspecifications

Installed Underinstallation/pipeline

Total

1 Rourkela/SAIL Hot Strip MillNo.1

2.0 2.0

Hot Strip Mill No. 2 3.0 3.02 Bokaro/SAIL Hot Strip Mill 4.0 4.03 Jamshedpur/Tata

SteelHot Strip Mill No. 1 2.0 2.0

CSP 2.54 2.544. Kalinga Nagar/Tata

SteelHot Strip Mill No. 1 3.0 3.0

Hot Strip Mill No. 2 3.0 3.05 Ghaziabad/Bhushan

SteelHot Strip mill 2.0 2.0

6 Meramanadali/Bhushan Steel

Hot Strip Mill 4.5 0.5 5.0

7 Toranagallu/JSW Hot Strip Mill No. 1 3.2 3.2Hot Strip Mill No. 2 5.0 5.0

8 Dolvi/Ispat JSW Hot Strip Mill (CSP) 3.3 3.39 Hazira/Essar Steel Hot Strip Mill 3.6 3.610 Nagarnar/NMDC Hot Strip mill 2.9 2.911 Wardha/Lloyds Steel Stackel Mill 0.78 0.78

Total 33.38 11.94 45.32

The above table shows that the existing running capacity of the hot strips is around 33-

34 million tons. This is against the equivalent Hot rolled coils requirement of 26.59

million tons in the immediate past as given in Table 3.13 and. it is known that all the strip

mills are not running to capacity. The capacity which is likely to be available around

2016-17 would be 45-46 million tons, again enough to meet the equivalent hot coil

requirement of about 38 million tons. It is only after 2020-21, the demand of as hot rolled

coils would outstrip the available capacity at that time. It is prudent therefore for AISL to

plan for production of carbon steel hot rolled coils in the second phase which is likely

come to stream after 20-21.

3.3.4 Demand availability of cold rolled and coated products.

Cold rolled steel coils and sheets are all derived from Hot rolled coils. Coated products

are mostly from cold rolled strips though galvanizing of thin hot rolled strips is already in

international market for some time and these have a small presence in India. The % of

the coated coils and strips which would be from hot rolled thin strips is difficult to access

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now and would depend on the newer hot strip mills taking up thinner gauges in the

product mix. But considering the price advantages of coated hot rolled strips over the

coated cold rolled strips it is expected that in near future most of thicker coated sheets

and strips would be directly coated after pickling of hot rolled strips. If one assumes that

after 20-21, about 15% of the coated sheets will be hot rolled then the position of

equivalent requirement of Cold rolled coils are projected in the table below:

Table 3.16: Projection of Cold rolled coil demand in terminal years (Million

metric tons)

Year 2016-17 2020-21 2025-26 2032-33Projection of CRC demand 9.48 14.1 23.2 45.57GP/GC coils and sheets 6.49 8.67 12.64 19.35Tin Plates/Tin free plates 0.58 0.78 1.12 1.96Coated products from HRC Small 10% 15% 15%Yields assumedCRC to GP/GC

97% 97% 97% 97%

CRC to TP/TFP 98% 98% 98% 98%Equivalent CRC 16.76 22.9 35.42 64.52

Against this projection, the existing capacity of cold rolling is about 11 million tons in

bigger as well as smaller rerolling sectors. For coated product also the existing capacity

is about 5.0 million tons after considering galvanizing, galvalume, tinning and Colour

coating facilities. Color coating again is done after one thin coating of zinc or Galvalume

for better surface protection. From that point zinc coating tonnage includes Colour

coated tonnage also. The present capacity of colour coating lines is about a million ton.

A list of cold rollers and coating units in India is compiled recently, is enclosed in

Annexure-3.2.

3.5 From the above considerations it is proposed to have the following product mix for the

Phase-2 of AISL.

1. Coils as hot rolled: 2,500,000 tons per year for direct sale and further

processing.

2. Coils as cold rolled 1,000,000 tons per year from hot rolled coils for direct sale

and further processing to coated products.

The tentative annual product mix at full rated capacity will be:

(1) Hot rolled coils for sale: 990,000 t

(2) Hot rolled cut Plates/sheets: 485,000 t

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(4) Cold rolled coils and sheets: 567,000 t

(5) Galvanized coils and sheets (saleable): 180,000 t

(6) Colour coated coils and sheets: 190,000 t

-----------------

Total saleable steel products at Phase-2: 2,412,000 t

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CHAPTER-4.0: GENERAL LAYOUT AND TRANSPORTATION

4.1 Plant Location

4.1.1. The steel plant is proposed to be located on NH-63 near Koppal and about 26 km from

Hospet in Bellary district of Karnataka. The centre of the existing acquired area lies at

1500.r H and 760/0,73r ?, The land profile is undulating and contours vary from lower

value of 517.8 to 540.0 m. The area falls in the Survey of India topo sheet No. 57A/3

About 418 ha of land (approximately 1935 m x 2164 m have already been acquired by

the company for the purpose of the project, this is sufficient for phase-1 project of 1

million ton alloy and special steel plant. Another 257 ha land has been applied for and is

likely to be acquired in near future.

The location of the site in the topographical sheet is indicated in the Drawing AISL-DRG-

Location Map. The adjoining area and land use pattern at present is indicated in the

Drawing: AISL_MSPL_Land_ details. This drawing also shows the Record number of the

land plots already acquired and proposed to be acquired for the project under the

boundary of the different villages.

For accommodating phase -2 units completely, the process of acquiring additional land

is in progress. It is anticipated that a total 675 ha of land would be finally available for

meeting the entire need of the 3.5 million ton project. The requirement of land including

green belt for both the phases is shown in the table below:

Table 4.1: Computation of land requirement in blocks for the steel plant

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6# 35T5# Fpewx#Jyvregi#rs1#5# 653/<<4# #

7# 38T5# FSJ# {mxl# wigsrhev}# xviexqirx#

erh#gewxivw#

633/764# #

8# 39T5# Lsx#Wxvmt#qmpp# 573/787# #

9# 3;T5# Gsph#Vsppmrk#Gsqtpi|# 533/799# #

# # Wyf#Xsxep#eview#jsv#yrmxw#tperrih# 4/666/;65# #

# # Kviir#fipxw#erh#tevow#tperrih## <=</;9<18# Tpiewi# wii#

Erri|yvi#714#

# # Wtegi#tperrih#jsv#tperx#vsehw### =9/669# Ew#Efszi#

# # Evie# jsv# gsrzi}svw# erh# mrxivrep#

vemp#xvego#

574/496# #

# # Wyf#Xsxep#evie#riihih#jyvxliv### 5/89=/===16# Sv#58;#Li#

# # Evie#viuymvih#jsv#Tlewi04#erh#5# # 9;8#Li1#

Note:

(1) The area requirements of individual units include the internal roads of the units and

service facilities like administrative office, canteens, stores, unit repair facilities etc.

(2) The layout of the current available area and the additional area applied for are taken from

the details of the drawing available from M/S MSPL and enclosed with this report.

4.1.2 The other location details of the site are given below:

(1) Meteorological details

Maximum temperature: 41.50 C

Minimum temperature: 9.50 C

Maximum and minimum humidity:

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Elevation of the site (Average) 522 m:

Rain fall pattern: 538.3 mm (Average)

Barometric pressure:

(2) Distances

Distance from state capital (Bangaluru): 353 Km

Distance from nearest railway station for goods movement: 5 km (Ginigera)

Distance from nearest major railway station/city (Hospet): 25 Km

Distance from port (Vasco- Goa): 344 Km (Road); 334 Km (Rail)

Distance from nearest airports: (Bangaluru): 370 Km

(Hyderabad):408 km

Distances from minor airport/strips: Hubli: 160 Km; Bellary: 70 Km; JSW: 45

Km; Baldota Group: 10 Km

The steel plant has been broadly planned on a single grade level Viz. 522 m. However,

locating units at different levels also may be considered during detailing. The details of

the layout are given in the drawing No. ENV/AISL/FR/GL/001 (R-2) enclosed.

4.2.01 Proposed units

The following units along with material conveying systems and other auxiliaries are

proposed for the steel plant in two phases.

Phase-1 Phase-2Raw Material storage yard for phase -1facilities

Raw Material storage yard for phase -2facilities

Coke oven department with coal yard ptwo batteries (Battery-1 and 2)

Coke oven department with coal yard ptwo batteries (Battery-3 and 4)

Sinter Plant-1 : 144m2 Sinter Plant -2 : 360 m2- Ore Beneficiation and Pellet Plant p 1.2

million ton of pellets.Blast Furnace- 1680 m2 Blast Furnace-3814 m2Steel melting shop -1 : 2 x 50 t EOF withsecondary treatment and Bloom andBillet casting

Steel melting shop-2 : 2 x 150 t BOF withsecondary treatment and slab casters

Billet and Bar mill Hot strip mill 2.5 million tons

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Round and wire rod mills Cold rolling mill 1 million ton HRC input.Coil coating lines p Zinc/Zn-Al and Colourcoating.

Coke oven and Blast furnace gas storagevessel in Phase-1

Coke oven and Blast furnace gas storagevessels in Phase-2

Furnace oil storageAuxiliary FacilitiesRaw water reservoir and water supplyfacilities

Expansion of water supply facilities

Electrical substation Expansion of electrical sub stationCompressed air station Expansion of compressed air stationOxygen Plant No. 1 Oxygen Plant No. 2Lime Plant No. 1 (BOO) outside Lime Plant No. 2 (BOO) outsideDolomite calcining Kiln (BOO) outsideCaptive Power Plant No. 1 -1 x 70 MW Captive Power Plant -2 : 2 x 100 MWIron ore fine beneficiation facility Capacity to increase with addition of

equipment.

The proposed general lay out of the steel plant for both the phases is developed keeping

the Phase-1 facilities within the already acquired site. Some of the phase-2 units also

have been located within the present acquired site. Additional area would be required for

accommodating phase-2 and meet the provision of maintaining a minimum 30% green

belt around the facilities. The additional area has been indicated in the general lay out

drawing. The scope of expansion to the east of the present acquired site will be difficult

YjZ id egZhZcXZ di]Zgrh [VXâî^Zh* id i]Z cdgi] i]Z HVi^dcVa ]^\]lVn VcY i]Z gVâ igVX` ^h

the limiting factor. The additional land beyond what had been already applied towards

the east needs to be from south mainly to maintain greenery. The proposed general lay

out has been developed keeping in view

' Movement of materials

' Ground profile

' Wind direction

' Minimum length of the service line

' Optimum utilization of space

' Connectivity to the external logical facilities available in the region Viz. railway line

and road link.

' Green belt barrier all around the plant site.

Considering the prominent wind direction is from North West towards South East

direction, the raw material handling and storage facilities have been located on the North

east side south of the water reservoir to avoid dusty wind entering the main plant area at

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stage-1, the storage pond and the oxygen plant. The hot strip mill and the cold rolling

mills at phase-2 and the finished bar dispatch and storage is also away from the

direction of wind.

The major technological units like coke oven batteries, sinter plant and blast furnaces

are closer and connected with the railway yard for ease of incoming material handling.

The finishing mills are all concentrated to the west and connected with the finished

product dispatch storage and yards. The technological units have been located as per

process flow in each area minimizing inter-shop movement. The coke oven batteries are

clubbed together which will make use of common facilities like dry quenching. The

storage of products such as rolled steel, pig iron, granulated slag, coke oven by products

are connected to the railway yard by a network of railway line.

The company has acquired land to the other side of the national high way and it needs

to be clarified if this area can be included in the plant area. This area has the possibility

of separate development as a truck yard for dispatch of saleable products by road. This

facility will be critical at stage-2 for movement of hot rolled and cold rolled coils.

However, this report has not dealt with this aspect.

The main Electrical switch yard is located on the southeastern side of the plant along

with the existing electrical yard for the existing pellet plant. The captive power plant

catering both for Stage-1and 2 is also located adjoining to this unit. This site of the

switch yard facilitates entry of power line from the southern side of the site.

The main water storage reservoir has also been located on the North eastern side of the

plant extending to western side keeping in view of the incoming water pipe lines from the

source of water from the upstream of Tungabhadra dam. A much larger water storage

facility however will be needed to keep the plant going during dry months of the year

since water pumping from the Tungabhadra dam will be allowed only during part of the

year (184 days after July 15). The Company intends to adopt public water body/bodies

for storing water during dry season.

The storage of finished products for stage-1 and 2 has been located on the North West

side of the plant to facilitate dispatch of products by Railway wagons.

4.2.2 Railway yards

Adjacent to the raw material storage yard, raw material railway yard has been planned.

This 2 km long yard is planned on side of units in between the major phase-1 and

phase-2 facilities consuming bulk raw materials. Initially, it will cater to phase-1 and then

would be extended to cater to phase-2. A rail mobile weigh bridge and Railway yard

office has been located between the two yards to control the movement of the incoming

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and outgoing wagons. One loco repair shop has been envisaged for the railway yard.

The railway yard will be connected to the Ginigera railway station. The Ginigera station

is connected to Hoobly en route to Goa port. At present doubling of the Ginigera-Hubly

line is on which would greatly facilitate up and down rail movement of raw material and

finished goods from Goa port.

A road fly over on NH 63 has been considered for NH-63 to facilitate the crossing of the

plant railway line connecting to the Ginigera Railway station. A road passing along with

the siding will facilitate movement of goods to the envisaged truck terminal on the north

of the NH-63 between the railway lines.

Construction of the road fly over on NH 63 would require the involvement of NHAI and

the state PWD agencies. It is understood that company has already taken it up with the

respective authority.

4.2.3 Roads

7.0 m wide (2 lane) road with side shoulders of 2 m width and underground drain is

mainly proposed around the main plant units and for the raw material storage yard.

2 x 7 m (Four lane) road with drains and shoulders of 2 m as above and raised median

strip of 1.5 m wide and space of planting trees is proposed from NH to inside the plant.

Some minor roads will be single lane with side shoulders. .

The paved areas /hard standing have been planned for storage areas and approaches

to the individual shops/units.

4.3 Transportation

Most of the raw materials including imported coal will be received at plant site in railway

wagons. Similarly it is envisaged that the outgoing finished products will also be

transported in railway wagons. However, facilities have been envisaged to set up a truck

terminal on the north site of the plant on the other side of the road and rail track to

facilitate road dispatch also. The exact proportion of road dispatch will depend on

conditions in future but facilities to cater 100% rail dispatch as well as 40% road dispatch

has been planned to maintain flexibility.

4.3.1 External Rail transport

The plant will be served by Ginigera railway station which lies on the Bellary Hoobly line.

Indian Railways will handle the incoming and outgoing trains up id i]Z eaVcirh ldg`

station within the plant boundary which will also serve as exchange yard. However when

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tipplers are available, the railway loco will bring the raw material trains directly to the raw

material yard for tippling and unloading. The heavy rail traffic starting from Phase-1 will

need increase in the no. of tracks in the siding of the Ginigera Railway station which will

call for actions from Indian Railways.

After receipt of incoming loaded trains, full or part trains will be sent to various unloading

ed^cih Wn eaVcirh dlc adXdbdi^kZh, ;[iZg jcadVY^c\, the empty trains will be brought back

to the works station. Empty wagons will be sent to respective loading points viz. rolling

mill yards, finished product storage yard, pig iron storage, by-product plant and

granulated slag storage. Finished product trains will be formed at the works station and

would be handed over to Indian railways.

The total external railway freight at phase-1 will be approximately 6.132 million tons

including 4.618 million tons of incoming and 1.514 million tons of outgoing freight. After

completion of both phase-1 and 2 the total external transport will be 18.514 million

including 13.8 million tons of receipt and 4.755 million tons of dispatch. The non coking

coal for captive power plants is included in these figures. It may be noted that in this

projection the entire outgoing movement of saleable products have been shown as rail

dispatch. However a part may also go by road. It is also possible to receive some of raw

materials by road also. The transport requirement is shown in Table 4.2 assuming that

all external movement of incoming and outgoing bulk materials will be by rail, the

average daily rake movement requirement has been projected in Annexure-4.2.

Table 4.2: External transport by rail

Gross weight including 5% moisture and 5% handling losses Oc^i8 q...i

Wp# Qexivmep# Jvsq# Xs# Tlewi04## Tlewi05## Tlewi#4.5#

E# Vigimtx# # # # # #

4# Mvsr#svi#Pyqt# Lswtix# Tperx## 838198# 447;1=5# 498618;#

5# Mvsr#Svi#jmriw## Lswtix# Tperx## 475815;# 6585143# 79;;16;#

6# Ve{#Pmqi#wxsri## Fekeposx2mqtsvxih# Tperx## 4=<14=# 77<1=8# 97;147#

7# Ve{#Hspsqmxi# Fekeposx2mqtsvxih# Tperx## 564185# 8591<;# ;8<173#

8# Qerkeriwi#svi## Glmxvehyvk/#Werhyv# Tperx# ;1;<# 4;199# 58177#

9# Uyevx~mxi# Psgep# Tperx# 6414# ;139# 6<149#

9# Gsomrk#gsep## Mqtsvxih#xlvsykl#

Qerkepsvi2Kse#

Tperx## 4849138# 4947139# 655<145#-#

;# Gsep#jsv#mrnigxmsr## Mqtsvxih#xlvsykl#

Qerkepsvi2Kse#

Tperx## 4=717<# 774185# 969#

<# Wxieq#gsep## Wmrkevirm2Mqtsvxih## Tperx## 6=;1<8# 44681;;# 4866195#

=# Qmwg1# Syxwmhi## Tperx# 443158# 6631;8# 774133#

#


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# Xsxep#vigimtx## # # 794<146# <=5519;# 468731<3#

# # # # # # #

F# Hiwtexgl## # # # # #

4# Vsppih#Tvshygxw## Tperx## Syxwmhi# <83133# 574=133# 659=133#

5# Tmk#Mvsr# Tperx## Syxwmhi## 635153# # 635135#

6# Kverypexih#Wpek# Tperx# Syx#wmhi# 69515# <55163# 44<7183#

# Xsxep#hmwtexgl## # # 4847173# 6574163# 7;881;3#

# Xsxep#i|xivrep#vemp#

jvimklx#xyvr#sziv##

# # 9465186# 454961=;# 4<5=9183#

* The coal throughput of battery 1 & 2 in phase 1&2 will be more than in Phase-1 due to

increased requirement of coke in the blast furnaces.

4.3.2 External Road movement

Several materials both incoming and outgoing coming from near sources/destination will

be moved through roads. The road movement is complementary to many material

movements. The projection is given below:

Table 4.3: External road movements HXT^3 c))) ^

Sl Material From To Phase-1 Phase-2 Phase1+2

A Receipt1 DRI/Sponge iron Outside SMS yards 185 243 4282 Burnt Lime BOO Plant

outsidePlant /SMS 111.9 150 261.9

3 Burnt dolomite BOO Plantoutside

Plant /SMS 25 66 91

4 Ferro alloys Local plant Plant/SMS 10 27 375 Refractory Local plants Plant 6 15 216 Bentonite Local plants Plant7 Fuel oil Hospet Plant 1.07 15.097 16.28 By p Products /CRM

acids and chemicalsMany suppliers By-products

/CRM11.97 11.97 24

9 Maintenance sparesincluding rolls

Many sources Plant 2 5 7

10 Misc. Many sources Plant 1 2.5 3.5Total receipt by road 353.94 535.67 890.61Despatch

1 SMS slag Slag recoveryPlant

Outside 135 291.6 426.6

2 Coke Oven byproducts

Coke oven by-product Plant

outside 110.7 116.96 292.4

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3 Muck/waste/rubbish Plant wastedump

Outside 10 25 35

Total dispatch byroad

255.7 433.56 689.26

Total external roadtransport

609.64 969.120 1578.760

4.3.3 Internal rail and road transport

The internal transportation of in process materials are partly by inter-unit conveyors and

some by road. Hot metal will be transported by Rail in special ladle cars or torpedo

ladles. The other materials will be transported in dumpers/trucks. The broad projection of

this movement is given below.

Table 4.4: Internal material movement by rail/road

Wp# Qexivmep# Jvsq# Xs# Tlewi04## Tlewi05## Tlewi#

4.5#

E# Vemp#qsziqirx## # # # # #

# Lsx#qixep# Fpewx#jyvregi## Wxiip#qipxmrk#

wlstw2Tmk#gewxmrk#

qeglmri##

448517<# 5936188# 6;89136#

F# Vseh#qsziqirx## # # # # #

4# Qsziqirx#sj#wpef## Gewxiv#

hitevxqirx#sj#

FSJ#wlst##

Wpef#}evh#sj#LWQ# 0# 58=513# 58=513#

5# Wepiefpi#tvshygxw## Qmpp#}evhw# Jmrmwlih#ksshw#

wxsgo#jsv#hmwtexgl#

843# 478417# 4=9417#

6# Wgvet#qsziqirx## GG#}evh2Qmpp#

}evhw##

Wxiip#qipxmrk#

wgvet#}evhw#

4<8# 4=7# 5;=#

7# Mrxivrep#qsziqirx#

sj#WQW#wpek#

WQW## Wpek#vigsziv}#

yrmxw##

483# 657# 7;7#

8# Qsziqirx#sj#qygo#

xs#hyqt#

Zevmsyw#yrmxw## Xiqtsvev}#hyqt# 43# 58# 68#

It may be noted that due to constraints of layout, the cold rolling mill complex is away

from the hot strip mill hence the necessity of movement of internal hot rolled coils by

road for processing. Again it is only envisaged that about 40% of the saleable product

dispatch can be directly loaded to Railway wagons at the rolling dispatch bays. Rest of

the product will have to be transported to the finished goods yard for rake formation.

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4.3.4 Transportation equipment

The internal rail movement of the plant l^aa WZ YdcZ l^i] eaVcirh dlc adXdbdi^kZh, N]Z

internal road movement by trucks and dumpers will be out sourced. However a small

road transport fleet will be maintained for emergency. The plant will have organization

for maintaining the rail tracks and the road repair will be out sourced. The major railway

and road transport facilities envisaged for the plant are given in the table below:

Table 4.5: Railway transport facilities

Wp1# Iuymtqirx## Rs1#mr#

Tlewi04#

Rs1#mr#

Tlewi05#

Xsxep# Viqevow##

4# ;33#LT#Hmiwip#Psgs# 5# 5# 7# #

5# Mrxivrep#{eksrw#

FS\2FS\R#8<#xsrw#

# 73# 73# #

6# Vemp#{imkl#fvmhki#433#x#

getegmx}#

4# # # Qsfmpi#

{imklmrk#

{lir#qszmrk1##

Table 4.6: Road transport facilities

Wp1# Iuymtqirx# Rs1#mr#Tlewi0

4#

Rs1#mr#

Tlewi05#

Xsxep# Viqevow#

4# ;#xsr#xvygow## 5# 5# 7# #

5# Xvegxsv#{mxl#xvempiv# 5# 5# 7# #

6# Hs~ivw2NGF# 5# 6# 8# 1##

7# Jsvopmjxw#42528x## 7# 9# 43# #

4.4 The summary of the Lay out

The breakup of the proposed land utilization of the site as given in the General lay out

drawing for phase-1 and 2 is detailed in Annexure 4.1. The summary is given in the

table below:

Table 4.7: Lay out indices

Wp1# Hiwgvmtxmsr# Yrmx# Uyerxmx}## # # Tlewi04# Tlewi4#erh#5#

41# Eview# Ligxeviw# 74<-# 9;8#

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# Tpsx#evie#gsrwmhivih# le# 74<# 9;8#

# Tperx#evie# # # #

# Wxiip#Tperx#mrgpyhmrk#GTT# le# 4<=16# 65519;#

# Tippix#tperx#+i|mwxmrk,# le# 4813# 4813#

# Kviir#fipx## le# 45=14;# 54=138#

# [exiv#tsrh#evie## le# 4317# 5619#

# Evie#ievqevoih#jsv#vseh# le# 5=133# 6<196#

# Evie#ievqevoih#jsv#vemp#xvego#

erh#gsrzi}svw#

le# 641=# 89135#

# Xsxep#Fympx#yt#evie#viuymvih# le# 58915# 765165#

# Fympx0yt#evie# (# 96177# 97137#

5# Vsehw# # # #

# Hyep#+7#peri#gevvmeki,# Oq# 6198=# 6198=#

# 5#peri#vseh# Oq# 4;13# 57178#

# Wmrkpi#peri#vseh# Oq# 717# 9189;#

6# Vemp{e}# Oq# 48# 4=16#

Note:

(1) The built up area includes the unit areas, the interplant roads, areas required for

internal rail track and conveyor galleries. The existing pellet plant is also included.

(2) The length of rail tracks is for inter-unit rail track and the track to be laid in the

common yards. The rail tracks to be laid within the boundary limits of the

individual units though tentatively shown in the general lay out drawing have not

been estimated since those are part of detailed engineering.

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Chapter 5: Raw Material Handling and Storage Facilities.

5.1 The proposed raw material handling plant located south of the water reservoir will be

used in both phase-1 and phase-2. It will cover receipt, unloading, storage and supply of

various raw materials to all the units. In order to meet the raw material requirement for

the proposed steel plant, the raw material handling facilities shall be planned to cater to

the present requirement of the 1 million ton stage and will be so conceived to enable

scaling of facilities to cater to the requirement of the 2.5 million stage of phase-2.

5.2 Raw material receipt, storage and reclamation.

The overall layout of the RMHS and the associated junction houses are shown in the

general layout drawing No: ENV/AISL/FR/GL/001(R-2). The raw materials of the various

units will be received by railway wagons or by trucks. For unloading of raw materials two

number of wagon tipplers are envisaged at the wagon tippler complex. The wagons are

unloaded by the wagon tipplers to dump hoppers from where it is two number of apron

feeders and fed to the belt conveyors for stacking in the beds. The receipt of materials

for the second stage also will be through this route with additional conveyors. The

provision for a third tippler on the expansion line will be kept. The wagon tipplers will

simultaneously unload two similar or dissimilar materials.

Two numbers of boom type stacker cum re-claimer are envisaged at phase -1. One will

be basically for ore and the other for coal and lime stone/dolomite. At phase-2, all the

beds will be expanded and would utilize the available area. A second set of two stacker

cum re-claimers will be installed to meet the increased material handling load. Shovels

also will be used at phase-2 for reclaiming lime stone and dolomite. The tentative

capacity envisaged for each of the stacker cum re-claimer will be:

For iron ore and lime stone: stacking 1100 tph and reclaiming 800 tph

For coal: stacking: 900 tph and reclaiming 500 tph.

Table 5.1: Storage capacity envisaged for various raw materials

Sl Material Consumption/daytons

No. of days stock Total storagetons

Bed utilized

Phase-1 Phase-1&2

Phase-1

Phase-1&2

Phase-1 Phase-1&2

Phase-1 Phase-1&2

1 CDI coal 533 1,742 15 7 7,995 12,194 One part One full2 Steam coal 1,090 4,201 15 7 1,6350 29,408 One full Two full3 Ore fines 3,905 15,509* 15 15 58,575 232,643 One part Two full

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4 Ore Lump 1,385 4,530 10 10 13,850 45,300 One part One full5 Lime stone 543 1,809 10 10 5,430 18,090 One part One full6 Dolomite 634 485.3 10 10 6,430 4,853 One part One full7 Manganese

ore21.3 63.6 10 10 213 636 One part One full

8 Quartzite 85 105 10 10 850 1050 One part One full9 DRI/HBI 506 665 10 10 5,060 6,665 Covered

#Covered

' Includes the fine input to the fine ore beneficiation plant at phase-2. For details

please see chapter 7A

# This storage can be alternatively at the respective steel melting shops where the

DRI/HBI will be delivered by road.

It may be noted that except ore fines the storage envisaged at stage-2 is for 10 days.

For ore fines it is 15 days. For coal it is for 7 days. Some additional storage capacity will

be provided in the CDI installation and in the CPP.

In the plant railway yard provision has been given in the lay out for a set of track hoppers

to cope up with additional unloading requirement at phase-2. If necessary the space can

be utilized to install a third set of wagon tippler at the stage of phase-2 detailing.

5.3 The material handling equipment envisaged at the two phases of the plant is given in the

table below:

Table 5.2: Material handling equipment

Sl. No. Description Phase-1 Phase-21 Wagon tippler 2 Nos. -2 Side arm charger 2 Nos. -3 Apron feeder 2 Nos. -4 Wheel on boom stacker cum re-claimer

(1100 tph)2 Nos. 2 Nos.

5 Diesel operated front end loader 3.5 m3bucket

2 Nos 2 Nos.

6 Diverter gate 1 lot 1 lot7 Metal detectors8 Magnetic separator9 EOT Crane (25/5 t ) in wagon tippler building 1 No -

10 Conveyor system 1 Lot Expanded system11 Fixed ground hoppers 4 Nos -12 Track hopper system with gates and

conveyors (at detailing stage)- One lot

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13 Electric hoists 1 lot 1 lot14 Dust suppression/extraction systems at

wagon tippler house, conveyor junctionhouses and from conveyor galleries.

1 lot 1 lot

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Chapter 6: Coke Oven Battery and By-Product Recovery Plant

6.1 Top charging by-product recovery type Coke Oven Batteries have been envisaged for

both the phases of the steel plant for supply of coke for the blast furnaces. 2 nos. of 5 m

tall batteries at phase-1 and 2 nos. of same size batteries have been envisaged at

phase-2 for uniformity of design & operation and battery machines. The batteries will be

by-product recovery type, twin flue under-jet, regenerative design with fire clay and silica

construction. Dry Quenching of coke with an emergency provision of wet quenching will

be provided for each battery pair at each phase. The table below gives the main

technological indices of the Coke Oven batteries at each phase.

Table-6.1.1: Coke Oven Batteries U Main technological indices

Sl.No.

Parameter Phase-1 Phase-2 Remarks

1 By-Product type Batterysize

2 x 69 oven n 5 mtall battery-Battery Nos. 1 & 2

2 x 69 oven n 5 mtall battery-Battery Nos. 3 & 4

2 Battery dimensions(Typical)

15.04 m x 0.410 mx 5 m

As in Phase-1

3 Oven useful dimensions 14.3 m x 0.410(0.39/0.43)m x 4.7m

As in Phase-1

4 Useful Chamber volume 27.3 m3 27.3 m35 Coking time 18 hrs 16.9 hrs In phase -2 all

the four batterieswill operate at16.9 h cokingperiod.

6 No. of pushing per day 92 987 Dry Coal throughput per

day/Battery1883.7 t 2000.6 t No. pushing per

day x usefulchamber volumex 0.75

8 Dry Coal throughput peryear/Battery

687550 732391 365 days working

9 Gross coke yield fromimported coking coalblend

72.4% 72.7%

10 Gross coke per year/battery

497787 532448

11 BF coke (+25 mm) yieldfrom coal input

63.8% 63.8%

12 BF Coke per year 438657 467265

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/battery13 Skip/belt coke (+40 mm)

after screening atBF/year/battery

394791 420589 With twobatteries there issurplus skip cokefor BF-1 atPhase-1. But atphase-2 the skipcoke is balanced.

14 Heat Consumption atbattery

540Kcal/kg of coalwith throughputwith 8% moistureusing coke ovengas for firing and570 Kcal/Kg withmixed gas firing.

Same as phase-1 CV of coke Ovengas n4200Kcal/Nm3CV of mixed gas1000 Kcal/Nm3.

15 Coke gas yield 320Nm3/t of drycoal charge

320Nm3/t of drycoal charge

Typical valuevaries withVolatile matter ofcoal.

16 Gross Coal required forCoke Oven batteries

1516050 3228120 With 5% moistureand 5% handlingloss.

17 Blast Furnace cokeoutput from the batteries

877314 1869060

18 Coke Oven gas requiredfor Battery heating (Cokegas CV- 4200 Kcal/Nm3)

185.17 x 10 6

Nm3/year394.29 x 10 6

Nm3/year

19 Mixed gas requirementfor battery heating (Mixedgas CV-1000 Kcal/Nm3)

820.94 x 10 6

Nm3/year1748.27 x 10 6

Nm3/year

20 Requirement of utilitiesSteam (LP) 16 t /Hr 30 t/HrCompressed air Small SmallPower Kwh/t of BF Coke 8.6 8.5

With two Battery operations, there will be some surplus coke from the Coke Oven

department after meeting the requirement of Blast furnace. However, at phase-2, the

production of blast furnace coke and requirement will match.

6.2 Coal input quality and coke quality:

Due to absolute scarcity of coking coal in India and the concentration of coking coals

only around Dhanbad area in the east, the coke oven batteries will use blended imported

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coals from Australia, New Zealand, Ukraine, USA/Canada etc. The coal to be used

would be a blend between prime hard coking coals and some % of soft coking coals for

overall economy of the operation without affecting the minimum desired coke

parameters.

This report envisages the following quality of blended coking coal:

Moisture: 8% max.

Ash: 10-14%

Sulphur: 0.58 max

Volatile matter: 23-24%

Crushing index: (-) 3.2 mm n 81-82%

(-) 0.6 mm n 50% appox.

FSI: 3.5 to 4.5

LTGK: F to G

Fluidity: 300-400 ddpm

Reflectance: (MMR): 1.12 minimum

Coke Quality envisaged:

Coke ash: 16-18%

M10: 8.5 max

M40: 80 min

CSR: 65 min

CRI: 21max.

6.3 Description of Coke Oven battery

All the four 5 m tall batteries envisaged for the project at phase-1 and 2 will have similar

type of batteries for the purpose of standardization and ease of operation. The Coke

Oven batteries will be by-product type, twin flue, under jet, regenerative design with

fireclay and silica construction. The basic features of the proposed batteries are given

below;

6.3.1 Oven brick work: From the concrete raft supporting the ovens, brick work of the bus flue

and first few courses of regenerator walls will be of first quality fire clay bricks. The brick

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work of the rest of the regenerator walls, inclined flues up to the oven sole level, heating

walls and the first three courses of the oven roof zone will be of high quality silica bricks.

6.3.2 Battery anchorage system: The battery anchorage system will consist of buck stays, tie

rods, springs, bracings and heat resistant casting such as flash plates, door frames,

oven doors etc. The oven castings will be of heat resistant quality together with

mechanical strength. The buck stays will be of welded box section construction and

provided with heat shield. Buck stays will apply uniform and controlled loads on the

brickwork through flash plates loaded by springs. Two transverse tie rods for each buck

stay will be provided at the oven top and springs will be provided at both coke and

pusher sides. The flash plates will cover the entire width of heating wall ends. Door

frames will sit on flash plates and will be fitted to the flash plates with T bolts. The oven

doors will be provided with spring latch mechanism and will be of self sealing type (zero

leak type)

6.3.3 Gas take off & charging system: There will be two gas take offs from each oven to the

two gas collecting mains- pusher side and coke side. The take off system will comprise

of ascension pipes, goosenecks, isolation valves, necessary flushing liquor spraying and

High pressure ammonia liquor aspiration (HPLA) devices. Each oven will have three

charging holes with heat resistant cast iron charging hole frames and lids.

6.3.4 Under-firing System: The battery will have facilities to be heated with coke oven gas as

well as mixed gas. Each heat wall will have 14 pairs of hairpin flues. The gas will burn at

the base of one half of each pair of flues and the products of combustion will travel up

and pass on to the other half of the flues through cross over duct. The regenerators are

placed under the heating walls and oven chambers. The coke oven gas will be

preheated in a pre-heater before under firing. With coke oven gas firing, half of the

regenerators will operate on air and the other half will operate on waste gas during a

cycle. The battery will be provided with combined waste gas and air valves at the coke

side. Flow of gas, air and waste gas will be reversed every 30 minutes and will be

achieved by means of hydraulic reversing mechanism.

The supply of coke oven gas will be provided through gas mains laid in cellar floor of the

battery. The gas will be pre-heated in a steam heater before the distribution head.

6.3.5 Coal Tower: One coal tower of RCC construction with a useful capacity of about 2500

tons will be provided. The coT_ gbjXe f[bh_W UX VTcTU_X bY `XXg\aZ Tg _XTfg baX WTlof

requirement of coal for each battery. At the bottom of coal tower, 8 rows of outlet will be

provided; each row will have 3 outlets along the transverse axis. At the outlet, necessary

mouthpiece and sector gates will be provided. These gates will be operated through the

coal charging car mechanism. Pneumatic blow down arrangement will be provided for

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easy flow of coal from the bunker into the coal charging car. One weigh bridge for

measuring coal weight will be provided. One passenger cum goods lift will be provided

for each coal tower.

6.3.6 High Pressure Ammonia Liquor Aspiration system (HPLA): To control charging

emissions from the coke oven battery, water sealed ascension pipe covers and High

Pressure Ammonia Liquor Aspiration system will be provided. It consists of high

pressure booster pumps for ammonia liquor, spray nozzles and pipe lines. The low

pressure ammonical liquor drawn from the liquor mains will be boosted to a pressure of

about 30 Kg/cm2 and injected into the gooseneck while charging. The charging gases

evolved will be sucked into the gas collection mains thus preventing emission of dust

and smoke into the atmosphere.

6.3.7 Spillage coke conveyor: The spillage Coke conveyor will be provided at each battery for

removal of hot coke spillage likely to fall during opening of the coke oven doors and

pushing of ovens on pusher side service platforms, The total system will consist of a

special chain conveyor fitted with drag plates running inside a lined trough on the service

platform.

The chain conveyor will discharge the material on a belt conveyor which will carry the

same to a structural storage hopper for disposal of spillages to a truck.

Proper water spraying system before the belt conveyor will be provided in the system to

take care of the temperature of coke to be transported on to the belt conveyor.

6.3.8 Computerized Combustion Control System (CCCS): Computerized combustion control

system aims at carbonizing the coal charge to a constant final temperature while

supplying optimum heat to the ovens. It would not only save energy and labour but

would reduce the variation of net coking time and would improve coke quality. Important

parameters of the battery will be monitored by instruments and other variables will be

manually entered into the system. The computer will calculate the heat input at a given

set of questions. Certain outputs like gas flow, chimney draft are controlled automatically

from the set point received from computer. Others will be adjusted manually as per

computer output. The model will have to procure from proprietary sources. A saving of

heat consumption to the extent of 3-6% is achieved with CCCS over an entirely manual

system.

6.3.9 Oven machines;

Each phase with a pair of batteries will have the following coke oven machines:

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Table-6.2: List of oven machines at each phase of the project

Coke pushing machine Nos. 3Coal charging cars Nos. 3Coke guide car with hood over the coke quenchingcar

Nos. 3

Quenching car Nos. 1Coke dry quenching cars Nos. 2Electric loco Nos. 3

All machines will be designed with electro-mechanical/hydraulic devices for auxiliary

operations like door opening, door frame cleaning, gooseneck cleaning etc. The

machines will be single spot type and would have features to minimize pollution. In

particular the coke guide cars would have hoods connected to a dust collecting duct to

suck the pushing emissions and cleaning of the sucked air through bag filters installed in

separate building. This would be common for a pair of batteries.

6.3.10 High pressure water jet cleaner: One set of hydro jet cleaner consisting of cleaning

station (one on pushing side and one on coke side at each battery) will be provided with

a recommended operating pressure of 600 bars. Designed to clean the doors, the doors

are held on the door extractor of the coke pusher and coke guide cars respectively. The

cleaning unit will be built at the side of the platform and fixed to those like door racks. A

common high pressure water power pack, electrical control of the door cleaner shall be

provided. The cleaner unit will be built into a heavy steel structure, supported and bolted

to the interconnecting platform frame work.

6.3.11 Quenching arrangement: Due to environmental regulation for building new coke oven

batteries, it is now necessary to provide for Coke dry quenching (CDQ) for the coke

oven batteries of the steel plant. However, a conventional quenching station will also be

provided at each coke oven battery to take care of periods of down time of the CDQ. It is

proposed to install CDQ for Battery Nos. 1 and 2 at Phase-1 towards battery 3 and CDQ

for battery 3 and 4 after battery 4 at phase-2.

6.3.11.1 Traditionally, wet quenching process is being adopted for the cooling of Coke produced

from the Coke Oven Battery in Steel Plants. Water is used as cooling media to cool the

hot coke which not only consumes large volume of water but also releases harmful

pollutants which is also not permitted by the government as per latest regulations. Also

the hot gas generated from the quenching process is released to atmosphere without

any commercial use.

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Coke Dry Cooling Plant is a clean technology that uses Nitrogen gas instead of water

in an enclosed system to cool the hot coke. The hot gas is recycled to generate steam

which can either be taken to the plant steam grid or used to generate power in a turbine

generator set.

Typical technical parameters of a CDQ installation are given in the table below:

Table 6.3: Typical technical parameters of a Coke Dry Quenching system

Description Unit Value

Temperature of Coke charged in the chamber Degree Centigrade 1050

Temperature of Coke after cooling Degree Centigrade < 200

Temperature of circulating gas before entering cooling chamber Degree Centigrade 160-180

Temperature of circulating gas before waste heat boiler Degree Centigrade 750-800

Thermal efficiency % 80-85

Pressure of steam generated Atm. 66

Temperature of steam generated Degree Centigrade 500

Generation of Steam/Boiler t/h 25

Time of coke cooling in chamber H 2-2.5

Expected total steam generated from each phase t/Hr 45-50

To start with, the CDQ steam is expected to be used as low pressure process steam

through PRDU units and connected to the plant medium pressure steam net work. At

phase-2 when substantial quantity of waste heat steam will be available, installation of a

turbine to generate power can be considered. A space provision of 70 m x 100 m has

been kept at the ends of the coke oven battery complexes to be installed at both phases.

6.3.11.2 Wet quenching system: Traditional wet quenching system will also be provided at the

Coke oven department with one station per 2 sets of batteries. The quenching tower will

be of RCC construction with acid resistant brick lining and arrangement of water spray

system. Grit arresters along with vapour spray system will be provided in the quenching

tower to contain the quenching emissions.

For wet quenching, with each station a suitable breeze pond with quenching pump

house shall be provided. Two quenching pumps (one working and one standby) will be

provided. Grab crane will be provided to remove coke breeze from the ponds. This wet

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quenching will be operative during the scheduled annual shut down of the steam

generators of the Dry Quenching units and also during unscheduled or scheduled shut

downs in the main CDQ units or the steam generators. Since a coke oven battery works

round the clock all around the year this provision is necessary for the safety of the

batteries. The schematic representation of a Coke dry quenching process is indicated at

Fig.6.1 inserted at the end of the chapter.

6.3.12 Auxiliary facilities

Each Coke oven battery will have service bench on both sides. One intermediate bench

and two end benches will be provided which will have maintenance facilities like fixed

door racks, ram beam charging station, door repair station etc. manual/electric hoists at

the coal tower and at end benches are also provided.

6.4 By Products Plant

6.4.1 Each battery will have a dedicated by-product plant to process coke oven gas 25,500

Nm3/Hr. With a view to keep the capital cost of the project low and techno-economic

viability, the by- product plant will be designed for recovery of only essential by-products

like ammonia and crude tar. In addition to that naphthalene scrubbing unit will be

installed at each by-product plant to remove naphthalene from coke oven gas.

Naphthalene rich solar oil generated in the naphthalene scrubbing unit will be processed

outside for recovery of naphthalene. The regenerated solar oil will be re-used in the plant

with addition of fresh solar oil. By-Product plant also includes removal of H2S to produce

80% pure sulphur cakes.

6.4.2 Technological parameters

Table 6.4: Annual production of by-products

Sl.No.

Item Unit Phase-1 Phase-1&2

PerBattery

Total PerBattery

Total

1 Coke Oven gas Nm3/Hr 25,150 50,300 26778 107,1122 Ammonium

Sulphatet/yr 7,563 15,124 8055 32,220

3 Crude tar t/yr 21,314 42,628 22,774 91,0964 Sulphur Cake t/yr 820 1640 873 3492

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Table 6.5: Typical analysis of coke oven gas at various stages

Sl. Item Unit ValueA Raw Coke Oven gas

1 Tar Gm/Nm3 100-120

2 Benzol Hydro carbons Gm/Nm3 30-36

3 Hydrogen sulphide Gm/Nm3 3-44 Napthalene Gm/Nm3 8-105 Ammonia Gm/Nm3 10-12B Quality of clean coke oven gas1 Hydrogen % 52-592 Carbon monoxide % 6-73 Carbon di-oxide % 3-44 Oxygen % 0.3 -0.65 Methane % 24-286 Nitrogen % 4-77 CnHm % 1.5-2.5C Residual impurities in gas1 Tar (g/Nm3) 0.052 Hydrogen sulphide (g/Nm3) 0.85 (max)3 Naphthalene (g/Nm3) 0.3 (max)4 Benzol hydrocarbons (g/Nm3) 30-325 Net calorific value Kcal/nm3 4200-4300

6.4.3 The principal units of the by-product plant with each coke oven battery:

' Primary Vertical gas coolers

' Tar decanters

' Coke Oven Gas Exhauster: Common for both batteries in each phase with electric

drive. Stand by with steam driven turbine exhauster. Same for battery 3 and 4 in

phase-2.

' H2S recovery unit

' Ammonium sulphate plant

' Final gas cooling and naphthalene scrubbing unit.

6.4.4 Requirements of chemicals in coke oven battery units

The table below gives the requirement of chemicals for the By-products plant

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Table 6.6: Requirement of Chemicals in the By-product plant (unit: t/year)

Sl. No. Requirement ofchemicals

Battery 1&2 Battery 3 &4 Total Phase-1&2

1 Ammonium sulphate plant

- Sulphuric Acid (100%)- Caustic Soda (100%)

5680 x 2303 x 2

6042 x 2303 x 2

6042 x 4303 x4

2 Naphthalene scrubbing unit- Solar oil (make up) 290 x2 308.5 x2 308 x 4

3 Catalyst for H2S recoveryunit

12 12 24

6.4.5 Utility requirement

The requirement of various utilities are given in the table below

Table 6.7: Requirement of utilities at the by-product plant

Sl. No. Utilities Phase-1 forBattery 1 & 2

Phase-1 &2 Remarks

1 LP steam 8-10 tons/Hr 20 t/hr Excludesrequirement of CDQwhich is availablefrom the unit

2 MP steam 4 tons /hr 8 tons /Hr. Continuous.Remarks as above

3 Circulation uncontaminatedcooling water

2000 m3/Hr 4000 m3/Hr Continuous

4 Circulation contaminatedcooling water

400 m3/hr 800 m3/hr Continuous

5 Chilled water 400 m3/hr 800 m3/hr6 Make up water 160 m3/hr 320 m3/hr. Continuous7 Technical water 100 m3/Hr 200 m3/hr Intermittent8 Nitrogen9 Instrument air10 Compressed air11 Power

The layout of each of the two twin Coke oven complexes is given in the Drawing

ENVIRO/AISL/FR/6/1(R-1)

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Fig. 6.1: Schematic representation of a Coke Dry quenching system

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#534;#TIGW##epp#vmklxw#viwivzih#################### Teki#4#sj#=##

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Chapter 7: Sintering Plant and Auxiliaries

7.0 The Blast furnaces of the steel plant in both the phases will use about 77% of iron

bearing materials as iron ore sinter. The rest will be lump ore and acid pellets. The

pellets can be from the group pellet plant on conversion of the beneficiated tailing of the

fine washing plant or the pellets can be purchased from the market.

It is proposed to install one sinter plant at each phase to take care of the input

requirement of the blast furnace to be installed and the size/ capacity of the sinter plant

has been envisaged to match the blast furnace requirement.

Each of the two sinter plant complexes will consist of the following basic units:

' Fuel and Flux crushing system

' Flux screening building

' Proportioning section

' Mixing and nodulizing units

' Main sintering machine

' Sinter cooler

' Product screening section.

The raw materials to be used for making sinter will be

' Iron ore fines

' Lime stone crushed

' Dolomite crushed

' Coke breeze crushed

' Calcined lime/ lime dust

' Mill scale

' Flue dust

' BOF slag (at phase-2)

' Sinter fines (in plant sinter returns as well as return from Blast furnaces)

7.1 Technological parameters

The technological parameters of the sinter plants at both the phases are given in Table

below;

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Table 7.1: Technological Parameters of the Sinter Plants

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7.2 Specifications of the product and input raw materials

Table-7.2: Sintering, Specification envisaged of the product and the input materials

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Chapter-7A: Iron ore fine beneficiation Plant

7A.1 The basis of beneficiation

(1) It has been decided subsequent to preparation of the PFR for the project to skip the new

pellet plant of 1.2 million ton capacity in the final FR. The total lump ore/pellet

requirement of the plant after completion of both the phases at 3.5 million ton stage will

be about 1.5 million tons. The capacity of the pellet plant already installed in the project

site through a group company is 1.2 million ton per annum which can be increased

marginally also. In view of this, the entire lump ore required by the plant at both stages

can be more or less met through acid pellet input from this sister unit. However, the

quality of fines (in terms of Fe %) is generally poor in Karnataka. It will be imperative

therefore to use low grade fines at least partly as input iron ore for sintering process after

beneficiation. At the same time, the cost and space required to process the discards in

iron ore beneficiation unit (materials with less than 40% Fe) are constraints to increase

the capacity of beneficiation operation.

(2) As a compromise, it is envisaged that for the fine ore feed of the plant at both the phases

50% of the input fines will of grades lower than 60% which will be beneficiated and

blended with better grade fines (around 64% Fe) to obtain an average Fe% in the sinter

feed fine ore at 62.1% as envisaged in the chapter describing the sinter plants. .

(3) The annual fine ore requirements (net and dry) for the sinter plants at planned

production levels at rated capacity for both the phases are given below:

Phase-1: 1,292,760 t

Phase-2: 2,949,748 t

Total 4,242,508 t

It was also noted that the group operates two mines in the Hospet sector: Viom: High

grade deposit (Fe: +65%) output around 1.6 million tons per year and Iyli: a

comparatively poorer grade deposit (Fe- 56-60%) 0.5 million tons production per year.

But the present rule of selling iron ore in Karnataka through open auction, does not

guarantee the AISL plant to receive ore supply from captive group sources. Further, the

reserves in both the deposits are limited and cannot cater to the need of the plant for a

very long period. So even for phase-1 facilities, AISL plant will have to procure iron ore

from the neighborhood and include poorer ores also to keep the landed cost of ore at

economic levels.

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(4) It is therefore envisaged that the fines to be used would be a blend of direct use fines

and beneficiated low grade fines. A 50:50 ratio is envisaged. The reduction in the

beneficiated fines in the total ore fines will also reduce the extent of rejects. The rejects

(with Fe <40%) as per environmental requirement need to dewatered, relocated to

assigned dumps and treated for green cover.

(5) It is therefore envisaged to procure about 2.3 million ton fines with +64% Fe and 3.361

million ton fines of Fe% in the range of 55-56%. The lower grade ore to be beneficiated

to yield maximum of sinter grade fines (2.2 million tons) and a small quantity will be

further beneficiated through magnetic separation to yield pellet grade beneficiated fine

ore which can be converted to pellets at the pellet plant run by the group company. It

may be seen that the scheme proposed is flexible enough to beneficiate the Iyli ore to

sinter grade and pellet grade feeds if required.

7A.2 Process of beneficiation

It may be seen from above that the capacity of the beneficiation process after phase-1

and Phase-2 has been envisaged as 3.361 million ton of fine ore throughput. The input

will be Fine iron ore (-) 10 mm with Fe% ranging between 55-56%. This ore will be

primarily upgraded to sinter grade fines of about 60% Fe and a small quantity of the

tailings of the primary beneficiation process will be upgraded to +64% Fe pellet feed

concentrate in the secondary magnetic concentration plant with or without ball mill

grinding. It is envisaged that the both the beneficiation plants would operate 312.5 days

in a year and 24 hours a day giving 7500 operating hours in a year.

The beneficiation processes are described in the schematic flow sheets q

Enviro/AISL/FR/7A/01(R-1) sheets 1, 2 and 3.

The major steps of beneficiation of ore would include:

7A.2.1 Beneficiation to upgrade sinter fines

The process flow is given in Enviro/AISL/FR/7A/01(R-1) sheets 1. The major process

steps as envisaged are:

' Dry screening of the input ore fines to remove +10 mm fraction which would be sent

to lump ore yard.

' Scrubbing of the ore fines in rotary scrubbers

' Wet screening and dewatering of the scrubbed fines

' Spiral classification of the screen slurry to recover classified ore sand

' De-sliming of the spiral classifier over flow in batteries of hydro cyclones. The

underflow to be dewatered and collected as sinter fines.

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7A 2.1.1 The major parameters of this process step are given in the tables below:

Table 7A.1: Parameters of the Sinter fine beneficiation process

A. Inputs and Outputs (In terms of dry ore) after phase-1 and 2 facilities.

Item Annual tons Tons per hour % FeInput Ore(-)10 mm low gradeore

3361,000 448.1 56.5

Output ore+ 8 mm fraction tolump stock

336,000 44.8 56.5

Beneficiated fines 2,252,250 300.3 60.12Tailings for furtherbeneficiation

772,500 103 49.88

B. Yields envisaged

Item YieldMaterial yieldBeneficiated fines 67%Over size for lumps 10%Tailing for furtherprocessing

23%

Fe recovery inbeneficiated fines

79.23%

C Process water input required: 870 m3/Hr

Process water recovered: 573.3 m3/Hr

Make up water for process: 296.7 m3/Hr

Water for spillages and loss: 50 m3/Hr

Total make up water required for the plant = 346.7 m3/Hr or 350 m3/Hr.

Specific requirement of makeup water = 0.78 m3/t of throughput.

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7A.2.1.2 Major Equipment envisaged:

Table 7A.2: Major Equipment envisaged at the sinter fine beneficiation unit.

Sl.No.

Equipment Phase-1 Phase-2

1 Fine ore bunkers q 200 T capacity 1 No. 1No.2 Vibrating grate below iron ore bunker 1 No. 1No.3 Vibro- feeders 1 No. 1No.4 Conveyor belt system from below bunker to

dry screen1 No. 1 No.

5 Single deck dry screen for screening +8mm ore q 250 TPH

1 No. 1 No.

6 Over size return conveyor to stock 1 No. -7 Fine ore feeding conveyor system to

scrubbers1 No. 1 No.

8 Rotary ore scrubbing drums q 250 TPH;2100 mm dia x 4500 mm length; 25 rpm;.-- DL r.2-- hfc ib_f h_d] Zh_l[i

1 No. 1 No.

9 Wet screens q 250 TPH 1 No. 1 No.10 Chutes for over flow 1 No. 1 No.11 Dewatering screens 1 No. 1 No.12 Launders for flow of the slurry to the

classifiers1 set 1 set

13 Spiral classifiers q 1000 mm dia. 2 Nos 4 Nos.14 Conveyor for classifier sand 1 set 1 set15 Launders for classifier over flow 1 set 1 set16 De-sliming battery cyclone 1 set 1 set17 Low speed spiral classifier for cyclone over

flow slurry1 set -

18 Low speed classifier sand conveyor 1 set -19 Scrubber water addition pumps 1+1 No. 1+1 No.20 Spiral over flow pump for feeding the

cyclones1+1 No. 1+1 No.

21 Slurry pump for feeding low speed classifier 1+1 No. -22 Slurry pump for pumping tail slurry to the

magnetic separation plant1 +1 No -

23 Crane 10 t under slung and P[b\[hsi 1 set -24 Air compressor

It has been estimated that the connected power for this unit will be about 1.7 MW and

average power required for operation at full capacity after phase-2 will be 1.2 MW.

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7A 2.2 Beneficiation of the tailings of the sinter fine plant

It is envisaged that the sinter fine beneficiation unit will be able to upgrade fine ore from

an average analysis of Fe 56.5 to 60% with about 23% as tailings with less than 50%

(49.88% Fe has been tentatively calculated) Fe. Such material however cannot be

discarded now as per current mining regulations and the net quantity of discards needs

to be limited to keep disposal costs of discards at a reasonably low level.

So treating these discards with Wet High Intensity magnetic Separation (WHIMS)

process is envisaged. The product of such separation would be essentially fine grained

and can be employed as pellet making feed only. For up gradation of 49.88% Fe fine ore

to a minimum 64% Fe material for pellet plant feed proper liberation of the Fe bearing

mineral will be needed. In the absence of any test report of the material to be actually

used, it is difficult to say whether it would be possible to upgrade to this extent without

grinding. However, recent tests with slimes derived from the tailing ponds of fine

washing plants of several iron ore mines have shown that generally it is possible to

upgrade the slimes without any further grinding. Even then it is desirable to provide

flexibility in the magnetic beneficiation unit. So in this report two circuits of beneficiation

have been envisaged. The first circuit uses the slimes without any further grinding. The

steps are de-sliming with hydro cyclones, followed by magnetic separation in two

WHIMS machines. The concentrate as well as tailings are thickened in separate

thickeners and the thickened products are dewatered to 10% maximum moisture in two

separate filter presses. In the second circuit, the slimes are first ground in a ball mill and

then de-slimed in hydro cyclone followed by two stage concentration with WHIMS. The

flow sheets of the two circuits with details of the process flow are given in drawings:

Enviro/AISL/FR/7A/01(R-1) sheets 2 and 3.

The concentrate after de-watering in a press filter will be converted to pellets. The

tailings which would contain less than 40% Fe will also be dewatered in press filters and

temporarily dumped in the assigned area inside the plant. But for environmental

reasons, these would have to be subsequently shifted to mine site to fill in abandoned

mine areas.

The major process parameters envisaged in the WHIMS circuits are given in the table

below:

7 A.3: Inputs and Outputs (In terms of dry ore) after phase-1 and 2 facilities.

Item Tons per hour % Fe YieldInput OreSlime tailings 103 49.88%

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Output ore concentrate

Circuit No. 1 (withoutgrinding)

49.44 64% 48%

Circuit No. 2 (withgrinding)

37.05 64% 37.05%

Tailing


53.56 36.8% 52%


39.17% 66.78%

Iron Recovery


61.5%


47.33%

The table above shows that liberation of iron bearing minerals if possible without

grinding can give much higher yields on beneficiation. But it will depend on the nature of

ore to be treated in the unit. For the purpose of this report, a 50:50 ratio of the two types,

with averages of 42.5% yield of concentrate out of the slime treated has been

envisaged. This leaves rising of 57.5% of the slime treated as rejects with less than

40% Fe. The concentrates amounting to 328,312.5 t/year after phase-1 and 2 can be

converted to equivalent tonnages of pellets to be used in place of lump ore in the blast

furnaces.

The discards would amount to 4,44,188 tons per year in terms of dry solids. This would

be temporarily stored inside the plant at the earmarked site in the general lay out till its

disposal to the mine site for filling abandoned pits.

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Table 7A.3: Major Equipment envisaged at the tailing beneficiation unit.

Circuit -1

Sl. No. Equipment Phase-1 Remarks1 Slime tank- 500 m3 1 Common for both the circuits2 De-sliming hydro-cyclone battery (#1) 1 set 300 m3/Hr3 WHIMS-1 1 104 m3/Hr fluid flow4 WHIMS-1 Concentrate sump 15 WHIMS-1 Tailing sump 16 WHIMS-2 Concentrate sump 17 WHIMS-2 tail sump 18 Concentration sump 19 Concentration thickener 130 m3/Hr 1 Common for both the circuits10 Tails thickener -250 m3/hr 1 Common for both the circuits11 Concentrate filter press -50 m3/Hr of

slurry1 Common for both the circuits

12 Tailing Filter press- 50 m3/Hr of slurry 1 Common for both the circuits13 Slurry Pumps(1) De-sliming Hydro-cyclone feed pump 1+1 300m3/Hr@ 30 m head(2) WHIMS-1 Concentrate slurry pump 1+1 110 m3/Hr @ 30 m head(3) WHIMS-1 tail slurry pump 1+1 110 m3/Hr @ 30 m head(4) WHIMS-2 concentrate slurry pump 1+1 30 m3/Hr @ 30m head(5) WHIMS-2 tails slurry pump 1+1 100 m3/Hr @ 30m head(6) Concentrate thickener feed pump 1+1 130 m3/Hr @ 30 m head(7) Tail thickener feed pump 1+1 250 m3/hr@ 30 m head(8) Concentrate thickener thickened pump

to filter1+1 45 m3/hr@ 30 m head

(9) Tailing thickener thickened pump to filter 1+1 50 m3/ hr@ 30 m head14 Water Pumps(1) Process feed water pump-1 1+1 50 m3/Hr hr@ 30 m head(2) Process feed water pump-2 1+1 110 m3/Hr hr@ 30 m head(3) Concentrate thickener return water

pump1+1 100 m3/Hr@ 30 m head

(4) Concentrate press filter return waterpump

1+1 30 m3/Hr@ 30 m head

(5) Tail thickener return water pump 1+1 200 m3/hr @ 30 m head(6) Tail press filter return water pump 1+1 30m3/Hr @ 30 m head15 EOT crane in ball mill and Whims bay 2 x 15 t

Circuit-2 with ball mill grinding

Circuit -2

Sl. No. Equipment Phase-1 Remarks1 Slime tank- 500 m3 Common for both the circuits2 Ball Mill 1 120 t/hr (solids)3 Classification hydro-cyclone battery 1 set 300 m3/Hr

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(#2)4 De-sliming hydro cyclone battery (#3) 1 set 300 m3/Hr5 WHIMS #3 for primary concentration 1 310 m3/Hr fluid flow6 WHIMS-3 Concentrate sump 17 WHIMS-3 Tailing sump 18 Hydro-cyclone thickener 19 WHIMS-4- secondary cleaning 110 WHIMS-4 Concentrate sump 111 WHIMS-4 tail sump 112 Concentration sump 113 Concentration thickener 130 m3/Hr Common for both the circuits14 Tails thickener -250 m3/hr Common for both the circuits15 Concentrate filter press -50 m3/Hr of

slurryCommon for both the circuits

16 Tailing Filter press- 50 m3/Hr of slurry Common for both the circuits13 Slurry Pumps

Classification Hydro-cyclone feed 1+1 250 m3/Hr @30 m head(1) De-sliming Hydro-cyclone feed pump 1+1 250 m3/Hr@ 30 m head

WHIMS-3 Feed pump 1+1 260 m3/Hr@ 30 m headHC thickener feed pump 1+1 100 m3/Hr@ 30 m head

(2) WHIMS-3 Concentrate slurry pump 1+1 110 m3/Hr @ 30 m headHC thickener return water pump 1+1 100 m3/Hr@ 30 m headHC thickener thickened slurry pump 1+1 30 m3/Hr@ 30 m headFeed slurry pump to WHIMS-4 1+1 30 m3/Hr@ 30 m head

(3) WHIMS-4 tail slurry pump 1+1 20 m3/Hr @ 30 m head(4) WHIMS-4 concentrate slurry pump 1+1 20 m3/Hr @ 30m head(6) Concentrate thickener feed pump 1+1 130 m3/Hr @ 30 m head(7) Tail thickener feed pump 1+1 250 m3/hr@ 30 m head(8) Concentrate thickener thickened pump

to filterCommon

(9) Tailing thickener thickened pump to filter Common14 Water Pumps(1) Process feed water pump-1 1+1 150 m3/Hr hr@ 30 m head(3) Concentrate thickener return water

pumpCommon

(4) Concentrate press filter return waterpump

Common

(5) Tail thickener return water pump Common(6) Tail press filter return water pump Common15 EOT crane in ball mill and Whims bay Common

The specific consumption figures envisaged in the beneficiation plant are given in the table

below:

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Table-7.1A: Consumptions and yields in the beneficiation process

A. Beneficiation of ore: Output t /year of concentrate.

Sl. Item Unit Consumption Remarks

1 Input ROM Tons/t 1.66

2 Balls in ball mill Kg/t 2.0

3 Consumption of makeup water M3/t 1.1

4. Lining board Kg/t 0.750

5. Grease Kg/t 0.060

6. Filter cloth m2 /t 0.005

7. Polyacrylamide Kg /t 0.008

8. Man hours of direct employment Hr/t 0.465

9 Lubrication and maintenance INR/t 100

10. Laboratory and testing INR/t 100

11 Power KWH/t 35

12 Compressed air M3/t 0.5

7A.3 The beneficiation plant layout

The location of the beneficiation plant is given in the General Layout Drawing No.

ENVIRO/FR/AISL/GL/001(R-2). The beneficiation plant has been located in close

proximity of the raw material storage yard for ease of movement of the raw iron ore fines

as well as the concentrated sinter grade fines. The beneficiation plant is connected to

the raw material yard with a conveyor gallery with two conveyors- one incoming from the

fine ore yard re-claimer and the other for transport of the fine ore concentrate back to the

yard. The pellet feed concentrate from the magnetic concentration plant is expected to

move to the group company pellet plant by road the distance being short and quantity

small. The rejects are to be temporarily stored on the southern side of the beneficiation

plant but will have to be continuously shifted to an assigned mine site for closer of old

pits.

The main beneficiation plant proper comprises of two sections each occupying an area

of 36m x 30 m. The northern shade will house the fine washing and classification units

while the southern one will house the magnetic concentration circuits.

The thickeners for concentrates, tailings and for the hydro-cyclone over flow are out door

ones. A separate shed has been envisaged for the dry screening plant for separation of

+8 mm fraction from the incoming fines which would be mixed with lump ores for

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charging into blast furnace. This fraction also will be dumped near the dry screen house

and regularly shifted to the lump ore beds. Separate sheds have also been envisaged

for the MCC room; water pumping station and primary tailing pump house. With space

given for temporary dumping of materials the area earmarked for the beneficiation

process is 241 x 215 m. The details of the plant layout are shown in the Drawing:

ENVIRO/AISL/FR/07A/02 (R-1).

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Chapter 8: Blast Furnaces and Auxiliaries

8.1 General:

The Blast furnace complexes in the two phases will comprise of:



In phase-1 the blast furnace will operate with sinter, lump ore or partially pellets, coke,

coal dust, fluxes and other additives. In phase-2, depending on the commissioning of the

pellet plant (1.2 million ton capacity), the lump ore will be mostly replaced with pellets.

The other inputs are similar. Sinter, pellets and coke will be produced by the company as

a part of the steel works at both the phases.

In phase-1, the blast furnace hot metal will be charged to the Energy Optimizing Furnace

(EOF) for conversion to steel. The liquid slag will be granulated at the cast house

granulation plant. Blast furnace top gas pressure will be used to recover energy in a Top

Recovery Turbine (TRT) and the gas cleaned in dust catcher and gas cleaning system

will be used for stove heating, runner drying , mixed with coke oven gas for general plant

fuel. Excess gas will be used in boiler for raising steam for both power generation and

process steam.

In phase -2, the blast furnace hot metal will be charged to the Basic Oxygen Furnaces

for making steel. The rest operations are similar to phase-1 except the blast furnace gas

will be mixed with coke oven and BOF gas for forming general plant fuel to be used in

the reheating furnaces of the mills and also for heating in the cold rolling mill

installations.

The Technological layout of the two blast furnace complexes will depend on the

technology providers. The locations of the blast furnace complexes 1 and 2 are shown in

the General lay out Drawing ENVIRO/AISL/FR/GL/001(R-2). The layouts of the Blast

furnace proper and the other units associated facilities are given in the Drawings:

ENVIRO/AISL/FR/07/001 & 002 (R-1).

8.2 Technological parameters of the two blast furnaces.

The technological parameters envisaged in the two blast furnaces envisaged in the two

phases are summarized in the table below:

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Table: 8.1: Blast Furnace Iron making main technical parameters

Wp1#Rs1# Teveqixiv## Tlewi04# Tlewi05# Viqevow##

# Fpewx#Jyvregiw#Irzmwekih## # # #

4# Ywijyp#zspyqi#+q6,# 49<3# 6<47# #

5# Tvshygxmzmx}#irzmwekih#+x2q62he},# 513# 513# #

6# Tvshygxmsr#tiv#he}#+xsrw,# 6693# ;95<# #

7# Rs1#stivexmrk#he}w#tiv#}iev## 683# 683# #

8# Kvsww#Lsx#qixep#tvshygxmsr#tiv#

}iev#+xsrw,#

4/4;9/333# 5/99=/<33# Tvshygxmsr2he}#|#Rs1#sj#

stivexmrk#he}w#2}iev##

9# Gsoi#vexi#hv}#ex#fipx2womt#+Ok2XLQ,# 753# 753# #

;# Wgviirmrk#psww#jvsq#FJ#gsoi#xs#womt#

gsoi#+(,#

43# 43# #

<# GHM#vexi#+Ok2XLQ,# 483# 488# #

=# Wpek#vexi#+Ok2XLQ,?#hv}#kverypexih# 5<3# 5<3# #

43# Kvsww#kverypexih#wpek#+43(#

qsmwxyvi,#Ok2XLQ#

63<# 63<# #

44# Wpek#fewmgmx}## 31=9# 31=9# #

45# Xst#tviwwyvi#+Exqswtlivi,# 418# 513# XVX#{mpp#fi#tvszmhih#

jsv#fsxl#xli#jyvregiw1#

46# Lsx#fpewx#xiqtivexyvi##Hik1#G# 4533#qe|mqyq#

+stivexmrk#

438304433#

Hik1#G,#

4583#qe|mqyq#

+stivexmrk#

4433#04483#

Hik1#G,#

#

47# Fpewx#lyqmhmx}#+kq2Rq6,# 73078# 78083# #

48# Fpewx#zspyqi#Rq62XLQ# 4363# 4363# #

49# Fpewx#jyvregi#kew#kirivexmsr#

+Rq62XLQ,#

49<3# 49<3# #

4;# GZ#sj#FJ#kew## <43# <33# #

4<# Wxsziw## 6# 7# #

4=# Wxszi#x}ti## Zivxmgep/#

giveqmg#

zivxmgep#

fyvrivw/#

wmpmge#hsqi1##

Zivxmgep/#

giveqmg#

zivxmgep#

fyvrivw/#

wmpmge#

hsqi1##

Oepykmr#x}ti#wxsziw#

{mxl#gsqfywxmsr#

gleqfiv#ex#xli#wxszi#

hsqi#qe}#epws#fi#

gsrwmhivih#ex#xli#

xirhivmrk#wxeki1##

53# Woypp#erh#pehpi#psww#jvsq#kvsww#xs#

rix#lsx#qixep##

518(# 518(# #

54# TGQ#}miph#jvsq#rix#Lsx#qixep## =5(# =5(# #

#

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8.3 Requirement of Raw materials

The requirements (dry and net) of raw materials at both the phases are given in the table

below:

Table 8.2: Blast Furnace Input material consumption parameters.

Wp1#

Rs1#

Teveqixiv## Tlewi04>#FJ04# Tlewi05>#FJ05# Xsxep#

viuymviqirx#ex#

Tlewi05#+x2}v,#

4# Mvsr#Svi#Pyqt2Tippixw#+Ok2XLQ,# 6=3#+78</973,# 6=3+4/374/555,# 4/7==/<95#

5# Wmrxiv+Ok2XLQ,# 45=3+4/8=9/333,# 45=3+6/<83/333,# 8/779/333#

6# Womt2Fipx#Gsoi#+Ok2XLQ,# 753+7=6/=53,# 753+4/454/649,# 4/948/569#

7# GHM#Gsep#+Ok2XLQ,# 483+4;9/733,# 483+733/7;3,# 8;9/<;3#

8# Pmqi#wxsri#+Ve{,#+Ok2XLQ,# <8+==/=93,# <8+559/=66,# 659/<=6#

9# Hspsqmxi#+Ve{,#+Ok2XLQ,# ;3+<5/653,# ;3+4<9/<<9,# 59=/539#

;# Qr#Svi#+Ok2XLQ,# 9+;/389,# 9+49/34<,# 56/3;7#

<# Uyevx~mxi#+Ok2XLQ,# 57+5</557,# 57+9/738,# 67/95=#

Rsxiw>#

+4,Jmkyviw#mr#tevirxliwiw#evi#erryep#viuymviqirx#sj#mrtyxw#mr#qixvmg#xsrw1##

+5,Ejxiv# mrwxeppexmsr# sj# Tippix# Tperx# +ri{,# ew# irzmwekih/# xli# ywi# sj# svi# pyqt# qe}# fi# qsvi# sv# piww#

hmwgsrxmryih#mr#jezsv#sj#ekkpsqivexiw#syx#sj#jmriw2jmri#{ewxiw2hyqtw###

8.4 Quality of products and by-products of Blast Furnaces.

The qualities of hot metal, slag and blast furnace gas are considered to be more or less

identical for the two furnaces with similar quality of raw material feed as envisaged. It

can vary slightly in case different sources are used at different phases of the project.

1. Typical analysis of Hot metal:

Carbon: 4.2%

Silicon: 0.8%

Manganese: 0.3%

Phosphorus: 0.12% *

Sulphur: 0.045%

Hot Metal Temperature: 1450 Deg. C

* Phosphorus content will depend on the P content of the ore used. The value as given

is a typical low value.

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2. Blast Furnace Slag:

CaO/SiO2: 0.96

Al2O3: 20%

MgO: 9%

Slag temperature: 1550-1600 deg. C

3. Blast Furnace gas:

CO2: 24%; CO: 26%; CH4: 0.15%; H2: 3.7%; N2: 46%; CO/CO2: 1.1; Calorific

Value: 810 Kcal/Nm3.

8.5 Raw material characteristics

As indicated above, a similar raw material characteristic is envisaged now for both the

blast furnaces though there would be a time difference between procurement of raw

materials for the two furnaces.

1. Lump Ore: Fe: 64% (minimum); Al2O3: 1-2%; SiO2: 2.0-3%; Tumbler Index: 7.5 (min)

+6.3 mm; Abrasion index: 6 (max) (-) 0.5 mm; Reducibility index: 65 (min); RDI 35

(max);

Size range: 10-30 mm; (-) 10 mm: 5% max; +30 mm: 10% max.

2. Sinter: Fe: 55-57%; CaO: 7.5-9%; SiO2: 4.0-5.5%; Al2O3: 2.0-3.0%; MgO: 1.8.-2.6%;

FeO: 7-10%; CaO/SiO2: 1.8 (about). Typical analysis: Fe: 55.6%; CaO: 7.8%; SiO2:

4.3%; Al2O3: 2.6%; MgO: 1.9%; FeO: 9.5%; CaO/SiO2: 1.8

Size range: 5mm to 50 mm; (-) 5 mm: 5% max; +50 mm: 5% max

3. Coke in house:

Coke ash: 16-18%; M10: 9 max; M40: 80 min; CSR: 65 min; CRI: 21 max.; moisture:

5% max.

Size range: 25-75 mm; 5% maximum undersize and oversize respectively.

4. Lime stone;

CaO: 49% min; Total insoluble (SiO2+Al2O3+Fe2O3): 4.5% max

Size range: 10-50 mm (90% in the range)

5 Dolomite

CaO: 30% min; MgO: 21%; Total insoluble (SiO2+Al2O3+Fe2O3): 5% max

Size range: 10-50 mm (90% in the range)

6. Quartzite

SiO2: 97% min

Size: 10-50 mm (90% in the range)

7. Manganese ore/Ferro-Manganese slag

MnO: (min): 20%

Size range: 10-50 mm

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8.6 Technological Units of the Blast Furnace No. 1.

8.6.1 Stock house and charging system

Raw materials from the storage yards to the stock house will be transported by belt

conveyors. The raw materials transported from the storage yards will be distributed into

the respective bunkers through two number of shuttle conveyors envisaged at the top of

the stock house bunkers.

The stock house will be of steel construction having two rows of bunkers. One row would

be for storage of coke and the other for sinter, iron ore, pellets (in BF-2), additives and

other raw materials.

Coke, sinter and iron ore bunkers will be provided with individual feeders and screens.

The bunkers storing additives, nut coke; lump ore and sinter will be provided with floor

mounted vibro-feeders. Rod gates will be provided below all bunkers to isolate the

bunkers during maintenance.

Coke will be extracted from coke bunkers by vibro-feeders and fed into screens. Coke

will be screened (+25 -75) for Blast furnace-1 while for the bigger blast furnace at phase-

2, the screened size would be (+40 -75). The coke undersize fractions will be carried to

fines bunker building. In fines bunker building the coke will be further screened by coke

screen to separate out (6-25 mm ) fraction and kept in nut coke storage bunker. The nut

coke will be fed back to nut coke bunker by belt conveyor as and when required.

Lump iron ore will be extracted from stock house bunker by vibro-feeders and screened

by screen to separate out (-) 8 mm size. The + 8 mm portion is discharged to the weigh

hopper. The undersize fraction will be carried to fines bunker building by conveyor in

fines bunker and subsequently disposed to the fines storage yard with dumpers.

Sinter will be extracted from bunkers by vibro feeders and screened by screens to

separate out (-) 5 mm fraction which will be conveyed to the fines bunker building for

disposal. The +5 mm fraction will be taken to the weigh hopper.

Additives like lime stone, dolomite, quartzite, Manganese ore will be drawn by floor

mounted vibro-feeders and fed into weigh hoppers. Nut coke will be drawn by vibro-

feeders and fed into weigh hoppers.

All materials stored in different weigh hoppers will be charged subsequently into

collecting conveyors which will discharge materials into common charging conveyor

which will in turn feed the materials to the blast furnace top charging equipment.

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The stock house bunker configuration with storage capacities are given in the table

below for both the Blast furnaces at the two phases.

Table 8.3: Stock house bunker configuration and storage capacity

Sl. No. Description Phase-1: 1680 m3 BlastFurnace

Phase-2: 3814 m3 BlastFurnace

Production per day ofHM

3360 t 7628 t

Material Bunker sizem3

Number ofbunkers

Bunker sizeM3

Number ofbunkers

1 Coke 325 6 950 52 Sinter 325 5 950 53 Iron ore 325 2 950 34 Lime stone 70 1 400 15 Mn Ore 70 1 400 1

6 Quartzite 70 1 400 1

7 Dolomite 70 1 400 18 Nut Coke 70 1 950 1

8.6.2 Blast Furnace Proper

Since the sizes of the two furnaces at the two phases are different, the blast furnaces

will be described separately.

8.6.2.1 Phase-1: Blast Furnace No. 1:

General features of Blast Furnace proper:

The size of blast furnace envisaged is 1680 m3 useful volume to meet the requirement

of hot metal needed at the phase-1 steel making. The furnace will be free standing

design, welded MS shell construction and four poster arrangement to support the top

structure. The charging system will be bell less design of charging system. The furnace

will be also provided with movable throat armor design to facilitate burden distribution.

The furnace will have two cast houses and two tap holes.

The refractory provided will be in line with standard practice to ensure longer furnace

campaign life. The furnace lining will generally be as follows;

Hearth bottom: Graphite and carbon with mulite top

Hearth walls: Carbon & 62% high alumina bricks

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Bosh area: 62% high alumina bricks

Bosh parallel and lower stack: 45% high alumina bricks

Upper stack & throat: 39% alumina bricks

Top cone: Refractory gunnite.

The blast furnace will have the following cooling arrangement;

The blast furnace will be provided with the state of the art open circuit stave cooling

system in conjunction with under hearth water cooling. The cooling system comprises of

pump house, high pressure and low pressure re-circulating system. The low pressure

cooling system will cater to hearth zone and the bosh zone, where as the high pressure

system will cater to stack zone, tuyere zone, tuyere elements and stove valves. For high

pressure cooling system tentatively, 1500 m3/Hr of industrial water will be circulated in

an open loop with pressure of 6-7 kg/cm2 pressure and inlet temperature of 35 Deg. C.

The low pressure cooling system 1180 m3/Hr of industrial water will circulate in an open

loop with a pressure of about 4 Kg/Cm2 and inlet temperature of 35 Deg C. External

water spraying system will also be provided for cooling the furnace shell at the end of the

campaign.

The hot blast to the blast furnace will be supplied through 18 No. of tuyeres. The solid

burden charged from the top will be smelted on its way down and liquid slag and metal

will be collected in the hearth. The hot metal tapped will pass to the ladles with rocking

runners. Typical capacity of the hot metal ladles will be 130-150 tons. Slag from the main

runner will flow to the slag granulation plant. A slag pit will also be provided for

emergency shutdown of the slag granulation plant.

The outgoing gases will be led through four off takes, two uptakes and one down comer

to the dust catcher for primary dust separation.

(1) Cast house:

The blast furnace will be provided with two diametrically opposite cast houses each

having one iron notch. The runner system will be provided with deep pool runner system

along with fume extraction system. The length of the main iron trough up to skimmer will

be about 13 m with a slope of around 2.5%. Hot metal from each tap hole will be sent to

the main runner to the rocking runner for tapping into the hot metal ladles. There will be

provision of one stationary spout in each cast house. Slag will be skimmed off at the

skimmer positioned at the end of the main runner and directed to the common slag

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granulation plant located adjacent to cast house No.1. The blowing boxes for both the

slag runners will be located in the respective cast houses.

Under normal condition all slag will be granulated. However, in emergency, slag will be

poured in the dry slag pits provided in each cast house. Each cast house will be

provided with one pneumatically operated tap hole drilling machine and one hydraulically

operated tap hole mud gun. Each cast house will be provided with an EOT crane of 20/5

t capacities. Manual and electric hoists will be provided at the buzzle main (for

maintenance of tuyere stock assembly at tuyere platform) and over the rocking runners.

Control posts in respective cast houses will be provided for operation of the mud gun

and drilling machine.

(2) Stoves:

The cold blast from the air blowers will be heated in 3 Nos. of regenerative type internal

combustion chamber hot blast stoves provided with ceramic burners. The stoves will be

of welded steel shell construction lined with refractory bricks and filled with refractory

checker bricks. The stove system will consist of fuel gas, combustion air facilities,

combustion air pre-heater, stove flue gas exhaust, flue chimney, cold blast and hot blast

system along with valves and controls.

Stove lining will be generally as follows:

Refractory bricks:

-Top stove wall and combustion chamber wall -62% high alumina bricks

- Middle part -45% high alumina bricks

- Lower part -30% high alumina bricks

Checker bricks:

Bottom course and top course bricks -62% high alumina bricks

Middle part -42% alumina fire clay bricks

Lower course -39% alumina fire clay bricks

Ceramic burner -Burner top part & crown section

-62% alumina bricks

-Under section including transportation section -42% alumina bricks

The heated blast from the stoves will be led through the hot blast main, bustle main and

tuyere stocks to the blast furnace. Stove operation will be automatic through PLC

controls. The major stove parameters will be as follows:

Hot Blast temperature 1100 Deg CMaximum dome temperature 1300 Deg C

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Heating surface per stove About 40,000 m2Checker chamber cross sectional area 28.10 m2 approx.Combustion chamber cross sectional areaper stove

5.5 m2

Normal mode of operation CyclicDiameter of stoves IDTotal inner height of stove steel shell

(3) Coal injection system

Pulverized coal injection system has been envisaged. The PCI system will comprise of:

- Raw Coal handling system

- Coal drying unit

- The pulverizer

- Coal conveying facility

- Coal dust collection system

- Fine coal storage bunker

- Coal dust injection system up to the blast furnace tuyeres.

A raw coal conveyor has been envisaged for charging raw coal into the raw coal bunker.

The raw coal bunker should have minimum 12 hours of feeding capacity,

Raw coal from the bunker will be used to feed the grinding mill through drag chain

conveyor. Design of the grinding mill will be such that it is capable of producing

pulverized coal of 80% below 75 microns. The mill shall be hot inert gas swept type

serving the duel purposes of drying and pulverization. Hot gas generator (HGG) will be

provided for production of high temperature inert gas. HGG will use blast furnace gas

while Coke oven gas/mixed gas will be used in the pilot burner. A combustion air fan will

be provided for combustion in the HGG.

The raw coal will be pulverized and the required size range swept by the hot gases from

the grinding mill to the bag filters through ID fan which will suck the gases through the

mill and carry it to the bag filter. The fine coal from the fine coal bunker is discharged to

the injection system located below. The pulverized coal is conveyed by nitrogen through

pipe line to the coal dust distribution system located in a separate building near the blast

furnace. From the coal distributer individual pipes carry the injection coals to the

individual tuyers.

The parameters of the CDI system for the Blast Furnace-1 are given below:

Net coal: 150 kg/tHM

Make up water: 140 Kg/t PCI

Power: 18 KWH/t PCI

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BF gas: 185 Nm3/ t PCI

Nitrogen: 105 Nm3/t PCI

Compressed air: 71 Nm3/t PCI

(4) Pig Casting Machine shop and Ladle repair shop

A twin stand pig casting machine of 1000 t/day capacity is envisaged for the plant. The

PCM and the ladle repair shop will be kept in the same premise. Additional quantity of

hot metal not going for steel making will be cast into pigs in a pig casting machine. All

the associated facilities like lime preparation unit, water supply and re-circulation, pig

storage yard are envisaged.

Ladle repair shop will cater to the needs of both hot repairs and cold repairs. PCM and

LRS building shall be a structural building and will have an EOT crane of 200/30 t

capacity for lifting and tilting of the ladles during pouring and also for repair jobs.

(5) Slag Granulation Plant

The liquid slag is granulated by water jet from the blowing boxes. The slag water mix

flows to the granulated slag tank through either of the cold runners. Water from the

granulated slag water mixture is filtered in the filter bed provided in the granulated slag

tank and collected in the under drain system and flows through the channel into the hot

sump of the slag granulation pump house. Compressed air network will be provided

under the bed for better bed filter efficiency.

The granulated slag will be removed by the grab bucket crane and loaded into the

bunkers planned by the side of the granulation slag pit. Granulated slag from the

bunkers will be disposed of through trucks/dumpers. Both the cold runners will be

provided with covers and a stainless steel chimney is planned to remove the water vapor

and other gases generated during granulation of the slag.

(6) Gas Cleaning Plant

Top gas from blast furnace will be led to dust catcher for primary cleaning of dust where

about 65% of the dust will be separated from the gas. The dust laden blast furnace gas

after the dust catcher is cleaned in the gas cleaning plant in two stages. In the first stage

of cleaning, hot dust laden gas coming from the dust catcher will be cooled below

saturation temperature in the variable throat venturi. Pressure drop across the venturi

will be adjusted by remote manual control so as to remove coarse dust particles and

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reducing the dust level of the gases by 90-95%. Water will be supplied to the venturi

scrubber through circulation pumps from the water outlet of the second stage venturi.

Two pumps r one working and the other stand-by will be provided for that purpose. Dust

laden water slurry (separated from the gas stream) will be discharged through sealing

system to the launder for treatment and recycling of water.

The pre-cleaned gases leaving the first stage venturi scrubber pass to the second stage

of gas cleaning plant. This plant comprises of a high energy venturi scrubber of

adjustable flaps. In the venturi scrubber the gas moves against the water spray film

which forms fine lamellae filters for separation of finer dusts. The venturi throat will be

equipped with mechanism to adjust the throat area, which will allow optimum adaptation

of the gas volume generated in the blast furnace. The differential pressure across the

GCP will be controlled automatically by the second stage venturi.

The gas leaving the second stage venturi enters the moisture separator where the finest

water droplets are flung against the separator shell and run down into the sump. The

blast furnace gas separated from water particles leaves the gas cleaning plant. Blast

furnace top pressure will be automatically controlled by septum valve provided at the

outlet of the gas cleaning plant. Clean Blast furnace gas will be distributed through pipe

line network to various consumers. The gas cleaning plant will be provided with service

platforms and supporting structures as required for operation and maintenance.

The parameters of the gas cleaning plant for the Blast Furnace no.1 at phase-1 are

given below:

1 Blast Furnace gas volume 235,200 Nm3/Hr (average)

2. Temperature of gas 150-300 0 C

3. Inlet dust at the dust catcher 20 gm/Nm3 (max)

4. Inlet dust at the GCP entry 15 gm/Nm3 (max)

5. Moisture content at inlet to GCP 60 gm/Nm3 (max) ?

6. Dust content in the clean gas 5 mg/Nm3 (max)

7 Outlet temperature of gas 45 0 C

8. Expected size of dust 0-1 mm

9 Moisture content of cleaned gas 5 gm/Nm3

(7) De-dusting system of the Blast furnace area

The major dust generating area of the blast furnace department is the stock house and

the cast house. A separate ESP has been envisaged for the stock house de-dusting

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system with a fan and a chimney of minimum 30-35 m height to reduce the dust content

of the cleaned air to less than 20 mg/Nm3. The dust below the hoppers of ESP is

collected by a conveyor and sent to a dust silo. The moistened dust and discharged with

a screw conveyor to dumpers for sintering plant. The cast house de-dusting system

consists of a bag filter house, fan and chimney. The fumes from the pouring spouts of

the cast house are sucked, cleaned in a bag filter house and sent to atmosphere through

a chimney of minimum 35 m high.

(8) Top recovery turbine

It is envisaged to install a top gas pressure recovery turbine with Blast furnace No. 1.

The exact details will be done at the detailing stage. While the gas cleaning plant will be

able to handle the entire volume of Blast furnace gas, a part will go to the TRT after

cleaning and partial pressure drop at the variable venturi scrubber. For this purpose an

inlet pressure of about 1.5 bar may be assumed at the TRT inlet. The tentative capacity

of the TRT will be 6 MW.

8.7 Facilities of Blast furnace No. 2 as envisaged at Phase-2

8.7.1 The 3814 m3 blast furnace (No. 2) envisaged at phase-2 of the steel plant will be a

separate unit with all auxiliaries located at a site adjoining to the Blast furnace -1. Only

the pig casting machine will be common for both the blast furnaces since the overall

balance of hot metal after meeting the requirement of the two steel making shops is not

likely to be large enough to justify a second PCM.

The second blast furnace unit will comprise of:

' Burden handling and charging system

' Top Equipment

' The Blast Furnace proper

' Cooling elements & Cooling system

' The cast house

' Hot Blast stove and hot blast system

' Gas cleaning system

' Slag granulation plant

' Cast house fume extraction system

' De-dusting system of the burden preparation and charging

' Refractory

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8.7.2 Description of units of Blast Furnace No. 2

(1) Burden handling and charging system

(a) The burden will comprise of sinter from sintering plants, coke from the coke oven

department, sized ore/pellet from the yard, and additives like lime stone,

dolomite, manganese ore/Ferro-manganese slag from the yards. These materials

will arrive through belt conveyors at the burden handling system.

' Coke: Coke from the incoming conveyor will be discharged to the two coke

feeding conveyors and subsequently discharged on two bin feeding shuttle

conveyors of 1600 mm width (tentative) These will feed five coke bins of 950

m3 capacity each and one bin of same capacity for nut coke. All the bins will

be of steel construction.

' Sinter: Sinter from the incoming conveyors will pass over two sinter intake

conveyors and then to two shuttle conveyors of also 1600 mm width

(tentative) to feed 5 nos. of sinter bins of 950 m3 capacity. All bins will be of

steel construction.

' Iron ore/pellet: Iron ore/pellet from the incoming conveyors will be fed to the

sinter feeding system as described above and fed to three Nos. of ore/pellet

bins of 950 m3 size each also of steel construction.

' Additives: The additives as listed above from the incoming belt conveyors

follow the path of coke feeding as described above. There will be four bins of

400 m3 capacity to store the additives in the burden preparation department.

(b) Screening: Ore, coke and sinter will require to be screened before charging to

the weigh hoppers. Additives will be fed directly to the weigh hoppers

through vibro feeders.

Ore will be screened for +5 mm and (-) 30 mm. Sinter will be screened for +5

mm and (-) 50 mm. double deck screens will be used below each bunker

with electromagnetic feed control gates. Coke will be screened for +25 and (-

) 75 mm. The top screen size of the coke screens will be 40 mm which can

be charged as per operational requirement. There may be a provision of

screening the coke fraction of 60-75 mm for charging at the central portion of

the blast furnace. These will be considered at the detailing stage as per the

technological requirements. The returns of the screenings sinter fines are

sent to the sintering plant for reuse, the ore fines are stored in a separate

bunker and dispatched to sintering plant through dumpers. The coke fraction

(-) 25 or (-) 40 as the case may be will be partly stored in the nut coke bin

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and partly sent to the sinter plant no. 2 for crushing and use as sinter

machine fuel. Adequate conveyor facilities for dispatch of the fines will be

provided at the detailing stage.

(c) Weigh hoppers: Below each screen weigh hoppers resting on three load cells

are provided. The tentative sizes of the weigh hoppers provided for feeding

different raw materials are given below:

Below coke screen: 180 tons/Hr 6 Nos

Below Sinter screens: 360 tons/Hr 5 Nos.

Below ore screens: 360 tons/Hr 3 nos.

The weighed materials from the weigh hoppers are fed to the collecting conveyor for

onward transmission to the charging conveyor.

The tentative specification of the collecting conveyor is given below:

Belt One No.

Capacity: 2000 m3/hr

Width: 2000 mm

Speed: 2 m/sec

Drives: 2 x 135 KW (tentative)

The tentative specification of the charging conveyor is:

Belt: One No.

Capacity: 2000 m3/hr

Width: 2000 mm

Speed: 2 m/sec

Drives: 4 x 500 KW (tentative)

Inclination: 10 0 1.s

(2) Blast Furnace Top equipment

The blast furnace top charging system will employ bell less top charging system as

currently practiced in all larger furnace for longer top equipment life, better maintenance

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of the furnace pressure all leading to better productivity and increased annual

production. The top equipment described below is as per current state of the technology

and can be modified at the time of detailing based on the technology provider.

(a) Off takes: 4 nos. of off takes are provided of 2000 mm diameter leading to two

vertical uptakes of 2550 mm dia. and one vertical down takes of 3300 mm

diameter to the dust catcher. The diameters are analogous figures for similar

furnaces.

(b) Bleeder valves: 3 Nos. bleeder valves of 800 mm diameter, hydraulically

operated operating at a pressure of 2.5 bars will be provided.

(c) Bell less top equipment:

- Movable material receiving hopper: It receives material from the belt and

transfers to either of the fixed material bins of the BLT system. The existing

systems employ movable hoppers with a travel of about 2100 mm. For ensuring

faster charging it is proposed to make this hopper fixed and shift materials to

either of the material stationary hoppers with tilting rockers.

- BLT stationary hoppers: 2 Nos. of about 65 m3 capacity will be provided.

- Seal valves; material gate valves (1100 mm); equalizing valves (500 mm). All

these valves will be hydraulically operated.

- BLT gear box with Nitrogen cooling system

- Distribution chute.

(3) Furnace Proper:

(a) The detailed design of the furnace will be finalized at the detailed engineering

stage. Tentatively,

- Furnace hearth diameter: 12,500 mm

- Useful height: 34 m (approx.) Useful height is defined as the distance from the

centerline of the iron notch up to the BLT distribution chute bottom in vertical

position.

- No. of tuyeres to be provided: 34

- No. of cast houses: 4 (Circular cast house)

- No. of iron notches: 4

(b) The tentative shell thickness of the furnace will be:

- Below hearth bottom; 30 mm

- Hearth shell: 36/40 mm

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- Bosh /belly/shaft: 30/40 mm

- Crown: 60 mm

(c)) The furnace will have the following probes:

' 2 nos. of over burden probe for measuring of gas temperature

' Stock level indicators: 1 radar type + 1 Electro-mechanical type

' Hydraulically operated under burden probe r 1 No.

' Profile-meter for assessing burden profile at the top and coke ore ratio in the

radial direction. r 1 No.

' Provision of amanoscope

(d) Bustle main and tuyere stock:

The tentative internal diameter of the bustle main will be 1250 mm with refractory

thickness of 530 mm and shell thickness of 20 mm. The bustle main will be

designed for a Hot blast temperature of 1300 0 C and 4.5 bar (g) blast pressure.

The shell outer surface would have a maximum temperature of 120 0 C.

34 Nos. of tuyere stocks will be provided and designed for a Hot blast

temperature of 1300 0 C

And a blast pressure of 4.5 bars (g). The blow pipe should have a provision of

installing lance for coal dust injection @ 150 Kg/THM (AV) and 200 Kg/THM

designed.

(e) Thermo couples will be installed to measure temperature of hearth bricks and the

temperature of the cast iron and copper staves provided in the hearth, bosh and

stacks. Thermo couples will also be provided for measuring skin flow

temperatures.

(f) Furnace cooling system:

Close loop soft water cooling system has been provided for the furnace except

for the tuyere stocks where open loop industrial water cooling system has been

envisaged.

(4) Furnace cast house

(a) Circular cast house has been envisaged for the furnace. The floor will be

preferably flat. There would be a ramp to take men and materials in vehicles from

the road directly to the cast house. The circular cast house will have right hand

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and left hand sections with 4 tapping systems installed 90 0 apart. Each cast

house will have:

- Main trough

- Iron and slag runner (covered)

- Tilting runner with hydraulic drive for filling open top or torpedo ladles.

Provision of heat shield will be given below the cast house.

The cast house will be provided with 2 Nos. of circular cranes each 20/5/5 ton lifting

arrangement.

The cast house will have splash covers with manipulator over the runners. The cover

lifting arrangement will be hydraulic.

The cast house equipment will include 4 Nos. of hydraulic drilling machines and 4

No. of hydraulic mud guns.

The hot metal transport to the BOF shop envisaged in Phase -2 will be with 140 ton

open top ladles and 300 tons torpedo cars.

(b) Cast house de-dusting system: As described before, the main trough, the iron and

slag notches will be fully covered with refractory lined covers with hydraulic

manipulating system, De-dusting hoods will be provided over iron notch, skimmers,

slag runners, tilting runners and top charging conveyor delivery points. The dirty

sucked air will be cleaned in an ESP to ensure that the ambient air let out through a

35 m tall chimney contains less than 20 mg/Nm3 of dust. The dust from the ESP

hoppers will be collected pneumatically to a dust silo at a height and the moistened

dust will be sent to sintering plant with dumpers.

(5) Hot Blast System

The blast furnace hot blast from the Turbo-blower unit will be regenerative heated in 4

No. of Hot blast stoves. The stove design should be to ensure furnace operation with

minimum 3 No. of stoves during shut down/repair of any one of the stoves. The tentative

parameters of the stoves are:

No. of stoves: 4 Nos.

Nos. under heating: 2 min.

No. under blast: 1

Heating surface area of each stove: 65,000 m2 appox

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Diameter of each stove; 9.5 m (tentative)

Height: 52-53 m

Hot blast temperature: 1300 0 C

Stove Dome temperature: 1450 0 C

Combustion air fans per stove: 2 (W) + 1(SB).

Provision of preheating of the combustion air for economy of BF gas usage in the stove

heating has been envisaged.

The stoves would have internal combustion ceramic burners preferably vertical.

However, other design like Kalugin type with dome combustion chamber can also be

considered at the detailing stage.

The hot blast main of approximately 1800 mm will branch to two mains for connection to

the buzzle pipe, the dia. of the branch mains will be approx 1500 mm.

The system for each stove will include: hot blast valves (water cooled and hydraulically

operated); cold blast valve and chimney valve.

The hot blast system will have provision of steam injection in the cold blast line and

equalizing valves for progressively reduced dilution of cold air to keep the hot blast

temperature constant at the tuyers.

(6) Blast Furnace Gas Cleaning System

Dry gas cleaning: The blast furnace down comer will be connected to the dust catcher of

12-13 m diameter for separation of about 60% of the Blast furnace gas dust load. The

dust catcher is refractory lines (about 120 mm refractory lining) and will discharge the

collected dust through two pug mills (1 W+1SB).The dust catcher will be provided with

cut off valve and hydraulically operated dust discharge valves with auxiliaries.

The blast furnace gas will be partly sent to TRT and the gas to the Wet gas cleaning

plant will pass to the furnace top via an equalizing valve. The exact details of this

arrangement will be decided along with the TRT supplier at the time of detailing.

Wet gas cleaning: The tentative capacity of the unit will be about 400,000 Nm3/Hr at 2.5

bar (G) pressure. From the dust catcher the gas will pass through the wet scrubber

about 9 m dia. , two venturi pipes with adjustable throats and a mist eliminator and

finally through a set of throttle valves. The throttle valves also act as by pass for the Gas

Energy turbine or Top pressure Recovery turbine which is also envisaged.

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The specification of the gas cleaning system is as given below:

- BF gas volume: 550,000 Nm3.

- Inlet temperature: 150-250 0 C

- Inlet pressure: 2.5 bar (g)

- Dust content of the gas after Dust catcher- 6.3 gm/Nm3 (typical)

- Dust content of the cleaned gas: < 5 mg/Nm3

- Moisture content of the gas: 5 gm/Nm3

- Gas pressure after cleaning: 800 mm WC

(7) Slag granulation plant: Two slag granulation plants will be provided each one with each

cast house. The granulation plants will be adjacent to the cast house on the opposite

direction. Each granulation plant will have two lines r one working and one standby.

Basically slag granulation plant is comprises of: (1) Granulation unit (2) Pneumatic and

hydraulic transport system (3) Dewatering system (4) Process water re-circulation

system

Each line will consist of the following units:

- One granulator (each granulator with a capacity of 200 t/Hr)

- One slag air lift (each slag air lift system with capacity of 240 t/Hr)

- One granulated slag dehydrator with 16 boxes of 8 m3 each capacity.

- One receiving bin

The moisture content of the granulated slag would be 10-15%.

(8) Refractory to be used:

A. Blast furnace:

(a) Hearth: The bottom layer of the refractory will be lined graphite above the carbon

ramming mass followed by two layers of high conductive carbon. The next two

layers will be super micro-pore carbon. The hearth protection pad shall be 4

layers mullite bricks (with 70% Al2O3).

(b) Hearth wall: The hearth wall will be lined with super micro-pore carbon in the

elephant foot wear zone followed by micro-pore carbon in the middle and high

conductive carbon up to the tuyers. The tuyere surrounds will be lined with nitride

bonded silicon carbide. The sacrificial layer in the entire hearth will be 30%

alumina bricks.

(c) Bosh: The lower bosh will be lined with silicon carbide bricks. The upper bosh

transition will have high alumina gunning castable over copper staves.

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(d) Belly, lower and middle stack: These will be lined with low iron high alumina

gunning over the copper staves and high alumina cast in refractory within the

cast iron staves.

(e) Upper stack: The upper stack will be lined with high alumina cast in refractory

within the cast iron staves. The top cone will be lined with carbon monoxide

resistant gunning castable. For anchor construction AISi 310 will be provided.

(f) Off-takes, Uptakes and down comers: These areas will be lined with CO resistant

gunning castable. For anchor AISi 310 will be used. Thickness of lining will be

typically 114 mm.

(g) Dust catcher: The lining (typical 114 mm) will consist of CO resistant gunning

castable. For anchor AISi 310 will be used.

B. Stoves

(a) Combustion chamber: Lower portion will be lined with mullite corundum, the

middle and upper portion will be lined with silica bricks

(b) Checker chamber wall: Lower wall hot face lining with fire clay (37% alumina).

Lower middle wall lining with fire clay (42% alumina); upper middle wall lining

with Mullite corundum; upper wall lining with silica bricks.

(c) Checkers: Four different types of refractory will be used for the checkers. 37%

alumina bricks at the bottom most portion followed by 42% alumina, mullite

corundum bricks and silica bricks.

(d) Dome: Hot face lining of the dome will consist of 450 mm thick silica bricks,

backed up by 230 mm thick porous silica bricks, 100 mm thick mullite silicic

plates and finally 80 mm thick insulating gunning over the shell;

(e) Ceramic burners: High alumina shapes.

C. Hot blast main, bustle main and tuyere stock:

For hot blast main the working face will comprise of two layers each of 120 mm

thick mullite corundum bricks. The third and fourth layers will be 124 mm thick

fire clay brick and 65 mm thick insulating brick. Asbestos board of 30 mm thick

will be used in contact with the shell. The bustle main will also have similar

materials. The total thickness will be about 50-60 mm more. Pre cast and pre-

fired blocks are envisaged in the bustle main tuyere stock junction. Tuyere stock

castable will be jelly bond self flow castable (ULCC) of 80% alumina.

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D. Iron and slag runners: These will be lined with carbon blocks with a thick layer of

trough mass over the blocks.

E. Back draft chimney: A back draft chimney will be provided and it will be lined with

Anadalusite base high alumina (58% Al2O3) bricks as working /hot face lining

followed by one layer of insulating bricks (ASTM 26) and backed up by insulating

castable. Top portion of the chimney (T pipe) will be lined with gunning castable.

(9) Top recovery turbine

It is envisaged to install a top gas pressure recovery turbine with Blast furnace

No. 2. The exact details will be done at the detailing stage. While the gas

cleaning plant will be able to handle the entire volume of Blast furnace gas, a part

will go to the TRT after cleaning and partial pressure drop at the variable ventury.

For this purpose an inlet pressure of about 1.5 bars may be assumed at the TRT

inlet. The tentative capacity of the TRT will be 12 MW.

8.8 Environmental Control measures envisaged in the Blast Furnace Complexes

(a) Air Pollution Control

Blast furnace off gas is a valuable fuel. It is removed of its dust load first at the dust

catchers which is basically a cyclone separator to precipitate bigger dust particles. The

gas is further washed at the gas cleaning units as described in the sections dealt before.

The cleaned blast furnace gas (with dust content less than 5 mg/Nm3) is fit to be a fuel

for use in gas burners and is used in stove heating and as a general plant fuel for

reheating of as mixed gas after mixing with coke oven gas and Converter gas (after

phase-2). The off gases of furnaces using these gases burnt with air do not require any

further dust separation units.

The Blast furnace hot metal and slag runners are planned to be covered with retractable

covers as now internationally practiced. The cast house and the area around tuyeres

would have de-dusting hoods to suck the ambient air and to clean those in ESPs or bag

filter houses. Both are possible and used and would depend on the final economics. The

other dusty areas of the blast furnace like the stock house, junction houses etc. will have

suction hoods leading to Bag filters and 35-40 m height chimneys. Closed dusty areas

which are wide and are difficult to cover with hoods will be kept dust free by employing

dry fog process. In some open areas simple spray de-dusting can keep dust away.

Each of the slag granulation boxes will have a stainless steel 40 m chimney to let out the

granulation stream.

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The solid dust recovered from the blast furnace complexes (called flue dust) are

collected and used as source of iron and fluxes in the sintering machine charge mix.

These are sent to the dedicated areas of the sintering plant.

(b) Water pollution control

(1) The blast furnace and stave cooling water is clean water involved in indirect

cooling. This water is cooled in cooling towers and re-circulated.

(2) The gas cleaning plant water is laden with dust. The dirty water is first clarified in

circular clarifiers and then passed through oil removal unit before re-use.

(3) The granulated slag comes out of the granulation boxes in the form of water

slurry. This slurry is de-watered in rotary filters. The filtrate water is filtered again

and cooled and re-used with addition of makeup water.

The solid recovered from gas cleaning plant water treatment also contains iron oxide and

used in sintering plants and later in the pelletizing plant as charge mix.

(c) Other solid wastes

(1) Most of the scrap, jams and iron muck are sent to the steel melting units for re-

melting.

(2) All blast furnace slag is granulated, de-watered and used in cement plants along

with conventional cement clinkers to be ground for making Blast furnace slag

cement.

(3) Refractory wastes: Major arising of refractory wastes is at the time of blast

furnace or stove relining and capital repairs. Otherwise major refractory waste

arising is from the ladle repair shop from de-bricking of ladles. Some bricks are

re-used, some ground to mortar and those mixed with slag or muck are dumped

for filling.

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Chapter-9: Steel Making and Continuous Casting Plants

9.0. General:

The steel making and continuous casting units are envisaged to be of different types in

Phase-1 and Phase-2. This is because of the production volume and type and quality of

products. As explained in the demand chapter, the immediate phase will target alloy and

special steels in long products in comparatively lower volume while the phase-2 is for

higher production of flat products both hot rolled and cold rolled. For phase-1 facility,

therefore, Energy Optimizing Furnace (EOF) process of steel making has been selected

along with bloom and billet continuous casting. In phase-2, the steel making process of

choice is Basic Oxygen Converters or Basic Oxygen Converter Furnace (BOF) process

with continuous casting of slabs.

9.1 Facilities envisaged at Phase-1:

9.1.1 At Phase-1, the steel making facility is designed to produce carbon construction steels

(CCS), Alloy Constructional steels (ACS) and other required alloy steels depending on

the market requirements.

The steel making shop will comprise of:

( 2 Nos. of 50/55 ton Energy Optimizing Furnaces (EOF)

( 1300 t inactive mixer or 300 t torpedo ladles (2 Nos.)

( Ladle refining furnace of 55 tons capacity

( Vacuum degassing unit of 55 ton capacity.

9.1.2 Hot metal will be received from Blast Furnace no. 1 in open ladles of 100 ton capacity

and stored in the inactive mixer. Hot metal desulphurization facility with de-slagging at a

desulphurization station has also been envisaged in the mixer bay. Hot metal

desulphurization will be necessary to bring down Sulphur for alloy and special steels at

the input hot metal level to avoid long processing time at the ladle furnaces. Further

operation of the blast furnaces at a lower slag basicity to increase blowing rate would

increase hot metal sulphur which needs to be brought down before charging to the steel

making furnaces. The intake hot metal ladles can be selectively desulphurized and taken

directly by- passing the mixer.

9.1.3 Both the furnaces will be operational simultaneously to produce around 1 million tons of

liquid steel. Secondary refining for production of special and alloy steels and also

adjusting steel chemistry will be done in the Ladle refining furnaces (LRFs) and in the

Vacuum degassing unit (VD)

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The main production units at Phase-1 (1 million ton stage) are envisaged as:

Unit NumbersEOFs (50/55 t) 2Mixer (1300 t) 1Ladle Furnace (55 t) 2VD 1Bloom caster 1Billet caster 2

9.1.4 Production program

The production program of the EOF shop and continuous casting shop is given below:

( Liquid steel production per year: 1,000,000 tons

( Continuous cast blooms and billets: 960,000 tons

This planned production will be achieved with a nominal heat size of 50 t from each

furnace and a maximum heat size of 55 t. The entire quantity of liquid steel is envisaged

to be continuously cast to blooms and billets. Unlike in many alloy and special steels

plants, ingot casting has not been envisaged.

About 65% of the liquid steel is for production of billets for feeding to the Bar and Rod

mill and the remaining 40% for casting blooms for feeding to Billet rolling mill. The above

product mix is only indicative and would depend on the market after start up of the steel

plant. Some portion of the semis can be sold also directly.

As regards quality break up, Alloy construction steel will comprise of 40% of the total

production, Carbon constructional steel will comprise of 35% and the rest will be other

alloy steels.

9.1.5 Technological Indices

The technological indices of the EOF shop are given in the Table below:

Table- 9.1: Steel Melting Shop No. 1 (EOF shop) parameters

Wp1#

Rs1#

Teveqixiv## Tlewi04# Viqevow##

4# Tvszmwmsr#sj#mregxmzi#qm|iv## 4#Rs#|#4633#x# #

5# Ywi#sj#xsvtihs#pehpi# 5#Rsw1## Xs#fi#vizmi{ih#

pexiv##

#


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6# Hiwyptlyvm~exmsr#wxexmsr## 5#|#48#x## #

7# Irivk}#Stxmqm~mrk#Jyvregiw## 5#|#83288#x# #

8# Pehpi#Jyvregi#w# 5#|#88#x# #

9# Zegyyq#hikewwmrk#jyvregi## 4#|#88#x# #

;# Rsqmrep#liex#wm~i## 83#x#+88#x#qe|,# #

<# Xet#xs#xet#xmqi## 78#qmryxiw## #

=# Liexw#tiv#he}#jvsq#fsxl#xli#

ISJw##

93#+#97#qe|,# #

43# Stivexmrk#he}w#tiv#}iev## 6530673## 48049#he}w#hs{r#

xmqi#tiv#}iev1#

44# Erryep#tvshygxmsr##sj#pmuymh#

wxiip#jvsq#xli#wlst#

=93/33304/353/333#

x#

Ez1#4333333#x#

45# Eziveki#}miph#sj#pmuymh#wxiip#jvsq#

qixeppmg#mrtyxw1#

<61<(# #

#

Xli# ryqfiv# sj# {svomrk# he}w# tiv# }iev# {mpp# fi# pmqmxih# hitirhmrk# sr# xli# ezempefmpmx}# sj# xli#

gsrxmrysyw#gewxmrk#wlst#erh#mw#i|tigxih#xs#fi#qmrmqyq#653#he}w1#Xli#x}tmgep#wiuyirgi#ryqfiv#

sj# 809# liexw# lew# fiir# irzmwekih# jvsq# xli# gewxiv# wlst1# Xli# egxyep# ryqfiv# sj# wiuyirgi# mr#

gsrxmrysyw#gewxmrk#{mpp#zev}#jvsq#wxiip#kvehi#xs#wxiip#kvehi#erh#xlimv#eziveki#xviexqirx#xmqiw#ex#

xli#PJ#erh#ZH1#

Xli# wlst#{mpp# lezi#e# wtevi# fsxxsq#{mxl# pmrmrk#erh# ejxiv# efsyx# =33# liexw# xli# fsxxsq# {mpp# fi#

glerkih1##

=1419# Pehpi#Vijmrmrk#Wxexmsr#+PVJ,#

PVJ#yrmxw#{mpp# fi#tvszmhih# jsv# epps}mrk/# hi0wyptlyvm~exmsr#erh# lsqskirm~exmsr#sj# xiqtivexyvi#

erh#gsqtswmxmsr#sj#xli#wxiip#xettih#mrxs#xli#wxiip# pehpi1#Xli#PVJ#yrmxw#epws#egx#ew#e#fyjjiv#jsv#

xmqip}#wirhmrk#xli#pehpiw#xs#xli#gsrxmrysyw#gewxmrk#wlst#{mxl#viuymvih#xiqtivexyvi1#Xli#egxyep#

kvehi#sj#wxiip#{mpp#fi#tvshygih#ex#xli#PVJ#wxexmsr1#Iegl#PVJ#yrmx#{mpp#lezi#e#pehpi#getegmx}#sj#88#x#

erh#e#xverwjsvqiv#vexih#44#QZE1#Xli#teveqixivw#sj#xli#PVJ#evi#kmzir#fips{1#

Xefpi0=15>#Teveqixivw#sj#xli#pehpi#Jyvregi#+PVJ,

Sl. No. Item Unit Parameter1 Heat size Tons 50 (maximum 55)2 Type of unit Ladle housed in the vacuum tank

stationed on the ladle car with watercooled cover.

3 Transformer capacity MVA 114 Heating rate 0 C/min 5

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5 Material charging The alloys and other additives will beplaced on over head bunkers servicedby conveyors and vibro-feeders formeasured discharge from the bunker.The additives will be collected on aconveyor to be charged into the ladlethrough via a weigh hopper through anaddition chute.

6 Typical facilities - Three electrode AC supply for archeating.

- Wire feeding of Aluminum wire andCa-Silicide core wire

- Bottom purging with argon to theladle through porous plug.

- Top Nitrogen purging tube- Scum breaker rod operated

hydraulically.- Addition chute- Automatic sampling arrangement

7 Treatment time Minutes - 45 depending on the grade8 Main functions of the

LRF- Alloy addition- Heating of the steel- Desulphurization- Homogenization of temperature

and chemistry- To act as a buffer to match the

sequence in continuous casting.- Cleanliness of steel

9 Fume collection andcleaning

- Bag filters with ID fan and 30-35 mchimney

10 LRF station output - Various grades of alloy steel.

9.1.7 Vacuum Degassing Unit.

A 55 ton VD unit will be provided mainly for producing high quality alloy steel. In the VD

unit dissolved gases such as Hydrogen and Nitrogen will be removed to produce clean

steel. The tentative technical parameters are given below:

Table-9.3: Parameters of the Vacuum degassing Furnace

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Sl.No.

Item Unit Parameter

1 Heat size T 552 Cycle time Min 45-603 Type of unit - Fixed cover with moving unit4 Vacuum system - Through steam ejectors5 Pump down time for

empty vacuum tankfrom atmosphericpressure down to 0.5torr.

Min < 5

6 Stirring - Equipped with argon stirring.

9.1.8 Process flow:

The scrap is preheated from the heat of the off gases coming from EOF. This pre-heated

scrap is charged into the furnace for making liquid steel along with liquid hot metal.

In view of the pre-heating of scrap, EOF takes larger amounts of cold charge than BOF.

Typically it can take up to 40% of cold charge if required in the charge. The heat energy

available during steel making process by using the CO to CO2 reaction heat energy

available is used to preheat the scrap. The oxygen for refining is blown through

supersonic lances, submerged tuyeres and through atmospheric injectors. The evolved

CO is combusted to CO2 by atmospheric injectors /supersonic lances. The typical flow

rate of oxygen through supersonic lance is 1200 Nm3/Hr with a speed more than 360

m/sec. Unlike in BOF intermediate de-slagging is done in the EOF.

The hot metal is charged in to the EOF furnace through the hot metal charging crane

into the charging launder, which is the part of the furnace body. The scrap pre-heater

charging box which is kept on the furnace top, the fingers get opened and the pre-

heated scrap from the previous heat falls into the furnace. The blowing of oxygen starts

through supersonic lances, through tuyeres and through atmospheric injectors. Mean

while, all the additives like lime, do-lime and DRI are added to the furnace. New scrap

box is kept of the furnace top for pre-heating of the scrap for the next heat. The cycle

time of the EOF heat is about 45 minutes. After the process, the furnace is tilted and the

steel is tapped through the launder to the steel ladle. Ferro-alloys will be added to the

ladle for de-oxidation of steel while tapping of steel. The liquid steel is transferred to the

ladle handling bay where the liquid steel is lifted by the ladle handling crane and placed

on a car for taking to the ladle furnace (LF) during the LF operation.

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During the LF operation, synthetic slag is added for de-sulphurization (whenever

required) and the metal will be purged with argon through porous plug from the bottom of

the ladle. Nitrogen purging also will be provided for non critical heats for stirring and

homogenization of temperature and chemistry. The facility of aluminum wire and calcium

silicide cored wire addition to the ladle and trim additions of Ferro-alloys and metals are

provided to reach the desired chemistry of the grade. After the ladle furnace the ladle

goes to the VD for de-gassing (if required) before the ladle is transferred to the casting

bay for continuous casting machine.

9.1.9 Technological auxiliary units

(a) Hot metal handling

Hot metal coming from the blast furnace in open top ladles is charged to the mixer.

Provision for using torpedo ladles and the necessary transfer from the torpedo

ladles to Hot metal charging ladles will be kept. Hot metal coming from Blast furnace

will be selectively de-sulphurized in a de-sulphurization unit using de-sulphurizing

agents like calcium carbide/lime and soda ash, these reagents will be injected in the

ladles with the help of injection lances. The desulphurizing slag will be raked off with

the help of a slag raking machine and would be disposed off.

In case of selective de-sulphurization, the desulphurized ladles will by-pass the

mixer. For other heats, the ladles are poured into the mixer and from the mixer, the

hot metal is collected into the EOF hot metal charging ladle.

(b) Scrap handling

A separate scrap storage yard has been considered for meeting the requirements of

EOF shop. The scrap bay will store internal scrap and when necessary purchased

scrap. The scrap will be loaded in the scrap charging boxes placed on the car,

positioned over the scrap weigh bridge by the over head magnetic crane in the

scrap bay. Scrap boxes will be brought to the charging bay by the scrap box car.

Scrap boxes will be lifted by the scrap charging crane and placed on the EOF

furnace mouth for scrap preheating before being discharged into furnace.

(c) Flux and Ferro-alloy handling

DRI, Coke and other materials will be received in over head bunkers in the EOF bulk

material charging bay from raw material yard by trucks. Lime, calcined dolomite will

be received from lime and dolomite plants (BOO) by trucks. No separate storage

sheds are envisaged for the Ferro-alloys and refractory. Sufficient storage will be

kept in the bins and in the shop only and the same would be obtained from outside

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as and when required. The EOF shop is designed with furnace feeding bunker

system and ladle feeding Ferro-alloy bunker system. The material for furnace

feeding will be charged into the EOF furnace through a system of conveyors, weigh

hoppers, charge holding bunkers and chutes. Similarly pre-determined quantities of

Ferro alloys for ladle addition at tapping will be delivered in to the steel ladles

through a system of weigh hoppers and chutes.

(d) Steel handling

Liquid steel will be tapped off from the EOF into the casting ladle placed on a self

propelled transfer car. After tapping, ladle will be sent to LF/VD installed in the ladle

furnace bay. From this bay the ladle is sent to the continuous casting plant.

(e) Slag handling

The EOF furnace is operated with intermediate slagging off facility. The slag will be

poured out from EOF into the ground. Hot slag dumped on the ground will be

allowed to cool and cold slag from the pit is removed by dozer and dumper.

(f) Secondary refining of steel

As already explained, the shop will have two nos of ladle heating furnace complete

with facilities as described in the preceding section for correction of chemistry of

steel as per requirement of the grade and achieve steel temperature with margin for

ladle holding as required by the continuous casting process. The LF will be used for

further heating of ladles held up in the queue for continuous casting machine and

returned if such situation arises. The vacuum degassing unit will be used for

degassing of heats when specified or for making ultra low carbon steels with low

inclusion count. Sometimes if the VD operation prolongs, ladles may have to be

returned back to the LF for raising temperature before sending to the casting bay.

(g) Gas Cleaning

The EOF furnace operates on complete combustion of the generated waste gas. So

no recovery is required. The gas need to be cooled, cleaned and let to the

atmosphere within specified maximum dust content.

Gas cooling and cleaning will be wet type variable throat venturi scrubber and re-

cycled water system. Each EOF is connected to an individual ID fan system.

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A schematic representation of the EOF furnace is given over leaf (Fig. 9.1).

Fig- 9.1: Energy optimizing Furnace (EOF)

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The EOF process as depicted on the furnace automation system computer screen is

also given in Fig. 9.2.

Fig- 9.2: The schematic Overview of the Energy optimizing Furnace

9.1.10 Continuous Casting Plant

(i) The entire quantity of liquid steel produced in the EOF shop will be continuously cast

into Blooms/billets to meet the requirement of Blooms of around 260,000 t and

billets of 625,000 tons per year. As the rolling mill input size requirements 160-350

mm2, the total about 60 heats per day would be processed the following way:

$ Bloom Caster 16 heats per day in 4 heats sequence s 260,500 t of liquid steelper year.

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$ Billet casters s 2 Nos. 44 heats per day (22 heats per machine) with 5/6 Nos ofheat sequence amounting to 639,500 t to cast nominal heat size of 50 tons.

(ii) The broad features of the Bloom and billet machines are given below. The above

caster machines are planned along with necessary tundish preparation and auxiliary

facilities.

(iii) The machines will be type curved mould radial type design with a base radius of

12.0 m for the bloom caster and 9.0 m for the billet casters. The casters will be

equipped with ladle turrets for transferring the liquid steel ladle from receiving

position to casting position for sequence purpose. Two self propelled tundish

transfer cars will be provided for each caster.

(iv) The CC machine is equipped with mould, mould oscillation mechanism , secondary

cooling segments, withdrawal and straightening units, gas cutting units, dummy bar

handling and run out roller tables, hot charging facilities and bloom and billet

storage.

(v) Other facilities such as tundish preparation repair and assembly of moulds and

secondary cooling segments, mould testing etc. would be provided.

(vi) The continuous casting machine will work on a three shift basis for 320 operating

days in a year.

The basic technological features of the Bloom/ Billet/casters are given below:

Table-9.4: Technological Features of Bloom casting machine

Sl. No. Item Unit Parameter

1 Heat size T 55

2 Type of CCM - Radial with curved mould

3 Designed section size sq. mm 200 x 200 to 350 x 350

4 Basic radius of the machine M 12

5 Straightening method Multi radius

6 Average section to be cast mm x mm 300 x300

7 Casting speed for average section m/min 0.6

8 Casting time Min 45

9 Casting practice Sequence casting

10 Heats in a sequence Nos. 4

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11 Machine preparation time Min 45

12 No. of strands 2

13 Ladle turret Lift able type

14 Tundish Equipped with slide gate

15 Mould type and length Copper plate assembled mould ,900 mm


17 Withdrawal and straightening unit DC drive, Hydraulically operated.

18 Gas cutting unit Automatic oxy acetylene cuttingtorches


20 Run out roll table AC individual driven rollers.

21 Marking unit Automatic.

22 Bloom cutting length M 7


% 96 (average)

24 Caster working days Days 320

Table- 9.5: Technological Features of Billet casting machine

Sl. No. Item Unit Parameter

1 Heat size T 55

2 Type of CCM - Radial with curved mould

3 Designed section size sq. mm 150 x 150 f 250 x 250

4 Basic radius of the machine M 9

5 Straightening method Multi radius

6 Average section to be cast mm x mm 160 x160

7 Casting speed for average section m/min 2.5

8 Casting time Min 45

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9 Casting practice Sequence casting

10 Heats in a sequence Nos. 05/06/16

11 Machine preparation time Min 45

12 No. of strands 4 for each machine

13 Ladle turret Lift able type

14 Tundish Equipped with slide gate

15 Mould type and length Copper plate assembled mould ,900 mm


17 Withdrawal and straightening unit DC drive, Hydraulically operated.

18 Gas cutting unit Automatic oxy acetylene cuttingtorches


20 Run out roll table AC individual driven rollers.

21 Marking unit Automatic.

22 Bloom cutting length M 09/12/16


% 96 (average)

24 Caster working days Days 320

9.1.11 Process Flow for casting of steel

(a) After refining of steel at the ladle furnace /VD degassing unit, the ladle will be picked

up by the ladle handling crane and placed on the ladle turret of the continuous

casting machine. In the meantime, a refractory lined tundish preheated to about

1000 Deg. C and mounted on the tundish car will be moved from the reserve

position to the casting position. The ladle turret will be rotated through 180 degrees

to bring the steel ladle into casting position.

(b) A refractory shroud will be fixed to the ladle slide gate which will be then opened to

allow flow of liquid steel to the tundish.

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(c ) Prior to start of the casting operation, the dummy bar will be introduced into the

mould. The gap between the dummy bar head and the mould walls will be sealed by

asbestos cords and small pieces of steel scrap will be placed on the dummy bar

head for chilling of initial metal.

(d) Water supply to mould, secondary cooling zone and machine cooling will be

switched on at this stage. When the liquid steel level in the tundish reaches a pre-

determined level of about 1000 mm, the slide gate of the tundish will be operated for

flow of metal into the mould.

(e) When the metal level in the mould reaches about 100-150 mm from the top, the

drive of the mould oscillating mechanism as well as secondary cooling segments

and withdrawal and straightening unit will be switched on. The withdrawal of the

dummy bar begins at the minimum speed and gradually increased to the normal

casting speed within a few minutes. The submerged nozzle attached to the ladle

and tundish avoids oxidation of metal stream during casting. The lubrication of the

mould walls will be done by addition of requisite quantity of slag forming mixture

over the mould.

(f) The partially solidified bloom/billet after leaving the mould will pass through stand

guide roller segments where intensive but controlled cooling of the cast product will

be achieved by air mist cooling. The solidified blooms/billets will be guided through

withdrawal and straightening unit before entering the gas cutting zone.

(g) Strand cutting and bloom/billet transfer. The dummy bar will be separated from the

bloom/ billet after the withdrawal and straightening unit and will be stored in a

dummy bar storage device till its introduction is required for the next cast.

(h) The cast Bloom/billet will be cut to pre-determined lengths by oxygen s acetylene

gas cutting torches. On the run out roll table, blooms/billets will be marked and then

be transferred to storage area of conditioning /piling. The conditioned bloom/billet

will be stored in the bloom/billet storage yard before dispatch to rolling mills.

Provision has been made for hot charging of blooms/billets into the reheating

furnace. Excess blooms and billets will be sold after meeting the rolling mill

requirements.

(i) Emergency casting of liquid steel

During an emergency, the casting operation will be discontinued and the overflow of

metal from the tundish will be received into a slag box through the tundish spout and

the overflow launder. In case the casting need to be discontinued due to cold heat or

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other reasons, the ladle turret will be rotated after closing the slide gate and the

remaining metal will be poured into an emergency ladle.

(j) Slag handling

After the liquid steel in the ladle is emptied, the ladle turret will be rotated through

180 Degrees and the steel ladle will be removed by the ladle handling crane. The

slag in the ladle will be poured into a slag pot kept at the ground level in the ladle

handling bay and the empty ladle will be sent to the ladle preparation bay.

(k) Tundish preparation

At the end of casting, the tundish will be shifted to the reserve position for drainage

of remaining slag and metal. The empty tundish will be lifted by the tundish handling

crane and sent to tundish preparation bay where facilities of tundish tilting, tundish

cooling, tundish drying, etc will be provided. The refractory lined tundish will be

placed on tundish cars located on the casting platform by tundish handling crane.

9.1.12 Raw materials and services for the EOF and caster plant

The EOF furnace is capable to take up to 40% of solid charge. The proposed plant has

been envisaged with a solid charge of around 30% with 70% of hot metal. The solid

charge consists of DRI and scrap. The typical hot metal composition is:

C: 4.3%; Si: 0.6%; Mn: 0.6%; P: 0.15% and S: 0.03%.

At phase-1 along with the 1 million ton steel making facility a separate calcinations plant

of 300 tpd capacity has been considered under BOO mode for catering to the

requirement of calcined Lime/dolo requirement of steel making. The fines/rejects

generated will be taken by the sintering plant.

The estimated specific consumption of inputs and services are given in the table below.

The figures below are typical of low/medium alloy constructional steels.

Table-9.6: Steel Melting Shop No. 1 (EOF shop) input Material parameters

Wp1#

Rs1#

Teveqixiv## Tlewi04# Erryep#

viuymviqirx#+x,#

Viqevow##

4# Wtigmjmg#Gsrwyqtxmsr#sj#mrtyxw## # # #

# Lsx#Qixep#+Ok2XPW,# <57# <57/333# #

# Wxiip#2GM#wgvet#+Ok2XPW,# 4<8# 4<8/333# #

# HVM2Wtsrki#mvsr#+Ok2XPW,# 4<8# 4<8/333# #

# Gepgmrih#pmqi#+Ok2XPW,# <3# <3/333# #

#


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# Gepgmrih#Hspsqmxi#+Ok2XPW,# 58# 58/333# #

# S|}kir#+Rq62XPW,# ;3# <918#|#43#9#Rq6# Mrgpyhmrk#gewxiv##

# Tixvspiyq#gsoi#+Ok2XPW,# 5# 5333# #

# Hi0s|mherx#Jivvs0epps}w#+Ok2XPW,# 43# 43/333# #

# Epyqmryq#+Ok2XPW,# 4# 4333# #

# Ge0wmpmgmhi#+Ok2XPW,# 315# 533# Ew#Efszi#

# Epps}mrk#ipiqirxw#+Ok2XPW,# 43# 43/333# Ew#Efszi#

# Vijvegxsv}#+Ok2XPW,# 53# 53/333# #

# Mrwypexmrk#gsqtsyrh## # 4463# #

# Qsyph#Pyfvmgerx## # 4463# #

# # # # #

Note: Specific consumption of Ferro-alloys, alloying elements etc. are typical average values

for Low/medium alloy steels and would vary depending on the steel final composition.

Table-9.7: Steel Melting Shop No. 1 (EOF shop) utility requirement

Sl. No. Services Unit Annual Requirement

Steam Tons

Argon MNm3 0.5

Acetylene MNm3 1.0

Compressed air MNm3 14

Electric Power MkWh 157

Make up water Mm3 3.1

Fuel oil T 9000

Shop layout and facilities

The main building of the steel melting shop will comprise EOF charging bay, mixer bay,

scrap bay, bulk material bay, secondary metallurgy bay, casting bay, discharge bay and

bloom /billet handling storage bay. The layout of the EOF-CCP is given in the drawing

ENVIRO/AISL/FR/09/01 (R-1). The dimensions of the various bays and the number and

capacity of the cranes installed there are indicated below:

Table-9.8: Details of the EOF layout and handling cranes

Bay Dimensions (m) CraneLength Width Designation No. Capacity Rail height

(m)Scrap Bay 60 21 Scrap handling

Crane2 25 +12

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Lean to bay 120 12 MaintenanceCrane

2 5 +11.5

Scrap Charging/bulk materialhandling bay

156 21 Scrap handlingCrane

2 50/20 +28

Mixer bay/Hotmetal handling/charging bay

192 27 Hot metalcharging Crane

2 220/70/15 +24

Ladle handling bay/ secondarymetallurgy bay

228 30 Liquid steelhandling crane

2 110/30/10 +24

Castingbay/Tundishhandling bay

228 24 Tundish Crane 2 50/10 +23.5

Intermediate bay 168 24 Maintenancecrane

1 5 +18

Bloom/billetstorage bay

276 33 Bloom/billetcrane

2 12.5 +12.5 +15

Scrap bay: The in plant generated scrap and purchased scrap (if required) is stored in

the scrap bay and is processed to the required sizes for feeding to the EOF furnaces.

The bay will be equipped with facilities of scrap handling crane for unloading the

received scrap and charging the scrap boxes for transfer to the EOF shop.

Bulk material handling bay: This bay is equipped with a scrap handling /bulk material

handling crane. The scrap box is lifted by the crane in this bay and put on the furnace

top. Similarly various furnace bulk materials coming in self discharging containers are

lifted by this crane and discharged into the furnace top bin system and Ferro-alloys into

ladle feeding bin system. Similarly this crane also handles the EOF furnace top segment

in case of repair.

Mixer bay /Hot metal handling /charging bay: This bay is having facilities for hot metal

handling. 130 t hot metal ladles from Blast furnace enters into this bay and are lifted by

hot metal handling crane for pouring into the mixer. Mixer unloads the required hot metal

into EOF charging ladle for charging into the EOF. In this bay also facilities for LF/VD

jc^ith transformers, MCC rooms have been installed.

Ladle handling bay/secondary metallurgy bay: This bay is having facilities for casting the

steel, tundish heating and tundish preparation facilities. The caster radial segment is

located in this bay. Also mould and segment maintenance area is located here.

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Intermediate bay: The caster machine torch cutting facilities , dummy bar separation

facilities and caster control room, MCC rooms, Hydraulic room are located in this bay.

Bloom /Billet storage bay: This bay will have facilities for storing the billets/blooms for a

lZZ`th gZfj^gZbZci VcY i]^h WVn l^aa WZ i]Z Xdbbdc WVn [dg i]Z gdaa^c\ b^aas of Phase-1.

Facilities of hot charging are also considered.

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9.2 Basic Oxygen Furnace e Phase-2

9.2 The steel production envisaged at the phase-2 facilities is 2.5 million ton of liquid steel,

making the total capacity of the steel plant after completion of Phase-2 facilities at 3.5

million tons of liquid steel. The stipulated product is flat product s hot rolled and cold

rolled coils with subsequent processing. The process envisaged for steel making is Basic

Oxygen Furnace process (BOF) or LD converter process along with secondary treatment

for making quality coils and strips (both hot rolled and cold rolled). BOF process

generally is the currently adopted process for making large tonnages of flat products of

carbon steels for casting to continuously cast slabs for further rolling at Hot Strip Mill and

subsequent processing at the cold rolling and processing facilities. The quality and

grades of steel to be made at the BOF shop and cast through 2 Nos of slab casters

would include:

(a) Mild Steel(b) Low carbon steels(c) Medium carbons steels(d) Deep drawing quality steels(e) Carbon constructional steels(f) Boiler grade steels(g) Galvanizing quality steels(h) Tin plate quality steels

The grades of steel in the above quality will also include the following special steel

grades:

( High Strength low alloy grades (HSLA)

( LPG grades

( API 5LX line pipe grades

( IS 2062-Cu/Ti micro alloyed structural steel grades

( JISG 3101 grades

( SAE 1010 grades

( Dual phase grades

( Bake hard enable grades

( Trip steels

9.2.1 The technological features of the BOF shop will be:

(a) 2 x 1300 t in-active mixers with provision of desulphurization of hot metal

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(b) Scrap storage and handling system including baling press for processing light

scraps

(b) 2 x 150 tons BOF converters with bulk material feeding arrangement to over head

charging bins, lance handling system, Ferro-alloy addition bins with chutes.

(c ) BOF gas collection, cleaning, cooling recovery system including BOF gas holder.

(d) 2 x 150 t ladle Furnaces for temperature adjustment, desulphurization and trimming

addition for chemistry adjustment.

(e) 1x 150 ton RH vacuum degassing unit of steel.

9.2.2 The principal technological parameters of the BOF shop are given below:

Table-9.9: Steel Melting Shop No. 2 (BOF shop) parameters

Wp1#

Rs1#

Teveqixiv## Tlewi05# Viqevow##

4# Qm|ivw## 5#|#4633# #

5# Xsvtihs#pehpiw## ]iw## Xs#fi#gsrwmhivih#ex#

hixempmrk#wxeki1#

6# Gsrzivxiv#w## 5#|#483#x##

Fsxl#stivexmrk#xskixliv##

[mxl#kew#gpiermrk#erh#

vigsziv}#w}wxiq1##

7# Rsqmrep##liex#wm~i## 483#x## #

8# Xet#xs#xet#xmqi## 7<#qmryxiw## #

9# Liexw#tiv#he}#jvsq#xli#wlst## 63## Tiv#gsrzivxiv#

;# Stivexmrk#he}w#tiv#}iev## 633# #

<# Tvshygxmsr#sj#pmuymh#wxiip## 5/;33/333#x# 483#|#93#|#633#

=# Gewxivw#>## 5#rsw1#wpef#gewxivw##

4983#qq#{mhi##

#

43# Gsrwyqtxmsr#sj#qixeppmg#

qexivmepw##

445;#ok2XPw# #

44# Pmrmrk#pmji#{mxl#wpek#wtpewlmrk## 43/333#liexw# #

45# Wpek#vexi## 453#ok2XPw# #

46# FSJ#kew#vexi## 448##Rq62XPw# #

47# FSJ#kew#Gepsvmjmg#zepyi## 5333#Ogep2Rq6# #

48# ]miph#sj#gewx#wpef#jvsq#Pmuymh#

wxiip##

=8(# #

9.2.3 The specific consumption of raw material input and utility along with annual consumption

at rated capacity is given in the table below:

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Table-9.10: Steel Melting Shop No. 2 (BOF shop) input raw materials and utility

requirements

Wp1#

Rs1#

Teveqixiv## Wtigmjmg#

gsrwyqtxmsr##

Erryep#

Gsrwyqtxmsr#ex#

vexih#getegmx}1#

Viqevow#

# Erryep#vexih#pmuymh#wxiip#getegmx}#

+xsrw,#

# 5;33333# #

4# Lsx#Qixep#+Ok2XPw,# =98# 5938833#xsrw# #

5# Wgvet#+Ok2XPw,# ;5# 4=7733#xsrw# #

6# HVM2LFM+Ok2XPw,# =3# 576333#xsrw# #

7# Fyvrx#Pmqi2Hsps+Ok2XPw,# <3# 549333#xsrw# #

8# S|}kir#+Rq62XPw,# 88# 47<18#|#43b9#

Rq6#

#

9# Rmxvskir#+Rq62XPw,# 63# <4#|#43b9#Rq6# #

;# Evksr#+Rq62XPw,# 415# 6157#|#43b9#Rq6# #

<# Gsqtviwwih#emv#+Rq62XPw,# 53# 87#|#43b9#Rq6# #

=# Qeoi#yt#{exiv#+q62XPW,# 31<# 5149#|#43b9#q6# #

43# Ts{iv#+O[L2XPW,# 93# 495/333#Q[l# #

44# Wxieq#+Ok2XPW,# =8# 589/833#xsrw# #

45# Ehhmxmsr#sj#Ji0epps}w#jsv#hi0s|mhexmsr#

+Ok2XPW,#

43# 5;/333#xsrw# #

46# FSJ#kew#ywih#mr#xli#wlst#+Rq62XPW,# 518# 91;8#|#43b9#Rq6# #

47# Qeoi#yt#{exiv#+q62XPW,# 31<# 5149#|#43b9#q6# #

48# Gsrwyqtxmsr#sj#hiwyptlyvm~exmsr##

gsqtsyrh#+Ok2XLQ,#tvsgiwwih#

Tewwmzexih#Qekriwmyq#ts{hiv##

Pmqi#Ts{hiv#

319#

813#

4893#x#

46383#x#

Jsv#433(#lsx#

qixep#

hiwyptlyvm~exmsr1#

9.2.4 Generation of by-products and wastes.

The specific generation of by-products and wastes envisaged from the BOF shop is

given in the table below:

Table-9.11: Steel Melting Shop No. 2 (BOF shop) generation of by-products and

wastes

Sl.No.

Parameters Specificgeneration

Annualgeneration atrated capacity.

Remarks

1 BOF gas generation 115 310.5 x 10^6 Used as plant fuel and

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(Nm3/TLS) Nm3 mixed with Coke gas andBF gas.

2 BOF dust and sludge(kg/TLS)

15 40,500 tons To be used in sinteringplant

3 BOF slag (Kg/TLS) 120 324,000 To partly replace flux atsintering process and wouldbe processed for ironrecovery.

4 Steam (KG/TLS) 90 253,000 For in plant process steam5 Waste water (m3/TLS) 0.08 216,000 m3

9.2.5 Quality of Inputs and Outputs:

The representative chemistry of inputs and outputs from the BOF shop is given in this

section.

9.2.5.1 Process Inputs

(a) Composition of Hot Metal (%)

Element Range TypicalCarbon 3.5 -4.4 4.2Silicon 0.4 s 0.8 0.8Manganese 0.3 s 1.0 0.4Phosphorus 0.1 s 0.3 0.12Sulphur 0.02 s 0.05 0.045With practice of running blast furnace with low basicity slag for better productivity, the

hot metal sulphur may go above 0.55% also. For this hot metal desulphurization has

been envisaged with the BOF shop.

(b) Composition of scrap internal (typical) from phase-2 rolling mills

Fe: 94%; C: 0.05%; Mn: 1.0%; P: 0.04%; S: 0.04%; Alloying elements < 0.2%

(c) Composition of Flux for BOF

Product quality Unit Lime Do-limeCaO % 92 51Mg % 2.5 32SiO2 % 0.6 5.0R2O3 % 2.5 3.0LOI % 4.0 6.0Size range mm 10-50 10-50

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(d) Composition Lime Powder for desulphurization of hot metal

CaO7 r 6/$8 M7 q -+-/$8 FIC7 q /$8 M^oZ7 .--$ &7 r -+-2 bb 7 q.+- bb '8 ;c\aZ d[

repose: q 12 >Z\+

(e) Composition of Magnesium powder for desulphurization of hot metal

;Xi^kZ bV\cZh^jb7 r 62$8 =dVi^c\ q .-$8 M^oZ7 . bb

9.2.5.2 Process outputs

(a) Composition of Tapped Liquid steel:

C: 0.025 to 0.05%; P: 0.005 to 0.01%; Mn: 0.01-0.03%; S: 0.02 to 0.04%; O2: 500-

1000 ppm; Temperature: 1600-1650 0 C.

(b) Composition of slag:

SiO2: 12-14%; CaO: 42-48%; FeO: 18-22%; MgO: 8-12%; Slag basicity: 3.5

(c) Composition of BOF gas

Parameters Unit ValueVolume Nm3/tLS 110-115Temperature (after cooling andcleaning)

Deg. C 60-80

CO % 60-67CO2 % 24-26N2 % 15-20Calorific value Kcal/Nm3 1700-2000.

9.2.6 Basic Oxygen Furnace Shop facilities.

Various units under the BOF shop with major facilities are indicated below:

(a) Converters proper: Each of the two converters will be equipped with integral

bottom with facilities of bottom stirring by inert gas: N2 or Argon. Each converter

should be complete with but not limited to s vessel shell, trunnion ring, trunnion pins,

vessel suspension, trunnion bearings, vessel pedestals, slag shields, dog house

around the converter tilt drive system including emergency drive, electrical

equipment, instrumentation and control.

(1) Vessel shell: The vessel shell shall comprise of a conical top with lip ring segment, a

cylindrical center section and a conical lower section and dished bottom section

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made of non aging steel. The taphole socket will be welded to the conical top

section. The taphole cover shall be fixed with the flange of the taphole socket by

pins and wedges. The schematic drawing of a converter is given in Fig 9+0 WZadlt+

(2) Vessel refractory: The vessel will be lined with refractory as per scheme given

below:

Fig.-9.3: Sectional elevation of converter vessel

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Lining zones:

1. Mouth2. Taping side3. Taphole sleeves4. Taphole surrounding5. Trunnion6. Scrap impact7. Bottom8. Metal layer9. Purging element10. Permanent lining

Fig-9.4: Sectional elevation of converter vessel showing zones of lining.

Table-9.12: Converter zones wear conditions and refractory envisaged

Converter zone Wear conditions Refractory envisaged

Cone 1) Oxidizing atmosphere 1) Standard quality magnesia f

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carbon bricks containing antioxidants

2) Mechanical abuse 2) Pitch bonded magnesia bricks

3) Thermo mechanical stress 3) Resin bonded low carbonbricks with anti oxidants

4) High temperature

Trunnions 1) Oxidizing atmosphere 1) Premium quality magnesia f


2) Slag corrosion 2) Premium quality magnesia fcarbon bricks containing fused

MgO and anti-Oxidants

3) Slag and metal erosion 3) High strength premiumquality magnesia f carbon

bricks

Charge pad 1) Mechanical impact1) Pitch impregnated burned

magnesia bricks

2) Abrasion from scrap and hotmetal 2) Standard quality high

strength magnesia f carbonbricks containing anti oxidants

3) High strength low carbonmagnesia bricks containing anti

oxidants

Tap pad 1) Slag erosion1) Premium quality magnesia f


2) High temperature 2) High strength low carbonmagnesia bricks with metallic

additives

3) Mechanical erosion 3) Standard quality magnesia fcarbon bricks containing anti

oxidants

Turndown slaglines 1) Severe slag corrosion 1) Premium quality magnesia f

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2) High temperature 2) Premium quality magnesia fcarbon bricks containing fused

magnesia and anti oxidants

(3) Converter tilting drive with emergency tilting system. The tilting of the converter will

be accomplished by four drive system. The rotation of the converter shall be 360

Degrees on either direction and the speed of rotation will be between 0.1 rpm to 1

rpm variable. The capacity of the tilting drives will be sufficient to tilt the converter at

minimum speed of 1 rpm under all operating condition with all the drives in service.

The tilting gear drive will be complete and have base frame coupling, bearing,

reduction gear, lubrication system, brakes etc. In case of power failure, brakes will

be set and hold the converter in position at power failure had occurred. Emergency

release system included for the brakes as safety device for bringing the converter to

the upright position in the event of power failure. The converter should be balanced

in such a way that under all operating condition, the converter will come back to the

up-right position by gravity. The drives are backlash free and easy to maintain.

(4) Oxygen lance system with slag splashing device: Each converter will be given an

independent oxygen lancing system with two identical water cooled multi hole

oxygen lances. Each lance system will remain mounted in position ready for

operation with oxygen and water hoses connected. The lance system would be

designed to meet the following operational requirement.

- Supply of oxygen at the rate and pressure required for blowing the heat in 14-16

minutes. Oxygen flow rate of about 600 Nm3/Min has been envisaged

- Quick exchange of the operating lance with the stand by lance in case of a

failure of the operating lance.

- Quick installation/dismantling of lance into/from the lance carriage.

- Use of blowing lance for pre-heating the newly relined converter and for slag

splashing the converter as and when required.

Each lance system will comprise of (not limited to)

% Lance carriage with guide frame.

% Lance hoist including rope drive.

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% Lance carrier

% Four oxygen lances

% Two oxygen hoses and four water hoses

% Valve stations and pipe work

% Closed circuit pressurized lance cooling system with heat exchanger

% Emergency lance lifting.

Lance de-skulling and re-tipping facility: In the lance cleaning stand the slag and

metal will be removed from oxygen lances. Slag and metal skulls are falling into the

container which is placed below the cleaning stand on the floor. Spare lances are

suspended in the lance system. Transport of damaged /new lances between lance

installation and lance station will be by crane.

(5) Bottom stirring system: The bottom stirring system consists of a set of porous plugs ,

hoses and pipe work from the porous plugs to the trunion ring and through the

trunion ring and through the trunion drive and trunion pin , valve station, control

instrumentation and auxiliary equipment. Through the porous plugs nitrogen or

argon can be blown in at the bottom of the vessel.

(6) Liquid steel handling: Liquid steel handling starts from tapping the heat from the

converter into the steel teeming ladle placed on the transfer car. The steel transfer

car will start from the converter charging aisle and shall terminate at the ladle

distribution aisle. The track from converter charging aisle shall be extended into the

slag aisle for transportation of slag pots. The wheel centers of the steel transfer car

and the slag transfer cars shall be identical enabling both the cars on the same

track.

(7) Slag handling system: The slag will be poured out from BOF converter into slag pots

placed on self propelled transfer cars and transported to the slag yard. Hot slag will

be dumped into pits and allowed to cool. Cold slag from the pit will be removed for

further processing for recovery of scrap. The job of removal of cold slag and

processing of slag for recovery of iron will be given to contractual agencies. Part of

the BOF slag will be taken to sintering plant/blast furnace substituting flux usage as

well as recovery of iron from iron oxide.

(b) Hot metal handling system: Hot metal will be delivered to the BOF shop via open

charging ladles of 155 t capacity. The ladle will be then picked up by the charging

EOT crane and placed on the transfer cars at hot metal desulphurization unit if

desulphurization is required. After desulphurization, hot metal ladle will transfer to

BOF shop for charging via EOT charging crane.

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(c) Scrap Handling System: Scrap and cold pig iron will be loaded in the scrap charging

boxes placed on the scrap car positioned over weigh bridge by the overhead

magnetic crane in the scrap bay. Scrap boxes will be brought to the charging bay by

the scrap box car. Scrap will be charged into the converters by means of crane.

(d) Hot metal desulphurization unit: Hot metal desulphurization station has been

envisaged to reduce the sulphur levels of the hot metal before charging to the BOF.

This would be required particularly for making low sulphur grades of steel required

for oil sector and deep drawing quality of steel. Desulphurization will be carried out

by magnesium containing agent and lime injected into the ladle with Nitrogen gas.

Alternatively calcium carbide also may be used in place of lime as desulphurizing

agent. The desulphurization time will be 30-40 minutes.

(e) Flux and Ferro-alloy addition : Lime, calcined dolomite, Lime stone, nut coke etc.

will be received in over head bunkers in the converter bay from storage silos located

outside the converter building by a conveyor system. Fluxes will be charged into the

converter from both sides through a system of weigh hoppers, charge holding

bunkers and chutes. Predetermined quantities of Ferro-alloys from the storage bins

will be delivered into the steel ladle through a system of weigh hoppers and chutes.

(f) Waste gas cooling and recovery

Considering the scarcity of water in the Hospet region, the gas cleaning system is

designed as a dry type cleaning system for efficient cleaning and further cooling of

the BOF gas. The system is designed for subsequent converter gas recovery. This

ineZ d[ \Vh XaZVc^c\ ^h i]Z iZX]c^XVa hdaji^dc id Xdbean l^i] idYVnth bdhi hig^c\Zci

environment requirement.

The gas cleaning system is only in operation with full capacity during blowing time.

After passing through the cooling stack where the gas temperature is reduced, the

gas enters the adjacent conditioning tower with a maximum temperature of 1000 0

C. The gas heavily laden with dust from converter process Viz. iron, slag, iron oxide,

flux etc. with size ranges from approx. 0.1 micron to several mm.

In the GCT, which is made gas tight with provision of high temperature

compensators, the BOF gas is cooled and conditioned by addition of measured

injection of a quantity of water. The water on evaporation cools the gas and the

coarse dust particles are separated and falls in the coarse dust silo provided below

the GCT. The coarse dust particles are separated in a dry state from the silo. The

conditioned gas at a temperature below 200 0 C is further cleaned in a horizontal dry

type electro-static precipitator. The fine dust is collected below the ESP in dust

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hoppers from where it is pneumatically collected and sent to a central dust bin for

onward transmission to sinter plants. The gas is collected through the gas cleaning

system with an induced draft fan. Depending on the actual CO content of the gas

the BOF gas enters the recovery system or passes to the flare stack.

A subsequent gas cooler installed in the gas duct to the gas holder further reduces

the temperature of the BOF gas down to 60-700 C range suitable for subsequent

handling of the gas. The system installed will be capable of reducing the dust

XdciZci d[ i]Z XaZVc \Vh Ydlc id q .- b\,Hb0 &Ygn'.

For switching over the gas from flare stack operation to gas recovery operation and

vice versa, a switch over station is used. The gas switch over station mainly consists

of two bell shaped valves which are adjusted hydraulically and separately from each

other. By means of this station the system can be switched over without any

pressure surge. The signal for switching over the system is given by the PLC based

on interlocks and process variables. The signal for switching comes from the CO

and Oxygen analyzer.

(g) Secondary emission control system

The secondary fume collection system will be designed to collect the fumes from the

following emission sources.

- Desulphurization station

- Converter charging, blowing (secondary fumes only) and tapping

- Flux and alloy system at BOF converters

- Ladle furnaces

The fumes are collected in specially designed hoods as close as possible at the

emission source. In the suction ducts of each hood there would be motor operated

dumpers installed for appropriate on/off operation and intermediate position.

The fumes are taken to a gas mixer where the gases are homogeneously mixed and

subsequently to a bag filter system to be released to the atmosphere through a self

supporting chimney of 40 m height. The dust content of the cleaned air would be less

than 30 mg/Nm3. The recovered dust from the collection hoppers of the bag filter

house will be taken to the sintering plant.

9.2.7 The details of the shop and cranes. The layout of the shop is given in the drawing

ENVIRO/AISL/FR/09/02 (R-1)

1. Scrap bay: 84 m x 30 m; 30 tons Magnetic cranes s 2 Nos.

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2. Mixer bay: Incorporating the mixers 2 x 1300 t and the hot metal desulphurizing

station. Mixer cranes: 2 x 240/50 t

3 Auxiliary bay; 100 m x 11.5 m:

4. Converter bay with lance handling and Bulk material charging: 100 m x 18m: lance

handling crane 30 t x2 Nos.

5 Charging bay: 100 m x 25 m; charging crane 2 x 240/50t t

6. Ladle handling bay with secondary treatment facilities: 100 m x 18 m; 2 x 240/30 t

Cranes

7 CCM turret bay with 2 Nos. 2 x 240/30 t cranes

9.2.8 Secondary Treatment of Steel

The steel tapped into steel ladles at the converter shop will be treated with de-oxidizing

Ferro-alloys after tapping from the over head Ferro-alloy bunkers though weigh hoppers

and chutes. The de-oxidized steel in ladles over ladle transfer car will pass on to the

ladle handling bay where the secondary treatment facilities are installed, In general the

secondary treatment facilities are similar to phase-1.

9.2.8.1 Ladle Furnaces:

There will be two numbers of 150 t Ladle furnaces each for each converter with facilities

of Bottom purging of argon/nitrogen though porous plug installed at the ladle bottom

refractory

( Top scum breaker with top nitrogen stirring,

( Three heating electrodes. The transformer capacity of each ladle furnace will be

28 MVA. The heating capacity will be 2.5 to 5 0 C. The expected treatment time

will be 30-90 minutes with an average of 45 minutes.

( Alloy addition chute. The alloys/Ferro-alloys will be stored in overhead bunkers

fed with conveyor system. 10 hoppers for each LF have been typically

envisaged. The alloys will be collected on a conveyor through vibro-feeders via a

weigh hopper also fitted with vibro-feeder to the additive chute to the ladle. The

entire operation will be programmed and controlled with PLC.

( Sample taking chute with automatic sampling arrangement

( Arrangement for feeding of aluminum wire and ca-silicide cored wire to the ladle

for de-oxidation

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Fig-9.5: 3D view of a typical ladle furnace installation.

9.2.8.2 Vacuum degassing with RH facility.

Since the heat size at phase-2 is larger and the requirement of degassing is often more

stringent for special quality flat products in critical applications, RH degassing is

envisaged at phase-2 with BOF process.

Fig-9.5: Principle of operation of a RH degasser.

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Fig-9.6: A schematic representation of a single vessel RH degasser.

Figures above shows the principle and 3D scheme of a single vessel RH unit as envisagedin the steel plant. A single vessel unit has one treatment position usually served by oneladle transfer car. The vessel is connected to an alloy addition system and the vacuumpump system. As this RH unit is only intended to be used for degassing treatments, it isonly equipped with an atmospheric burner lance to heat up the vessel or keep it at therequired temperature. Vessel change can be done by crane or using the vessel liftingequipment. A complete vessel is typically exchanged within about 90 minutes. Forsnorkel maintenance, a maintenance car is provided.

Key technical parameters of this plant are as follows:Inner snorkel diameter: 460 mm,Deep vacuum: 500 kg/h at 0.67 mbar,Hydrogen content after degassing: max 1 ppm.

9.2.9 Continuous Casting of Steel with slab casters

At phase-2, flat products are envisaged. The primary flat product mill will be Hot Strip

Mill of 1600 mm wide, rolling slabs up to width of 1550 mm. The product mix will be all

strips both hot rolled and cold rolled and very wide products are not envisaged. To

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produce the primary slabs 2 nos. of slab casters are envisaged. The steel ladles after

secondary treatment are placed in the caster turret bay to wait for lifting to the turret to

maintain a sequence of casting.

9.2.9.1 The technical characteristic of the caster

The technological features as envisaged for each of the two casters are given in the Table

below:

Table-9.13: Technological features of the Envisaged Slab Caster

Sl.No.

Parameter Value

1 No. of casters 22 Heat size (liquid steel) 150 t3 Caster type Multipoint liquid core bending with straight

Mould

4 No. of strands 1 x 1

5 Machine radius As per technology suppliers equipmentdesign (however, approximately 10500 mmwith multi point unbending)

6 Mould type Vertical mould

7 Metallurgical length 10.5 m (Tentative)

8 Casting speed 2.0 m/min(Tentative)

9 No. of tundish cars 2 Nos.

10 Tundish capacity 20 t

11 Slab width (design) 950-1650 mm

12 Slab thickness 200-250 mm

13 Mould slab sections to beprovided

Width : 2 sections (950 s 1250 mm; and1250 s 1650 mm)

14 Width changing On line changing facility to be provided

15 Slab length 7500 to 10,500 mm

16 Casting time of a heat 35-40 minutes

17 Machine preparation time (re-stranding)

50 minutes

18 Yield (Liquid to slab) 98.5% (design)

19 Tundish practice Hot tundish

20 Liquid stream protection Refractory shroud between ladle and tundish.And SEN between tundish and mould

21 Dummy bar Flexible chain type s bottom fed

22 Mould oscillation Hydraulic mould oscillator suitable to quickchange practice

23 Mould level control Automatic mould level controller (Eddy current

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type)

24 Secondary cooling Air mist/spray cooling (as per technologyprovider.

25 Soft reduction of strand Dynamic control

26 Gas cutting machine Oxy-Propane gas based

27 Slab identification Automatic slab marking machine

28 Slab discharge Roller table

29 Process control PLC controlled

30 Sequence casting Should be 10 heats approx.

31 Flying tundish Machine should be designed for flying tundishalso

32 No. of working days for SlabCaster

320 days

9.2.9.2Proposed CCM shall broadly consist of following equipment / system:

i) Technological Structureii) Cooling Chamberiii) Ladle Turret- 1 set

The steel ladle from the BOF is placed on the ladle turret by means of a crane andpositioned above the tundish. The Ladle Turret shall consist of following equipments:

( Ladle cover manipulator( Ladle slide gate connecting platform( Ladle slide gate mechanism( Emergency launder for ladle( Ladle weighing system- 2 sets:

iv) Ladle slide gate lance- 1 set

In the event that liquid steel does not flow after opening of the slide gate, theLadle slide gate oxygen lance is utilized to burn open the ladle nozzle. The lanceis also used for cleaning of the ladle shroud between ladle exchanges.

v) Shroud manipulator (Hydraulically operated).

vi) Tundish - The tundish receives the liquid steel and distributes the steel throughone tundish bottom opening to the mould. There shall be provision for hottundish with dual heating system with CO gas as well as propane. Slide gatesystem along with system for emergency closing shall be provided for controllingthe flow of liquid metal from tundish to mould. Flow modifier will be provided..Thesubmerged entry nozzle quick change mechanism shall be provided under thetundish outlets so that preheated submerged entry nozzles can be quickly

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changed during casting without interruption or delay in the process. The tundishshall be made of welded steel plates of heavy section. Each tundish shall besupplied with refractory lined metal covers having suitable openings. It shall alsobe provided with weighing facility. Ladle to tundish slag detection system shallalso be provided. Emergency box for tundish (3 sets), Over flow box for tundish2 sets) and overflow trough for turret (2 set) per machine shall also be provided.

vii) Tundish Car-2 sets per machine Tundish car picks up the tundish in heatingposition and transports it to the casting position and positions it above the mould.In combination with a second tundish car, tundish change is possible withoutinterrupting the casting process.The tundish cars shall be operating on the casting platform. It shall be providedwith electro mechanical drives for travelling and hydraulic system for lifting andlowering. It shall also be provided with hydraulically operated centeringmechanism to facilitate centering of SEN with respect to mould.Weighing system shall be strain gauge type load cell based and the system shallbe able to monitor individual signal from each load cell. Tundish car shall havecalibration arrangement with standard weight pieces.

viii) Mould & Mould assembly- 5 sets per machineMould assembly is located below tundish on the oscillating table. It providesinitial solidification to forms slab shell in the adjusted thickness and width.Straight type mould shall be provided. Mould assembly along with foot rollersshall be quick change cartridge type. The mould shall be located on theoscillating tables at the start of the casting machine. The mould assembly shallbe having water cooling arrangement for the copper plates and complete withnecessary fittings for cooling water arrangement for fixing on to the mouldoscillation table and protection cover to avoid damage due to metal splash andmetal overflow. Mould shall be provided with Automatic Width Change Facility oflatest design to adjust section without stoppage of machine. Off-line mould widthcalibration facility shall be provided.

ix) Automatic Mould Level Control (AMLC)- 1 setAn eddy current based Automatic Mould Level Control (AMLC) system shall beprovided. AMLC shall be mounted directly above the mould. AMLC shall be usedto maintain the level in the mould constant during casting.

x) Mould Oscillation System- 1set/machineHydraulic type Mould oscillation system shall be provided. Oscillation frame shallbe water cooled. Frequency of oscillation shall change automatically with changein casting speed. Quick release coupling shall be provided for water hoseconnection / disconnection. Off line

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Calibration facilities shall be provided. Necessary grease lubrication system shallbe provided. All necessary access and maintenance platform shall be provided.

xi) Strand Guide System- 1 setSets of rollers and their supports, strand guides and various segments Segment-0 (Vertical), Segment-1, Various segments (bending / un*bending / bow /horizontal, etc.), with working exchange set (Bidder to design / indicate /recommend) along with drives, Segment exchange arrangements / facilities(quick change with automatic connections) and all accessories shall be provided.Strand Guide System shall be multi point bending and straightening with softreduction. Design of segments will ensure easy access formaintenance & inspection. Automatic roll gap adjustment facilities will beprovided.

xii) Withdrawal & Straightening Segment - 2 sets/machineWithdrawal & straightening units with direct drive shall be provided. Thewithdrawal & straightening units shall have reversible drives with infinitelyvariable speed and shall be complete with motors, gear boxes, brakes etc.Withdrawal speed shall be synchronized with the frequency of mould oscillation.Top rolls shall be provided with hydraulic cylinders. The design of frame andhousing shall be such that roll changing can be carried out with minimum dis-assembly within minimum time. The housing frame, rolls and bearing housingsShall be water cooled. An electric hoist of suitable capacity shall be provided formaintenance of withdrawal & straightening units.

xiii) Dummy Bar System- 1 setDummy Bar System for each machine consisting of Dummy bars (3 sets),Dummy bar body, Dummy bar heads (4 nos. for each section of slab), Dummybar disconnecting & storage facility(1 set), Dummy bar receiver with platform,Storage stand and transport device for dummy bar heads, Roll gap checker(dummy bar head type) etc. shall be provided. Suitable handling facilities fordummy bar shall be provided.

xiv) Torch Cutting Machine (TCM)- 1 setThe cast strands shall be delivered from the last segment of the strand guide tothe approach roller table of torch cutting machine. The products shall be cut withthe help of oxy-propane flame. A cutting torch for the strand of CCM shall beprovided for cutting the products and the operation of the unit shall be fullyautomatic. The unit shall comprise of a machine frame, oxy- propane torcheswith pre-heating burners, a gas distribution system including necessary hoses,connectors, hose guides, travel and pneumatic clamping mechanism for thetorch cutting machine and the related control and electrical equipment. The unitshall be suitable for cutting the maximum size of products envisaged to be castin the CCM. Facilities for sludge granulation and disposal shall be provided. The

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xx) Steel ladle & Slag pot transfer car (self-propelled). The broad details are givenbelow;

1. Quantity (Nos.) 1 per converter and casting machine2. Capacity (t) - Heat Weight 1503. Speed of Car 30 (m/min) approx4. Drive Electro-mechanical5. Travel length (m) approx. 506. Level (m) ±0.07. Power supply: Supply will be through cable reeling drum8. Control from control post (2nos) at ±0.00 levelIt shall be designed to transfer slag pots and steel ladles.

xxi) Tundish transfer car (self-propelled)A Tundish transfer car shall be provided to transfer tundish to the Tundishpreparation bay of CCS.

Brief description of the tundish Transfer car is as below:-1. Quantity (Nos.) 1 per caster machine2. Capacity (t) 503. Speed of Car 30 (m/min) approx.4. Drive Electro-mechanical5. Travel length (m) approx 406. Level (m) ±0.07. Power supply Supply will be through cable reeling drum8. Control From control post( 2nos) at ±0.00 level

xxii) Inter bay Transfer car for segment & slab transfer (self propelled)1no. Segmenttransfer car shall be provided to transfer segments In addition, 1 no. slab transfercar shall be provided to transfer slabs on the same track. It shall also be used fortransferring slabs from -- bay to -- bay in case of emergencies. Slabs shall belifted from the strands in case of emergencies and placed on the transfer car bymeans of a suitable tong type attachment attached with the EOT crane.

% Quantity (Nos.) 2% Capacity(t) 100% Speed of Car 30 (m/min)% Drive Electro-mechanical% Travel length (m) approx. 60% Level (m) ±0.0% Power supply: Through cable reeling drum% Control From control post( 2nos) at ±0.00 level

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-xxiii) Slab transport buggies for dispatch of CC slab to HSM. 18 nos buggies of 100 t

capacity each shall be provided for transportation of continuous cast slabs fromdispatch bay of CCM Shop to Hot Strip Mill (HSM).

xxiv) Mould & Segment Repair shopMould & Segment Repair shop (30 X 120 m approx.) shall broadly consist oflathes, drilling machine, milling machine, grinder etc for repair of Mould &Segment along with material handling equipments. All equipments / facilitiesrequired for repair/ maintenance of mould & segments shall be provided inMould & Segment Repair shop.

xxv) Tractor-trailerOne no tractor-trailer shall be provided for transportation of replaceableequipments from steel melting shop to the Repair Shop (RERS)

xxvi) One number of Passenger lift shall be provided from ground level to castingplatform for each of the two casters.

9.2.9.3 Handling Equipment at the CCM section.The handling facility envisaged in the slab casting area is given in the table below:Sl. No. Description Quantity Capacity Span (m)

1 EOT crane for steel ladle handlingin the turret bay

2 Nos. 240 +50/20

27

2 EOT crane in CC machine bay 2 Nos. 100 t 273 EOT crane in the dispatch bay for

slab handling2 Nos. 100 t 27

4 Pump house, compressor room,scale pit

3 Nos. 10 t 20

5 Mould segment repair shop 2 Nos. 20+5 226 Scale pit grab crane 1 No. 10 -

9.3 Environmental control measures envisaged in the steel making processes atboth the phases of the steel plant.

9.3.1 EOF shop: For EOF process, the following measures are envisaged for prevention ofair and water pollution.

9.3.1.1The air pollution control measures include:(1) The cooling and cleaning of the EOF waste gas. This gas has no heating value

and the cooled and cleaned gas is let out through a tall chimney. The gascleaning plant is envisaged to be of wet type and comprise of (a) refractory lineddown comer (b) quenching chamber (c) venturi (d) Cyclone separator (e) ID fansand Chimney. Each of the two EOF furnaces is provided a separate gas

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cleaning and cooling system with separate chimney. The venturi is the heart ofthe system which not only helps to separate dust from the waste gases due tosudden drop of pressure but helps to maintain the negative pressure inside theEOF furnace. The outlet of the GCP is dirty water which is further treated.

(2) Maintaining the shop atmosphere and prevention of fugitive dust in the air is doneby installing suction hoods in all dusty places and use of bag filters to clean thedusty air before release through medium height chimney (40-50 m)

(3) The fumes of the Ladle furnaces and VOD are also collected through a duct,cooled in air cooled tubes and cleaned in bag filter houses before releasethrough chimneys.

9.3.1.2Water pollution control in EOF shopThe water pollution control measures in the EOF shop; the dirty water from thewaste gas cleaning plants is conveyed to a thickener after dozing with chemicals forsettling. The clear water from the thickener is cooled in cooling tower and pumpedback to the system. The collected mud has 60-70% Iron and is used in sinteringplant and later in the pellet plant.

The cooling water for the furnace parts are clean water which are cooled in coolingtowers and re-circulated.

9.3.2 BOF shop

The BOF waste gas has valuable heat value and is re-used after cleaning andcooling of the gas. For this project a dry type of gas cooling and cleaning system hasbeen envisaged. The system is described in pages 29-30 before. The cleaned BOFgas with a residual dust content less than 5mg/Nm3 is used as plant fuel incombination with Coke Oven gas and Blast furnace gases and can be burnt with airwith waste gas let off without any pre-treatment.The BOF shop also will have dust collecting hoods in particularly dust stressed areaslike the bulk material handling platform and transfer chutes the dust laden collectedair will be cleaned with bag filters.The areas like BOF furnace hoods and up-comer will have evaporative coolingsystems and would use DM water.

9.3.3 Pollution control measures at Continuous casting units.The main treatment is for water. The strand cooling water is dirty, laden with millscale. The water for each of the bloom/billet casters and the slab casters is collectedin scale pits for the scales to settle and the clear water overflows and is pumped to aoil removing units after which the water is cooled and re-used. The scale is collectedfrom the pits with grab cranes and the scales are used in the sintering plants asvaluable Fe input.

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The mould and machine cooling water used in the continuous casting machines areused for indirect cooling and only needs cooling at cooling towers before re-use.

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CHAPTER-10: Hot Rolling Mills

10.0 It is proposed to install two hot rolling mills at Phase-1 to produce special and alloy steel

billets, bars and wire rods in the size range from 6.5 mm dia. to 200 mm dia. for meeting

the requirement of various special steel consumers and industries. At phase-2, where

flat products would be the line of products, a hot strip mill to rolls cast slabs to strips in

the size range of 800-1550 mm and thickness of 1.6 to 12 mm will be installed. A cold

rolling and processing facility to cold roll part of the hot rolled coils and coat it with

zinc/aluminum/Colour will be installed at phase-2, to meet the increased sophistication of

the consuming markets in the coming years.

10.1 Phase-1 facilities:

The capacities and product ranges of the two phase-1 rolling mills viz. the Bar and rod

mill and the Billet & Bar mill are given in the table below.

Table-10.1: Product mix of Phase-1 facilities

Sl.No.

Mill Products Grades Size range(mm)

Annualtonnage (t)

1 Bar & RodMill

Wire rod incoils

DD, BBQ, CHQ, BQ,FCS, Spring Steel &other EN grades

5.5 to 16 200,000

Bars in straightlengths

ACS, CCS, BQ,Spring steel & otherEN grades

16 to 60 400,000

Sub Total 600,0002 Billet &

Bar MillRounds ACS, CCS, BQ,

Spring steel & otherEN grades

60-200 150,000

Squares(round corner)

ACS, CCS 60-200 50,000

Flats ACS, CCS, BQ,Spring Steel etc.

60-140 50,000

Sub Total 250,000Grand Total 850,000

Note: ACS: Alloy Constructional steel; CCS: Carbon Constructional Steel; BQ: Bearing quality;

BBQ: Bright bar quality; DQ: Drawing quality; CHQ: Cold heading Quality; FCS: Free

cutting steels.

10.1.1 Bar & Rod Mill

10.1.1.1 The proposed bar & Rod mill will have 600,000 tons per year capacity and will roll

rounds in straight lengths and wire rods in coils from square continuously cast

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billets. The mill will be suitable for producing special steel for a maximum output of

150 tons per hour (tph) with cold billet charging. Provision of hot charging of billets

where inspection and surface correction of billets are not necessary has also been

envisaged. The technical parameters of the Bar & Rod Mill are given in the table

below:

Table-10.2: Major Parameters of the Bar and Rod Mill

Sl.No.

Item Unit Parameter

1 Type of Mill Single strand continuous mill2 Capacity of the Mill t/y 600,0003 Rolling (operating ) speed

maxm/s 16 for bar dia. 16 mm

110 for 5.5 to 8.0 mm rods4 No. of operating days in a

year (availability)Days/year 300

5 Shifts/day 36 Hot rolling hours Hrs 60007 Utilization of available hours % 838 Reheating Furnace (Single) Walking beam type 150 t/hrs

nominal capacity9 Input billets 160 x160 x 12000; 2400 Kg

10 Fuel for reheating Mixed gas : CV 1900-2000Kcal/Nm3

11 Annual billet required t 625,00012 Finished product size range Straight length products:

Rounds16-60 mmWire rod in coils 5.5 to 16 mmBundle weight: 3000-5000 KgCoil weight: 2500 kgCoil ID: 860 mm ; Coil OD:1250 mm

13 Billet to product yield % 9614 Specific Fuel Consumption G Cal/T

of billets0.55

15 Specific Power consumption KWH/t 60

10.1.1.2 Special features of the Bar & Rod mill

The envisaged Bar & Rod mill will be of modern design and will have the following

special features to secure superior surface finish, close dimensional tolerance and

physical properties of the special steel products.

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' Billet weighing facility

' Walking beam type reheating furnace

' High pressure de-scaling facility

' Single stand high speed continuous mill arranged in horizontal-vertical configuration

for twist free rolling.

' Facility of modern housing less stands for rolling.

' Quick roll changing facility

' Inter stand tension control

' In-line rapid water quenching unit for production of thermo-mechanically treated high

strength bars.

' Pre finishing mill and no-twist block unit for wire rod production.

' Control cooling conveyor.

' Automatic bar bundling and tying facility

' Coil handling and compacting facility

' Level-2 automation control for mill and re-heating furnace.

10.1.1.3 Major facilities in Bar & Rod Mill

The major facilities for the Bar & Rod Mill with their brief technical features are given

below.

Table-10.3: Major facilities in Bar & Rod Mill

Sl. No. Equipment /facilities Unit Technical features1 Reheating Furnace

Number & Type No. 1 No. walking beam type; sidecharging and side dischargetype.

Nominal throughput t/h 150 with cold chargeFuel - Mixed gas with CV: 1900

Kcal/Nm3Billet charge Cold charge with provision of

hot charging from case to caseTemperature of the re-heatedbillets

0 C 1100-1150

Air preheat temperature 0 C 500-550Furnace charging Comprises of cold billet

charging equipment such asbillet charging grid and rollertable and billet weighingarrangement.

2 Rolling mill proper

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Water de-scaling unit - One high pressure watersystem for de-scaling of hotbillet

Heat insulated roller table No. One, to work as feed roller tableto the first mill stand.

Pinch roll unit No. One, to assist feeding of billetsto the first mill stand.

Emergency shear No. One, toggle shear before standNo. 1 for cutting the incomingbillet in case of cobble afterstand No. 1

Mill stands No. Total 20 stands (tentative)comprising of roughing train,intermediate and finishingtrains.

Crop and cobble shear No. One each, ahead of roughing,intermediate trains of millstands for cropping andemergency cobble cutting.

Pinch roll unit and dividing shear No. One set, shear to divide the barinto cooling bed lengths

Cooling bed No. One, rake type , 90 m long toaccept bars from 16 mm to 60mm.

Cold shear with shear gauge No. One set, to divide the finishedbars to cut lengths 6-12 m

Bundling, piling and bindingstation

No. Two sets, each automaticoperation for bundling & bindingbars. Bundle weight 3-5 tons.

Bundle collection and unloadingstation

Two sets, to receive tiedbundles from binding station,equipped with bundle weighingfacility.

3 Facilities for Wire rod coilsPre-finishing & No-twist blocks No. 2 strand pre-finishing mill and 8

stand no-twist blockPinch roll and laying head No. One set of pinch roll and laying

head to ensure high speedlinear path of rod to circularpath and form convolutes.

Control cooling conveyor No. 1 No. cooling conveyorcomplete with insulating covers,fans and cooling air ducts forcontrolled cooling of wire rodconvolutes.

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Coil reform tub No. One no. to facilitate coil fromcooled wire rod convolutes.

Chain/pellet conveyors No. One set to handle coil forcooling and transport to coilcompactor.

Coil compactor No. One for compacting coilsUnloading station No. One, for coil unloading and

dispatch.4 Roll turning & Repair shop - Roll turning lathes

- Shear blade and rollgrinders

- Drilling machine- Template cutting machine- Roll tackle repair unit- Choke assembly unit- Roll racks

5 Auxiliary units - Oil Hydraulic station- Centralized oil lubrication

stations- Centralized grease

lubrication systems.- Pump houses- Scale pit and scale removal

and disposal facilities

10.1.1.3 Process Description

Continuously cast cold billets will be received from the continuous casting shop through

roller conveyor. The mill floor will be tentatively at +5 m level. The billets thus received in

the billet bay will be lifted to +5 m level and will be charged to the furnace charging grid/

roller table by the EOT crane for transport to the reheating furnace.

The billets after heating to the required rolling temperature in the re-heating furnace will

discharged from the furnace delivery end and fed to the first mill stand of the roughing

group of stands after passing through the de-scaling unit. Subsequent rolling will be

done in the roughing, intermediate and finishing trains of mill stands. The crop/cobble

shears are provided before each mill stand train from crop cutting of each bar and

cobble cutting in case of a cobble ahead of the shear.

Each stand of the roughing, intermediate and finishing trains will be individually driven by

AC motors. The mill stands will be laid in Horizontal s vertical configuration. All the

horizontal stands will be designed with shiftable sliding bases for quick alignment of the

roll groves with the pass line. The mill stands will of modern compact cassette type.

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Necessary guide troughs, roller and static guides, loopers etc. will be provided at the

entry and exit ends of each mill stand.

The plane round and equivalent squares will be rolled in the roughing, intermediate and

finishing stands in single strand. A dividing shear will be provided to cut the bars into

cooling bed lengths.

A cold shear will be provided to cut full length rolled bar in the commercial lengths of 6-

12 m lengths. The cut lengths will pass through the bundling and binding section for

bundle formation and tying operation to form bundles of 3-5 ton weight.

Finished bundles of rounds will be weighed and transported to the bundle unloading

station. From Unloading bed, bundle will be lifted by EOT crane and stored in the

dispatch bay or loaded directly into the railway wagons for shipment.

For production of wire rods in coils, the rolled stock emerging from the stand No. 20 will

be diverted by means of switch tables and pass through feeding troughs to pre-finishing

mill (PFM) comprising of two stands. The precise input size required to be fed to the no-

twist block (NTB) will be rolled in the PFM. A set of horizontal looper will be provided for

tension free rolling. Before PFM and NTB, set of shears with crop/cobble disposal

systems will be provided to crop each bar feeding end and cobble cut the bar in case of

problem ahead. The bar will pass though cooling boxes before rolling at the 8 stand no

twist block and the finish rolling will be performed at the 4 stand reducing and sizing mill.

Finished rolled products leaving the reducing and the sizing mill will pass again through

water cooling boxes to control scale generation and rod microstructure before being laid

in convolutes on the controlled cooling conveyor with the help of pinch rolls and laying

head. Convolutes laid on the conveyor will be subjected to controlled air cooling for

which blowers will be provided below the cooling conveyor.

A coil reforming station will be provided at the end of the conveyor to convert convolutes

into coils. The coil is collected on the vertical pallet, it will be then discharged on the

horizontal power and free hook conveyor for further cooling during the travel of the

conveyor. Cooled coil will be compacted and tied at the coil compacting stations and

then weighed and tagged before unloading at the unloading station. Coils will then be

lifted by over head crane/forklifts for placement in the dispatch bay for shipment.

The special steel quality bars will be rolled at finishing group of stands at low

temperature to impart better metallurgical and mechanical properties to the finished

products. The low temperature finish rolling will be applied at the last two stands

depending on the size and the quality of the bars. The bars will be rolled within the

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temperature ranges corresponding to the thermo-mechanical rolling process. The bars

will be cooled to the desired temperature before entering the finishing group of stands.

The low finish rolling of many of the grades of alloy and special steel will give the

following benefits:

' Fine grain size

' Avoidance of normalizing in carbon steel

' Improved low temperature toughness

' Better properties after heat treatment in case of case hardening steels

' Shorter annealing time for spring steels

' Improved fatigue strength on the final component

' Higher tensile strength for micro alloyed steel directly inline.

' Reduced depth of decarburization

' Improved surface quality.

It is envisaged that the Bar & Rod Mill will be provided with level-2 automation having

features of interaction with PPC computer, product tracking and process control

functions. The proposed level-2 automation will provide the following major advantages:

' Lower manpower requirement

' Reduces scale and crop losses

' Reduced down time for campaign change

' Reduced mill setting time

' Elimination of human error

' Increased mill availability and productivity.

10.1.1.4 Lay out of the Mill with handling facilities

The layout of the Bar & Rod Mill is shown in the drawing No: ENVIRO/FR/10/01 (R-1).

The layout is designed to ensure smooth and unobstructed movement of men and

materials in the mill bays with minimum handling.

The mill building will be of steel structures. The mill floor will be at +5 m level. The roll

and repair shop will be at ± 0.00. The various auxiliary and service facilities will be

housed below the mill floor to utilize the space as far as possible and avoid creation of

underground cellars. The major parameters of the mill building complex are given below:

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Table-10.4: Bar & Rod Mill Complex building details with crane handling facilities

Designation Length x Widthm x m

Type of thebuilding

Height ofcrane rails (m)

Handling craneType, No. Capacity

Billet storage bay 144 x 33 Structural +15 EOT 1 x (12.5 +12.5)Mill Bay 467 x 36 Structural +14 EOT 1 x 35/5

EOT 1 x 10/5Dispatch bay forbars

285 x 30 Structural +9 EOT 2x 15

Dispatch for coils 168 x 30 Structural +9 EOT 2 x 15Roll and repairshop building

144 x 30 Structural +9 EOT 1 x 35/5

Furnace bay 36 x 24 Structural +14 EOT 1 x 10Electrical controlroom cum LT substation

168 x 24 Two story civilbuilding

Electrical hoist2 x 3 t

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10.1.2 Billet & Bar mill

10.1.2.1 General

The proposed Billet & Bar mill of capacity 250,000 tons per year will roll round cornered

billets and flats of special steels in straight lengths in size range 60-200 mm diameter

from continuous cast blooms of 200-350 mm square cross section. The mill will roll

various grades of special steels as envisaged in the product mix. It is envisaged that

70% of the finished products as black bar /semi for end users for further processing and

about 30% as finished products for which necessary heat treatment facilities have been

envisaged.

10.1.2.2 Special features of the Billet & Bar Mill

The mill will be of modern design and will have the following special features to ensure

superior surface finish, dimensional tolerance and physical properties of the envisaged

product mix.

' Walking beam type reheating furnace

' High pressure de-scaling facility

' 2 high reversible stand followed by 6 nos. of two high stands in vertical-horizontal

configuration.

' Quick roll change facility

' Turn over type cooling bed

' Automatic bundling and tying facility.

' Facilities of heat treatment such as annealing and normalizing

' Bar finishing facilities like bar straightening, bar peeling machine etc.

' Level-2 mill automation and control over level-1 instrumentation and control.

10.1.2.3 Technical features of the Billet & Bar Mill

The major technical parameter of the Billet & bar mill is given in the Table below:

Table-10.5: Major Parameters of the Billet and Bar Mill

Sl. No. Item Unit Parameter1 Type of Mill Single strand mill. Mill Floor at

+4m2 Capacity of the Mill t/y 250,0003 No. of operating days in a year

(availability)Days/year 300

4 Shifts/day 3

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5 Hot rolling hours Hrs 50007 Utilization of available hours % 69.58 Reheating Furnace (Single) One Walking beam type 60 t/hrs

nominal capacity9 Input bloom size 160 - 350 mm (Round or

Square ) 4-6 m length.10 Fuel for reheating Mixed gas : CV 1900-2000

Kcal/Nm311 Annual billet required t 260,00012 Finished product size range Straight length products:

Rounds/RCS: 60 to 200 mmDia/sidesFlats: 60-140 mm

13 Billet to product yield % 9614 Specific Fuel Consumption G Cal/T

of billets0.75

15 Specific Power consumption KWH/t 100

10.1.2.4 Major facilities in Billet and Bar Mill

The major facilities envisaged for the Billet & Bar mill is given in the table below:

Table-10.6: Major facilities in Billet and Bar Mill

Sl. No. Equipment/facilities Unit Technological features.1 Reheating furnace

Number and type No. 1 No. ; Walking beam type,end charging and enddischarging.

Nominal throughput t/Hr 60Fuel Mixed gas with CV 1900

Kcal/Nm3Bloom charge Cold charge at ambient

temperatureReheating temperature of thebloom

0 C 1200 max. (1100-1150)

2 Rolling Mill properWater de-scaling unit No. One No. with high pressure

water jet system for de-scaling at an operatingpressure of 210 bar.

Mill StandBreak down mill No. One number break down

stand (BD) mill provided with

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grip type tilting and centeringdevice in front of behind themill.

Turning device No. 1 No. hydraulically operatedturning device beforecontinuous group of stands.

Continuous stands No. Six (6) two high standsarranged in vertical-horizontal configuration.Stand change carpet will beprovided.

Hot saw No 2 Nos. one movable and theother fixed saw to cut the barin cooling bed lengths andsample cutting.

Cooling bed No. One, turn over type coolingbed to accept 60 mm to 200mm rounds/RCS/flats

Piling and bundling facilities andmovable binding device

No. One No. to collect the barsand form them into bundlesprovided with movablebinding machine.

Bundle collecting station No. 1 no. consisting of dischargeroller table and disappearingconveyors.

3 Heat treatment facilities - 1 no. roller hearthannealing/normalizingfurnace (mix gas fired)

- 2 nos. electrically heatedannealing/normalizingfurnaces

4 Finishing facilities - Roller straighteningmachine

- Precision straighteningpress

- Bar peeling machine5 Roll and repair shop - Roll turning lathes

- Shear blade and rollgrinders

- Drilling machine- Template cutting machine- Chokes and bearing fixing

arrangement- Roll racks etc.

6 Auxiliary units - Oil Hydraulic station

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- Centralized oil lubricationstations

- Centralized greaselubrication systems.

- Pump houses- Scale pit and scale

removal and disposalfacilities

10.1.2.5 Process description

Continuously cast blooms will be received from the CCS shop at SMS through roller

conveyors. The mill floor will be at +4 m level. Thus the bloom received in bloom bay will

be lifted to +4 m level and will be charged to furnace charging grid /roller table by the

EOT crane for transporting to the Re-heating furnace.

The re-heated blooms at required temperature will be discharged from the reheating

furnace end and led to the Break down mill (BD) through the de-scaling unit. The passes

given in the break down mill (either three high or reversing two high depending on the

design of the mill) would be as per requirement of the rolling scheme. After rolling in the

BD, the bar will move to the continuous group of stands. The bar will be tilted before

being fed to the continuous group of stands.

The mill stands of the continuous train will be individually driven with variable voltage

variable frequency AC drives. The mill will be laid in Vertical-horizontal configuration.

The continuous mill stands will be provided with stand change carpet.

Necessary guide troughs, roller and static guides etc. will be provided at the entry and

exit side of each stand.

The bars will be cut into saleable lengths of 6-12 m by hot saw. The cut lengths of the

bar will pass to the cooling bed, piling and bundle forming station, bundle former and

tying operation to form dispatch able bundles.

Finished bundles of rounds/bars will be weighed and transported to bundle unloading

section. From unloading beds, bundles will be lifted by EOT crane and stored in the

dispatch bay or loaded directly to wagons for shipment.

The bars requiring heat treatment will be shifted to an adjoining bay through inter-bay

transfer car. The products will be processed through the normalizing /annealing furnace

to obtain the desired heat treatment. The heat treated bars will be straightened in the

straightening machine before re bundling and dispatch.

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The Billet and bar mill will be provided level-1 instrumentation and automation system

based on PLC logic. A level -2 automation systems with interaction with the PPC

computer, product tracking and process control features has been envisaged.

10.1.2.6 Lay out of the Mill

The layout of the Billet & bar mill is given in the drawing No: ENVIRO/FR/10/01 (R-1).

The lay out will ensure smooth and unobstructed movement of men and materials in the

mill area with minimum handling.

The mill building will be mostly steel structure. The mill floor will be at +4 m level. The roll

shop and the finish product storage will be at ± 0.00 level. The major parameters of the

Mill complex building is given in the table below:

Table-10.7: Billet & Bar Mill Complex building details with crane handling facilities

Designation Length xWidthm x m

Type of thebuilding


Handling craneType, No. &Capacity

Bloom storage bay 132 x 33 Structural +15 EOT 1 x (12.5+12.5)

Mill Bay 338 x 34 Structural +14 EOT 1 x 35/5EOT 1 x 15/5

Finished productstorage

240 x 30 Structural +9 EOT 2x 15

Heat treatment &product storage

240 x 30 Structural +9 EOT 1 x 10EOT 1x 5

Furnace bay 36 x 18 Structural +14 EOT 1 x 10Roll shop 120 x 18 Structural +9 EOT 1 x 35/5Electrical control roomcum LT sub station

144 x18 Two story civilbuilding

Electrical hoist2 x 3 t

10.2 Hot Strip Mill (Phase-2)

10.2.1 At phase-2, the steel plant facilities will cater to flat products produced out of about 2.5

million tons of continuously cast slabs. The steel making and casting facilities have been

described in the previous chapter. The entire production of cast slabs will be processed

through a Hot Strip Mill to produce hot rolled coils. These hot rolled coils will be partly

processed to cold rolled strips in a cold rolling mill complex. The rest will be sold partly

as hot rolled coils (as rolled in hot strip mill or silted to narrower coils) to other cold

reduction mills and partly as cut sheets/plates. These will form the hot rolled coil

processing facility which would be coming along with the hot strip mill. The cold rolling

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and strip processing facility will be a separate complex away from the hot strip mill but

within the steel plant boundary.

10.2.2 Technical parameters of the Hot Strip Mill

The technological parameters of the Hot Strip Mill are given in the table below:

Table-10.8: Major Technological parameters of the Hot Strip Mill

Sl. No. Item Unit Parameter1 Type of Mill Six stand 4 high finishing train with 4

high reversing universal roughing standand a coil box. Two coilers; facilities ofAGC; Work roll shifting and work rollbending.

2 Capacity of the Mill t/y 2500,000Based on 1050 mm x 2.8 mm coils;rolling rate at reversing rougher s 474tons/hr.

3 No. of operating days in ayear (availability)

Days/year 300

4 Shifts/day 35 Hot rolling hours Hrs 55007 Utilization of available

hours% 76

8 Reheating Furnace Two Walking beam type 300 t/hrs nominalcapacity each.

9 Input slab size 210 mm thick; 800 to 1550 mm; 10 mmax length; Weight 25.5 t max. .

10 Slab Quality Mild Steel, low Alloy Steel. Mediumcarbon steel. (69 Kg/mm2 variety)

11 Annual slab required t 2,577,32012 Rolled coil specification 1.6 to 12 mm thick

800-1550 mm wideMaximum coil weight- 25.59 tCoil ID: 76 mm; OD: 2100 mmPIW:

13 Slab to product yield % 96.714 Specific Fuel Consumption G Cal/T of

Slabs0.65

15 Specific Powerconsumption in the mill

KWH/t 150

16 Connected load MW 30 MW (Mill proper) + 10 MW coilprocessing facilities.

17 Specific consumption ofrolls

Kg/t of coils 0.54

18 Specific consumption ofguides

Kg/t of coils 0.52

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19 Annual requirement of tyingstraps

Tons 2500

20 Steam Tons/Hr 221 Compressed air (Dry) Nm3/Hr 500022 Lubricating oil Kg/t of coils 0.0623 Grease Kg/t of coils 0.04524 Hydraulic Fluid Kg/t of coils 0.028

Special features of the Hot Strip Mill

' The mill will have two walking beam slab reheating furnaces with air preheating and

automatic combustion air control fired with mixed gas.

' The primary mill will be a reversing four high rougher with edging mill. The roll table

from the furnace exit to roughing mill entry will be provided with insulating cover to

conserve heat of the incoming reheated slab.

' The mill will be provided with a coil box to limit the transfer roller table length

between the rougher and the finishing train.

' The finishing train will have six, four high finishing stands.

' All stands in the mill will be provided with automatic thickness control as well as roll

shifting and bending systems.

' For the purposes of profile and flatness control all the leading stands in the finishing

train will operate with CVC rolls and the last stand will operate with shiftable work

rolls for contour control and for the purpose of schedule free rolling (SFR) strategy.

' Hydraulic looper control between the finishing stands.

10.2.3 Description of facilities in the Hot Strip Mill

(a) Reheating Furnace and the slab feeding arrangement:

It is envisaged to provide two walking beam reheating furnace with 300 tons per

hour capacity for the nominal slab size for reheating of the continuously cast slab to

a temperature of 1150 + 50 0 C. Provision of charging of hot slabs also will be

explored at the detailing stage. The furnace will be a three zone (with bottom firing )

furnace where the slabs will rest on insulated hollow water cooled skids (called

beams)- fixed and moving beams alternating having on their top a narrow pieces of

high alloy metallic bars called riders. The slabs move forward with the cycle of lifting

and forward movement of the moving beams with eccentric action and lowering of

the slabs on the fixed beams and the moving beams coming back to position. It is

expected that that heating time of the slabs in the reheating furnace should be 0.7 to

1.0 mm/min of slab thickness. The tentative furnace characteristics will be as given

in the table below:

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Table-10.9: Furnace characteristics of the Hot Strip mill

Sl.No.

Item Unit Parameter

1 Type Walking beam, top, bottom fired,side fired

2 No. of furnaces Two3 Capacity Tons/Hr 350 each for cold charged slabs4 No. of zones 8 Zone (Tentative)5 Fuel to be used Mixed gas of 1900-2000

kcal/Nm3.6 Pre-heating For both gas and air. Pre heating

temperature s Air 550 Deg C ;Gas s 300 deg. C

7 Furnace dimension Mm Width s 13,500 mm ; length s40,000 mm

8 Furnace combustion control PLC based s level-1 automation.Provision for level-2

9 Input slab dimensions mm Thickness= 210Width s 800-1550Slab length s 8-10 m (single row);4-4.75 m (double row)

10 Maximum slab weight Tons 26.0

Walking beam furnaces are usually designed with end or side charging anddischarging. For the furnace envisaged end charging and discharging has beenenvisaged. The beams can be actuated either hydraulically or mechanically. Crossfiring with side wall burners above and below the material stock being heated will beprovided along with radiant type roof burners placed in the roof and below thematerial.

The advantages of walking-beam furnaces are:

' The material to be heated can be separated from each other in order to avoid

stickers

' Pile ups in the furnace and the retention time in the furnace are reduced.

' It is feasible to empty the furnace from either side by activating the beam

mechanisms.

' Skid marks are no more there since there is no line contact with water cooled

skids.

' Hearth wear and material damage is practically absent since there is no

rubbing between the material and with the hearth.

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' Better hearth utilization can be obtained when charging mixed sizes by

selecting the proper number of walking beams.

' There is potential available for the extension of overall furnace length to

improve the utilization of furnace waste gases and to reduce fuel

consumption.

The major equipment in the furnace area is given in the table for major equipment in

the next section.

(b) The mill proper

(1) The products of the mill will be hot rolled coils of the following quality/grades as

given in the table below:

Table-10.10: Quality of products envisaged from the Hot Strip Mill

Sl.No.

Grade Y.S(N/mm2)Min

T.S(N/mm2)Min

TS(N/mm2)Max

Elongation%

C%

Si%

Mn.%

S%Max

P%Max

Alloys%

1 CortenPlates

343 481 - 22 0.08/0.18

0.25/0.75

1.2max

0.05 0.1Max

Ni. 0.8Cr 0.3-1.2Cu 0.25/0.55

2 Light plates 250 410 530 23 0.2/0.25

0.4max

1.6max

0.04 0.04 -

3 HT Plates 410/440 540/550 660/740 20/20 0,16/0.22

0.35/0.50

1.0/1.8

0.050 0.05 Nb 0.3/0.4V 0.08/0.15Ti0.04/0.06

4 Long &Crossmembers

373 440 560 25 0.06/0.09

0.10/0.20

0.55/0.75

0.025 0.05 V 0.06-0.09

5 DD/EDD 260 390 17/23 0.06/0.08

Trace 0.30/0.45

0.04 0.04

6 HR for coldrolling

260 390 17/23 0.08/0.15

0.08 0.30/0.50

0.05 0.05

7 Commercial tubes

210 330 25 0.10Max

Trace 0.50Max

0.04 0.04

8 Mediumcarbon

360 650 12 0.55/0.60

0.15/0.35

0.50/0.90

0.04 0.04

9 Highcarbon

400 800 1000 12 0.75/1.35

0.15/0.35

0.30/0.50

0.04 0.04

10 Precisiontubes

240 360 0.8/1.2

Trace 0.35/0.50

0.40 0.40 V treated

11 LPG 270 350 27 0.15max

- 0.90max

0.35 0.35 Micro alloying-0.15 max

12 API 240 370 560 26 0.15/0.20

0.30/0.40

1.1/1.35

0.035 0.035

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(2) The product dimension:

Thickness (mm) 1.6 to 12.0

Strip width (mm) 800 to 1550

Coil size: (mm) ID: 760

OD 2100

Weight (tons) 25.5 max (16.5 Kg/mm)

(3) The mill composition is given in the table below. The figures are tentative and may

undergo some change depending on the technology provider.

Table-10.11: Mill characteristics: Hot Strip Mill

A. Roughing Mill

Item Vertical Edger Roughing Mill

Work roll (max) q //..-77. m 23. } Ø 1050/960 x /5.. }

Back up roll (max) - Ø 1350/1200 x 1700 }

Roll separating Force

Main Motor power (KW) DC 300/600 KW X 2 DC 3500 KW x2

Main motor rpm 360/720 50/120

Rolling speed 120 m /min at Ø 990 120 m /min at Ø 960

Screw down Hydraulic AGC Hydraulic AGC

.

B Finishing Mill

Equipment F1 F2 F3 F4 F5 F6Work roll (Diax barrel)

Ø 690/630x1700

Ø 690/630x1700

Ø 690/630x1700

Ø 690/630x1700

Ø 690/630x1700

Ø 690/630x1700

Back up roll(Dia x barrel)

Ø 1350/1200x1700

Ø 1350/1200x1700

Ø 1350/1200x1700

Ø 1350/1200x1700

Ø 1350/1200x1700

Ø 1350/1200x1700

Main Motor(KW/rpm)

4500 x175/420

4500 x175/420

4500 x175/420

4500 x175/420

3000 x160/320

4000x180/360

Roll rpm 51/102 74.5/149 102.5/205 135/270 160/320 180/360Gear Ratio 1/ 4.12 1/ 2.82 1/ 2.05 1/ 1.56 1/1 1/1Rolling speed(max)Meter perminute

219 320 440 579 688 774

Work rollshifting stroke(mm)

± 200 ± 200 ± 200 ± 200 ± 200 ± 200

HydraulicJack(Cyl dia/Roddia x stroke

1100/940 x 60 1100/940 x 60 1100/940 x 60 930/750 x 30 930/750 x 30 930/750 x 30

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Bending forcefor work roll(ton/Chk)

0-150 0-150 0-150 0-150 0-150 0-150

AGC Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic HydraulicSpindlecoupling

Gear coupling Gear coupling Gear coupling Gear coupling Gear coupling Gear coupling

Loopers Motor direct typeSide guide Hydraulic; 600-1650 mm ; self centering, Hydraulic cylinder retract.Work rollchanging

Hydraulic cylinder single sled type

Pass lineadjust

DC 75/150 KW x 515/1030 x 1 for each stand

Back up rollchange

With C hook

Controls

-Hyrop-F-WRS APC-BFC (WRbending forcecontrol)-AGC, REC,Crown &shape control

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

%

(4) List of Equipment in the Mill

The List of major Mill Equipment is given in the Table below:

Table-10.12: List of Major Mill Equipment: Hot Strip Mill

Sl.No.

Section ItemNo.

Equipment Quantity

1 Slab Charging andFurnace EntryEquipment

1.01 Slab charging grid One1.02 Slab receiving table One1.03 Furnace approach roller table One1.04 Furnace charging table One1.05 Furnace pusher ram One1.06 Furnace entry skids One set1.07 Walking Beam type 300 tph reheating

furnace proper with all accessoriesand auxiliary like recuperator, airblower, water cooling system,hydraulic system, lubrication systemand 60 m Chimney.

Two

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2 Furnace Deliverysection

2.01 Slab Extractors Two on each endof the dischargeside for liftingdouble rowcharged slabs orwork together forsingle rowcharging.

2.02 Furnace delivery table One2.03 Slab reject table One2.04 Slab reject grid One

3 Hydraulic de-scaler 3.01 De-scaler entry roller table One3.02 Primary hydraulic de-scaler One3.03 De-scaler exit roller table One

4 ReversingRoughing Mill withattached entryedger

4.01 Roughing mill entry table One

4.02 Roughing mill manipulator on theentry side

One

4.02 Vertical edger One4.03 Roughing Mill One4.04 Rouging mill manipulator on the exit

sideOne

4.05 Roughing mill exit table One5 Delay table, coil

box and crop shear5.01 Delay table One

5.02 Cobble pusher One5.03 Cobble skid rack One5.04 Coil box One5.05 Rotary crop shear One

6 Finishing Mill 6.01 High pressure water de-scaler One6.02 Finishing 6 stand four high mill train One set6.03 Roll transfer trolley One

7 Mill run out table,strip cooling andcoiling facility

7.01 Mill run out table One

7.02 Strip cooling section (lamellar cooling) One7.03 Pinch roller entry side guide One7.04 Pinch roller assembly One7.05 Down coilers Two

8 Coil delivery coilersystem

8.01 Coil stripper car One

8.02 Coil delivery conveyor system One

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8.03 Strapping machine for circumferentialstrapping.

Two

8.04 Coil weighing machine Two8.05 Paint marking machine Two8.06 Sample station Two

9 Lubricationsystems

9.01 Oil Lubrication systems Eight (tentative)

9.02 Grease lubrication system Ten(tentative)

9.03 Air oil lubrication system one9.04 Other special lubrication system One9.05 Grease station One9.06 Lubricating oil station Three

10 Hydraulic system 10.01 Hydraulic system Nine(tentative)

10.02 Valve stands Four10.03 Nitrogen gas charging booster One10.04 Hydraulic oil station One

11 Water System 11.01 Inter-connecting pipe system for de-scaling water

One set

11.02 Pump station for de-scaling water One11.03 Indirect cooling water station One11.04 Cooling water station for Re-heating

furnaceOne

11.05 Mill cooling water station One11.06 Hot run out table lamellar cooling

water stationOne

11.07 Sludge water treatment section One11.08 Oil water separation system One11.09 De-mineralized water plant One11.10 Compressed air supply system One

12 Utility Pipe work 12.01 Interconnecting pipe system for water One set12.02 Interconnecting pipe system for

compressed airOne set

12.03 Interconnecting pipe system for steam One set13 Roll shop and

repair post13.1 Roll grinder for back up rolls One

13.2 Roll grinder for work rolls One13.3 Shear blade grinder One13.4 Circular knife grinder One13.5 Chock and bearing cleaning facility One13.6 Chock turn over unit One13.7 Morgoil Bearing cleaning tank One13.8 Morgoil bearing assembly device One

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13.9 Handling equipment , racks etc. One set13.10 Equipment for cooling the rolls One13.11 Special roll shop equipment One

14 Ventilation and Airconditioning

14.1 Ventilation system for electric motors One set

14.2 Air conditioning system for all controlpulpit

One set

14.3 Ventilation system for electric controlrooms and cable cellars

One set

14.4 Air conditioning for the automationcontrol and computer room

One set

14.5 Ventilation system for oil cellars One set14.6 Sump drainage for oil cellars One set

15 Fire protectionsystem

15.1 Fire protection system with watertank, high pressure pumps,emergency diesel pump, pipe line,water pipe line

One set

16 Instruments forcontrol

16.1 Re-heating furnace combustioncontrol and temperature controlsystem along with sensors, controlequipment etc.

One set

16.2 Load cells Fourteen(tentative)

16.3 Thickness gauge Two sets16.4 Width gauges Two sets16.5 Profile meter One set16.6 Shape meter One set16.7 Strip temperature pyrometer Five sets

(5) Process Description:

The primary function of the Hot Strip Mill is to reheat semi-finished steel slabs uniformlywell within the temperature range of single phase austenite micro structure and then rollthem thinner and longer through successive rolling mill stands driven by motors withcapacities approximately 33,000 KW and finally coiling up the lengthened steel sheet fortransport to the next process. The Hot Mill will roll slabs weighing up to 26 tons and 10meter long and roll into a strip as thin as 1.6 mm and up to 1 Km in length. Coils areegdYjXZY lî] 56. bb '1.,5t ^ch^YZ Y^VbZiZg 'uZnZv( dc dcZ d[ ild XdâZgh* lî] djih^YZY^VbZiZg a^bîZY id 0/.. bb '60,4t( Xdggesponding to 18.5 Kg/mm with the coil (max)corresponding to 1025 pounds-per-inch-width (PIW). The mill supplies coil for each ofi]Z hiZZa eaVcivh gZbV^c^c\ deZgVi^dch Vh a^hiZY WZadl* Vh lZaa Vh i]Z gdaaZY Xdâh VgZfinished product for shipment directly to customers.

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- Coil slitting and re-coiling for dispatch as narrower coils- Coil cutting to sheets and plates for dispatch- Transfer to the cold rolling and processing department to cold roll the hot rolled coils

and process a part of the cold rolled coils for galvanizing and Colour coating.

The tentative breakup of the coil produced for the above purposes is proposed as:

) Coils for processing in the cold rolling and processing department: 1,000,000tons/year

) Coils for slitting and recoiling: 200,000 tons/year) Coils for cutting into plates and sheets: 500,000 tons/year) Coils for direct dispatch as hot rolled coils (as rolled): 800,000 tons/year

ReheatingCritical to the Hot Strip Mill is its walking-beam Re-heating furnaces (two numbers),state-of-the art equipment that replaced and now outperforms the older pusher stylefurnaces. Nominally rated to heat 350 tons-per-hour of slabs, these furnaces ensureuniformity of slab temperature and efficiency in fuel usage to heat slabs from roomtemperature to 1200 -1250 degrees C. The furnaces consume around 0.16 million cubicfeet of mixed gas (CV 1900 Kcal/Nm3) each hour.

As slabs are assigned to orders, schedules are written and entered in a PPC computersystem and material is staged with overhead cranes in the slab yard at the entry of theHot Strip Mill. Slabs are placed, one at a time, on a charging grid as per rolling schedulealso given by the PPC computer system. The slab marking are computer sensed and thehaVWvh Y^bZch^dch VcY lZ^\]i VgZ Xdc[irmed as it is positioned in front of the charge dooron the charging end of the furnace. Large electro-bZX]Vc^XVa uejh]Zg Vgbhv VgZ Zc\V\ZYto move the slabs into the furnace.

Once inside, the slabs are supported about 2.5 m off of the furnace floor by water-cooled, refractory-XdViZY e^eZh XVaaZY uh`^Yhv, Od b^c^b^oZ i]Z XdaY hedih 'uh`^Y bVg`hv(left in the slab, the skid spacing changes approximately two-thirds of the way through thefurnace. Two independent sets of skids, one fixed, one walking, take turns in supportingthe slab as it is walked through the furnace by a massive sub-frame energized by a pairof large hydraulic cylinders.

The interior of the furnace is 13.5 m wide, 5 m from floor to ceiling, and 40 m long. It isdivided into eight zones for temperature control: preheat, top-and-bottom; heating, top-and-bottom; and soak, top-and-bottom, east-and-west. The preheat and heating zonescombust a mixture of by-product gases generated in the plant (Viz. Coke gas, Blastfurnace gas and BOF recovered gas to form a mixed gas of 1900-2000 kcal/Nm3calorific value). The combustion gases are fed with combustion air with massive burnerson the side walls of the furnace, both above and below the skids. To heat the slab nearlyto its discharge temperature, much of the preheating of the steel is achieved by the hotZm]Vjhi \VhZh gjh]^c\ eVhi i]Z haVWh dc i]Z lVn id i]Z urecuperatorsv VWdkZ i]Z X]Vg\Z

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door. Whatever heat is left in the exhaust gases preheats the incoming combustion air toover 550 Deg C and mixed gas to 300 Deg C in re-cuperative type heat-exchangers.

Refractory dividers help to physically distinguish the zones, and thermocoupletemperature sensors throughout the furnace interact with the automatic burner controlsystems to maintain the target temperatures in each zone.

Both level-1 and level-2 automation with process computer models are envisaged andthe models calculate the targeted roughing mill exit temperature to obtain a furnacedischarge 'uYgde-djiv( V^b iZbeZgVijgZ, @hi^bVi^c\ i]Z iZbeZgVijgZ egd[^aZ i]gdj\] i]Zthickness of each slab in the furnace on an ongoing basis, the computer aids theoperator in selecting the production rate and zone set-points that will maximizeproduction of steel slabs uniformly heated to as close to the target temperature aspossible. After the rolling process begins, as the steel exits the roughing mill, itstemperature is fed back to the furnace, updating the computer models and informing theHeater as to the iZbeZgVijgZ jc^[dgb^in, R]Zc i]Z haVW gZVX]Zh i]Z Y^hX]Vg\Z Yddgv Vithe exit end of the furnace, and the computer has determined that the slab has beenhj[[^X^Zcian ]ZViZY* i]Z Yddg deZch VcY bVhh^kZ uZmigVXidg Vgbhv gZVX] WZcZVi] i]Z haVW*lift it off of the skid supports, and draw it out of the furnace. The east and west extractorscan act independently of one another to remove double-charged slabs one-at-a-time, orin conjunction to extract longer slabs. The intensely hot slab is placed on a roller tablewhich carries it into the roughing mill.

De-scalingAfter exiting the reheat furnace, the slab passes through a de-scaling unit, an enclosureemploying two pairs of spray headers that blast the intensely hot slab with 1,500 psipressurized water to remove about 3 mm thick layer of oxidized iron that forms at thesurface of the slab in the oxygen-rich atmosphere of the reheat furnace. De-scaling isdone twice more during roughing, immediately prior to the third and to the last rollingoperation, to remove the scale that has grown back over the three minutes or so that itspends in the roughing mill.

RoughingThe roughing mill is made up of a single combined vertical and horizontal four highreversing stand fitted with manipulators at the entry and exit sides. The slabs re-heatedin the furnace are rolled through the roughing mill in 7 passes with a duration varyingbetween 2.5 to 3 minutes to roll transfer bars at a thickness of 25 mm suitable for finishrolling. High-pressure water-jet nozzles clean the oxidized iron, or scale, from thesurface along the way. As the transfer bar exits the last roughing mill stand, thethickness of the leading edge of the bar is estimated. Similarly, a pyrometer measuresthe temperature profile of the bar from head to tail and a special camera photographsboth ends. Depending on the gauge, width, and grade of the product to be rolled, theaverage temperature of the bar as it exits the last roughing mill normally ranges from1035 to 1150 Deg. C. This data is collected in anticipation of finish rolling. Computers

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immediately begin calculating the speeds and gaps for threading the six finishing mills,which will roll the steel in tandem with one another.

Coil box

The process of hot strip rolling is envisaged to be with a Coil box located between theroughing mill and the finishing stands on the transfer bar table. Coil boxes are now partof all modern hot strip mills and almost common item to be introduced during revampingoperation. In the coil box, the transfer bars from the roughing mill are rapidly coiled thensubsequently uncoiled and fed at a lower speed to the finishing stands. The coil box willaccommodate strip thickness from 21 to 30 mm. Forming a transfer bar into a coildramatically reduces radiant heat loss and produces a virtually uniform temperature inthe uncoiled transfer bar as it enters the finishing stands. These results in

' Less power needed to roll the bar to desired dimensions' Fewer finishing stands and a shorter run out table' Uniform metallurgical properties in the product

The compactness of a coiled transfer bar also reduces space requirements and capitalcosts and affords many process benefits as well. For example, during a stoppage orcobble, the coil can be held for many minutes and still be successfully processed or ifneeded, coils can be safely and quickly removed allowing for faster restart times. On thisbasis, a coil box (either with mandrel or without mandrel) has been envisaged in the hotstrip mill.

De-scaling

Between the Crop Shear and the first Finishing Mill stand sits the #2 Scale breakers,which is tasked with the final scale removal operation. Sprays above and below thetransfer bar blast it with 1,500 psi jets of water to break-up the scale that has re-formedsince the de-scaling operation at the entry of the roughing mill, as well as any scale thathas persisted through earlier de-scaling operations. After de-scaling by the low-pressureheaders, the bar is pinched by a pair of pneumatically-actuated rolls to mechanicallyloosen any remaining scale, which, as the processing temperatures cool off, becomesincreasingly sticky, as it returns even more slowly to the surfaces of the still red-hotsteel. Finally, a pair of high pressure headers operating at nearly 3,000 psi makes a finalpass at both surfaces of the transfer bar shortly before it enters F6 for finish rolling. Asl^i] i]Z gdj\]^c\ b^aavh YZ-scaling system, for some thinner-gauge, wider, and/or stifferproducts, the low-pressure header is disabled to conserve heat for rolling. In partbecause further de-scaling is not particularly practical once finish rolling begins, the #2Scale Breaker is the last opportunity to remove oxidation before the finished hot-rolledstrip is coiled. Typically, the de-scaling system in the Hot Strip Mill is very effective atremoving primary (from the furnace) and secondary (re-grown during roughing rolling)scale.

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Cropping

Because a square head-end is critical to properly threading the finish mills and the downcoilers, and because an uneven tail can bruise work-roll surfaces or cause threadingproblems for the next production process, the head and tail-ends of nearly every transferbar are cropped by a pair of large steel drums each with a shear blade extending alongits length. With the bar crawling along the roller table at around 100 fpm, sensors detectits position and speed in order to time the crop shear drums to optimize the amountcropped; since transfer bars are over an inch thick, each extra inch of crop-length scrapsanother 8-15 kg.

FinishingThe envisaged Hot Strip Mill includes six finishing mills, which reduce the thickness ofthe transfer bar down to the gauge required by the customer or the next process. Therolling speed is set to allow the last stand to perform the final reduction at the finishingtemperature, between 815° to 900°C as, specified to reach certain mechanicalproperties. By now, the steel has been rolled into a flat bar as long as 60 m. In contrastto the roughing mill, the finishing mills roll the transfer bar in tandem, meaning each barwill be rolled through all six stands at once. The hot steel is quite fragile as it is rolledand tension between the finishing mill stands must be closely controlled at very lowlevels in order to avoid stretching or tearing the strip. Prior to the finish rolling operation,the head- and tail-ends of the transfer bar will be sheared to square them up, helping toensure proper threading and tail-out. A final two-stage de-scaling operation is performedto clean off the scale that has grown on the bar during roughing. Once the bar isthreaded between each successive pair of mills, a free-turning roll on an electro-mechanical pivot called a looper roll engages the bottom of the strip to monitor thetension between the stands. Adjustments are made as necessary, to ensure the stripthreads properly through each of the mills without looping up and folding over orhigZiX]^c\ VcY iZVg^c\ VeVgi, O]Z edh^i^dc d[ ZVX] gdaa ^h [ZY WVX` id i]Z [^c^h]^c\ b^aavhsophisticated automation system which, along with information from the load cells thatmonitor rolling force and from the X-ray gauge measuring final strip thickness, work tosmoothly adjust the roll gaps and speeds to maintain stable rolling of strip to thenecessary thickness in spite of the temperature variations present in every bar.

Temperature Control

A profound metallurgical transformation in the crystal structure takes place as thematerial cools, which, depending on the specific chemistry of the material, typically isbetween790°and 870 °C. Additionally, the mechanical properties of the final productrespond to some degree to the specific temperature at which the final reducing pass istaken. Consequently, a finishing temperature for each product is specified and millautomation will adjust the speed of the first finishing mill stand based on its temperatureand the extent to which the bar is expected to cool as it makes its way through eachstand, in order to allow the strip exiting the finishing stands to meet the target

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temperature. Since each transfer bar spends approximately one minute in the finish mill,from head to tail, the temperature of the steel going into the finishing stands will besignificantly lower, perhaps 100 ° C, by the time the tail-end is rolled as compared to thehead-end. Consequently, once the first 150 m of strip has been rolled at the threadspeed and a down-XdâZg ]Vh WZZc i]gZVYZY* i]Z bâa WZ\^ch id VXXZaZgViZ Vi V uoddbvrate that had been calculated from the temperature profile of the bar as it exited the lastroughing mill. Top speeds as high as 2,700 fpm (30 mph) are reached by the millautomation seeking to maintain the specified finishing temperature throughout the finalegdYjXi, < engdbZiZg eaVXZY V[iZg i]Z aVhi hiVcY jeYViZh i]Z [^c^h]^c\ bâavh XdbejiZgmodels and allows for the addition of this temperature to strip quality records.

Gauge Control

With the tremendous rolling forces present in a rolling mill, it is not sufficient to simply setthe gap between the work rolls to the thickness desired and expect the strip to come outthe other side at that thickness. With rolling forces regularly exceeding 3,000 tons in theearly finishing stands, the mill housings can be expected to stretch after the bar entersthe bite when rolling wide, stiff, and/or light-gauge products. When setting the roll gapsfor threading, it is critical that this factor be compensated for in each of the mill stands; todo so, sophisticated models are used by mill automation to estimate the rolling force foreach transfer bar in each stand based on, among other things, the incoming andoutgoing thickness, width, steel grade, and estimated instantaneous temperature. Themodels employed by the mill automation are updated with the rolling parameters andproduct measurements each time a new slab is rolled, Xdci^cjVaan dei^bôZY i]Z bâahvautomation set-ups. Product quality and production yield benefit from schedulingproducts with similar gauge and grade to roll in succession, allowing automation todeploy the most recently utilized rolling model.

Flatness and Crown

In addition to the degree to which mill stands stretch under rolling loads, as describedpreviously, the rolls will deflect, or bend, under load since they are being forced apart inthe middle by the strip but are supported at the ends by the bearings. This deflection isthe source of the strip attribute commonly referred to as crown. Strip crown is initiated inthe roughing mills and continues through each successive rolling mill stand. Strip crownis measured at the exit end of the finishing mills by a second, scanning X-ray gaugewhich traverses back-and forth across the width of the strip as the steel is rolled. Thethickness it measures is compared to the thickness measured by the primary X-raymonitoring the center-line gauge through the length of the strip and the difference is thenplotted as a product quality record. Typically, the Hot Strip Mill produces material widthWZilZZc .,../t VcY .,..1t d[ Xgdlc YZeZcY^c\ dc V cjbWZg d[ [VXidgh i]Vi ^cXajYZ i]Zgauge, width and grade of the finished product. Operators of any rolling mill have adegree of control over the shape of the roll gap by adjusting the screw-downs toincrease or decrease the roll force present in that stand, influencing the degree to which

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the rolls deflect. The last four finishing mill stands, like most modern rolling mills,incorporate hydraulic work-roll bending to give the operators additional control over theshape of the loaded roll gap. Operators will adjust work-roll bending in these stands toinfluence the crown in the final product. The work-roll bending in the final finishing standis used exclusively to create a roll gap shape that matches the profile of the strip exitingthe prior finishing mill to produce a flat, final product.

CVC is a way to change the strip profile by using rolls with a profile. The gap betweenthe rolls can be changed by axial shifting of the rolls. The CVC technique is also knownas roll shifting technique. CVC technique has slower dynamics but a wider range thanwork roll bending. Since CVC and work roll bending complement each other, both thetechniques are normally used in the modern hot strip mills. CVC is also envisaged in thismill.

After exiting the finishing mills, the strip is carried down a succession of more than 260individually-driven rolls through four banks of low-pressure, high-volume water spraysthat cool the red-hot strip to a specified coiling temperature between 1000°F (560°C)and 1250°F (690°C) and into one of two down-coilers. Side guides on either side of therun dji iVWaZ hZZ` id `ZZe i]Z hig^evh ]ZVY-end pointed at the coilers; the final section ofguides in front of each coiler adjusts to match strip width and features a pneumaticquick-close system that allows the operator to center the strip head-end as coilingbegins.

Laminar Cooling

With respect to metallurgy, coiling temperature is critical to the properties of hot-rolledsteel as the coil will cool from this temperature to ambient over the course of three days.Essentially a heat treatment comparable to annealing, the stresses imparted to the steelduring reduction from nine inches thick down to ordered gauge are given the opportunityas the coil cools to relieve it selves. Though the steel is continually re-crystallizing duringhot rolling, reductions in thickness sometimes in excess of 99% and taking place in lessthan ten minutes stress the steel considerably; coiling temperature is specified byproduct metallurgists to harness and manipulate those stress levels in search of optimalmechanical properties. Product sold as hot rolled and hot rolled pickled and oiled to belaser cut by a customer is coiled at relatively high temperatures to try to relax the steelas much as possible so that parts cut from the coil will lie flat even after residual stresses]VkZ gZhdakZY i]ZbhZakZh VgdjcY i]Z eVgivh Xdc[^\jgVi^dn. Conversely, coiling at arelatively cool temperature allows physical quality steel grades to retain higher internalstress levels and limits the size of the individual crystals and of the carbides that formwithin and between the crystals; each of these factors contributes to higher strengthlevels in the finished hot-rolled strip. Cooling steel 400°F as it rushes past at speeds upto 2700 fpm requires tremendous amounts of water, so a total of 152 spray headers withindividual valve and controlled by the automation system, drench the steel from the topand bottom with curtains of water sheet. The computer estimates, based on the threadspeed of the strip and target finishing temperature, how much water will be needed to

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cool the head-end, and the accuracy of this estimate is confirmed by a pyrometer in frontof the down-coilers. As adjustment to the number of sprays in use is needed, thecomputer will turn sprays on and off to meet the targeted temperature through the lengthof the coil. Since the finishing mills will accelerate once the down-coiler is threaded tocontinue to make finishing temperature, increasingly more sprays are activated as thesteel is rolled in order to compensate for the reduced time it spends on the run-out table.

Up to 300 m3 of water are pumped each minute throughout the Hot Strip Mill to coolfinish-rolled strip, furnace skids, mill rolls, and coiler components, and to de-scaletransfer bars. All water is recycled through a system of scale/sludge collection pits,through the laminar cooling system, and back to one of the two dedicated coolingtowers.

Coiling

O]Z egdedhZY Cdi Nigê Hâavh Xdc[^\jgVi^dc gZa^Zh dc ild >dâZgh, =di] deZgVWaZ XdâZghbegin with a pair of pinch rolls that catch the strip head-end and establish tension acrossthe run-out table and back to the finishing mills. The head-end is deflected by a gateYdlc id i]Z 1.t bVcYgZa VhhdX^ViZY lî] i]Z XdâZg VcY ^h \j^YZY VgdjcY i]Z bVcYgZa Wnpneumatically-actuated wrapper rolls linked by aprons. Once the head-end is all the wayaround the mandrel, laps begin to build around the mandrel, forcing away the wrapperrolls. Once the head-ZcY ^h uX^cX]ZYv VcY [g^Xi^dc VcY iZch^dc egZkZci i]Z lgVeh d[ hiZZafrom slipping relative to the mandrel, the wrapper rolls disengage from the growing coilof steel. After the strip tails out of the finishing mill, the pinch rolls continue to hold back-tension to prevent the coil from unraveling; before the strip tail is pulled through thepinch rolls, the wrapper rolls are reengaged. A hydraulic coil car moves into placeWZcZVi] i]Z Xdâ* VcY* V[iZg g^h^c\ je id hjeedgi i]Z Xdâvh Wja`* higêh i]Z Xdâ [gdb i]Zmandrel and places it in position for transport to the tagging and automatic bandingprocedures.

Coil Handling

Coils are remdkZY [gdb ZVX] XdâZg Wn ]nYgVja^X uXdâ XVghv i]Vi hZi i]Z egdYjXi Ydlc dci]Z eaVi[dgb ^c i]Z u]daZv l]ZgZ dcZ d[ i]Z ild ulVa`^c\ WZVbhv XnXaZ WVX` VcY [dgi] idmove coils into position to receive identification and banding. Since the product is stilltoo hot to apply the paper tickets that identify coils throughout the rest of the plant, a paird[ uiV\\Zghv Zbeadn aVhZgh id Wjgc ^YZci^[n^c\ ^c[dgbVi^dc dcid hiV^caZhh hiZZa iV\hgZ[ZggZY id Vh ua^XZchZ eaViZhv, O]ZhZ VgZ hedi lZaYZY id i]Z djih^YZ lgVe of steel beforethe band is applied. Slabs that previously were identified by Heat and Cut numbers fromthe caster are re-identified as a specific roll item with a six-digit alpha-numeric code. Asecond coil car takes the coil from the banding station to a rotator outside of the millbuilding which slowly spins the coil 90° so yet another coil car can take the coil east toi]Z ua^[i-and-XVggnv, Old bdgZ ']^\]-speed) coil cars and another lift-and-carry completei]Z Xdâvh _djgcZn Zî]Zg id i]Z XdckZndg i]Vi will take it into Hot Strip Finishing or to the

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Cooling area. In all, the automated system employs ten distinct electro-hydraulic devicesZVX] YZeZcY^c\ dc bjaiêaZ hZchdgh id igVchedgi 7.% d[ i]Z Cdi Nigê Hâavh egdYjXi^dc idthe building, where the next operation will be performed.

(6) Hot Rolled Coil Finishing Section (HRCF)

The rolled coils of 2,500,000 t per year are envisaged to be utilized further as givenbelow:

' Coils for processing in the cold rolling and processing department: 1,000,000tons/year

' Coils for slitting and recoiling: 200,000 tons/year' Coils for cutting into plates and sheets: 500,000 tons/year' Coils for direct dispatch as hot rolled coils (as rolled): 800,000 tons/year

Coils for direct dispatch will move in a coil conveying conveyor to the coil cooling storageand dispatch bay placed at right angle to the main mill bay. The coils for processing inthe cold rolling department will move from the storage bay by transfer cars to a separatebay for cooling and subsequent dispatch to the cold rolling department which is about 1Km away in trailers. The slitting and shearing operation will be performed in the HRCFsection located in two bays- one for the process and the other for storing the processedcoils/sheets. All these bays will be parallel to the main coil storage bay.

The direct dispatch storage bay will receive coils from the hot strip mill for cooling. Thebay will have railway lines for loading on wagons and weigh bridges for weighing thecoils as those are placed on the wagons. The coil transfer from this bay to the other bayswill be done with self driven transfer cars.

The HRCF bay will be provided with two slitting lines to slit the main rolled coils tonarrower widths for subsequent cold rolling by smaller cold rolling mills or for thepurpose of ERW tube units to suit their input requirement of the coils. One slitting linewill cater to 1.6 to 5 mm thickness range and the other 5 mm to 12mm. The slit coil widthrange will be 650 to 1650 mm in increments of 150 mm. The combined capacity of thetwo units will be 400,000 t/year in 40:60 ratio.

The HRCF bay will be provided with two automatic coil shearing lines with levelers, sidetrimmers and automatic length setting facilities. Here also one shearing line will be for1.6 to 5 mm and the other for 5 mm to 12 mm. The maximum packet size will be 15 tons.

10.2.4 The mill building and handling facilities.

The details of the mill building and the material handling facilities are given in the tablebelow:

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Type of thebuilding

Height ofcrane rails(m)

Handling craneType, Capacity,Nos.

Mill Bay 400 x 30 Structural +15 EOT 40/10 x1;EOT 80/20 x1EOT 80/30 x1EOT 30/10 x 1

Mill Electrical Bay 250 x 24 Structural +15 EOT 80/20 x 1Slab Charging bay 110 x 36 Structural +15 EOT 80/20 x1

Semi Gantry overcharging grid 15 mspan 30 x1

Transformer penshed

140 x 15 RCC Telfers

Roll shop andrepair shop bay

400 x 30 Structural +9 EOT 80/30 x 1EOT 30/10 x 1Gantry- 10T

Main coil yard anddirect dispatch bay

36 x 250 Structural +9 EOT 40/10 x 2

Coil yard for CRMcoils


Coil yard for HRCF 36 x 250 Structural +9 EOT 40/10 x 2HRCF Dispatchbay


10.3 Environment Control Measures in the Hot Rolling Mills

Air Pollution:

The reheating furnaces in all the hot rolling mills will use mixed gas (Blast furnace gasmixed with Coke gas and BOF gas (At phase-2). Since these gases are pre-cleanedbefore being used as a fuel. The fuel gases are fully combusted inside the furnace andthe off gases do not contain any CO. Therefore, these off gas normally do not requireany treatment to remove dusts. These hot waste gases from the re-heating furnaces arepassed to heat re-cuperators to heat the combustion air and the cooled gas is let outfrom a tall chimney. The iron oxide dusts carried with the gases are usually deposited inthe outgoing gas path and at the base of the chimney.

Water pollution:

The major dirty water comes from the scale breakers; mill stands cooling waters, barcooling water post rolling which are laden with mill scale. Every mill will have a scale pit

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to collect these waters and the heavy mill scale will settle at the bottom to be collectedwith grab cranes. The overflow water will pass through oil removal systems to skim offany oil collected in the water from the mill bearings, cooled in cooling towers and to bereused in the cooling water system after addition of makeup water.

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Chapter-11: Cold Rolling and Processing Complex

11.0 It is envisaged to install a Cold Rolling and Processing complex at the Phase-2 stage of

the steel plant for partly converting the hot rolled coils in the Hot Strip mill to cold rolled

and processed products. The General layout envisaged the Cold Rolling Mill Complex is

away from the main units near the high-way for saving the complex from the dust and

also for ease of dispatch of the finished products.

11.1 Comparison between hot rolled and Cold rolled steel products

Hot rolled coils as coils, sheets/plates are used in pipe/tube manufacture, industrial

products, thicker coils are cut and used as plates for structural applications, manufacture

of thick walled ducts, outer wall of many equipment, container tanks etc. Zinc coating of

thinner hot rolled coils for direct application as roofing sheets and containers has also

started. But for thinner gauges of steel, for surface finish and various surface coatings for

corrosion prevention and also esthetics, cold rolled steel products are being used and

will continued to be used. The essential differences are given in the table below:

Table-11.1: Comparison of properties between hot rolled and cold rolled steel

Property Hot rolled flat products Cold rolled flat productsSurface Finish Not critical in most of the

applicationsCritical for almost all applications

Minimum thickness commerciallyavailable

1.2 mm (1.6 mm for the proposedHot Strip Mill)

0.15 mm

Maximum thickness 12 mm 2.5 mmCoating Requirement Generally not required, though

galvanizing of Hot rolled thin coilshas started.

Large % of the product needscoating.

Ease of coating Difficult EasyCost of product - About 1.7 times of Hot rolled.Down stream processing Generally not required-though

slitting and cut to length facilitiesare given to most hot strip mills

Required for almost allapplications

Drawability Low to medium HighWeldability Medium High

11.2 Process steps in a Cold Rolling Mill Complex:

The following are the basic process steps in a modern large capacity Cold Rolling and

Processing Complex for steel.

(1) Receipt of hot rolled coils in the complex

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(2) Pickling of the coils in Hydrochloric acid in a continuous pickling line to remove

scales formed during hot rolled process.

(3) Oiling of the pickled coils and transport to the cold rolling section

(4) Cold rolling of the coils to the required gauge in a 4/5 stand four high/six high

tandem cold rolling mill to form as rolled hard cold rolled coils.

(5) Degreasing of the coils and annealing in Batch Annealing Furnaces

Or. Annealing of the cold rolled coils in a continuous annealing line (CAL)

(6) Temper rolling of the annealed coils to arrive at the required yield strength and

eliminate HkZ[hxi b_d[. ijh[jY^[hxi ijhW_d 'U_[bZ fe_dj [bed]Wj_ed( Zkh_d] ikXi[gk[dj

forming operation.

(7) Slitting/cut to length line to dispatch slit coils/cut sheets

(8) A part of the cold rolled coils are dispatched to the galvanizing bay. The continuous

galvanizing line (CGL) can be Hot Dip Galvanizing (HDGL) or Electro Coated

Galvanizing line (EGL). The former is used also for providing basic material for

roofing/container sheets and also as a raw material for subsequent colour coating

the coils. EGL lines provide a substrate for subsequent coating either in line or by

the user. Often the galvanizing and colour coating lines are installed together.

Galvanized coils are temper rolled and sold as plane or corrugated sheets. So also

colour coated sheets/coils.

(9) Tin Plate:

Some Cold rolling mills produce tin plate thickness (<0.3 mm) of cold rolled coils.

These coils are used for making containers. The conventional method of making

these tin plates are:

- Electrolytic cleaning

- Batch Annealing

- Coil cooling

- Temper rolling

- Recoiling

- Dispatch to Electrolytic tinning line

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The above steps are combined in a modern Continuous Annealing & Processing line

(CAPL) which can also result a soft annealed product similar to what is obtained in the

conventional process. The Electrolytic tinning line deposits tin on the coil surfaces

through electro deposition.

11.2 Units Envisaged in the Cold Rolling Mill Complex.

As described in Chapter 10, the input capacity of the complex in terms of Hot rolled coils

will be 1 million tons per year. The entire input hot rolled coils will undergo pickling in a

continuous pickling line and cold rolling in a five stand 4 high/six high tandem cold rolling

mill. Out of the cold rolled coils, a part will be sent to the galvanizing line of 400,000 t

/year capacity. CGL will coat the coils with zinc for galvanized sheets (plane/corrugated)

and the Colour coating line and subsequent slitting and cut to length lines for making

colour sheets.

Since galvanizing lines take as rolled cold coils and has annealing and temper rolling

processes in built in the line, the batch annealing furnace section capacity will be

600,000 t of coils per year. The temper rolling mill will also have similar capacity. The

inspection, slitting and cut to length lines will cater to dispatch of about 600,000 t of

uncoated cold rolled coils. These will cater to the needs of smaller coating installations.

At present in India, demand of tin plates are not very high even for the existing tin plate

manufacturers due to competition from aluminum and plastics. So installation of a tinning

line has not been envisaged.

11.3 The Material Flow Chart in the Cold Rolling Mill Complex (CRMC) is given in the Figure-

11.1 in the next page. The layouts of the different bays housing the individual processing

units are given in the Drawing- ENVIRO/AISL/FR/11/01kR-1. The location of this

complex in the overall plant layout is shown in the GLT Drawing -

ENVIRO/AISL/FR/GL/001kR-2. It may be noted that this complex is located on the north

Eastern Corner of the plant site which is in line of Hot strip mill its mother mill. Hot rolled

coils will be transferred from the dispatch bays of the Hot strip Mill by road.

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Hot rolled coils: 1,000,000 T

Fig-11.1: Material flow in the Cold Rolling Mill Complex

TANDEM 5 STAND COLD ROLLING

MILL- 4/6 HIGH

CAPACITY 1000000 T PER YEAR

ELECTROLYTIC CLEANING

LINE

CAPACITY 600,000 T /YEAR

BATCH ANNELAING

FURNACES

CAPACITY 600,000 T/YEAR

CONTINUOUS GALVANIZING LINE

CAPACITY: 400,000 T /YEAR

COIL COOLING

TEMPER ROLLING

RECOILING, SHEET

CUTTING & PACKING

SHEET

CUTTING,

CORRUGATION

COLOUR

COATING LINES

CAPACITY

200,000 T/YEAR

WIRE HOUSE- CR SHEETS

/COILS

567,000 T/YEAR

GALVANIZED

PRODUCTS

180,000 T/YEAR

COLOUR

SHEETS

190,000 T/YEAR

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A short description of the major units of the CRMC is described in the sections below:

11.3.1 Hot coil receipt bay.

(1) As per the general layout drawing prepared for the site, the location of the CRMC is

near the hot strip mill. Hot rolled coils will be transported in internal transport trailers

by plant internal roads from the CRM dispatch bay of the Hot strip mill to the hot coil

receipt bay of the CRMC, Here the coils will be inspected and move to the Pickling

department located in the next bay through transfer cars. The input hot rolled coil

specification will be:

Coil width: 600-1600 mm

Thickness: 1.6 to 6 mm

Coil ID: 760 mm

Coil OD: 2100 mm

Maximum Weight: 26.6 tons

(2) As per the available demand break up of cold rolled products, the proposed product

mix of the cold rolled products in the CRMC is given in the Table below:

Table-11.2: Product mix in the Cold Rolling Mill Complex.

Grade ThicknessmmWidth mm

0.25-0.3 0.31-0.6 0.61-0.9 0.91-1.2 1.21-2.-0 2.1-2.5 Total

O/DCR C/S 1000-1250

1250-150022,00021,000

61,00028,000

60,00013,000

53,00013,000

14,000-

210,00075,000

DDCR C/S 1000-1250

1250-150011,000 5,000

3,0007,0002,000

3,0001,000

26,0006,000

EDDCR C/S 1000-1250

1250-150014,00013,000

38,00058,000

35,00035,000

21,00025,000

11,000 119,000131,000

Total CR C/S 81,000 193,000 152,000 116,000 25,000 567,,000*

Galvanized/Colourcoated

800-1000800-1500

28,000 66,00032,000 166,000 70,000 14,000

94,000282,000

Totalcoated

28,000 98,000 166,000 70,000 14,000 376,000

Cold rolledGrand Total

28,000 179,000 359,000 222,000 130,000 25,000 943,000

CR C/S: Cold rolled coils/sheets.

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*94.3% average yield envisaged for processing hot rolled coils before pickling. to cold

rolled sheets/coils and coated coils.

11.3.2 Continuous pickling line

(1) The pickling process:

This unit will process 1 million tons of hot rolled coils. Its primary function is toremove the thin layer of oxidized iron, or scale, that forms on the surface of the steelat the temperatures employed during hot rolling. This includes all Cold Roll andGalvanize products, as well as Pickled and Oiled hot rolled coils (P&O) purchasedby customers who desire a surface quality more conducive to painting or plating.

Scale itself is chemically very similar to rust, being made up of iron and oxygenbonded together in various molecular arrangements. Like rust, scale develops atij[[bxi ikh\WY[ m^[h[ j^[ _hed _i [nfei[Z je W_h+ [nY[fj j^Wj _j \ehci Wj ^_]^[htemperature such as those used during hot rolling. The scale layer grows deeperinto the steel over time at a rate that increases rapidly as the temperature rises; forinstance, slabs exit the reheat furnace at the Hot Mill with a layer of scale up to 3.2mm thick. The typical lao[h e\ iYWb[+ eh wiYWb[ `WYa[jx being pickled is less than onethousandth of an inch thick and has a dull gray appearance.

The heart of the Pickling Line, its acid baths, consists of four or more tanks in a rowcontaining hydrochloric acid in concentrations ranging from 2% to 10% attemperatures held between 85 and 950C. Chemical inhibitors are added toZ_iYekhW][ j^[ WY_Z \hec WjjWYa_d] j^[ ij[[b X[d[Wj^ j^[ iYWb[ 'j^[ wXWi[ c[jWbx(-

The strip is pulled through the bath section at speeds up to 540 feet (170 m) perminute, and then rinsed with water sprays and air-dried, leaving bare steel with adull silver luster. Massive strip accumulators, on both the entry and exit ends of theacid tanks are employed to keep steel moving through the pickle baths and rinsetanks at a constant spe[Z Wi Ye_bi Wh[ beWZ[Z 'wY^Wh][Zx( edje the line and taken offof the line. This is important, both to maintain productivity and to avoid the stainsthat may occur when the strip stops between the acid baths and the air dryer.

Continuous OperationThe continuous nature of the Pickle Line requires that the coils be joined together,head to tail. To accomplish this, hydraulic shears at the entry end cut a section ofthe strip from each end of the coil, squaring up the ends of the coil and removingdamaged outer wraps. To expedite the preparation of each coil, the head end issheared shortly after the band is cut, before it is even charged onto the line.The head of the next coil to be charged is butted up against the tail of the last coil,and high voltage (and current) is applied across the seam, melting the two ends.

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The two strips are then forced together (upset) hydraulically, joining them togetherm_j^ m^Wj _i YWbb[Z W wXkjj-m[bZx- P^[ Wcekdj e\ Ykhh[dj [cfbeo[Z+ j^[ kfi[jdistance, and the time each process is allowed are all pre-programmed in aYecfkj[h Wi lWh_eki wh[Y_f[ix- Kl[h W ^kdZh[Z ikY^ YecX_dWj_edi Wh[ feii_Xb[+ WdZthe dimensions and grade of the steel being welded determine which will beemployed. Cutting tools immediately after the welder, trim the flash that is forced outof the seam during the upset. Coils are built up to heavier coils in the pickling lineand therefore the integrity of the weld is, naturally, very important since with a weakweld the strip would break and strip breaks on the line tend to be time-consuming torepair. For this reason, specific limitations are placed with respect to schedulingorders so as to maintain strong welds between coils of different dimensions andchemistries.

For Pickled and Oiled products, the welds are typically removed with a shear at theexit end of the line prior to shipment. Conversely, many coils destined for cold rollingm_bb X[ b[\j wXk_bj kfx+ _cfhel_d] j^[ fheZkYj_l_jo e\ Zemdijh[Wc kd_ji; j^[ ^_]^ j[di_edapplied to the strip during cold reduction must be withstood by these welds.

Flatness Correction

At the extreme entry end of the line, even before the shear and welder, two sets ofrolls, three below and two above the strip, mesh together to tightly work the steel upand dowd- P^[ wQd-Ye_b[h H[l[b[hx i[hl[i je cel[ j^[ ^[WZ e\ j^[ Ye_b je j^[ m[bZ[h+remove the memory in the steel of being coiled up (coil set), and break up the scalejacket prior to pickling. Ahead of the bath section, a more powerful version of the un-coiler leveler, with seven rolls total, operates under high strip tension to improve the\bWjd[ii e\ j^[ ij[[b- P^_i wP[di_ed H[l[b[hx h[ZkY[i j^[ ]Wk][ Xo WhekdZ ed[-half ofone percent and further breaks up the scale jacket. Pressure on the rolls is relievedas welds between coils of different dimension pass through to avoid damaging thehebbix ikh\WY[i-

Final ProcessingAt the exit end of the line the edges of P&O product are trimmed by rotary shearwad_l[ix m^[d h[gk_h[Z+ h[ikbj_d] _d W ceh[ kd_\ehc width and edge condition.Pof_YWbbo+ i^[Wh_d] j^[ [Z][i Wj j^[ L_Yab[ H_d[ h[cel[i WhekdZ 0�v e\ wi_Z[-jh_cxfrom the width, though as little Wi � v WdZ Wi ckY^ Wi 1v eh ceh[ YWd X[ i^[Wh[Z Wi necessary.

Oil is applied with one of two electrostatic oilers, which use electrical charges toattract oil mist to the surface of the steel just before it is recoiled. The P&O oilerapplies a protective film of high-quality oil to the steel to prevent it from rusting untilthe customer can process it, and may protect the steel for upwards of six months.The second oiler applies oil with sulfur additives to cold rolled sheet products toimprove the cleanliness of the final product. Galvanized products typically are notoiled after pickling. The pickled steel is then recoiled, weighed, and banded with a

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pair of high-ijh[d]j^ ij[[b ijhWfi Y_dY^[Z WhekdZ j^[ Ye_bxi Y_hYkc\[h[dY[ 'wX[bboXWdZix(- E\ if[Y_\_[Z _d j^[ ehZ[h+ ed[ eh ceh[ w[o[ XWdZix YWd Wbie X[ ki[Z+ m^_Y^are threaded through the middle of the coil and then around, cinching the insidewrap to the outside wrap.

Inspection

Between the rotary knives and the oilers is a brightly-lit inspection area with ascanning x-ray thickness gauge. The quality of the top and bottom surfaces, as wellas the flatness, is confirmed and a tape measure is used to check the width at thehead and tail of each coil. The x-ray measures the gauge at the center of the stripthroughout each coil, and at the strip edge at each end of P&O coils.

Agk_fc[djxi employed in the Pickling Line:

(a) Double entry coil preparation section(b) Tension leveler(c) Entry and exit accumulators utilizing tension bridle units and multi level loop

cars(d) The pickle section comprising of four acid pickling process with four circulation

tanks , squeezer rolls, tank support beams, circulation piping system, acid heatexchanger, fresh acid and waste acid piping system and controls.

(e) Dual re-coiling section.

Technological parameters of the continuous pickling line are given in the tablebelow:

Table-11.3: Technological parameters of the continuous pickling line

Item Unit ValueLine type ContinuousCapacity (input HR coils) w/// 1000Maximum thickness mm 6.3Maximum width of coil Mm 1550Maximum weight of incoming coils Tons 26.0Weight of built up coils Tons 45Speeds (maximum)Entry sectionProcessing sectionExit section

m/min400200300

No. of tanks No. 4Flow of acid Counter flowAcid used Hydrochloric acid (17%)Yield of pickled coils % 98Power required KWHr /t of coils 18

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Water required M3/t 1.21Make up acid Kg/t 135Spent acid Kg/T 156Acid rinsed water M3/t 1.21Free acidity in water Kg/t 0.43Total acidity in water Kg/t 0.84Chlorine Kg/t 0.6Spent liquor recovery by product Fe2O3/Fe3O4

(3) Tandem cold rolling mill

The pickled and built up coils are rolled in a five stand continuous tandem coldrolling mill. It is envisaged to transfer the built up coils from the pickling bay thetandem mill bay with transfer cars. It is possible also to couple the pickling and thecold rolling process to make the line a continuous pickling and cold rolling line. Thistechnology and design is offered by a limited number of companies. Though thisarrangement has many plus points but the major disadvantage is loss of flexibility.The decision to go for a fully coupled pickling and cold rolling or separate may betaken at the detailing of Phase-2 after examining the number of technologyproviders and the relative economics. This report however envisages pickling andcold rolling as separate stages.

The technical characteristics of the tandem cold rolling mill are given in the tablebelow:

Table-11.4: The technical characteristics of the tandem cold rolling mill

Stand No. 1 2 3 4 5Mill Type 4-high 4-high 4-high 4-high 4 high/

six highMain drive AC AC AC DC DCMain drivePower (KW)

3,500 5,200 5.200 5,200 3000

Main drive rpm 215/660 215/660 215/660 199/600 190/600Gear Ratio (i) 2.34 1.54 1.19 0.9 0.64Work rolldiameter (mm)

595/536 595/536 595/536 595/536 460/420

Work roll barrellength (mm)

1600 1600 1600 1600 1600

Back up rolldiameter (mm)

1550/1400 1550/1400 1550/1400 1550/1400 1470/1400

Back up rollbarrel length(mm)

1600 1600 1600 1600 1600

Roll gapadjustment

AGC AGC AGC AGC AGC

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Roll separatingforce (kN)

30,000 30,000 30,000 30,000 30,000

Bending ForcekN

±440 ±440 ±440 ±440 +500(-)350

Automaticthicknesscontrol

%

Thicknessgauge

% %

Laser speedmeasurement

%

Tensionmeasurement

% % % % %

Flatnessmeasurement

% %

The mill will have the following facilities to ensure a high productivity and quality of the

cold rolled strips.

' Flatness control with positive and negative roll bending and roll shifting

' Multi zone cooling

' High speed Automatic gauge control (AGC)

' Automatic pass line adjustment by a hydraulically actuated wedge below the

bottom roll assembly or with any similar arrangement.

' Automatic work roll change with a cassette type work roll chocks.

' Efficient emulsion blow off system from the strip and the interface between the

backup roll and work roll.

(4) Strip cleaning line

Cold rolled coils meant for dispatch as cold rolled coils/sheets and required to be

box annealed in the subsequent process step will pass through a Electrolytic

Cleaning Line (ECL) to remove the rolling oils from the strip so that these do not

result black soot patches while box annealing. The ECL cleans the strip from and oil

and dirt with an alkaline solution (Typical Na4SiO4 solution). The strip passes

through the electrolyte in a tank with electrodes dipped in the solution. A high

current density ECL with multiple brushes is envisaged to ensure more than 95%

removal of the oil and dirt present on the strip after cold rolling. Since the capacity of

a typical ECL is about 300,000 tons per year, it is envisaged to install two ECL lines

to meet the requirement of 600,000 tons of rolled coils which are likely to be box

annealed. Each of these lines will have arrangement for strip lead and tail end

joining.

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(5) Box Annealing Section

The process

During cold rolling process the reduction in thickness is due to plastic deformation

which occurs by means of dislocation movement. Steel gets hardened because of

the buildup of these dislocations. These dislocations reduce the ductility of cold

rolled steel making it useless for forming operation. To recover the ductility, cold

rolled steels need to undergo an annealing process for the relieving of the stresses

that have buildup within the microstructure during the process of cold rolling.

Annealing consists of heating of the steel to above the re-crystallization

temperature, soaking at that temperature and then cooling it. Heating of the steel

during annealing facilitates the movement of deformed iron grains, resulting in the

disappearance of dislocations and formation and growth of new grains of various

sizes. It has three different stages namely (i) stress relief, (ii) re-crystallization, and

(iii) grain growth. During stress relief which takes place around 480 deg C to 500

deg C, the atoms move only small distances, pushed and pulled by the surrounding

atoms into a configuration in which the internal stresses are reduced but the

boundary between the crystals remains unchanged. The stage of re-crystallization

takes place at around 550 deg C and during this stage new crystals begin to form at

the boundary of the original rolled grain. These crystals grow roughly into spheres,

realigning atoms from the cold rolled grains until their boundaries meet up with those

of other newly formed grains. Once the cold worked grains are fully consumed, the

steel is fully re-crystallized. In the third stage of grain growth the steel gets softened

as the grains consume other newly formed crystals and grow in size. This stage

takes place usually during the period of soaking.

The final mechanical properties and the microstructure of the steel are largelydependent upon the annealing process since it significantly influences thecrystallographic texture of the steel. Further precipitates decompose to solute atomswhich subsequently dissolve into the steel matrix on heating and holding, then re-precipitate in various sizes and distributions, depending on the rate of cooling.These changes in the size and distribution of the grains and precipitates also affectthe hardness of the steel.

The annealing is usually carried out under protective gas atmosphere for preventingsurface oxidation in order to meet the high demand on the surface of the cold rolledsteel. The protective gas atmosphere consists of nitrogen gas, hydrogen gas, or amixture of these two gases in various proportions. Hydrogen gas has higherconductivity and hence it is preferred sometimes. Mixture of the two gases isobtained through cracking of ammonia (5 % H2 and 95 % N2).

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For production of cold rolled steel usually two types of annealing processes areused. They are as follows.

' Soft annealing of steel u This type of annealing precipitation of cementite and

pearlite to reduce the strength of the steel for facilitating the forming operation.

Common temperature for this annealing ranges from 680 deg C to 780 deg C.

' Re-crystallization annealing u This type of annealing reconstitutes the crystallites

forms to their pre rolling state. The steel is heated in this type of annealing to a

temperature between 550 deg C to 700 deg C, slightly above the re-crystallization

temperature. The re-crystallization depends on the steel material and the degree of

deformation during rolling.There are two processes which are being used for the annealing of cold rolledsteels. These are (i) batch annealing process and (ii) continuous annealing process.Continuous annealing is more suitable to tin plates and less flexible. It is envisagedto have box annealing process at the CRMC

Batch Box annealing processThis is the older of the two processes. The process is preferred where large ferritegrains are needed as in the case of electrical steels. The design of a batchannealing plant depends on the material to be annealed. Basic equipment neededfor batch annealing of steel are as follows.

' Base unit provided with a circulation fan

' Protective gas tight cylindrical cover

' Heating hood or heating furnace with burners arranged tangentially. The furnace is

also known as bell furnace due to its shape.

' Cooling hood

Cold rolled steel coils (charge material) are stacked over the base three or four highon top of each other, separated by convector plates. The interior cover is placedover the coils and its volume is filled with the protective gas to prevent the steelsurface from getting oxidized under the high temperature. After this the heating hoodis placed in position. Burners of the hood are lighted and the heat from the burnerscauses inner cover to heat up. Heat from the cover is radiated to the steel coilscausing them to heat up. Heat is also transferred through convention to the coilinner surface by the circulating protective gas. The steel coils are then held orsoaked at a temperature aimed for annealing. After this the furnace is removed andthe cooled hood is placed and the steel coils are then left to cool to roomtemperature. For ensuring the required temperature being achieved through thecomplete steel coil, long heating, soaking and cooling times are needed. Typicalschematics of batch annealing furnace and equipment along with annealing cycleare shown in Fig 11.2.

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Fig-11.2: Schematic representation of Box Annealing process.

The section is envisaged to be having 40 bases; 20 furnaces and 20 cooling boxes. The

decision to go for only hydrogen annealing process or go for conventional H2 + N2

annealing atmosphere will be taken at the time of writing detailed specification

depending on the market situation. Hydrogen annealing though costlier, produces better

quality of annealed products particularly the ones requiring higher grain sizes and higher

annealing temperature. However, one hydrogen bell annealing furnace with a base,

furnace, cooling hood and accessories is also envisaged out of the 40 bases proposed.

(6) Skin Pass mill

The envisaged skin pass mill will be a Twin stand Double Cold Reduction (DCR) mill

stand 2 x 4-high cold rolling mill meant for giving a small cold reduction to the fully

annealed coils with the help of twin four high stands. Skin passing operation after

annealing is an essential part of cold rolling process. Skin passing is required to:

' Causes the unsteady yield point range called LÜDER band (or StrejY^[hxi ijhW_d( je

be transferred to definite yield point. This process improves flow behavior in the

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subsequent deep drawing operation of the flat product and prevents unwanted lines

of stress.

' Sets the desired roughness of the strip necessary for subsequent paint adhesion

' Improves surface flatness.

Best results are obtained and maximum flexibility is achieved by using a Twin four

high stand in tandem to skin pass and give some small reduction in the cold rolled

and annealed strip. Coils meant for coating will not pass through this mill as

separate skin pass mills are integral part of the coating lines.

The technical details of the DCR skin pass mill are given below:

Table-11.5: Technical characteristics of a DCR skin pass mill

Characteristics Unit DataRolled stock Low carbon steelsStrip width mm 1000-1500Thickness Mm 0.3 u 2.5Thickness reduction max in the first stand % 40Elongation in the second stand (max) % 1Maximum strip elongation % 2Maximum coil weight Tons 45Mill stand Twin stand 4-high (CVC)Roll diameter:Stand -1Stand -2

mm 360-400500-560

Rolling speed (skin passing) m/min Up to 2000Rolling speed (DCR Operation) m/min Up to 1600Roll force MN 12Capacity Tons/year 600,000Other features - Work roll bending

- Multi zone cooling

(7) Cold rolled products u slitting and shearing section.

The finished cold rolled uncoated coils can be dispatched in any of the three modes

with proper metal packed condition:

- As cold rolled coils with outer metal packing and eye protection inserted

- As slit narrower coils processed in a slitting line with outer packing and protection as

above

- As cut to length sheets cut in two shearing lines, packed in outer metal cover. .

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The finishing packing operations will be carried out in separate dispatch bays as

given in the lay out drawing of the Cold Rolling Mill Complex.

The major facilities will include:

(1) A slitting line: The line will process cold rolled coils as specified for the CRM

complex and slit those into narrower coils In increments of 100 mm. The slit coils will

have 600 mm inner dia and 1600 mm max outer dia. with maximum 18 tons weight.

The process will include: side trimming, slitting, sorting and oiling. The facilities to be

installed will include: receiving device, pay off reel, Guillotine shears, rolling shears,

oiler, re-coiler reels and delivery facilities. A thickness gauge will also be provided.

The annual capacity will be 250,000 tons.

(2) Shearing Lines: Two shearing lines are envisaged. The first shearing line will shear

coils of 0.3 to 1.2 mm with widths up to 1550 mm and the second shearing line will

shear coils 0.6 to 2.5 mm with widths up to 1550 mm. Cut sheet lengths will vary

between 1000 mm to 4000 mm. The cut sheet bundle will weigh up to 10 tons. The

shearing lines will be operated with a maximum speed of 5 m/Sec with threading

speed of 0.5 m /sec.

The facilities will include: Receiving device; pay off reels; levelers; guillotine shears;

rotary shears; flying shears for cutting the front and back ends; cut sheet conveyor;

sheet pilers and weigh scales.

(8) Hot Dip Galvanizing Line

The CRMC is envisaged to process 1,000,000 tons per year of input in terms of hot

rolled coils (HRC). Out of these 400,000 equivalent hot rolled coils are meant for

coated products: Galvanized and colour coated. Colour coated sheets require a thin

galvanizing pre-coat better paint quality and resistance to corrosion in ultimate use.

So it is proposed to galvanize the entire produce of 400,000 tons of hot rolled coils

to zinc/zinc aluminum coated coils and out of that 200,000 tons of equivalent HRC

will be colour coated in two colour coating lines.

Hot dip galvanizing protects steel from corrosion by providing a thick, tough metallic

zinc envelope, which completely covers the steel surface and seals it from the

corrosive action of its environment. The galvanized coating provides outstanding

abrasion resistance. Where there is damage or minor discontinuity in the sealing

coat of zinc, protection of the steel is maintained by the cathodic action of the

surrounding galvanized coating. Metallic zinc is strongly resistant to the corrosive

action of normal environments and hot dip galvanized coatings therefore provide

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long-term protection for steel. By contrast, most organic paint coatings used on steel

need frequent renewal and when coatings are breached, corrosion begins at the

exposed area of steel, spreading rapidly below the coated layer. That is why it is

desirable to provide a zinc protection layer below the colour coating.

(a) The process:

The schematic representation of the Hot dip galvanizing is given in the Figure-11.3below.

Fig-11.3: Hot Dip Galvanizing Process- Schematics.

Coils to be processed on the galvanizing line are charged, or loaded, onto one of twoPay-Off Reels. The head of the coil being charged is welded to the tail of the coil beingprocessed by a lap seam welder. Between 1 mm and 6 mm of the two coils are over-lapped onto one another, and a pair of high-voltage copper wheels, one above and onebelow, roll from one edge to the other, melting the laps and pressing them into oneanother. The resulting weld is nearly flattened to the gauge of each coil, but with a slightbulge in the center of the seam. The voltage applied between the two dies and thespeed at which they roll across the width of the strip are pre-programmed in a computeras various recipes that are called up according to the gauges and grades beingprocessed.

After welding, the ijh_f jhWl[bi _dje j^[ wAdjho Heef ?Whx+ eh WYYkckbWjeh i[Yj_ed+ m^[h[enough material is stored to allow the entry section to shut down for at least a minuteand a half while another coil is charged without slowing the process (annealing and zinc

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pot) section. The Loop Cars may travel horizontally or multi-strand, vertical accumulatorscan be employed as per the detailed design.

Cleaning & Preheating Before heat treating: the strip is cleaned of rolling oils and ironfines with rotating brushes and diluted sodium hydroxide (caustic soap). The steel ispreheated in the process section to a relatively low temperature in order to further cleanthe strip surface and minimize the time needed for the reducing zones to bring the steelup to its annealing temperature.

Burners in the Preheat section, combust Plant by-product gases in open air to maintainzone temperatures as high as 1230°C. Under normal operating conditions, the steel is inthis section for only a few seconds and never actually reaches this furnace temperature.LheZkY_d] w\kbb ^WhZx ]WblWd_p[Z ij[[b h[gk_h[i, striking a delicate balance betweencleaning the surface adequately for good zinc adherence and not sacrificing the strengthdesired by the customer by allowing the steel grains to re-crystallize. Costly low-carbonsteel grades with small additions of titanium are sometimes used because they anneal atrelatively high temperatures and can be thoroughly cleaned prior to coating. HeatTreatment is required because the majority of feed-stock for the galvanizing lines is FullHard from the 5-Stand tandem mill. The line incorporates processing steps to removerolling oils, iron fines and surface oxides from the strip to ensure good zinc adherence,and to anneal the material to achieve the combination of formability and strength soughtby the customer.

Ecc[Z_Wj[bo W\j[h j^[ fh[^[Wj i[Yj_ed+ j^[ ijh_f [dj[hi j^[ wh[ZkY_d] ped[x m^[h[ _j _iWdd[Wb[Z je WY^_[l[ j^[ Ykijec[hxi f^oi_YWb h[gk_h[c[dji \eh \ehcWX_b_jo _d W ^[Wj[Zatmosphere of 1 part hydrogen, 3 parts nitrogen. The atmosphere prevents the growth ofscale during heat-jh[Wjc[dj+ WYjkWbbo wh[ZkY_d]x b_]^j ikh\WY[ en_Z[ XWYa je _hed- D[Wj _isupplied by burning Coke oven gas/mixed gas inside sealed tubes above and below thestrip, with the heat produced radiating from the walls of the tubes out into the reducingzones. These zones are held at temperatures up to 900°C, and, under normal operatingconditions, the product is annealed for less than a minute. Thin strips may spend only 10seconds in the reducing zones, while heavier gauges at the #1 CGL may take a coupleof minutes to reach the necessary temperature. The steel is heated to temperaturestypically in the range of 700° to 850°C . Because the furnace is cannot achieve abruptchanges in temperature, specific limits are placed on the scheduling of coils in order toensure smooth transitions between products with different annealing requirements.Since the annealing process depends on both time and temperature, operators are ableto ease the transitions by adjusting the speed of the line. Immediately after annealing,the strip travels through cooling zones incorporating air jets and re-circulating fansX[\eh[ X[_d] Z_h[Yj[Z Zemd j^[ widekjx je j^[ p_dY fej- P^[ eX`[Yj_l[ _i je Yeeb j^[ ij[[bto a temperature that roughly matches that of the molten zinc; too warm and theYeWj_d]xi WZ^[h[dY[ m_bb X[ Yecfhec_i[Z Xo Wd el[hbo j^_Ya p_dY-iron transition layer; too

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cool and the aluminum can begin to precipitate (freeze) out of the molten zinc and getpicked up by the pot roll, marking the steel.

Galvanizing facilities envisaged \eh YeWj_d] ij[[b Wh[ e\ j^[ w^ej-Z_fx jof[+ Wi effei[Z jeelectro-galvanizing, which is a plating process comparable to chroming. After the steelhas been thoroughly cleaned, annealed, and cooled to a temperature that roughlymatches that of the molten zinc bath, the strip enters the zinc pot and travels around awfej hebbx m^_Y^ h[Z_h[Yji _j kf j^hek]^ Wd wW_h ad_\[x ioij[c- ?eWj_d] j^_Yad[ii _icontrolled by blowing off excess molten zinc; the air pressure applied to a tapered gap inthe knife lips, as well as the distance between the knives and the strip, regulate howckY^ p_dY _i YWhh_[Z ekj e\ j^[ fej ed j^[ ij[[bxi ikh\WY[- P^[ ^[_]^j e\ j^[ W_h ad_l[iabove the zinc pot is adjusted according to strip speed. Additional blow-offs called edgebaffles serve to prevent the excess zinc coating inherent to the edges from resulting in aYedZ_j_ed YWbb[Z w[Z][ Xk_bZ-kfx j^Wj YWki[i j^[ Ye_b je \bWh[ kf Wj j^[ i_Z[i+ ijh[jY^_d] j^[material to the point that it will not lay flat during further processing.

The thickness of the zinc applied to the steel is specified by customers as a coatingweight, in the unit of gm per square m- =d ehZ[h \eh wC-5/x i[[ai 180 gm. per squaremetre, which, when evenly distributed, equates to a coating thickness of about one-halfof one thousandth of an inch (0.006 mm) per surface. Since the heavier coating weightsadd as much as 0.1 mm (for G-235) to the overall thickness of the coated steel, aimgauges at the rolling mills provide for this so the finished product will meet theYkijec[hxi ]Wk][ h[gk_h[c[dji- P^[ j^_Yad[ii e\ j^[ p_dY YeWj_d] _i c[Wikh[Z m_j^ WGamma-ray and fed back into the computer which in turn makes adjustments to the airknives to optimize the coating weight. Changes in required coating weight, steelj^_Yad[ii+ WdZ [l[d b_d[ if[[Z Wh[ hWf_Zbo Yecf[diWj[Z \eh WkjecWj_YWbbo- P^[ wfejx _ireplenished periodically with 1-ton ingots of 99.9% pure zinc. Massive induction heatersin the basement maintain the pot at temperatures about 50 above the 426-degree C meltpoint of the zinc. Small additions of aluminum improve the adherence of the zinc to thebase metal by inhibiting the growth of the brittle zinc-iron transition layer. The striptravels more than ten stories straight up into the air out of the pot to allow time for thezinc to solidify against the steel. Large fans in the cooling tower air-cool the freshlycoated steel before it is sent through a water-gk[dY^ wi^eYa hebbx jWda- CWblWnnealingLheZkYji Z[i_]dWj[Z Xo Wd w=x _d j^[_h YeWj_d] m[_]^j '\eh _dijWdY[ =-40) arewCWblWdd[Wb[Zx+ W fheY[ii m^[h[_d j^[ `kij-YeWj[Z ij[[bxi ikh\WY[i Wh[ _cc[Z_Wj[boreheated by open-air burners. The zinc is baked into the steel until the two are alloyed,or metallurgically blended, with one another at the surfaces of the strip. The finishedproduct has a dull gray appearance due to the large proportion of iron that has diffusedto the surface. Galvannealed product corrodes more readily than galvanized steel, and isintended for end-uses that will be painted, such as computer brackets and appliancepanels. While hot-dip galvanize must be chemically treated before painting, galvannealdoes not. The alloyed layer is relatively brittle and will tend to fracture and flake off'wfemZ[h_d]x( _\ \b[n[Z i_]d_\_YWdjbo Xo W fW_dj b_d[ eh hebb-former. Reheating isaccomplished for this operation with a short, vertical, oil/gas furnace that is positioned

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above the b_d[xi p_dY fej- >[YWki[ e\ j^[ b_c_jWj_edi e\ j^[i[ furnaces, line speeds areslowed considerably when producing galv-annealed steel and available coating weightsare normally limited to A-5/ eh b_]^j[h je [dikh[ j^Wj w\h[[ p_dYx Ze[i dej h[cW_d Wj j^[ij[[bxi ikh\WY[-

Flatness correction situated after each pay-off reel is a small un-coiler leveler thatflattens the head-end of the steel by removing its coil-set, or memory of having beencoiled up. After the steel has been through the cooling tower and is roughly roomtemperature again, it passes through a Tension Leveler much like that at the Pickle Linewhere the strip is tightly worked up and down by a series of roll cassettes. Shape defectsare removed from the strip as its thickness is reduced by around one-half of one percent.The Galvanizing line includes a 4-hi skin-pass mill stand situated just in front of thetension leveler to reduce strain marks and impart a uniform surface texture on theYeWj[Z fheZkYj+ ikX`[Yj je j^[ Ykijec[hxi if[Y_\_YWj_edi-

Final processing

When required by the customer, a thin coat of rust inhibitor is applied to the strip as ittravels through the chemical treat section after the tension leveler. A solution issqueegees onto both surfaces and then air-Zh_[Z+ _d^_X_j_d] j^[ \ehcWj_ed e\ wm^_j[ hkijx(water-stained zinc) for six months or longer. Just before final inspection, the productpasses into the stamping area where, when indicated on the schedule, the strip isfh_dj[Z f[h_eZ_YWbbo m_j^ j^[ fheZkYjxi if[Y_\_YWj_edi- S^[d _dZ_YWj[Z Xo j^[ Ykijec[h+the strip is oiled after inspection. A spreader roll/electrostatic oiler is used to spread oilevenly across the top surface of the steel shortly before it is recoiled, Typically,galvanize products that will be painted are oiled, while end-uses calling for exposed zincreceive only Chemical Treat.

Inspection Before recoiling, the strip is inspected to ensure it is dimensionally sound, andthat any surface or shape defects are acceptable, based on customer and end-use-specific criteria. Each line has a small laboratory used to monitor the process on anongoing basis. Rockwell Hardness tests are performed on each parent coil to evaluatethe annealing heat treatment and feedback is normally given to the operator in time tomake adjustments for the next coil. Additional tests are performed to evaluate thecoating quality; weighing a sample, chemically removing the zinc, then reweighing thecoupon confirms the coating weight; creasing a sample with a tight bend tests theadherence of the zinc to the base metal. Periodic checks are performed to monitor theYb[Wd[hxi Z[j[h][dj b[l[bi+ j^[ cebj[d p_dY XWj^xi Wbkc_dkc WdZ b[WZ Yedj[dj+ WdZ j^[chemical jh[Wj iebkj_edxi cWa[-up. Tensile test coupons to qualify Physical Quality steelare sent to the main lab for evaluation. The finished strip is recoiled and cut to the weightrequired by the customer.

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(b) Technical characteristics of the line

The technical characteristics are given in the table below:

Table-11.6:Technical Characteristics of the Galvanizing Line

Item Unit Data

Strip Speed:Entry sectionProcess sectionIntermediate sectionExit sectionFlying shear

M/Min(max) 230

180 for Gal; 140 for galvanneal22025040

Strip DimensionThicknessStrip widthMaximum dia.Roughness

mm0.3 to 2.0 mm800 to 15003200 mm0.8 to 1.5 micro meter

Coil diametersOuter (max)Inner (max)Coil weight (max)Coil weight (min)

mm

Tons

2300508-6103210

Quality of material coated CQ,DQ,DDQ,EDQ,SEDDG,HSS etc.

StrengthsTensile strength (max)Normal rangeYield Strength (max)Normal range

N/mm2980270-640780120-340

Capacity Tons/year 400,000Entry & Exit facilitiesCoil reelsCoil lift platformExit Flying shear cut scrap lengthExit Flying shear sample length

2 x 41 x 2500 mm500 mm

(c) The Major units in the line

The following are the major sub process units in the galvanizing line:

1. Coil transport and pay off reels: 2 Nos. of coil lifting cars lift coils from the racks turnthose into right position, place on the strap removal table, weighing station andplace in one of the two entry un-coilers (pay off reels)

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2, Welding machine to join the head end of one coil with the tail end of the proceedingcoils.

3. Entry looper: Usually vertical looper to store 400 m of the strip sufficient to keep theline running for 2 minutes while joining the two coil ends at the welder.

4. Strip cleaning section: Uses both mechanical and chemical cleaning.

5. The furnace section for heating the strip to 750-850 Deg. C at reducing atmosphereto reduce all surface oxides and provide suitable base for adhesion of zinc. The stripwill be then progressively cooled to 460-480 0 C near the zinc pot temperature.

6. The zinc pot: 330 tons of molten zinc pot has been envisaged in the line with a 500KW inductive heater to keep the zinc at proper temperature. The strip enters thezinc bath from above and travel round a guide roll (coating roller) that guide the stripupwards again vertically out of the bath.

7. Air knife system: The air knife system controls the thickness of the strip coating.Nozzles arranged on both sides of the strip blow nitrogen at a predeterminedpressure on both the strip surface to blow zinc off evenly. Control systems ensurethat the nozzles are aligned centrally and in a straight position over both thesurfaces of the strip.

8. Galvanneal furnace section: This section is used for production of Galv-annealstrips, where the strip is re-heated to 550 0 C for a few seconds and then cooled.

9. Intermediate loopers: 380 m horizontal or vertical to maintain buffer between theprocess and the post treatment section.

10. Skin pass mill: A four high skin pass mill will be provided similar to the last stand ofthe DCR mill described before.

11. Tension leveler: Installed to provide improved shape of the strip.

12. Roll coating section: In this section the strip is chemically treated with a pick up rolland an applicator roll. The chemical can be the conventional chromate used toprevent white rust formation in the galvanized products or chromate free compoundsor anti figure print chemicals. After coating the strip is dried and then cooled.

13. Exit looper: It will store about 300 m of strip.

14. Side trim shear will be provided to side trim the strips when necessary

15. Strip inspection table where the strip passes horizontally for inspection and stripthickness and width measurement with gauges provided.

16. Oiling machine: Installed to apply oil on the coated surface when desired with rustprevention and deep drawing oils singly or in combination.

17. Flying shear for cropping front ends and also for taking samples

18. Exit coilers- 2 nos for finally making the coated coils. .

19. Galvanizing section finishing facilities:

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The coated coils will be dispatched/processed as follows:

(1) Will be dispatched as coated coils to be sent to service centers for cutting intosheets and corrugation into designs for use as roofing or partition sheets.

(2) In house cutting/slitting and corrugation with facilities of shearing line andcorrugation rolls.

The in house facilities will be decided at the detailing stage. It is recommended todispatch the coated coils to near the end use centers and process those coils furtherfor facilitating transport and avoiding product damage.

(9) Colour coating line:

It is envisaged to install two colour coating lines in the CRMC at phase-2. Each linewill be 100,000 tpy capacity. Due to a large number of colour coating facilitiesinstalled recently, it is envisaged to built up capacity of colour coating progressively.

The term and the Process: Colour coating is a term used to describe the applicationof a decorative and/or protective organic coating to steel substrate, supplied in coilform. Colour coated steel is also called as pre-painted steel. Colour coating of steelis a continuous and highly automated industrial process for efficiently coating of coilsof steel. In this process of application of colour coating, the substrate steel getsprotective and decorative coating. This process of colour coating is also called aduplex coating.

P^[ fheY[ii e\ Yebekh YeWj_d] e\ ij[[b WYYehZ_d] je AJ 0/05891/0/ _i W wfheY[ii _dwhich an organic coating material is applied on rolled metal strip in a continuousprocess which includes cleaning, if necessary, and chemical pre-treatment of themetal surface and either one side or two side, single or multiple application of(liquid) paints or coating powders which are subsequently cured or/and laminatingm_j^ f[hcWd[dj fbWij_Y \_bcix-

The thickness of Colour coating is usually in the range of 15 microns to 40 micronsand the finishes are smooth, matt, high gloss, textures and printed. For standardcolour coated sheet, the thickness of substrate steel usually varies from 0.2 mm to1.6 mm and width varies from 600 mm to 1600 mm.

Colour coating is done on various substrates of steels to produce most costeffective, quality assured products with the top coat compatible with environment.The substrate steels normally used are given below.

' Cold rolled steel

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' Hot dipped galvanized steel

' Electro galvanized steel

' Galvalume u It is also known as Zinc-alume and consists of 55 % aluminum, 43.5 %

zinc and 1.5 % silicon by weight.

' Galfan u It is 95 % zinc and 5 % aluminum

The schematic arrangements of colour coating structure is shown in Fig -11.4

Fig-11.4: Schematic arrangements of colour coating structure

Coating processThe colour coating line processes both cold rolled and metal coated steel coils. Thecontinuous colour coating line starts by uncoiling the coil to be processed andmechanically joining the head end of the strip to the tail end of the previous coil. Due tothe continuous operation, the line includes two strip accumulators, which feed the strip tothe coating process during coil changes.

As the first step of producing such material, pre treatment is carried out to ensure auniform and clean substrate surface. Pre treatment of the substrate is a very importantoperation required for better adhesion formability of colour coated steel sheets.Subsequently, the surface is activated by means of chromate free conversion to ensure

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good corrosion protection and adhesiveness of the following prime coating. This can beapplied either to the top and/or bottom surface. Before entering the next process step,the strip must be dried uniformly. Some Colour YeWj[Z fheZkY[hi ki[i wde h_di[xtechnology in place of phosphating (phosphate coating) over the substrate steel stripbecause of better bath maintenance, uniform crystal structure of coating as well as tomeet the demand of end users for more flexibility of coated steel.

No rinse coating pre treatment is a very thin layer of chemical treatment that bonds thecoating surface to steel to the subsequently applied organic coating materials to ensureexcellent adhesion of the organic coating material and corrosion resistance of the steelsubstrate.

In case of the chemical pre treatment, the strip surface is washed and a passivationlayer is added in four phases. The passivation layer improves the corrosion resistance ofthe product and adhesion of the primer. After the pretreatment, the primer of uniformlayer of uniformly controlled thickness is applied on the pre treated surface. The primerprovides flexibility to the colour coating system as well as corrosion resistance since itcontains corrosion inhibitors. The primer is cured in the oven with precise temperaturecontrols and with great precision.

Different types of primers are available based on various resins such as epoxy,polyester, polyurethane and PVC (Polyvinyl chloride). Epoxy primers are preferred foruse in roofing as it contains chromate pigments for better corrosion resistance.Hexavalent chromium (chromium VI) serves electrochemical couplers that can resist thecorrosive action on most metal surface. However, these compounds are widely used in_dZkijh_Wb YeWj_d]i+ Wh[ YbWii_\_[Z Wi wYWhY_de][dix 'YWj[]eho 0 and 2) as well being toxicand dangerous to environment. Hence some producers have developed chromate freeprimers.

The Colour coating line has normally two coaters. The first one applies the primer onboth sides of the strip and the second one applies the top coat and the backing coat.After the two coaters, there are convection ovens, where the colour coatings are cured

by hot air.

Most of the roofing and construction markets for colour coated sheets use top coatswhich are based on polyester, Polyurethane (PU), fluorocarbon, poly-vinyl-i-denefluoride (PVDF), silicone modified polyester (SMP) and plastisols for cost effectivenessand durability.

For multi-layer coating, a finish coat can be applied on top of the prime coating layer(also to the top and/or bottom surface) to meet the highest quality demands on the finalproduct. The top coat contains a combination of colour pigments and additives which

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provides the required colour and other performance properties like ultra violet resistanceetc.

After the ovens, the painted strip is quenched in water. If laminate is applied as the topcoating, the later coater applies adhesive that is activated in the oven. A laminate film ispressed on the steel strip by a roll immediately once the product has left the oven. Aprotective film may also be applied onto the coating, which will protect the coating fromdamage and dirt during subsequent processing by the customer. Before coiling theijh_fxi ikh\WY[ _i Y^[Ya[Z l_ikWbbo- = iWcfb[ Ykj \hec j^[ ijh_f kdZ[h]e[i quality controlin the laboratory of the colour coating line.

Before final cooling, a device can be installed for applying a protective foil to the hotikh\WY[+ Z[f[dZ_d] ed Ykijec[hix h[gk_h[c[dji-

Finally, the strip can be inspected in the inspection area and classified according to theYkijec[hix if[Y_\_YWj_edi WdZ j^[ Z[cWdZi e\ j^[ cWha[j- The schematic diagram of acolour coated line is given in the figure 11.5 below.

Fig-11.5: Schematic representation of a Colour coating line.

Main Technical characteristics in the colour coating line

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Table-11.7: Technical characteristics of the Colour coating Line

Item Unit DataNo. of Units TwoCapacity of each line Tons/year 100,000Material to be coated Cold rolled strips

Galvanized stripsStainless steel strips

Coil specification:ThicknessWidth

mm0.15 to 1.5600 to 1500

Line speed m/min 20-150Thickness of dry coating Micro m 15-60Energy of heating Mixed gas

OilElectricity

The principal units of the colour coating line are shown in the Figure given below:

Fig-11.6: Principal units of a Colour coating line.

11.4 Utility requirement in the Cold Rolling Mill Complex:

The Utility requirement in the CRMC is given in the table below:

Table-11.8: Utility requirement in the CRMC

Sl.No.

Utility Parameters Unit Consumption

Maximum Average1 Plant Compressed air 6-7.5 Kg/Cm2 (g) Nm3/Hr 9000 60002 Dry Compressed air 5-7 Kg/Cm2 (g) Nm3/Hr 2100 1900

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3 Steam 6-8 Kg/Cm2170-190 Deg. C

t/Hr 26 17

4 Nitrogen (Process) 6-8 Kg/Cm2 Nm3/Hr 5000 1500Nitrogen (Instrument) 6-8 Kg/Cm2 Nm3/Hr 1100 1000

5 Hydrogen 1-5 Kg/Cm2 Nm3/Hr 3506 Coke Oven gas 1200 mm WG Nm3/Hr 15,000 12,0007 Pilot gas 2000 mm WG Nm3/Hr 200 1508 Chilled water 9 Kg/cm2 at 9

Deg. & 14 Deg. Cm3/Hr 750

9 Filter Water 3.5 kg/Cm2 atroom temperature

m3/Hr 5000

10 Soft water 3.5 kg/Cm2 atroom temperature

m3/Hr 1000

11 Filter water make up 2 kg/Cm2 at roomtemperature

m3/Hr 35

12 DM water 2 u 2.5 kg/Cm2 atroom temperature

m3/Hr 54

11.5 Building and Cranes envisaged in the Cold Rolling Mill Complex

The general lay out of the cold rolling Mill complex is given in the Drawing:

ENVIRO/AISL/FR/11/01 R-0. The table below gives the details of the buildings and handling

cranes envisaged in the CRMC.

Table-11.9: Details of the buildings and handling cranes in the CRMC


Type of thebuilding


Handling craneType, Capacity, Nos.

Main Coil receipt, picklingline and tandem mill bay

500 x 30 Structural +15 EOT 80/20 x2; EOT50/15 x3

Roll shop & maintenancebay

300 x 30 Structural +15 EOT 55/20 x2EOT 15/5 x 2

Batch annealing, Electrolyticcleaning & Skin Pass millbay

300 x 30 Structural +15 EOT 60/20 x3

Tandem Mill Motor houselean to bay

100 x 20 Structural + 9 m EOT 15/5 x1

Cold rolled coil storage &transfer bay -1

300 x 30 Structural + 9 m EOT 75 /20 x 3

Galvanizing line bay 300 x 30 Structural EOT 60/20 x 2EOT 40/15 x1

Colour coating bay 300 x 30 Structural EOT 60/20 x 2EOT 40/15 x1

Cold rolled coil storage &transfer bay -2

300 x 30 Structural + 9 m EOT 75 /20 x 3

Cold rolled coil finishing &dispatch bay

300 x 30 Structural +9 m EOT 75/20 x 1EOT 40/15 x 1

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EOT 20/10 x 1Galvanized finishing anddispatch bay

300 x 30 Structural +9 m EOT 75/20 x 1EOT 40/15 x 1EOT 20/10 x 1

Color coated coils shippingbay

300 x 30 Structural +9 m EOT 75/20 x 1EOT 40/15 x 1EOT 20/10 x 1

Water pumping station 200 x 100 Structural +9 m EOT 10/5 x 1Electric telfers

Main CRM step down substation

150 x 75 Civil + yard

Tandem mill Electric controlroom and load distributioncentre

125 x 25 Civil Winches

Roll coolant pumping station 70 x 25 Civil Manual hoist/pulleyCODG and N2 Plant 75 x 75 Civil Manual hoist/pulleyAir compressor house 50 x 25 Civil Manual hoist/pulleyElectrical control room forbatch annealing furnace

75 x 25 Civil Manual hoist/pulley

Electrical control room forSkin pass Mill


De-humidifier Equipmentroom


Electrical control room forCGL


Electrical control room forColour coating line


Electrical control room fordispatch bays & finishingunits-1


Electrical control room fordispatch bays & finishingunits-2


11.6 Environment Control Measures to be adopted in the cold rolling Mill Complex

11.6.1 The table below lists the gaseous/liquid pollutants/effluents resulting from cold rolling

process and the proposed methods to treat those:

Sl.No.

Process Step Pollutants Treatment envisaged in the Complex.

1 ContinuousPickling line

Contaminated air frommechanical de-scaling.

Air sucked through ducts and cleaned in bag filter.

Hydrochloric acidfumes from the tanks

Fumes to be exhausted through acid resistant linedducts and would be treated in packed scrubbers toensure less than 10 mg/m

3of acid in the exhaust air.

The return scrubbed water containing acid is sent to

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the acid regeneration unit.Spent acid frompickling process

Sent to acid regeneration unit to recover HCl and theFerric Chloride is sold as by-product. The regenerationunit also treats the rinse water which also containsacid. For a description of Hydrochloric acidregeneration plant please see the section below.

Pickled strip rinsedwater

Sent to acid regeneration unit. Please see sectionbelow.

2 Cold rollingMill

Oil Mist Sucked through air exhaust through ducts installedover the mills. The mist is removed from the air with anelectro-static mist eliminator to collect the oil beforeletting the air out through a 40 m chimney. The outletair would have oil level less than 10 mg/Nm

3.

Cooling water Water is laden with scale and oil. Would be treated inscale pits to settle the scales and the water with oil willbe treated in water treatment plant to separate the oil.The scales would be treated in a scale treatment plantto burn the oil before sending to sintering plant for re-use. Please see water treatment section below.

3 Electrolyticcleaning line

Rinse water Contains cleaning alkali. Would be neutralized byadding acid and used for internal use.

4 Annealing Outlet waste gas In the steel plant clean mixed gas will be used and theheated product will be cold rolled degreased coils. Sono special treatment of the waste gas is at presentenvisaged. The heating system will employ low NOxburners.

5 Skin passingMill

Same as cold rollingmill but in lesser extent

Similar to cold rolling mill.

6 Galvanizing Line6a Degreasing

sectionSimilar to Electrolyticcleaning line

Vide item 3 above

6b The furnacesection

Waste gas with fumes To be cooled in air coolers and cleaned in bag filterhouse to ensure solid dust less than 10 mg/Nm3 ofoutlet gas.

6c The coatingsection

Air containing zincfumes

To be collected through hoods and exhausters andcleaned in bag filter house. The zinc dust collected inthe hoppers below the bag filter to be sold as zinc ash.

6c The zinc pot Zinc dross The zinc dross which is mostly zinc oxide is about10% of the zinc used. It is regularly removed from thepot and collected and sold to zinc extractors as sourceof metallic zinc.

6d Rinsing outletwater frompassivationtreatment

Water containingchemical.

Will be treated to remove the chemicals in a multistage iron exchange process plant.

7 Colour coatingline

Ambient air with paintfumes.

Extracted through hoods and cleaned bag filter housesand let out through two chimneys of 40 m height.

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11.6.2 Details of two major environmental control measures in the CRM complex

In this section a brief process description of the Spend HCl regeneration unit and

treatment of acid water from the pickling unit is given because these two are

important environmental control measures in the CRM complex.

(1) Regeneration of spent Hydrochloric Acid

For pickling of hot rolled coils use of Hydrochloric acid is envisaged in line with

modern practice. The free acid reacts with the scale (FeO mostly) and forms FeCl3

(mostly) which forms in the pickling tanks and the concentration of acid in the tank

decreases. In order to permit proper pickling, the bath must not exceed a certain

concentration of the soluted metal salts. It is possible to maintain a definite level of

free acid by continuous re-generation or treatment process of the spent pickle linked

directly to the baths. In general, it is desirable to obtain a total regeneration of the

acid, i.e. a recovery of the free acid and the recovery of acid bound chemically to

metals. Two methods are commonly used for regeneration of Hydrochloric acid from

pickling lines: These are:

' Regeneration by fluidization

' Regeneration by spray roasting.

The actual process may be selected at the time of tendering. A brief description of

these two processes is given below.

Hydrochloric acid regeneration by fluidization

Figure 11.7 shows the essential features of the main sub processes of the fluidized

bed acid re-generation process. The spent pickle is pumped into a separating vessel

and then concentrated in a Venturi loop by hot gases from the reactor. A share of

concentrated pickle from this loop is continuously fed into the fluidized bed of the

reactor. Within the fluidized bed which consists of iron oxide granulates, acid carry

over and water are evaporated at a temperature of about 8500 C and iron chloride is

converted to iron oxide and Hydrochloric acid. The setting parameters in the reactor

allow the iron oxide to be pulled off with a grain size of 1-2 mm dia. and a piled

weight of about 3.5 t/m3. This is pulled off continuously in bigger installations to

maintain a constant height of the fluidized bed. The resulting iron oxide is used in

several applications like input to production ferro-magnetic material, production of

iron powder.

The hot gas from the reactor contains hydrochloric acid, overheated steam,

combustion products and small amount of iron oxide dust. The solids are separated

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from the gas in the cyclone and recycled to the fluidized bed. The off gas is cooled

in the Venturi scrubber to about 1000 C. The thermal energy of the hot gases is used

to thicken the spent pickle, in order to pre-concentrate to the reactor. The cooled off

gases from the Venturi scrubber is ducted to an absorber. Within that the

hydrochloric gas is adiabatically absorbed by using rinsing and fresh water. The

resulting Hydrochloric acid (about 18%) can be directly recycled to the pickling tanks

or stored in acid resistant tanks. The off gases pass through a scrubber in order to

remove the remaining traces of the acid and released to atmosphere through a

40/50 m chimney practically free of the acid.

Hydrochloric acid regeneration by spray roasting

The spray roasting process is often employed for the recovery of metal oxides from

metal chloride solutions. The Ruthner-spray roasting process recovers the iron oxide

and hydrochloric acid from iron chloride and water. Figure 11.8 shows the process

schematically.

This pyro-hydrolytic separation of the iron chloride is carry out in the spray roasting

reactor at a temperature of about 4500 C. The spent pickle, containing iron chloride

is fed from the pickling station to the pre-vaporizer. There it comes in contact with

hot gases from the reactor and is partly evaporated. The concentrated iron chloride

solution is injected from above into the reactor. Hot burn gas causes the fine

droplets to evaporate as they decent. Iron chloride is separated into hydrochloric

gas and iron oxide by means of steam and oxygen in the air. The resulting fine iron

oxide is continuously pulled off at the bottom of the reactor. The piled weight of the

powder is about 0.3-0.4 ton/m3.

The hydrochloric gas, steam and combustion gases are ducted via the pre-vaporizer

to an absorber; there it is absorbed adiabatically by means of the rinsing water of

the pickling plant. The resulting acid (about 18%) can be returned to the pickling

process. The resulting off gas is cleaned in a subsequent alkaline washing and

released practically acid free via a stack into the atmosphere. The by-product iron

oxide can be sold for use to different customers depending to the quality.

(2) Management of waste water within cold rolling mills

Waste water within cold rolling mill complex arises due to the process pickling and

cooling/lubrication during the process of cold rolling. Pickling and related processes

(rinsing, gas cleaning operations, acid regeneration) cause acidic waste water

streams. Cooling and lubricating processes in the rolling sections give rise to oil and

suspended solid loaded waste water streams. Depending on the steel grades

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processed, several measures are relevant. In general use of process water in loops

or cascades and the use of coolants/lubricants in loops as far as practical would be

used. But to permit its use in loops, treatment measures are necessary and have

been envisaged. Waste water treatment is separated into processes for acidic

streams and those for oil loaded components.

For treatment of water with acids, acid recovery will be practiced as already

described in the previous section. The recycling loop of a Hydrochloric acid pickling

waste water is given in Figure 11.9. This shows the waste water inputs to the

Fluidized bed acid regeneration unit.

In some situations, acid recovery from waste water may not be possible due to

breakdown or maintenance of downstream plants. In that case the acidic water will

be neutralized with milk of lime to bring the pH of water to acceptable level before

re-use inside the plant for spraying etc.

Treatment of water from rolling stands coolants/lubricants

The main components of coolants and lubricants from the cold rolling stands are

water, oil and emulsifying agents. The emulsions can contain stabilizers,

antifoaming agents rust preventive agents, biocides etc. Coolants/lubricants are to

be used in cascades to maintain their properties as long as possible. The cleaning

and treatment measures to be adopted are as follows:

' Removal solid properties: several proprietary processes are available involving

magnetic separation, gravity separation, centrifugal separation, and filtration.

' Removal of non emulsified oil by skimming

' Monitoring of composition, aeration to prevent putrefaction and cooling

Often industrial waste water treatment plants offered combine some or all of the

above steps to result reusable water.

Spent oil emulsions will be given to outside agencies for processing.

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Chapter-12: Captive Power Plants and Turbo Blower Stations

12.1 To meet the power requirement of the steel plant, it is proposed to install captive power

plants of the following configuration.

Phase-1: Coal/waste gas based CPP- 1 x 70 MW

Phase-2: Coal/waste gas based CPP- 2 x 100 MW.

The generation of power from these two Captive Power plants will be supplemented by

auxiliary generation of power from the TRT of blast furnace no 1 and 2. The nominal

envisaged capacity of these two units is 6MW and 12 MW respectively. Further, steam

will be available from the coke dry quenching units of the coke oven complex. While at

phase-1, the steam is proposed to be used for the process but at 3.5 MTPA stage (in

phase-2) installation of steam turbines will be considered for a total generation of

another 7 MW.

Coal is envisaged as the principle fuel. Heavy oil is the support firing fuel for low loads

and LDO/HSD would be fuel for start ups. However all the boilers will have facility to use

spare Blast furnace or mixed gas if surplus is available. This can happen when some of

the consuming mills are down.

12.2 Steam generators: For feeding the steam turbines for captive power generation, the

following configuration has been envisaged.

Phase-1: Coal fired boiler p 1 x 350 tph at 90 bar steam pressure and 530 0 C. The boiler

would be circulating fluidized bed combustion (CFBC) type. The boilers will be

membrane water wall, natural circulation, water tube, balanced draft furnace, non reheat

suitable for semi outdoor installation.

Phase-2: Coal fired boiler- 2 x 450 tph at 150 Kg/Cm2 and 5400 C. The boiler is

currently envisaged as dual fired with pulverized coal and by-product gases. The option

of going for CFBC type will be explored at the detailing stage depending on the choice of

available coals. The boiler will be drum type (natural/assisted) single double pass (tower

type or two pass type), single reheat, radiant furnace, dry bottom, balanced draft,

outdoor type top supported direct pulverized coal fired.

12.3 Steam turbines:

Phase-1: At phase-1, the proposed steam turbine would be rated 70 MW maximum

continuous rating at the generator terminals with inlet HP steam conditions of 90 bar and

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530 0 C. The steam turbine will be extraction and condensing type. Steam inlet to the

turbine will be through emergency stop and control valves. The condensers will be air

cooled type. The generator will be rated at 70 MW, 11 KV, 3 phases, 50 Hz and 0.8

power factors. The generator and rotor will be suitable for air cooling with the windings

cooled with air circulated by fans mounted on the rotor.

Phase-2: At Phase-2, the proposed steam turbine would be rated 100 MW maximum

continuous rating at the generator terminals with inlet HP steam conditions of 150 bar

and 540 0 C. The steam turbine will be extraction and condensing type. Steam inlet to

the turbine will be through emergency stop and control valves. The condensers will be

air cooled type. The generator will be rated at 100 MW, 11 KV, 3 phases, 50 Hz and 0.8

power factors. The generator and rotor will be suitable for air cooling with the windings

cooled with air circulated by fans mounted on the rotor.

12.4 Characteristics of the steam generators (Boilers)

Phase-1: At this stage boiler of Circulating fluidized bed Combustion (CFBC) has been

selected. It is a well established technology for adopting inferior quality of coals and burn

these in an efficient and environmentally acceptable manner. In fluidized bed

combustion, a bed of finely divided solid particles such as ash crushed refractory, sand

or lime stone is supported on a perforated plate. During combustion, this bed is

transformed into a pseudo fluid state. It behaves like a highly turbulent boiling fluid due

to a stream of air passing upwards through the perforated plate. The air velocity is

chosen such that the particles are not carried out of the furnace by the air stream. The

fuel like coal is injected into the bed either through over bed or under bed feeding

system. Part of the heat absorption surface is immersed in the bed and its surface area

is matched to the heat release rate so that the bed temperature is maintained at 850 to

9000 C.

FBC boilers are of two types. Atmospheric types or pressurized type depending on the

operating pressure of the combustor (Fluidized bed). Atmospheric types are more

common and economic and hence recommended. The FBC boilers are classified as

bubbling type or circulating type. In the later type higher air velocity of air is employed to

circulate the bed material and the fuel through the combustion chamber. This type is

more efficient in consumption of fuel.

The advantage of using Fluidized type boilers is:

' Flexibility in burning wide range of fuels including low grade coals and washery

rejects. Sufficient cushion has been provided in the boiler capacity to take care of

such fuels.

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' High efficiency of the order of 80% even with inferior fuels.

' Reduced maintenance costs due to elimination of moving parts.

' Reduced atmospheric pollution: SO2 emission can be controlled by adding lime

stone in the fluidized bed and lower temperature of combustion reduces the nitrogen

oxide level in the out gas.

In view of these merits and difficulty of getting better coals as fuel, atmospheric type,

circulating fluidized bed combustion type steam generator (Boiler) is recommended. The

steam generator will be natural circulation, coal fired, balance draft, semi outdoor units.

Only one boiler is proposed at phase-1. The boiler will mainly consist of bed/over board

super heater sections, bed evaporator, water walls, refractory walls, economizer and air

pre-heater. The balanced draft in the furnace will be maintained by the induced draft and

forced draft fans. For maintaining the dust content in the effluent gases Electro Static

precipitators will be provided to ensure a particulate level of not more than 30 mg/Nm3 of

waste gas with a provision of providing additional field in future to reduce the emission

level to 25 mg/Nm3. Pneumatic ash handling system will be provided from the ash points

in the boiler as well as from the ESP hoppers to be stored in an ash silo and disposed in

moist form with screw feeders to trucks or in dry form to cement carriers for making

bricks.

Phase-2: At this phase pulverized coal fired boilers 2 Nos. of steam raising capacity of

450 tph each at 150 Kg/Cm2 and 5400 C has been envisaged. The option of going for

AFBC boiler at this stage may be examined after fuel supply position of stage-2 is

decided. For pulverized coal fired boilers, the coal burners will be suitable for low NOx

emission to comply with the recent norms of 100 mg/Nm3 in the stack gases. Broadly

the steam generator characteristics would be:

(a) Furnace will be radiant, dry bottom type with tangential or opposed wall firing and

enclosed by water cooled and all welded walls. The furnace bottom shall be suitable

for installation of a water impounded bottom ash hopper. Spray type attemperator is

envisaged to control the super heater outlet temperature for varying loads. The

super heater and re-heater tubes will a combination of radiation and convection

type. Economizer will be non steaming type and shall be of modular construction

with a provision of providing additional loops.

(b) The steam generator circulation system shall employ either controlled circulation

concept or natural circulation concept.

(c) Air and flue gas system: A balanced draft system will be provided. There shall be

two axial FD fans and two radial ID fans each of approximately 60% capacity ; two

number of regenerative rotary type tri-sector air pre-heaters; two number of steam

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coil air pre-heaters one on primary and one on secondary air system for startup, low

load condition and abnormalities for ensuring an increased air inlet temperature.

(d) Fuel oil firing system: For startup, worm up and low load (up to 30%) operation of

the boiler, LDO/HFO firing has been envisaged.

(e) Coal firing system: This system will comprise of:

(1) Coal mills of vertical spindle type, which would include bowl mill (XRP type);

roller mill (MSP type), ball and race mills (E type) or any equivalent. Adequate

spare capacity will be provided in the mill capacity for worst type of coal to be

fired.

(2) Raw coal bunkers with belt driven gravimetric coal feeders for feeding coal to

the mills.

(3) Two axial PA fans for transportation of coal from the mills to the boiler burners.

(f) Soot blowing system: Fully automatic, sequentially controlled, micro processor

based steam soot blowing system will be provided. The system will have short

retractable rotary wall blowers for the furnace and long retractable rotary blowers for

the super heater region and the economizer.

(g) Auxiliary Steam system: Two auxiliary PRD systems (One high capacity and the

other low capacity) with auto exchange provision.

(h) Electrostatic Precipitators: A high efficiency Electrostatic precipitator with efficiency

to limit the outlet emission to 50 mg/Nm3 (maximum) will be provided. It would have

a provision of providing additional field in future to reduce the emission level to 25

mg/Nm3. Provision of Flue Gas Conditioning (FGC) system if required in future will

be kept. Pneumatic ash handling system will be provided from the ESP hoppers to

be stored in an ash silo and disposed in moist form with screw feeders to trucks or in

dry form to cement carriers for making bricks.

(i) Ash handling system: The bottom ash will be collected and disposed off in dry form.

The fly ash shall be extracted in dry form from the ESP hoppers. The dry ash will be

pneumatically conveyed to the ash bunker as disposed as given above.

(J) Water system and utilities: This system will be common for the entire power plant.

The phase-1 facilities will be expanded by providing additional modules in phase-2.

The system will include:

(1) Make up water system

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(2) Circulating water system

(3) Equipment cooling system

(4) Misc water system

(5) Water treatment section comprising of p Water pretreatment section; water

demineralizing plant; Chlorination plant; chemical treatment plant ; effluent

treatment plant; fire detection and protection system.

12.5 Turbine and its auxiliaries:

The envisaged turbine capacity as enumerated earlier will be:

Phase-1: 1x 70 MW

Phase-2: 2 x 100 MW.

(a) The scope of the TG units shall broadly cover the steam turbine along with its

integral systems and auxiliaries like lube oil system, air cooled condensers,

condenser air evacuation system, HP & LP by pass system, complete

regenerative feed heating system, condensate pumps along with drives, boiler

feed water pumps along with drives; LP chemical dosing system; automatic

turbine run up system, instrumentation and control devices, turbine supervisory

instruments, turbine protection and interlock system and automatic turbine

testing system.

(b) The steam turbines will be of extraction and condensing type. Steam inlet will be

through emergency stop and control valves.

(c) Governing system: The turbines should have throttle or nozzle controlled type

governing. The TG unit should have electro-hydraulic governing system backed

by 100% mechanical hydraulic or electro-hydraulic governing system. The

system should be able to control the over speed of the turbine on loss of full

load to value less than 8% of the rated speed. The steady state regulation shall

be adjustable within +3% to +8% of the rated speed. The dead band of the rated

speed and at any power output within the rated output shall not exceed 0.06%

of the rated speed.

(d) Turbine lube oil system: A self contained combined lubricating and governing

system for each turbine generator set has been envisaged. Each oil system will

comprise of the following:

' One 100% duty steam turbine shaft driven main oil pump.

' 2 x 100% capacity AC motor driven auxiliary oil pump.

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' 1x100% DC motor driven emergency oil pump to supply bearing lubricating

oil to the system.

' One 100% capacity AC motor driven jacking oil pump and one 100%

capacity DC motor driven jacking oil pump.

' One main oil tank of adequate capacity

' 2 x 100% capacity oil coolers

' Lub oil purification equipment capable of treating 20% of oil charge in the

system on a continuous basis per hour.

The main oil pump will be capable of supplying the complete requirement of

regulating, lubrication and seal oil. The AC auxiliary pump will supply the

required oil during turbine start up and shut down operations and also in case of

fall in the main oil pump pressure. The emergency oil pump (with DC drive) will

start automatically in case of power failure.

The jacking pump will supply high pressure oil to all bearings during turning

gear operation. The jacking oil pump is of high pressure but of low discharge

capacity.

(e) Turning gear: Electric turning gear (AC electric motor with hand barring facility)

will be provided to rotate the turbine shaft to enable fast and uniform cooling

and warming during the shutdown and start up respectively. The turning gear

will engage and disengage automatically depending on the speed of the turbine

shaft.

(f) Turbine gland steam sealing system: The gland sealing system will be complete

with electro-hydraulic / pneumatic controller and actuators, gland steam

condenser exhaust and de-superheating unit for fully automatic operation.

(g) Turbine protection system and turbine supervisory control system: This system

ensures safe operation and monitoring of the turbine performance. The major

protections envisaged are:

' Over speed protection

' Low lubricating oil pressure

' Bearing temperature high

' High axial shift

' Failure of thrust bearing

' Low condenser vacuum.

(h)Turbine by-pass and steam dumping: The HP and LP bypass should be able to

meet the following conditions.

% Quick start up of the steam generator from cold, warm & hot conditions

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% Parallel operation of the by-pass system with turbine in case of a large

load throws off.

% House load operation following a large load throws off.

% To keep the steam generation in operation so as to avoid a fire out in the

steam generator following full load rejection

% The HP/LP by pass system shall be sized for 60% of BMCR steam flow

with rated MS parameters at upstream of valve and CRH steam

parameters on downstream. The LP by pass will be sized for steam inlet

conditions (pressure and temperature) of HRH line. The bypass system

will connect the main steam pipes with the condenser through by pass

pressure reducing valves and de-super heaters. Oil system of turbine

bypass will be independent of the turbine governing system and will have

adequate protection.

(i) Steam Condensing system: The steam condensing and condensate

extraction system of each unit will consist of:

' Turbine steam Condenser air cooled p one No.

' Condensate extraction pump- 2 x 100%

' Condenser air extraction device- 2 x 100%

' Staring steam jet ejector p One no.

' Gland steam condenser, drain cooler, mountings and fittings etc.

' The condensers will be of air cooling type.

(j) Feed cycle equipment: For each unit It shall consist of two low pressure

heaters, one high pressure heater and a gland steam condenser. The

regenerator feed heating plant shall be designed for all operating

conditions including transients like sudden low throw off, HP/LP by pass in

operation, one or two heaters going out of service etc. The condensate

from the condenser shall be pumped by the condensate extraction pumps

through the train of LP heaters to the de-aerator. In de-aerator, the

condensate is heated to saturation temperature and fed to boiler feed

pumps which increase the feed water pressure to suit the steam generator

requirement.

Feed water then passes through HP heaters which raise the feed water

temperature to nearly 25 to 260 0 C (tentative). Finally the feed water is

fed to the boiler.

(h)Boiler feed pumps: 2 x 100% capacity motor driven boiler feed pumps

would be provided to pump the feed water from the de-aerator feed water

heater to the steam generators through HP water. One pump would be a

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standby for each turbine. The boiler feed pumps would be horizontal

multistage centrifugal pumps of ring section type.

(i) Auxiliary steam for the power plant and for coke oven by-product.

(a)Besides the live steam requirement of turbo-generators, steam at low and

medium pressures is required to meet the demands of the other

auxiliaries of the station (de-aerator, fuel oil heating etc.) The requirement

of such steam at phase-1 will be about 20 tons at 1880 C and 12 kg/cm2

pressure. This auxiliary steam will be tapped from an appropriate stage of

the thermal cycle and passed through a pressure reducing and De-

superheating station (PRDU) to maintain the required temperature and

egZhhjgZ Vi i]Z jhZghq ZcYh+

For phase-2 with 100 x 2 MW generations, the steam requirement will be

about 40 tons and would be supplied in a manner similar as described

above from the phase-2 steam generation units.

(2)There would be process steam requirement for the coke oven sections at

both phases. It is tentatively estimated for each phase as:

2 tph @ 16 Kg/cm2, 3200 C. This will be met from the extraction of turbine

generators through PRDU.

12 tph @ 6 Kg/cm2, 2500 C. This will also be met from the extraction of

turbine generator at appropriate stage and through furnace oil fired

external super heater.

During shut down of the TG sets, the above steam will be met from the

boilers through PRDU.

12.6 Turbo-blowing station:

Turbo-blowers will be used to supply cold air to the blast furnaces via

stoves. The calculations for turbo-blower capacity and the capacity

requirements of the steam generators feeding the turbine of the TB sets

are given in the table below:

Table-12.1: Capacity calculations of the Turbo-blowers and the steam

generating sets.

Item Phase-1 Phase-2Average Hot metal/Hr 140 t (3360/24) 317 t (7628/24)Net air required @ 1030Nm3/THM

1030 X 1030 =144,200Nm3/Hr

317 X1030 = 327,368 Nm3/t

Gross air required with 144,200/0.9 x 1.15 = 327,368/0.9 X1.15 = 418,304

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10% air loss and 115%envisaged peakproductivity

184,256 Nm3/hr. Nm3/Hr.

Capacity of each of twoTurbo-blowers envisagedfor each BF.

184,256/0.85/2 = 108,385Nnm3/hr at 2.9 Kg/cm2 and110

0C

418,304/0.85/2=246061Nm3/Hr at 3 Kg/Cm2, 110

0 C

Each Turbine capacity 9 MW (appox.) 20 MW (appox.)Process steam or inputsteam to turbines

60 Kg/cm2, 4850

C 60 Kg/cm2, 4850

C

Process steam envisagedto be met from the unit

50.5 tons/hr 91 tons/Hr.

Extracted steam fromturbines at 16 Kg/cm2

2 x 8 = 16 tons /Hr. 2 x 18 = 36 tons/Hr

Steam required fromboiler via PRDU

50.5-16= 34.5 t/Hr 55 t/Hr

Capacity of the boilerenvisaged

18 X 5 + 34.5= 125 t/Hr. 40 X 5 + 55 = 255 t/Hr

The Turbo-blower station for both phases is proposed to be located adjoining to

the power plant. Two turbo-blowers with output as envisaged above will be

installed in each phase to cater to the two blast furnaces envisaged one each in

phase-1 and 2. Each phase will have an exclusive boiler fired with by-product

gases to supply steam to the turbines of the TB sets. These boilers will also

supply process steam at lower pressure to the various units of the steel plant at

each phase. Low pressure steam for coke ovens can be supplied either from the

CPP units or from the TB units as per convenience.

12.7 Supplementary Generation of power

Apart from generation of power from the conventional captive power plants,

power will be available from the top pressure recovery turbines (TRT) of the Blast

Furnaces. A capacity of 6 MW and 12 MW has been envisaged for the two TRTs

planned for Blast Furnace No, 1 and 2 respectively. Further, steam will be

available to the extent of 40-50 t per hour from each phase. While at phase-1 the

waste heat steam is proposed to be used as process steam after pressure

reduction through PRDU, at phase -2 with provision of steam turbine, about 15-

20 MW of additional power can be supplemented to the main power generation

capacity.

12.7.1 Blast Furnace Top Gas recovery turbines for generation of power (TRT)

These are energy saving equipment used for a blast furnace. These replace the

conventional septum valves used to control blast furnace gas top pressure after

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blast furnace gas cleaning. The cleaned blast furnace gas is led to the turbine

and drives it while expanding it from furnace top gas pressure to slightly above

atmospheric pressure. The power generated in the turbine is transferred to a

generator and converted to electrical power. In conventional practice, the power

in the blast furnace top gas (1.5 and 2 kg/cm2 respectively) is wasted in pressure

reduction through septum valve while with TRT these are gainfully converted to

electrical energy. To control of furnace top gas pressure with volume of blast

furnace gas generated, the first stage stator blades are opened or closed. This

has largely replaced the older design of governor valves for regulation of

pressure. The septum valve is however installed in the bypass line of the blast

furnace gas path for any emergency situation in the TRT. The schematic

representation of the gas cleaning and pressure regulation system of a blast

furnace with TRT is given in the Figure 15.1. The gas cleaning can be either dry

or wet type. The former method generates more power from the TRT. In this

report at chapter 8, conventional wet type of gas cleaning of blast furnace gas

has been envisaged but the option of going for dry type can be explored with the

technology and equipment suppliers at the detailing stage. Typically power to the

extent 15-40 KWH/t of hot metal can be produced through TRT depending on the

extent of gas by pass and design of the turbine. The higher value has been

considered for selecting the capacity of the turbines.

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Fig-12.1: Schematic representation of the position of a TRT in the blast furnace gas

cooling and pressure regulation system.

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CHAPTER- 13: CRYOGENIC OXYGEN PLANT

13.01 In order to meet the requirement of oxygen, nitrogen and argon in the various processes

and services in the steel plant, it is envisaged to install an Oxygen plant (Cryogenic Air

separation and purification unit) at each phase of the project. The capacity selected is

700 TPH capacity oxygen plant at phase-1 and 900 TPH capacity at phase-2. Each plant

will be complete with all related auxiliary and service facilities.

13.02 Oxygen will be required for oxygen blowing in the steel making process m at both EOF

and BOF shops at phase-1 and 2 respectively, for cutting of blooms/billets and slabs in

the continuous casting departments, for enriching air for better blast furnace productivity

and for general plant maintenance. Nitrogen is used as a protective inert gas in various

processes like coal dust injection to blast furnaces, BOF gas cleaning plant, hot metal

desulphurization, top charging equipment of blast furnaces, safety in the blast furnace

stove area and ladle purging in the secondary treatment, as a heat transfer agent in coke

dry cooling etc. Argon will be purified in the argon purification plant located along with

the oxygen plants. Argon will be used in the secondary treatment of steel for stirring of

steel in the ladles, as a shroud for protecting the steel flow from the nozzles and many

other uses. Oxygen and Nitrogen at high pressure will be distributed throughout the plant

area for use in the respective shops. Oxygen for maintenance purposes will be also

made available in cylinders.

The tentative requirements of Oxygen in the steel plant at both the phases are given in

the table below. It may be seen that the units selected has enough cushion for any

unforeseen requirement and demand for expansion of production capacity.

Table-13.1: Requirement of Oxygen at the two phases.

Phase-1: 1 million ton stage Phase-1:2.5 million ton stageSl.No.

Uses of Oxygen Consumptionrate Nm3/t

Consumption10^6 Nm3/year

Consumptionrate Nm3/t

Consumption10^6 Nm3/year

1 Steel making 70 70 59.2 148.52 CCM 6 6 6 153 Blast Furnace 5 5.88 5 13.334 Maintenance 10 20

Total 91.88 196.835 Losses @ 5% 4.6 9.846 Grand Total 96.48 206.67

Say 97 Say 207Requirementper day (tons)

353.7 754

Units envisaged 700 TPD 900 TPD

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13.03 The production parameter of the oxygen plants are given in the Table below:

Table-13.2: Production parameters of the Oxygen Plants

Sl.No.

Product Production capacity Nm3/Hr Purity

Phase-1(700 TPH)

Phase-2(900 TPH)

1 Gaseous oxygen 19,800 25,500 99.5%2 Liquid oxygen (gaseous

equivalent)445 570 99.5%

3 Gaseous Nitrogen 10,200 13,100 99.9%4 Liquid Nitrogen

(gaseous equivalent)510 655 99.9%

5 Liquid Argon (gaseousequivalent)

127 165 99.99%

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Chapter-14: Pollution Control and Environmental Management

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An Integrated steel plant employs a number of processes to manufacture steel products

in saleable form. Each manufacturing process has sources of environment pollution. The

pollutants in the form of solids, liquid and gases are generated from different processes

and need to be treated to harmless products before discharge to nature. Adequate

provision has been kept in selecting the processes, the machinery and the lay out to

keep emission pollutants after treatment within the current acceptable limits.

14.1 Air pollution control measures

Air in and over the plant area and beyond the boundaries gets polluted with gases,

fumes and dust particles emanating from the processes , chimneys, transfer points of

conveying and handling equipment. The principle air pollutants from the steel plant are

solid dust and gases like Sulphur di-oxide, carbon monoxide and oxides of nitrogen.

The measures to control the air pollution will ensure the ambient air quality standards as

laid down by Central pollution Control Board (CPCB) as given in the table below:

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The systems envisaged for air pollution control will provide acceptable environment

condition in the working area and abate air pollution in the surrounding area of the

integrated steel plant. The technological equipment and processes have been selected

with the above objective. The pollution control measures adopted have been tailored to

the quantity and nature of the pollutant coming from a particular source. The broad

measures envisaged to control air pollution control are:

(1) Utilization of by-product gases and waste gases as fuels and also as sources of

energy before letting out to the atmosphere.

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In general, an integrated steel plant produces considerable amount of gases from

various technological units like Coke Ovens, Blast furnaces, BOF converters which

have chemical heat energy and will be utilized as plant fuel either singly or as mixed

gas. These are the basic source of secondary fuel apart from coal and would be

extensively used in all furnaces needing heating with an external fuel. Surplus gases

will be used in the boilers of the power plant as a supplement to coal. The gas

balance of the plant at both stage-1 and 2 are shown in the accompanying tables

Table 14.2 A and 14.2 B given at the end of the chapter. The data has been also

schematically shown in the Drag ENVIRO/AISL/FR/14/01(R-1) giving the flow of the

by-product gases within the steel plant units for both Phase-1 and 2.

(2) Utilization of waste gases with sensible heat in waste heat boilers

Example of this is provision of using the heat of coke dry cooling to raise steam

before recycling the coke cooling gases

(3) Use of de-dusting equipment like cyclone, bag filters and Electro-static

precipitators to de-dust waste gases before their entry to stacks.

(4) Use of tall stacks (as per CPCB norms) to let out the gases to atmosphere. Table

14.3 A and B gives the list of stacks in the steel plant for both Phases 1 and 2 and

also the measures adopted to clean the waste gases before letting those to the

stacks. The table also gives the volume and other parameters of the waste gases

flowing out of the chimney.

(5) Use of water spray/water fogging practice to reduce ambient air dust

concentration in all open transfer /unloading points where dust collection with

suction ducts are not very effective.

(6) Provision of Low NOx burners at the reheating furnaces in the rolling mills.

14.2 Water pollution

Extensive measures have been envisaged to contain water pollution and in general the

plant will adopt a policy of Zero Discharge of water from the plant area to the adjoining

water bodies. However, some discharge/discard of water from the processes is

inevitable. These would be treated to a safe usage level and as far as possible used

inside the plant. The general principle for achieving the aim of zero discharge would be:

% Unit wise recirculation of water will be ensured, after cooling and treatment to reduce the

requirement of makeup fresh water and avoid wastage of water.

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% Measures will be taken to treat water to remove suspended/colloidal matter and if acidic,

to treat with lime to make it neutral.

% For cooling of water adequate cooling towers is provided.

% Oil and grease from the contaminated water will be removed by skimming and use of

traps.

% Installation of sewage treatment plants in all major units for treatment of the fecal waste

and removal as sludge after biological treatment.

Some of the specific measures for treatment of waste water envisaged in the plant, unit

wise are given in the table below.

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Sl.No.

NIT/Waste water Measures envisaged Final use of thewater

1 Coke Oven & By product area at bothPhase-1 (battery 1 & 2) and Phase-2(Battery 3 & 4)Wash water with suspended solids likecoke fines, tar

Water to be treated bysedimentation and then bysand filtration

Goes back tosystem

Water with phenol, cyanides and thio-cyanides

0 Homogenization andsulphide removal bycatalytic oxidation in thepresence of a catalyst.

0 1st. stage aeration for

removal of phenol,cyanides and thio-cyanides.

0 First stage clarification0 Second stage aeration for

removal ammonia0 2nd. Stage aeration.0 BOD plant for phenol water

treatment.0 Adaptation of coke dry

quenching with Nitrogen tominimize the phenolcontaining quenchingwater.

Water partly re-used as make upwater and partlyused for plantspraying for de-dusting.

2 Sintering plant (No.1 in Phase-1 andNo. 2 in phase-2)

0 Wash water containing ironore mud and fine coke willbe treated in settling tanksand the water reused.

Goes back as makeup water and forspraying in yards.

3 Blast furnace (No.1 in Phase-1 and No.2 in phase-2)

0 The blast furnace gas iscooled and dusts separatedwith a variable venturi

Goes back as makeup water and forspraying in yards.

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scrubber, the dirty waterfrom the scrubber isconcentrated in a thickener.The overflow water is re-used. The thickened slurrywill be further dewatered invacuum disc filter and thefilter cake used inside theplant as land fill.

4 Steel meting shops 0

EOF and bloom & Billet castercontinuous shop (Phase-1)

0 The waste gas will becleaned with wetscrubbers. The dirty waterwill be thickened and slurrytreated with vacuum discfilters to make solid cakesto be re-used as ironbearing raw material in thepellet plants. Water will bere-used partly as make upwater and partly for coolingsteel slag.

Goes back to makeup water and alsoused for cooling ofsteel slag.

Continuous casting unit 0 The scale laden strandcooling water goes to ascale pit where the oxidescale settles down and theclear water is overflows tothe system. Scale isperiodically removed.

Goes back ascooling water withmakeup.

BOF and slab casting shop (Phase-2) 0 The BOF gas is treated in awet scrubber before going togas holder or flare stack.The dust laden water fromthe scrubber is thickenedand water partly reused asmake up water. The slurry isthickened and dewateredwith vacuum filters and re-used in the pellet/sinteringplant.

Partly goes to makeup water and partlyfor cooling of steelslag.

Continuous slab casting unit 0 The scale laden strandcooling water goes to ascale pit where the oxidescale settles down and theclear water is overflows tothe system. Scale isperiodically removed withbucket crane.

Goes back ascooling water withmakeup.

5 Long Product Mills (Phase-1) 0 The water from roll cooling Goes back to plant

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from the mill and barcooling from the coolingboxes will come to scalepits. The scale settles atthe bottom and recoveredto be used in the sinteringplant/pellet plant as sourceof iron. The water is reusedas cooling water aftertreatment to remove oil andgrease.

water system.

6 Hot strip Mill (Phase-2) 0 Furnace cooling water isnon-contaminated and isre-used.

0 Roll cooling water, waterfrom de-scalers etc. aretreated in mill scale pits toscale to settle and re-usedin sintering/pellet plants assource of iron. The water isreused as cooling waterafter treatment to removeoil and grease.

Goes back to plantwater system.

7 Cold rolling Mill Complex 0 The process is mostly dryexcept the acidregeneration system forregeneration of pickle acid.Water is mostly used ascooling of oil etc. in a non-contaminating mode. Wateris cooled in cooling towers.

Reused in the watersystem.

8 Boilers for steam generation at CaptivePower Plant and Turbo-blower station(Both at Phase-1 & 2)

0 The boilers will use dry ashdisposal system. The spentwater from the DM watertreatment plants will beneutralized and used formoistening of ash/dustfrom ash silos to thedischarge dumpers.

To be used asmoistening agent inash silos andspraying for de-dusting in theyards.

14.3 Noise pollution

The major noise polluting areas in the steel plant are Captive power plant turbines and

generators, Blast furnace air blowing station, compressed air station, Oxygen plant

compressors, Blast Furnace area, hot rolling mills etc. In cases of rotating equipment the

noise level will be specified as per international standards at the time of procurement.

Suction side silencers will be specified in all such equipment. The isolation of working

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persons from the noise level by placement of acoustic barrier will be provided. The

working personnel exposed to high noise will be provided with earmuff and their

exposure such high noise source will be limited.

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The solid waste stipulated to be generated within the steel plant and their method of re-

use/disposal is described in the table below:

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Tlewi04#sj#xli#wxiip#Tperx##

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1 Coke Ovens and By -product departmentTwin 5 m Battery mcoal throughput1375100t per year

Coal dust 6,876 Blending back with the coalcharge

Coke dust 4,978 Blending with sinter charge mixTar sludge 240 To add to coal blend to increase

densityAcid sludge 100 To dispose as land fill after

neutralizing with lime.2 Sintering plant -144

m2 area; Gross sinter1,596,000 t per year

Dust recoveredfrom mainprocess ESPand sinter plantbuilding de-dusting units

83,570 To re-use partly at sinter plantand partly at the pellet plant asraw feed material due to highiron content.

Sludge fromwater treatmentplants

500-700 To be reused in the charge mixafter drying of if iron content ishigh. Otherwise, to use as landfill.

3 Blast Furnace No. 11680 m

3useful

volume ; Gross Hotmetal production1,176,000 tons peryear

Blast furnaceslag(granulated)

362,208 To be supplied to cement plantfor manufacture of SlagCement.

Blast Furnaceslag(air cooled)

Only inemergency

To be used as land fill

Blast furnaceflue dust from

11,760 Supply to sinter plant as rawmix feed.

#


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dust catcher unitGas cleaningplant sludge

2000-2500 To be dried and supply to sinterplant for mixing with the feedmix.

Stock house andcast house de-dusting material

12,000 Contain iron bearing materialand coke. To return to sinterplant for charge mix.

Sinter screenunder sizefraction

75,000 Return to sintering plant asminus fraction.

Coke screenundersizefraction

26,000 Return to sintering plantcrushing plant for input tosintering plant.

Hot metal skull 23,520 Cut and sent to steel makingRefractorybroken bricks(ladle bricks)

5,880 Fresh broke bricks are groundto make refractory mortar.Contaminated old bricks (20%)are used as land fill or sold forordinary purpose use.

PCM skull 25,227 To be cut and used in steelmaking as iron bearingmaterials

Cast housemuck

1000-1500 To be used as land fill

Lime sludge 400-500 To be used for neutralizingpurposes of spent water.

5 EOF and CCM shopCapacity m 1,000,000tons per year of liquidsteel.

EOF gascleaning dustand sludge

15,000 Dried and used as charge mixin sintering plant.

EOF slag 150,000 To be crushed for recovery ofiron bearing materials. Therecovered material (about15,000) to be re-used in theshop as scrap.Crushed and screened material(about 135,000 t ) to be used asfoundation filling/ land fill/roadmaking inside the plant and alsoin the neighborhood. Newdevelopments commerciallyviable to use these materials inany other way would beexplored.

Ladle andfurnace Skull

25,000 Used as scrap after gas cutting

Refractory brickwaste

5,000 Un-contaminated (about 80%)bricks to be crushed or soldoutside as mortar.

#


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#

#

Contaminated bricks are to beused as landfills.

Mill scale fromCCM

15,000 Sent to sintering plant asvaluable iron source.

CCM processscrap

20,000 Sent to steel making.

6 Hot rolling millsBar & Rod mill with600,000 tons per yearand Billet & bar millwith 250,000 tons peryear capacities

Mill Scale 17,800 Sent to sintering plant asvaluable iron source.

Muck 1800 Land fill after drying.Cobbles andshear scrap

20450 Sent to steel melting as processscrap

7 Captive power plant-1Generation of 70 MWcapacity m coal fired

Fly ash 127360 Sent to cement plant as dry flyash in cement tankers

Bottom ash 31,840 Used as land fill8 General plant muck

and debris2000 Dumped inside the plant

dumping area.

#Tlewi05#sj#xli#wxiip#Tperx##

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1 Coke Ovens and By -product departmentTwin 5 m Battery(Battery-3 & 4) coalthroughput 1,464,782t per year

Coal dust 7329 Blending back with the coalcharge

Coke dust 5324 Blending with sinter charge mixTar sludge 256 To add to coal blend to increase

densityAcid sludge 100 To dispose as land fill after

neutralizing with lime.2 Sintering plant -360

m2 area; Gross sinter3,850,000 t per year

Dust recoveredfrom mainprocess ESPand sinter plantbuilding de-dusting units

206,735 To re-use partly at sinter plantand partly at the pellet plant asraw feed material due to high ironcontent.

Sludge fromwater treatmentplants

500-700 To be reused in the charge mixafter drying of if iron content ishigh. Otherwise, to use as landfill.

3 Blast Furnace No. 1 Blast furnace 822,298 To be supplied to cement plant

#


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#

3814 m3 usefulvolume ; Gross Hotmetal production2,669,800 tons peryear

slag(granulated)

for manufacture of Slag cement.

Blast Furnaceslag(air cooled)

Only inemergency

To be used as land fill

Blast furnaceflue dust fromdust catcher unit

26,698 Supply to sinter plant as raw mixfeed.

Gas cleaningplant sludge

3500-4000 To be dried and supply to sinterplant for mixing with the feed mix.

Stock house andcast house de-dusting material

20,000 Contain iron bearing material andcoke. To return to sinter plant forcharge mix.

Sinter screenunder sizefraction

186,886 Return to sintering plant as minusfraction.

Coke screenundersizefraction

59,020 Return to sintering plant crushingplant for input to sintering plant.

Hot metal skull 66,745 Cut and sent to steel makingRefractorybroken bricks(ladle bricks)

13,349 Fresh broken bricks are ground tomake refractory mortar or sold forordinary purposes. Contaminatedold bricks (20%) are used as landfill

Cast housemuck

1000-1500 To be used as land fill

4 BOF and CCM shopCapacity m 2,700,000tons per year of liquidsteel.

BOF gascleaning sludge

40,500 Dried and used as charge mix insintering plant.

BOF slag 324,000 To be crushed for recovery ofiron bearing materials. Therecovered material (about32,400) to be re-used in theshop as scrap.Crushed and screened material(about 291,600 t ) to be used asfoundation filling/ land fill/roadmaking inside the plant and alsoin the neighborhood. Newdevelopments commerciallyviable to use these materials inany other way would beexplored.

Ladle and 25,000 Used as scrap after gas cutting

#


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Gletxiv047#

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#

#

furnace SkullRefractory brickwaste

13,500 Uncontaminated (about 80%)bricks to be crushed or soldoutside as mortar. Contaminatedbricks are to be used as landfills.

Mill scale fromCCM

40,000 Sent to sintering plant asvaluable iron source.

CCM processscrap

54,000 Sent to steel making.

5 Hot rolling millsHot strip Mill with2,500,000 tons peryear capacity in termsof Hot rolled coils

Mill Scale 51,540 Sent to sintering plant asvaluable iron source.

Muck 2500 Landfills after drying.Cobbles andshear scrap

25,570 Sent to steel melting as processscrap

6 Cold rolling MillComplex

Scrap 20,000 Partly sold and partly re-meltedafter baling & bundling at Steelmaking.

Ferric oxidefrom acidregeneration

40,000 Sold as raw material for furtherprocessing.

Sludge andmuck

8 Captive power plant-2Generation of 200 MWcapacity m coal fired

Fly ash 490,758 Sent to cement plant as dry flyash in cement tankers

Bottom ash 122,689 Used as land fill9 Fine ore beneficiation

PlantRejects afterTwo stageWHIMStreatment.

444,188 (Dry) To be temporarily stocked at thedesignated site in the plant andlater transported to a nearby oremine pit for re-filling and greendevelopment.

10 General plant muckand debris

4,000 Dumped inside the plantdumping area.

4718# Tsppyxmsr#Qsrmxsvmrk##

An In- house pollution monitoring laboratory has been envisaged in order to monitor the

levels of various pollutants in the plant namely air, water and noise. The stacks will have

laser based device to measure continuously the PM levels in the waste gas through

each stack and record. Several air monitoring stations will be set up inside the plant

complex to monitor the levels of PM10, PM2.5, SO2, NOx and CO in the ambient air

inside. Water quality of the re-used circulating water will be checked on daily basis at

#


#

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Gletxiv047#

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#

#

every water complex and the flow of water through the plant outfalls to the public water

channels would be strictly monitored during dry season.

14.6 Monitoring of the hazardous waste management

As explained above more than 80% of the solid wastes generated would be re-used

within the process. Still making slag from both the phases after recovery of iron would be

in granular form. Only a part of BOF slag can be utilized in the sintering process as a

replacement of lime stone. Rest would have to be dumped in landfills or sold for

compacting civil foundations. Part of the refractory brick waste also cannot be reused in

the process and would have to be dumped as land fill. A temporary dumping area would

be set up inside the plant complex since the out flow of these is likely to non uniform and

occasionally very tardy.

Crude tar, acid sludge from Coke Oven mByproduct complex in phase-1 and 2 and acid

sludge from the cold rolling mill pickling section can be called hazardous material and

would be stored in accordance with the manufacture & Hazardous waste storage rule as

amended.

14.7 Rain water harvesting.

The area of Karnataka where the plant is located is a relatively dry area. So all efforts

will be taken to conserve rain water and recharge the soil. For this end two actions will

be taken.

(1) All storm water drains in the plant network will be connected to an underground

storm water tank towards north of the plant site as shown in the General lay out drawing.

A check dam will be suitably provided to prevent excessive silting of the tank. Pumping

arrangement of this water to the plant water storage pond will be provided.

(2) The subsoil of the plant in many areas is weathered granite and does not have

capacity for rain water to percolate. However in some areas weathered soil is visible.

Wherever the soil is pervious, rain water harvesting pits will be planned mainly to take

the water from gutters of the building tops and factory sheds. This aspect will be detailed

after the complete soil survey of the area is done and characteristics of the sub

soil/underground rocks are identified.

14.8 Major equipment for ensuring environmental protection

8 ^[ef aX _S\ad Wcg[b_W`fne fa TW W_b^akWV Xad fZW ebWU[X[U bgdbaeW aX W`h[da`_W`fS^

protection is given phase wise at Annexure-14.1

#


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Gletxiv047#

######################

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Chapter-16: Instrumentation, Automation & Telecommunication

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16.1 Adequate measurement and control facilities have been envisaged for all theshops/units of the plant with a view to achieve safe, reliable and efficient operation of

the plant and optimum utilization of the inputs, safety of the plant machinery,operating personnel and user friendly man jmachine interface.

For this purpose, hierarchical process control of the plant and equipment has been

envisaged and the automation equipment and devices have been identified bydifferent levels. The latest state of the art instrumentation and automation equipment

from product ranges of reputed manufacturers have been envisaged for all the shops

/units of the plant.

The instrumentation system will be based on 4-20 mA unified current signal system.

In addition to the required measurements and controls, adequate sequential and

safety interlocks and logic functions, monitoring and display of all abnormal processconditions have also been envisaged. Final control elements will be pneumatically orelectrically actuated types depending on specific applications.

16.2 Process Control Hierarchy

The Process control and Automation system shall be designed with geographical &

functional distribution of hardware in a multi-level hierarchy, viz. Level-0, Level-1,

Level-2 etc. as applicable to meet the specific requirement for monitoring, control,process visualization & optimization of all the plants /shop units. The instrumentation& automation system shall be structured in general, considering the following

hierarchical levels.

Level-0: This level is realized on the primary sensing elements, transmitters,switches, converters, micro-processor based intelligent systems and final

control elements. The components of this level shall be grouped anddistributed geographically around the plant as per main process equipment

location. In many cases, there will be switches at the local field level tocontrol equipment manually in case of emergency.

Level-1: This level is called supervisory level is functionally responsible for

supervision of individual process equipment and functions, monitoring ,control, visualization and regulation of the process parameters to the

desired extent based on the signals generated from level-0. This level isalso responsible for processing of signals for generating compatible control

commands to control the process parameters by activation of the finalcontrol elements.

This level is realized based on the controllers & systems, input & output

systems, data based units, data communication, visualization systems(HMI stations) and interface units for connectivity to the other levels of the

instrumentation & automation system. In addition to the routine PID

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functions, advanced process optimization functions comprising special

control algorithms, mathematical computations etc. will be able to permitdistribution of control and data acquisition functions throughout the entireplant.

Level-2: This level is functionally responsible for the process control through level-1automation system by process guidance & optimized control of the processparameters to the desired level of perfection based on the available signals

from the supervisory level.

This level is also called process control level and is responsible for generating setpoints/control commands to the level-1 equipment based on pre-loaded process

specific mathematical models. This level receives the process feedback from level-1and gives corrective signals for any abnormality in the process conditions. This level

can both generate signals to control the process automatically or gives a commandto the operator for manual control of the process through a separate HMI. This level

is realized based on a separate computer data server communicating with the level-1system for input/output, a separate computer for storing the process models and

other data/software, separate visualization system (HMI) and interface units for

connectivity to the other levels. Level-2 is schematically shown IN Fig. 14.1 at theend of the chapter for a typical illustration for control of BOF process. For other

processes, the principle is same.

16.3 Coverage of the Instrumentation and automation system in three levels.

The units proposed to be covered are:

Phase-1 (1 Million ton per year crude alloy and special steel long product phase)

% Raw Material handling yard operation: Level-0 & 1

% Coke Oven battery and By-product unit (Twin 5 m Battery)% Sintering plant -1 (144 m2) Level-0, 1 &2

% Blast Furnace -1 (1680M3) Level-0, 1 &2% Pig Casting machine Level-0 & 1

% Steel melting Unit-1 (2x 50 t EOF) Level-0, 1 &2% Continuous casting Plant (Bloom caster 250,000 TPY Level-0, 1 &2

Single strand x1; Billet casters 600,000TPY four strands x2)

% Bar & Rod mill (600,000 TPY) Level-0, 1 &2

% Billet & Bar Mill (250,000 TPY) Level-0, 1 &2% Laboratory facilities Level-0, & 1

% Oxygen Plant Level-0, & 1% Captive Power Plant No. 1 Level-0, & 1% Turbo-Blowing Station No. 1 Level-0, & 1

Phase-2 (2.5 million ton carbon and special steel flat product phase)

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% Raw Material handling yard operation (Expansion units): Level-0 & 1

% Coke Oven battery and By-product unit- 2 (Twin 5 m Battery)% Sintering plant -2 (360 m2) Level-0, 1 &2% Blast Furnace -2 (3814M3) Level-0, 1 &2

% Steel melting Unit-2 (2x 150 t BOF) Level-0, 1 &2

% Continuous casting Plant- 2 (Slab caster single strand x2) Level-0, 1 &2% Hot Strip Mill Level-0, 1 &2% Pickling Line Level-0 & 1

% Tandem Cold Rolling Mill Level-0, 1 & 2

% Coil degreasing line Level-0 & 1% Batch annealing Unit Level-0, & 1

% Galvanizing Line Level-0, 1 & 2% Colour coating lines Level-0, 1 & 2

% Laboratory facilities for 2.5 million ton units Level-0, & 1% Oxygen Plant No. 2 Level-0, & 1

% Captive Power Plant No. 2 Level-0, & 1% Turbo-Blowing Station No. 2 Level-0, & 1

Control room instrumentation equipment will be microprocessor based control system

(DCS or PLC) for major shop/unit. This will basically comprise of coloured videomonitors with key boards, log, event and alarm printers, coloured hard copy units,

field control stations, input/output systems, power supply units, control andcommunication processors, data high way and interfering facilities for integrated

operation with PLCs. Suitable power supply and distribution network has also beenenvisaged. While designing the instrument and automation system enough

redundancy in network, servers, UPS, battery banks and power chargers will beprovided.

16.4 Plant monitoring and historian system

In line with the modern steel plants, it is envisaged to set up a central visual plant

monitoring system indicating the status of each units and details of production,energy consumption etc. along with past data. The past data would be presented in agraphical form on the monitors in the central monitoring room. This system would

have connectivity with SAP system which would be installed in a central place

preferably in the 79Dkb ^UUXRT)

16.5 Centralised energy monitoring system

This system would communicate with all the major power consuming units and thestate Electricity computer system to give a live picture of the power situation on a real

time basis. This system which may be located in the MRSS would have connectivitywith the Plant monitoring and historian system described above.

16.6 Intra plant audio-visual communication

These communication systems would be at three levels:

' Announcer systems inside the shop areas

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' CC TV visual system inside each unit and also at key locations inside the plantfor security and monitoring purposes

' Dedicated telephone network throughout the plant with an electronic telephone

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Melting task, Initialdata

The project

LEVEL-2

level 2

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Commands

Executive

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Acquisition

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Chapter-17: Water Supply Facilities

17.01 The water supply for the proposed steel plant is basically for cooling of various solids,liquid and gaseous intermediate products and also for machinery cooling. Water is

also required to make up boiler water requirement in the DM plants for steam raising.There is also requirement of water for drinking and other washing/cleaning purposes.

To minimize the fresh water drawn from the source, cooling water re-circulationsystems have been envisaged.

The blow downs from cooling towers and the neutralized effluent discharged from the

processes are proposed to be utilized for coke quenching, slag granulation, steel slagcooling, de-dusting/defogging and other direct contact water treatments aiming atzero discharge.

17.02 Requirement of water

The fresh water requirement of the steel plant in two phases is estimated as

Phase-1: 1 million ton crude steel stage: 1305 m3/h (6.97 MGD)

Phase-2: 2.5 million crude steel facilities: 2615 m3/h (13.96 MGD)

Total Steel Plant after phase-2: 3920 m3/h (20.93 MGD)

Recirculation systems have been envisaged in the plant for reusing the majorquantity of water after treatment in various units. The intake water for the plant from

the water source after phase-2 installation of the whole plant before the watertreatment plant will be 4170 m3/Hr (22.24 MGD) considering about 6% loss of water

during treatment.

The unit wise break up of re-circulation and fresh make oup water requirement in the

steel plant for both the phases is indicated in the table given below:

Table 17.1A Estimate of Re-circulation and make up water requirement for thesteel plant in the First Phase of 1 million ton crude steel output.

Sl. No. Shop/consumer Re-circulation water(M3/Hr)

Fresh make up water(M3/Hr)

1 Coke Oven and By-product Department0 Coke Oven area 600 60

0 By product area 3000 165

0 CDQ steam generator (DMmake up water)

- 10 *

2 0 Sinter plant No. 1 340 403 0 Blast Furnace-1

0 Blast Furnace and stoves 2900 80

0 GCP 500 400 Slag granulation plant 1700 55

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0 Turbo-blower station 3600 100

0 Pig casting machine 1000 504 0 EOF shop

0 2 Nos. of EOFs 4600 138

0 2 GCPs 540 270 2 ladle furnaces 900 17

0 Vacuum degassing unit 455 90 Boiler o 16 t/Hr. - 16

0 2 Nos. billet casters & Bloomcaster

4220 93

5 0 Bar & Rod Mill0 Indirect cooling 750 22

0 Direct roll cooling 1800 1366 0 Billet and bar mill

0 Clean water cycle 750 220 Direct cooling cycle 600 40

7 0 Oxygen Plant0 Clean water 2000 50

8 0 Captive power plant0 Clean water 1000 30

0 DM Plant (make up) - 359 0 Compressed air station

0 Clean water 400 1010 0 Ventilation , air conditioning &

dust suppression systems- 50

11 0 Domestic water - 1012 0 Fire water system - 10

0 Total 1305

With coke dry cooling, the consumption of water for wet quenching would be reducedwith roughly same increases of water feed for DM water plant for the steam

generators for the waste heat recovery of the dry coke cooling gas (mostly nitrogen)

Table-17.1B: Estimate of Re-circulation and make up water requirements for

the steel plant in the second Phase of 2.5 million ton crude steel output.

Sl. No. Shop/consumer Re-circulation water(M3/Hr)

Fresh make up water(M3/Hr)

1 Coke Oven and By-product Department-20 Coke Oven area 600 60

0 By product area 3000 165

0 CDQ steam generator (DM makeup water)

As in the above note

2 0 Sinter plant No. 2 820 963 0 Blast Furnace-2

0 Blast Furnace and stoves 6400 1720 GCP 1100 88

0 Slag granulation plant 3952 1200 Turbo-blower station 8000 220

4 0 BOF shop0 2 Nos. of BOFs 11000 3300 2 GCPs Included included

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0 2 ladle furnaces 2000 36

0 Vacuum degassing unit 900 180 2 Nos. slab casters 5000 110

5 0 Hot Strip mill0 Indirect cooling 1000 250 Direct roll/strip/coil cooling 1500 45

0 Hot rolled coil processing 500 126 0 Cold Rolling complex

0 Clean water cycle 3000 60

0 Direct cooling cycle7 0 Oxygen Plant

0 Clean water 3000 358 0 Captive power plant

0 Clean water 1700 5000 DM Plant (make up) 60

9 0 Compressed air station0 Clean water 500 13

10 0 Ventilation , air conditioning &dust suppression systems

50

11 0 Iron ore Beneficiation Plant 36012 0 Fire fighting system 1013 0 Drinking water 30

0 Total 2615

Note: In both the phases the tank flushing water will be reused for de-dusting, cooling

of slag and moistening of dust from the dust silos. The fresh water requirementshown in row No. 10 under dust suppression is over and above this.

The combined water requirements of the steel plant at the complete installation of the

3.5 million ton crude steel capacity as well as after Phase-1 are given in the drawing:ENVIRO/AISL/FR/17/1 (R-1) sheets 1 & 2.

17.03 Source of water

The source of water has been identified as the Tungabhadra Reservoir located at adistance of about 20 Km from the plant site, from where raw water will be pumped to

the plant storage reservoir located on the northern side of the site near the national

highway. The present available low area where the storage tank can be formed isabout 23.6 hectares. It is proposed to develop the eastern part of this area for phase-

1 storage of water. The area is 10.4 hectares. The capacity of the plant reservoirassuming 80% of the area will have actual water body with 10 m average holding

capacity:

At phase-1: 0.832 million m3 to cater to 20 days storage of phase-1 waterrequirement of the plant at rated capacity production.

After phase-2: the storage capacity will be expanded to 1.89 million m3 for about 19XUmpg requirement of the plant at 3.5 million ton rated capacity production.

It is understood that the present agreement of AISL with Karnataka State

Government regarding withdrawal of water from Tungabhadra dam stipulates a

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pumping @12.55 mgd for the full year. But pumping will be allowed for 184 days

(after July15th) and not be allowed in the dry season (January to mid July). Thismeans though 4809 million gallons of gross water (12.55 mgd x 365 x1.05) can bewithdrawn from the dam during the wet season after allowing for 5% loss during

pumping and 4580 million gallons of net water can be received. The annual

requirement of water at phase-1 as per estimate given above will be = 6.97 x 1.06 x365 =2696.7. Though it is less than the water withdrawal allowed for the whole year,the water to be consumed during the non pumping period of 181 days with

evaporation loss added, need to be stored. For phase-1 requirement it amounts to =

6.97 X 1.06 x 181 x 1.03 = 1377 million gallons or 6198 million m3 (1.06 is the factorfor water treatment loss and 1.03 is for evaporation loss of water). The plant water

reservoir has been provided for only 20 days storage at phase-1 which will cater toonly supply and pumping disruptions. The bulk of the water storage is envisaged to

be done by adopting public tanks and bundhs in the area.

For the combined operation of 3.5 million ton plant, the total annual requirement of

water amounts to 8095.7 million gallons which shows that more water need to becommitted by the state Government before Phase-2 facilities can be started.

17.04 Proposed facilities

To cater to the water requirement of the plant, the following facilities are envisaged:

17.4.1 Raw Water treatment plant

The raw water drawn from the plant storage reservoir will be treated inclariflocculators and filters to remove suspended solids and stored in underground

storage tanks. This water will be used as make up water for the individual re-circulation systems of the plant and for drinking and domestic use after chlorination.

The clarified water from the clariflocculators will be used for fire fighting in the firehydrant piping network.

Raw water treatment plant will be erected near the raw water reservoir o In two

phases along with the phase-wise expansion of the plant.

17.4.2 Fire fighting facilities

To cater for the water based fire fighting system needs, a wet riser ring main hasbeen envisaged which covers the complete plant complex. Main fire fighting pumps,

jockey pumps, hydraulic accumulators and diesel engine driven pumps are provided.Landing valves type fire hydrants are considered for in-shop application and for

outdoor fire fighting.

17.4.3 Drinking water facilities

The drinking water system comprises pumps, drinking water storage tanks andoverhead tank and chlorination facilities.

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Filtered water from gravity filters of the treatment plant will be chlorinated and stored

in the drinking water storage tank and pumped to an overhead storage tank. Drinkingwater from this overhead storage tank will be supplied to the various units of the steelplant through G.I. piping network.

17.4.4 Cooling water Recirculation systems:

(a) Coke Oven and by-product plant system

The water requirement in the coke oven and by-product plant area will be for

indirect cooling of the gas condensation plant, exhauster house and for directcooling quenching of hot coke in case of use of direct quenching tower of coke

cooling or DM water makeup of the steam generators for use of CDQ. Sincesimilar twin batteries are envisaged in both Phase-1 and Phase-2, the water

requirements and facilities to be installed will be similar.

For these sections, one clean water re-circulation system with pumps andcooling tower and one contaminated water system with settling tanks and pumps

have been envisaged. Apart from these, when wet quenching will be used, thequenching water will be taken to a quenching water tank with provision of

recovering the breeze coke form the tank. The blow down water being phenolicwill be treated in a phenol water treatment plant and a BOD water plant.

(b) Cooling system for Blast Furnace Complex

The cooling water system for the Blast Furnace complex meets the requirement

for blast furnace and hot stoves and requirement of water for the auxiliary unitslike Blast furnace gas cooling plants, turbo blower stations etc. Each blastfurnace complex will have individual pump house containing four groups of

pumps to supply cold water and the hot return water is cooled in cooling towers

and returned to the system.

The return water from the gas cleaning plants of the individual furnaces is treated

in radial settling tanks/thickeners and the overflow is pumped to the cooling

towers before returning to the system.

The slag granulation plants with the blast furnaces will be supplied with direct

quenching water. The granulated slag slurry is filtered and the water is cooled in

cooling towers and re-circulated with addition of makeup water.

Pig casting machine envisaged only in phase -1 blast furnace No. 1. The

machine is supplied with direct spray cooling water. The return water from the

pig casting machine will be treated with a settling tank before the water is re-used.

(c) Water system for the Sintering plants

Water is required in the sinter plant for cooling of equipment and for suppressionof dust at open transfer points. A clean water system for indirect cooling

comprising pumps and cooling towers is envisaged for each of the sintering

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plants at each phase. Dust suppression systems o open spray or defogging

system will comprise of water tanks, pumps and pipe lines.

Sludge generated at the different direct contact water cooling system generally

will contain iron oxides; These will be collected and after drying used in the

sintering plants as a charge mix.

(d) Water system at the steel making units.

Separate water system has been envisaged for the EOF shop to be installed at

Phase-1 and the BOF shop to be installed at phase-2. In both the cases, thewaste gas will be cooled and cleaned with wet gas cleaning system, except in

case of the BOF, the gas is cooled, cleaned and collected for use as plant fuel.

For each steel making facility, two groups of water systems are envisaged. Thefirst group is for indirect cooling of parts like panels, oxygen lances, sealing,

various segments, cooling of hydraulic systems etc. For this purpose each majorunit like the individual EOFs or BOFs, ladle furnaces, vacuum treatment furnaces

will have individual industrial water pumping and cooling systems. Gas coolingplants will be serviced with separate water systems with pumps, return water

thickening system and cooling of the overflow water and return to the systemwith makeup water added.

(e) Water facilities in the continuous casting departments

The bloom and billet caster are adjoining to the EOF shop and the slab casters

are adjoining the BOF facilities. The casters need soft cooling water for mouldcooling and cooling of machine parts. A water softening plant for each of thecasting departments has been envisaged to cater to the need of soft water along

with separate pump house, heat exchangers and cooling towers for cooling of

heat exchanger industrial water.

The industrial water used for direct spray on the strands and machine cooling will

be scale laden and would be treated at scale pits to be installed at each

continuous casting shop. It is then pumped to secondary settling tanks for furtherclarification. The overflows from secondary settling tanks are pumped to coolingtowers through filters and the cooled water is re-circulated to the system with

makeup water addition from time to time. Each continuous caster

(bloom/billet/slab) will have dedicated water system. Overhead emergencywater tanks will be installed for machine, strand and mould cooling for

processing the poured steel in the mould and the cast strand.

(f) The Mill Complex

The mill complex at phase-1 comprises of the bar & rod mill and the billet andbar mill. At phase-2, installation of a Hot strip mill has been considered. At

phase-2, there will be a cold rolling mill complex comprising of hot strip picklingline, cold rolling mill, strip degreasing, batch annealing and temper rolling. Apart

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from these, a separate galvanizing line and two colour coating lines have been

envisaged.

For the hot rolling mills, in general the water system will be two types. The

indirect cooling system for cooling of re-heating furnace parts, lubrication and

hydraulic system cooling, motor cooling, etc. The indirect cooling water and re-circulation system will have separate pump houses with water hot return waterpumps, cooling towers, by-pass filters, cold water supply pumps and emergency

over head tanks to deal with power failures.

The other contaminated water systems cool the rolls, and coiler, slab/boll de-scaling, strip cooling at the run out table etc and are contaminated with mill scale

and oil. The water system will comprise of scale pits to collect water undergravity for primary settling of mill scales to be followed by secondary clarification

with removal of oils. . The treated water will be filtered and cooled in coolingtowers before recirculation with makeup water addition.

The cold rolling mill complex

In the cold rolling mill complex water is required in the Pickling section for make

up to the acid regeneration plant and also for makeup to the rinsing water afterpickling. The waste waters are treated in the acid regeneration plant where ferric

oxide is the by-product and the regenerated acid along with fresh acid is sentback to the pickling process. The waste water system of acid regeneration plant

comprises of acid neutralizing plant and the water is re-used inside the plant fordust suppression etc.

Cold rolling mill complex has water from the process which is mixed with scale

and oil. This water is treated in settling tanks along with oil separationarrangement before use back to the system. The complex also will have a clean

water system for indirect cooling of machine parts which comprises of pumpswith cooling towers.

(g) Captive power plant

The requirement of water for the power plant and its auxiliary units is for thepurpose of feed water for boilers and for cooling of boiler auxiliaries. Cooling

water is pumped to the consumers and is cooled in cooling towers before re-use.

Boiler feed water is demineralised water and for its makeup, streams of DM

water plant with pre-water softening is envisaged. The DM plant complex will beprovided separately for the boiler facilities at each phase.

(h) Oxygen plants

The requirement of water in the oxygen plant is only for indirect cooling of theplant equipment. Cooling water is pumped to the equipments needing cooling

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and the water cooled at cooling towers before re-use with addition of makeup

loss.

17.4.5 Water Pollution Control and Conservation

Extensive re-circulation of water has been envisaged in the design of cooling water

re-circulation system for the various technological units. The quality of re-circulationwater will be maintained by dosing of conditional chemical solutions for controlling

corrosion, scale formation and microbiological growth. Waste water from raw watertreatment plant and DM water plants will be neutralized before re-use as dust

suppressing agent.

The makeup water requirement at the contaminated water re-circulation system willbe partly met from the blow down of the clean water re-circulation systems. The

sludge arising out of the number of clarifiers/thickeners will be re-used in the sinterplants. The treated effluent from Coke oven and power plants will be used in coke

quenching, cooling of steel slag and moistening of dust from dust silos before loadinginto dumpers for transportation.

The water supply scheme envisaged for the steel plant ensures practically zero

discharge of waste water from the plant area to the public water flow system.

Extensive rain water harvesting system will be adopted to tap surface flow of water inthe area. The storm water drains will be mostly covered and would be connected to

the main water reservoir via a dam to retain the flow of silt with rain. Regular de-sitingoperation would be carried out during the dry season.

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Chapter-18: Steam and Compressed Air Facilities

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18.1 Steam facilities and requirements

18.1.1 The process involved in Iron & Steel making will generate considerable quantities of

surplus by-product gases. Also processes like Coke Dry Quenching has the

quenching medium gas with lots of sensible energy. The chemical energy of the by-product gases and the sensible waste heat have to be converted to steam to be

used as such or converted to power through steam turbines.

For supply of category -1 load involving cooling pumps and other safety devices, thepower supply from the external grid cannot be depended upon. So the captive power

plants are envisaged at both the phases of installations along with turbo-blowerstations. The Turbo-blower stations will have dedicated boilers for supply of steam for

the turbo-blowers as well as process steam needed in the plant and would be running

on By-product gases. The Captive power plants will be basically use power coal asfuel with available surplus by-product gases. The waste heat boilers from units likeCDQ will come to medium pressure steam grid of the plant for use as process steam.

The steam generated in the BOF shop from the evaporative cooling systems the

hoods and off gas ducts will be utilized in the shop itself.

18.1.2 The estimated overall requirement of process steam and cold blast is given in

the table below:

Table-18.1: Requirement of steam and cold blast

Sl.No.

Service Unit Requirements

Phase-1: 1MTPA

Phase-2: 2.5MTPA

1 Process steam at 6-9 ata. t/Hr. 69.5 1012 Cold Blast to Blast

Furnaces (Max)Nm3/Hr. 2 x 108,385 2 x 213,966

3 Maximum steam requiredfor the turbo-blowers

t/Hr. 2 x 45 2 x 100

Based on the above the following steam generating facilities have been envisaged atboth the phases.

' Captive Power Plant-1 (1 million ton phase)

Boiler No 1 with capacity 350 t/ Hr of steam at 90 bar and 5350 C feeding 1No Turbo-generator of capacity 70 MW

' Turbo-blowing station -1 (1. million ton phase)

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Boiler 1 No. with capacity 125 t/Hr of steam at 60 bars and 4850 C feeding the

turbines of the blast furnace blowers and supplying process steam fromturbine extraction as well as direct from boiler through PRDU.

( Captive Power Plant-2 (2.5 million ton phase)

Boilers 2 Nos. With combined capacity of 2 x 500 t/Hr of steam feeding 2 x100 MW Turbo-generators Generators.

( Turbo-blowing station -2 (2.5 million ton phase)

Boilers 1 No. with capacity 250 t/Hr of steam feeding Turbo-blowers of 60 bar

and 4850 C feeding the turbines of the blast furnace No 2 blowers andsupplying process steam from turbine extraction as well as direct from boiler

through PRDU.

18.1.3 Unit wise availability and requirement of steam of different pressures.

The steam balances for different categories of steam (depending on pressure) are

given in the Tables below.

Table-18.1A: High pressure steam balance n super heated steam 90 bar 5350 C at

rated capacity

Sl.No.

item Generation (t/Hr.) Utilisation (T/Hr.) Extraction (T/Hr.)

1MTPA 2.5MTPA

1MTPA 2.5MTPA

1MTPA 2.5 MTPA

1 CPP BoilerGeneration

315 2 x450

2 Utilisation atthe Turbo-generators

315 2 x 450 - -

Note: (1) The figures indicated in the foregoing sections as installed capacity for

boilers have 10% cushions.

(2) At feasibility stage no extraction from the CPP turbines are envisaged.

Table-18.1B: High pressure steam balance n super heated steam 60 bar 485 0 C atrated capacity

Sl.No.

item Generation (t/Hr.) Utilisation (T/Hr.) Extraction (T/Hr.)

1MTPA 2.5MTPA

1MTPA 2.5MTPA

1MTPA 2.5MTPA

1 TB BoilerGeneration

103 225 13 t/Hrextractionfrom TBboiler No.

25 t/Hrextractionfrom TBboiler No.

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1 throughPRDU

2 throughPRDU

2 Utilisation atthe Turbo-Blowers

90 200 2 x 8 t/Hrextractionfromeach TBturbine

2 x 19t/Hrextractionfromeach TB-2turbines

Table-18.1C: Process steam balance ^ steam at 6-16 bar at rated capacity of the

plant

Sl. No. item Generation (t/Hr.) Utilisation (T/Hr.) Remarks1MTPAStream

2.5MTPAStream

1MTPAStream

2.5 MTPAStream

Availability1.1 Extracted

steam16 38

1.2 From TBboiler throughPRDU

14 25

1.3 Steam fromCoke dryquenchingunits

40 40

Totalavailability

70 103

2 Utilisation atthe Processes

2.1 Coke Oven &By-productcomplex

28 28

2.2 SinteringPlants

4 6

2.3 BlastFurnaces

16.5 30

2.4 EOF/BOFunits

14 10 This is afterutilization ofsteam generatedin the ECS.

2.5 Hot rollingmills

- 2

2.6 Cold rollingmill complex

- 30

2.7 Inter plantGas lines

5 5

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2.8 Misc.Requirements

2.5 2

Total 70 113

18.2 Requirement of Compressed air for the plant

Table given below gives the estimated compressed air requirement at the different

units of the plant at the two phases of development.

18.2.1 Phase -1: 1 million ton plant requirement

Table-18.2A: Requirement of compressed air

Sl.No.

Description Generalpurpose air(Nm3/Hr)

Instrumentquality air(Nm3/Hr)

Pressure(Kg/cm2 (g))

1 Coke Oven complex No. 1 5000 500 5-72 Sintering Plant No. 1 550 230 5-73 Blast Furnace 2340 1400 5-74 EOF shop along with

LF/VD and casters10,400 1250 5-7

5 Bar & Rod MillBillet & Bar mill

6200 500 5-7

6 Others 10,000 400 5-7

At Phase-1, it is envisaged to install two centralized compressed air stations.Compressed air station No. 1 will cater to COBPP, Sinter Plant No.1 and Blast

Furnace No. 1 along with auxiliaries. Compressed air station No. 2 will cater to Steelmelting shop No. 1 along with secondary treatment and casters and the two hot

rolling mills envisaged at phase-1. The miscellaneous requirements of minorconsumers also will be met from ACP-1


centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unitwill also supply instrument quality air to the above processes. The equipment to be

installed at ACP would include:

( Centrifugal Air Compressors (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 4 Nos.(3W+1SB)

( Refrigerant air dryers (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 4 Nos.(3W+1SB)

( Blower activated desiccant air driers (capacity 3000 Nm3/Hr @8.5 Kg/cm2): 1No.

( Circulating cooling water pumps of suitable capacity -): 4 Nos. (3W+1SB)( Cooling towers along with accessories of suitable capacity 4 Nos. (3W+1SB)

( Handling equipment in the ACP-1

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The Air Compressor No. 2 will cater to the EOF shop along with the auxiliaries and

the hot rolling mills to be installed at pase-1 for 1 million ton capacity. The ACP-2 willhave the following facilities.


centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unitwill also supply instrument quality air to the above processes. The equipment to beinstalled at ACP would include:

( Centrifugal Air Compressors (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 4 Nos.

(3W+1SB)( Refrigerant air dryers (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 4 Nos. (3W+1SB)

( Blower activated desiccant air driers (capacity 3000 Nm3/Hr @8.5 Kg/cm2): 1 No.( Circulating cooling water pumps of suitable capacity -): 4 Nos. (3W+1SB)

( Cooling towers along with accessories of suitable capacity 4 Nos. (3W+1SB)( Handling equipment in the ACP-2

18.2.2 Phase-2: 2.5 million ton plant requirement

Table-18.2B: Requirement of compressed air at Phase-2, 2.5 million level facilities.

Sl.No.

Description Generalpurpose air(Nm3/Hr)

Instrumentquality air(Nm3/Hr)

Pressure(Kg/cm2 (g))

1 Coke Oven complex No. 1 5000 500 5-72 Sintering Plant No. 2 650 300 5-73 Blast Furnace 3000 1500 5-74 BOF shop along with

LF/VD and casters7500 1250 5-7

5 Hot Strip Mill & Auxiliaries 34,200 3000 5-76 Cold Rolling Mill Complex 30000 3500 5-77 Others 10000 400 5-7

At Phase-2, it is envisaged to install two centralized compressed air stations and two

dedicated ACPs for Hot strip mill and cold rolling complex respectively due to theirlarge consumption. Compressed air station No. 3 will cater to COBPP complex -2,

Sinter Plant No.2 and Blast Furnace No. 2 along with auxiliaries. Compressed air

station No. 2 will cater to Steel melting shop No. 2 along with secondary treatmentand casters. ACP No. 5 and ACP No. 6 will be located in the Hot strip Mill and Coldrolling Mill complex areas respectively.

Air Compressor Plant (ACP) No. 3 will have 4 Nos. (3 operating + 1 Stand by) ofcentrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unitwill also supply instrument quality air to the above processes. The equipment to be



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( Refrigerant air dryers (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 4 Nos.

(3W+1SB)( Blower activated desiccant air driers (capacity 3000 Nm3/Hr @8.5 Kg/cm2): 1

No.

( Circulating cooling water pumps of suitable capacity -): 4 Nos. (3W+1SB)

( Cooling towers along with accessories of suitable capacity 4 Nos. (3W+1SB)( Handling equipment in the ACP-2

This unit will be located adjoining to the ACP No. 1

The Air Compressor No. 4 will cater to the BOF shop along with the auxiliaries TheACP-2 will have the following facilities.


centrifugal air compressors each of 5500 Nm3/Hr, 8.5 Kg/Cm2 pressure. This unitwill also supply instrument quality air to the above processes. The equipment to be



( Refrigerant air dryers (capacity 5500 Nm3/Hr @8.5 Kg/cm2): 3 Nos.(2W+1SB)

( Blower activated desiccant air driers (capacity 3000 Nm3/Hr @8.5 Kg/cm2): 1No.

( Circulating cooling water pumps of suitable capacity -): 3 Nos. (2W+1SB)( Cooling towers along with accessories of suitable capacity 3 Nos. (2W+1SB)

( Handling equipment in the ACP-4

The two dedicated ACPs installed at the two rolling mill complexes will be designedas per the specific requirement of the units based on the technology supplied. But in

general each will have 5 Compressors each of 10,000Nm3/Hr air capacity (4 working+1 Stand by) along with other auxiliary equipment like Refrigerant air dryers, Blower

activated desiccant air driers, cooling circulating water pumps and cooling towerswith handling devices like EOT cranes/MX_YXeof.

The compressors and its accessories will be complete with drive motors, control

panels, air inlet and discharge systems, cooling and lubricating systems, unloadingarrangements, protective devices, instrumentation and control, acoustic hoods,

silencers, bearings, pipes, valves, fittings, air filters and necessary electrics and

instrumentation.

18.2.3 Compressed air pipe line

For distribution of compressed air up to consumer points, a network of in-plant and

inter-plant interconnected pipe line has been envisaged. The pipe line will begenerally routed overhead along the building columns /walls for in-shop pipe network

and on stockades for inter-shop pipe lines. Isolating valves, control valves, drain taps

and compensators will be in the pipe line net work as per process and engineeringrequirement. Isolation valves will be provided at the entry of the pipe line to the

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shop/unit of steel plant. Platforms, access ladders, hand railings etc. Shall be

provided for operation and maintenance of valves, instruments and controls providedin the pipe line network.

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© 2017 PECS all rights reserved Page 1 of 4Chapter-19

Chapter-19: Fuel Oil storage & Distribution system and Interplant pipe lines

19.1. Fuel oil will be required in the Captive Power Plants as an auxiliary fuel in the coal fired

boilers to aid combustion. In all other units in both the phases of plant, generally coke

oven gas and mixed gas will be used as plant fuel. Fuel oil storages are being envisaged

at sintering plants, steel melting shops and rolling mills basically for start up and as

emergency measure to provide alternative fuel.

19.1.1 Captive Power Plants

Fuel oil storage system is designed to store furnace oil in vertical tanks and HSD/LDO in

horizontal tanks in separate dyke with common fencing, pump house and unloading

areas to cater the requirement of oil in the plant.

(1) Storage system for Furnace oil consists of the following:

( Main storage tanks l 2 Nos.

( Tank size l 7 m dia. x 8 m height (300 KL)

( Type CRVT

( Two numbers of unloading pumps (1W + 1 SB) of 30 m3/Hr capacity at 25 m

head & 7.5 KW rating each.

( 6 Nos. of transfer pumps (1 W + 1 SB) for each unit of boiler. Pumps each of 8

m3/Hr capacity at 30 kg/cm2 & 18.5 KW rating each for pumping oil to the CPPS.

( Flow meters of capacities 30 M3/Hr and 8 M3/Hr for flow measurement.

( 8 Nos. of strainers on the suction side of the pumps.

( Dyke of 29 m length x 15 m width and 1.5 m height around the storage tanks.

( Piping network of, valves, fittings for unloading oil into tank and distribution of

furnace oil to the consumers.

(2) Storage system for HSD/LDO


( Tank size l 1.8 m dia. x 4.25 m long (10 KL)

( Type Horizontal above ground



( 3 Nos. of transfer pumps (1 W + 1 SB) for each unit of boiler. Pumps each of 3

m3/Hr capacity at 20 kg/cm2 & 5 KW rating each for pumping oil to the CPPS.


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( Dyke of 6.5 m length x 10 m width and 1.5 m height around the storage tanks.

( Piping network of, valves, fittings for unloading oil into tank and distribution of oil

to the consumers.

3) Common pump house

All the pumps for both oil facilities will be accommodated in a common pump house

of tentative size 15 m x 6 m with separate electrical room of 6m x 5 m.

(4) Common unloading area

Road tankers are connected to the unloading pipe line headers through flexible

hoses for respective oils. Furnace oil from road tankers is unloaded into the main

storage tanks using unloading pumps. Separate respective transfer pumps for oils

located in the pump house are used to supply oil to the boilers of power plants.

(5) Common fence

The entire storage and pumping facilities shall have common fence with barbed wire

with gates.

19.1.2 Steel making units and hot rolling mill

The fuel oil storage system LSHS envisaged for the steel making units and hot rolling

mills is mainly for start up and emergency purpose use in the furnaces, ladle heating

systems and reheating furnaces.

The main storage system consists of the following:


( Tank size l 6 m dia. x 7.5 m long (210 KL)

( Type CRVT

( 2 Nos. of heaters of 20 KW rating each for online heating of oil from the outlet

nozzle of the tank.



( 2 Nos. of transfer pumps (1 W + 1 SB). Pumps each of 5 m3/Hr capacity at 20

kg/cm2 & 10 KW rating each for pumping oil to the consuming points.



( Dyke of 26 m length x 16 m width and 1.5 m height around the storage tanks.

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to the consumers.

( Fencing with barbed wires with two gates.

Road tankers are connected to the unloading pipe line headers through flexible hoses

for respective oils. Furnace oil from road tankers is unloaded into the main storage tanks

using unloading pumps. For SMS, separate pumps for oils located in the tank area will

be used to supply oil to the furnaces in a closed loop. .

19.1.3 Sinter Plants

The ignitions furnaces of the sinter plants installed at both phases will be fired with Coke

Oven gas/mixed gas. Oil will be used as an auxiliary fuel in case of drop in the CV of the

gaseous fuels. The common storage facility envisaged for HSDD/LDO is as follows;


( Tank size l 1.95 m dia. x 5.5 m long (15 KL)

( Type Horizontal above ground



( 2 Nos. of transfer pumps (1 W + 1 SB). Pumps each of 2 m3/Hr capacity at 5

kg/cm2 & 3 KW rating each for pumping oil to the consuming points.



( Dyke of 7.5 m length x 8 m width and 1.5 m height around the storage tanks.


to the consumers.

( Fencing with barbed wires with two gates.

Road tankers are connected to the unloading pipe line headers through flexible hoses

for respective oils. HSD/LDO from road tankers is unloaded into the main storage tanks

using unloading pumps. For sinter plants, separate pumps for oils located in the tank

area will be used to supply oil in a closed loop.

19.2 Interplant Gas pipe lines

Interplant gas pipe lines are proposed to supply gases like Blast Furnace gas, Coke

oven gas, Mixed gas, oxygen, nitrogen, argon, general compressed air and instrument

air to the various consuming points. The inter-plant gas pipe lines will be taken over

dedicated stockades.

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Coke Oven gas pipe line: Coke Oven gas generated from the COBPP will be partly

consumed in the battery heating, conveyed to all furnaces as source of high calorie gas

for initial furnace heating and sinter plant for use as fuel in the ignition furnace. Surplus

coke oven gas will be mixed with Blast furnace gas at 1 million ton phase and with blast

furnace gas and converter gas to form a mixed gas. At phase l 1 plant, the mixing will

be done at the gas mixing station near blast furnace-1. Both coke oven and the mixed

gas line will be extended to the BOF shop at phase -2 to mix with Converter gas at

Mixing Station no. 2.

Blast Furnace Gas lines

Blast furnace gas generated after the gas coolers of BF-1 will be partially utilized for

stove heating and the rest will be mixed with Coke oven gas to for mixed gas at phase -1

1 million ton stage. At phase-2, the gas from BF-2 will be mixed with the Coke Oven gas

of the second COBPP complex and the converter gas at the Mixer station no. 2 near the

BOF shop.

Mixed gas:

As explained above, the gases are mixed in the two mixer stations to be installed each

at each phase of the plant to form a mixed gas of about 1900 Kcal/Nm3 calorific value.

This will be the primary fuel in the entire plant to be supplied to the rolling mills l both

hot as well as cold mills. Use of mixed gas can be in the sintering plant ignition furnace

also depending on the burner designs selected by the technology provider. Surplus

mixed gas will be first used at the boilers of the Turbo-blowers (which are envisaged to

be fired with gas only) and then as supplement to coal firing to the boilers of the Captive

Power Plants.

For balance of in plant generation of fuel gases please see Chapter 13.

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Chapter-20: Industrial Safety and Fire Protection Facilities

20.1 Many units and working premises of an integrated steel plant have hazardous and fire

prone environment. To protect the working personnel, equipment & machineries and raw

materials and stores from any damage or loss to ensure uninterrupted production,

adequate safety and fire fighting measures have been planned for the proposed plant at

both the phases of plant development.

20.2 Safety of personnel

The facilities envisaged for production and maintenance provide for the latest degree of

automation involving minimum manual work near the equipment. Most of the control of

the processes will be done through the level-1 and 2 instrumentation and automation

controls as elaborated in Instrumentation & Automation chapter (Chapter 16). This will

ensure minimum presence of workmen near hazardous processes. But many

maintenance activities will have to be done manually with the equipment. All work men

and engineers working in hazardous working conditions will be required to use the safety

appliances like:

' Industrial helmets (Compulsory for all entering into the plant area)

' Industrial safety shoe (Compulsory for areas involving heat or corrosive liquids)

' Hand gloves

' Plant overalls

' Ear muffs for noisy areas

' Nose dust filters for dusty areas

' Carbon monoxide detectors with gas masks for areas involving gas poisoning (areas

with CO gas)

' Respirators

' Resuscitators

' KSZRS`aj aQ`SS\ O\R O^`]\ UOa [OaYa)

% The hazardous areas will be clearly demarcated on the shop floor with permission

for only authorized persons to enter.

% Road Crossings with locos or any moving carriage with hot material would be

minimized. All busy intersections involving road/rail traffic will be provided with

flyovers.

% All electrical Main step down stations; sub stations, MCCs etc. will be protected with

entry to authorized personnel only.

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% All elevated areas above ground level would have hand rails/fencing and proper

ladder/stairs. For lifting men and materials to heights lifts would be provided

whenever required.

% The water tanks unless overhead will have proper fences.

Elaborate provisions of de-dusting through ESP/Bag filter house have been provided to

reduce the spm levels at the shop floor for safety of working personnel.

20.2 Firefighting arrangements

Because of processes involving high temperatures and use of inflammable gases as

fuel, fire is a hazard in a steel plant to be warded off. The following levels of protection

have been envisaged for the steel plant.

(a) Portable fire extinguishers: At the working level, be it plant area, office, store, laboratory

etc. portable fire extinguishers will be provided and kept as first fire safety measure. The

distribution and maintenance of the portable fire extinguishers of the three classes will be

as per the guidelines of the fire prevention manual of the tariff advisory committee.

(b) Fire hydrant systems with a fire water ring main system complete with water

underground tanks, jockey pumps both electric power motor driven and emergency

diesel engine driven will be provided in the plant area. Considering the area to be

covered the No. of such fire water ring mains may be decided so that not much pressure

of water is lost. Individual shops/units will have connections from the ring main and

would have sprinkler arrangement for areas which are underground or enclosed (like oil

cellars) and are fire prone.

(c) Automatic fire detectors. Unattended areas with high fire hazards like electrical control

rooms, cable tunnels, MCC, oils cellars etc. will have automatic alarms and sprinkler

actuation system for fire detection and prevention. Installations like Main step down

transformer stations will be provided with automatic fire detection and high velocity

emulsifier water sprinkling system.

(d) Fire stations with call points

The plant will have one central fire station located near the main entry gate and five fire

posts at:

% Coke Oven and By- product area

% Blast furnace and sintering plant area (both for 1 million ton & 2.5 million ton stages)

% Steel making & Hot rolling area at 1 million ton phase.

% Steel making and hot rolling at 2.5 million phase

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% Cold rolling mill complex at 2.5 million phase.

The central station will have two fire engines and one fire engine each at each fire post.

Apart from water tenders attached to each fire engine, there will be provision for 3 Nos.

water tenders, one foam tender and one combined CO2-DCP-Cum foam tender for the

plant at the 1 million ton phase itself. Each fire engine will have portable pumps, wireless

sets, hoses ladders etc.

(e) Manual call points

All major units and welfare buildings /administrative buildings will have red coloured

manual fire alarm buttons for summoning the nearest fire station for assistance.

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Chapter-21: Air Conditioning, Ventilation and De-dusting Facilities

21.0 Ventilation, air conditioning and air pollution control facilities will be provided for the

various buildings of the steel plant to ensure proper working conditions for both

machines and men and to maintain necessary environmental conditions for proper

storage of equipment and materials.

21.1 Mechanical Ventilation

Pressurized plenum ventilation will be provided in electrical premises, turbine halls of

CPP-1 & 2 and pump houses. The systems include centrifugal fans, dry panel filters,

ducts, adjustable louver grilles for air supply, dampers for volume control, supports,

electrics, instrumentation and controls etc. The air pressure in these buildings should be

around + 3 mm of Water column to prevent ingress of dust. Ventilation equipment for

plenum ventilation would be housed in a separate room adjoining the room it has to

pressurize. These rooms are provided with separate approaches and handling and

hoisting facilities.

At premises of stores, Battery rooms, toilets etc. general exhaust ventilation with wall

mounted axial fans along with cowl and bird screen has been envisaged.

21.2 Air Conditioning

Various PLC rooms, control rooms of processes, office cabins, Laboratories etc. will be

provided with air conditioning to ensure personal comfort of the persons working at those

places. Bigger rooms like control rooms of processes, control room of power plants and

control rooms of steam boilers will be provided with water cooled package air

conditioners. This includes also ducting, supply of grilles with VCD, insulations, piping

etc. Mounted split air-conditioners will be provided for all office rooms and Laboratories.

Wall mounted air and split air conditioners will be provided for PCM and mills facilities in

the plant.

21.3 Dust Extraction System

Dust extraction system shall be provided for the dust generating points in all shops to

control fugitive dust generation in the work zone. The dust laden air shall be sucked from

the generating points through hoods and duct work and collected generally in a pulse jet

bag filter. In some cases, ESP also will be used to clean the collected air and these

cases are mentioned in the text/drawings of those units. The dust from the bottom

hoppers of the bag filters will be collected (preferably pneumatically) and stored in local

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dust silos from where it will be discharged to dumpers after moistening for transport to

points of disposal/re-use. Necessary air compressors for providing for supply of oil and

moisture free air for the pulses required for cleaning the bags will be an integral part of

the bag filter system. Free standing chimneys (30 m high) will be also provided for each

bag filter system.

The dust extraction system will include Centrifugal fans, pulse jet bag filters, suction

hoods, ducting dampers, valves, steel stack, supports, electrics and instrumentation.

21.4 Dust suppression systems

The dry fog dust suppression system will be employed to suppress the fugitive dust

generated at areas like wagon tippler complex and junction houses.

Each transfer point shall be provided with a set of main defogging equipment which will

include spray bar assembly fitted with dual fluid dry fog atomizing nozzle, pressure

regulating units, flow activation system for ON/OFF control of system and

instrumentation for auto operation. It would be preferable to install individual water tank

for each of the defogging installation. There would be one set of main equipment for

each transfer point.

For suppressing dust in open areas like stock pile areas, sprinkler system will be

employed. This system will comprise of sprinklers of suitable throw, piping, pumps and

storage facility for water.

In general, the dust suppression system will operate with reclaimed water not fit for re-

cycling in the water system of the individual units.

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Chapter- 22: Repair Shops

22.0 To ensure un-interrupted operation of the various equipments required for production

and services, the plant will be provided with adequate repair and maintenance facilities.

For this purpose every technological unit will have its own repair facilities to carry out day

to day repairs, modification to equipment as required. However, considering the

engineering facilities which has come up in the Bellary l Hospet area, primary facilities

like foundry, forging and large scale machining facilities are not required to be provided

now in that area along with new steel plants. These items/services now can be easily

offloaded to the local industries. Still, considering the continuous nature of the steel

industry some in-site facilities are necessary. The centralized repair facilities proposed

for the steel pant are given below. These facilities will come in two phases. These will be

set up at the 1 million ton phase itself with provision for expansion in the sheds during

the 2.5 million ton phase 2.

' Central repair shop

' Loco and wagon repair shop

' Utility repair shop

' Area repair shop for hot rolling mills and for the cold rolling mill complex

' Central electronics and instrumentation repair shop

' Repair posts.

22.1 Central Repair Shop

This shop will have both mechanical and electrical repair facilities. It is envisaged

to be housed in a shed with two bays of 15 m X 80 m sizes each and a lean to

with provision of expansion with handling facilities like EOT crane 10/3t & 5/3t in

each bay; electric transfer car 10 t capacity and forklifts of 3 t capacity. The

available area will be divided between mechanical repair and electrical repair in

3:1 ratio. The mechanical facilities envisaged basically will comprise of a machine

shop with lathes, milling, boring, grinding and drilling facilities. The fabrication

facilities will include plate bending, profile gas cutting and welding facilities. A

small forging hammer with a reheating facility will be provided for any emergency

repair jobs.

The electrical repair facilities will comprise of basic facilities for overhauling

induction motors (Squirrel cage) and transformers of smaller sizes for

emergency.

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All bigger jobs required for repair of mechanical or electrical nature will be

offloaded to local industry.

22.2 The loco and wagon repair shop

This shop accommodated in a shed of 36m x 46 m will be located in the Raw material

handling area. It will have 2 nos. of EOT crane of 15/3 t capacity, one pillar jib crane of 2

t capacity and 10 t capacity transfer car.

22.3 Area repair shops for rolling mills

Each of the rolling mills at both the phases: Bar and rod mill and Billet and bar mill at

phase-1 ; Hot strip Mill and the cold rolling mill complex at phase-2 have been provided

with roll turning and repair shop in the shop lay outs. The composite shops will have

facilities for roll turning (For phase-1 mills) and roll grinding and making of rolling tackles

as well as general mechanical and electrical repair facilities in the respective repair

shops. Four such repair posts are envisaged along with the roll turning and grinding

facilities.

22.4 Utility repair shop

A centralized repair facility has been envisaged for carrying out the maintenance of

auxiliaries and utilities like pumps, refrigeration systems, ventilation equipment and pipes

etc. This shop is envisaged to be housed in a structural building of 8 m x 30 m with one

5 t under-slung crane.

22.5 Central electronics and instrumentation repair laboratory

The steel plant will have a very large number of instrument components- sensors,

transducers; a large number of electronics parts like power supply sources, electronic

control cards, thyristors etc. This facility will be basically for testing of these components

and replacement whenever necessary. This will serve the purpose of central testing

facility of the instrumentation and automation facilities installed in the plant.

22.6 Repair Posts

Apart from the central repair shops and the area repair shops, repair facilities will be

provided in the individual shop building for basic facilities like machining, drilling,

grinding, welding, gas cutting etc. at the following units.

Coke oven and By-product units (No. 1 and 2 twin battery complexes)

Blast Furnaces No. 1 and 2

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Sintering plants No. 1 & 2

Iron Ore Fine Beneficiation Plant

Captive Power Plants

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Chapter -23: Inspection, Quality Control and laboratory facilities

23.1 Objective and Scope

The proposed integrated steel plant of 3.5 million ton capacity at Hospet will produce

high quality low alloy and special steel long products at the phase -1 installations of

capacity 1 million ton of equivalent crude steel. At the phase-2 facilities it is envisaged to

produce Hot rolled strips/plates/sheets and cold rolled and coated strips/sheets

equivalent to 2.5 million ton crude steel produced at this stage. At phase-2 also the

emphasis will be products with higher strengths, better formability and superior surface

finish and corrosion properties. At both the phases, quality assurance in the products will

be very important to penetrate into the existing market initially and to continue in a

supposedly fiercely competitive surrounding. Moreover, considering the capital cost of

the equipment and facilities required at present, the Company will not be profitable

unless a large part of the product mix for sale is of value added products. The ordinary

quality products both hot rolled and cold rolled can be conveniently produced by older

units with depreciated values of the equipment and with lower capital servicing charges.

23.2 Quality assurance can be effectively implemented:

(1) Through Installation of modern processes and equipments which ensure better and

consistent qualities in the intermediate and finished products. The facilities

envisaged for this steel plant complex will meet this requirement.

(2) Adequate control on the basic raw material inputs to the plant and the quality of the

intermediate products.

(3) Physical inspection; mechanical testing and chemical & metallurgical analysis of the

products to confirm to the specified standards/ sales specifications.

(4) Corrective follow up at all stages.

23.3 Quality Control Organization

The actions envisaged at points 2 to 4 will be realized in the setting up of a Quality

control organization with process control and inspection wings. The process control wing

with branches in every process unit will advise operating personnel to control the

processes as per feed backs received from the other wings. There will stage inspections

too, with visual and laboratory based feed backs to the process control groups.

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The inspection wing which will be backed up by a string of laboratories equipped with

modern testing facilities which will generate the feedbacks. The inspection wing will

segregate intermediate and finished products for further use/sale or for re-working or

rejection as scrap.

23.4 R&D Organization

The plant will need to develop newer products and newer steel grades as per the

demands of the industry. There is a need to provide customer support system in

identifying the application and mode of usage of newer products. There will be needs for

fixing and evaluating the various norms for process parameters at different processes. In

some organization these activities is termed R&D. Whatever be the name given these

activities will be closely connected with the quality control activities and depend on the

feed backs received.

23.5 Collection and preparation of samples

Collection of representative bulk samples and proper processing of the bulk samples for

actual testing is very crucial in correct testing of various items. For raw materials the

samples will be collected at the yards as well as at the incoming points at the various

shops. For major raw materials like iron ore, coal, lime stone, dolomite etc. and bulk

materials like calcined lime/dolomite etc; and intermediate products like pellet/sinter, by-

products, the bulk samples will be collected from the conveyors through mechanical

sampling devices automatically. The detailed specification for the conveyors will provide

for these. Further averaging etc. will be done at the local laboratories. For liquid products

like hot metal, slag, steel etc. the samples will be cast, cooled and transported to the

local laboratory preferably through capsules transported pneumatically. Similar transport

will be provided for hot trip, cold rolled sheet and other similar product also after sample

cutting from the processing lines. For analysis not requiring instantaneous actions,

samples will be transported from the shop floor to the laboratories manually.

23.6 String of laboratories

The Laboratories envisaged to be set up under both 1 million ton (Phase-1) and 2.5

million ton (Phase-2) is schematically shown in Fig. 23.1 at the next page.

#


#


Phase-1 Laboratories Phase-2 laboratoriesRaw material Sample preparation lab. Raw material Sample preparation lab (Exp)

Coal washery area labCoke Oven & By-product lab Coke Oven & By-product lab (Exp)

Sinter Plant No. 1 lab Sinter Plant No. 2 labNew Pellet Plant Lab

Blast Furnace No. 1 Express lab Blast Furnace No. 2 Express labEOF & Caster shop Express lab BOF & Caster shop Express lab

Hot rolling Mill chemical, mechanical andmetallographic Lab

Hot Strip Mill chemical, mechanical andmetallographic Lab

Cold Rolling Mill Complex labCPP & TBS water testing lab CPP & TBS water testing lab (Expansion)

Fig-23.1: Structure of Quality Control Facilities

23.6.1.1 Central Laboratory Complex

The central Laboratory complex will be housed in a multi storied building near the Office

building of the Plant in kCharge. The tentative area requirement will be 5000 m2 in five

floors with a land space requirement of about 2000 m2 to include the front greenery. The

central laboratory complex will house both the quality control organization (main central

office for process control, testing and inspection) and the R&D organization. Apart from

offices and Library, the building will incorporate:

' Facilities required for spectrometric and wet analysis of samples of Coal, raw

materials, steel, iron, refractory etc. The facilities will be focused for detailed analysis

and not for day to day control which would be set up at the area abs.

CENTRAL QUALITY CONTROL

AND R&D COMPLEX

Central laboratory

R&D department

AREA LABORATORIES

#


#


' Facilities for estimation of gases in steel; analysis of gases produced as by-products;

analysis of waste gases.

' Facility for testing mineralogical properties of coals, iron ores, sinters, pellets

' Testing of the physical properties of coke, sinter, pellets, refractory bricks etc. over

and above those provided in the area labs.

' Facilities of testing of the Mechanical properties of steel products including Impact

values, creep, formability etc.

These laboratories will support the R&D work also.

23.6.1.2 Area laboratories

The functions of the different area laboratories along with their sections are given in the

table below;

Table-23.1: Area Laboratories and sections with basic functions

A. Laboratories under Phase-1 (1 million ton facilities)

Sl.No.

Name of the Laboratory Sections Functions

1 Raw material ArealaboratoryApprox. area k 100 m2

- Sample preparation- Chemical & physical

- Sample Preparation- Chemical Analysis- Size analysis

2 Coke Oven & By-productlaboratoryApprox. area k 1000 m2To be housed in theCOBPP administrativebuilding.

- Instrument analysis- Wet Analysis- Coke Physical testing

- Proximate analysis ofcoals, coal blends andcoke.

- By-product analysis- Analysis of gas- Coke sample preparation

and physical analysis likemecum, CSR.CRS

3 Sinter plant LaboratoryApproximate area k 200m2To be housed in theSintering plantadministrative building

- Physical analysis ofsinter

- Chemical analysis

- Determination of sintergranulometry, sinterstrength, Reductionindices etc.

- Chemical analysis ofsinter including moistureand FeO.

- Analysis of lime and cokebreeze.

4 Blast Furnace Expresslaboratory.Tentative space required

- Instrument laboratorywith spectrometer

- Wet laboratory

- Chemical analysis of hotmetal, coke, slag and rawcharge inputs.

#


#


300 m2 - Analysis of BF gassamples

- Determination BF gasheat value.

5 EOF shop expresslaboratoryTentative space required :500 m2

- SpectrometerLaboratory with samplepreparation.

- Back up wet laboratory- Cast product macro

etching laboratory withmachine shop.

- Chemical analysis of steelsamples, slag samples,Ferro-alloys, lime etc.

- Macro etching of caststrand samples.

6 Rolling mill LaboratoryTentative space required:200 m2

- Spectrometer forchemical

- Back up wet laboratory- Mechanical testing

laboratory

- Chemical analysis ofsamples

- Physical properties ofsamples

7 Captive power PlantLaboratory includingTurbo-blower boilersTentative area required: k200 m 2

- Spectrometer foranalysis of VM and ashof input power coals.

- Spectrometer for wateranalysis

- Wet analysis for coals,oils and calorific valuemeasurement.

- Chemical analysis ofincoming coals, fly ash,oils.

- Chemical analysis ofincoming water to the DMplant and analysis of de-ionized water, boiler feedwater etc.

B. Laboratories under Phase-2 (2.5 million ton facilities)

Sl.No.

Name of the Laboratory Sections Functions

1 Raw material ArealaboratoryApprox. area k 100 m2

- Same as in Phase-1with added facilities

- Sample Preparation- Chemical Analysis- Size analysis

2 Coke Oven & By-productlaboratoryApprox. area k 1000 m2To be housed in theCOBPP administrativebuilding.

- Same as in Phase-1with added facilitiestesting

- Proximate analysis ofcoals, coal blendsand coke.

- By-product analysis- Analysis of gas- Coke sample

preparation andphysical analysis likemecum, CSR.CRS

3 Sinter plant LaboratoryApproximate area k 200m2

- Physical analysisof sinter

- Chemical analysis

- Determination ofsinter granulometry,sinter strength,

#


#


To be housed in theSintering plant-2administrative building

Reduction indices etc.- Chemical analysis of

sinter includingmoisture and FeO.

- Analysis of lime andcoke breeze.

4 Sinter Fine BeneficiationLaboratoryApproximate area k 200m2To be housed in theBeneficiation Plantadministrative building

- Physical- Chemical

- Determination of theparticle size andanalysis of incomingsinter fines anddifferent fractionsduring the process.

4 Blast Furnace-2 Expresslaboratory.Tentative space required300 m2 to be housed inthe BF-2 complex nearfurnace cast house.

- Instrumentlaboratory withspectrometer

- Wet laboratory

- Chemical analysis ofhot metal, coke, slagand raw chargeinputs.

- Analysis of BF gassamples

- Determination BF gasheat value.

5 BOF shop expresslaboratoryTentative space required500 m2 to be located in theBOF-CC complex nearBOF furnace stage.

- SpectrometerLaboratory withsamplepreparation.

- Back up wetlaboratory

- Cast productmacro etchinglaboratory withmachine shop.

- Chemical analysis ofsteel samples, slagsamples, Ferro-alloys, lime etc.

- Macro etching of caststrand samples.

6 Hot strip mill LaboratoryArea required 1000 m2 tobe housed in the Hot stripmill complex.



- Mechanical testinglaboratory


- Physical properties ofsamples

7 Cold rolling mill complexlaboratory



- Mechanical/physical testinglaboratory


- Physical properties ofsamples includingsurface coatingproperties.

9 Captive power Plant - Spectrometer for - Chemical analysis of

#


#


Laboratory includingTurbo-blower shop-2boilersTentative area required: kOld laboratory expanded to300 m2.

analysis of VM andash of input powercoals.

- Spectrometer forwater analysis

- Wet analysis forcoals, oils andcalorific valuemeasurement.

incoming coals, flyash, oils.

- Chemical analysis ofincoming water to theDM plant andanalysis of de-ionizedwater, boiler feedwater etc.

AARESS IRON & STEEL LIMITEDTEFR for 3.5 MTPA Integrated Steel Plant At Halavarthi, Koppal, Karnataka


Chapter-24: Construction Planning

24.1 The major technological facilities envisaged for the plant at both phase-1 (I million ton

phase) and phase-2 (2.5 million ton phase) have been described in the previous

chapters along with supporting and auxiliary facilities like oxygen plants, compressed air

stations, pig casting machines, water supply , gas mixing stations, power supply

facilities, repair shops, laboratories etc. A list of the major structural and civil building

envisaged in the plant at the two phases has been given in the Annexure-24.1

24.2 Construction quantities

A tentative estimate of construction quantities envisaged is given in Annexure- 24.2 to

get an idea of the volume of the construction job.

Briefly, the phase wise volume of erection quantities will be as given in the Table below:

Table 24.1: Construction quantities (Tentative) for the steel plant at both phases.

Item Phase-1: 1 million ton facilities Phase-2:2.5 million ton facilities

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24.3 Construction schedule


start up and production in 30 months for Phase-1 facilities.




start up and production in 36 months for Phase-2 facilities. The additional time is envisaged

on account of larger % of imported components at phase-2 and relative difficulty in construction

due to presence of an operating plant at the site.

(3) The construction schedules are given in Drg: ENVIRO/AISL/FR/24/01(R-0) sheet 1 & 2.

The summary schedules for the principal activities have been given in Table 24.2 A and 24.2 B

below.

(4) The time schedule is from ZERO date which in this case is the date of placement of

order for the major plant equipment. This period will cover detailed engineering, supply,

erection and commissioning of the units.

(5) The interspacing between the two phases is not certain at the present. It will depend on

the market demand of steel flat product and prices as well as the availability of funds from

institutional sources. Generally a spacing of 2-3 years is expected between commissioning of

one phase and start of construction of the next phase. From that point of view, the full 3.5 million

ton phase of the plant could be completed in about 8 years time from the phase-1 zero date.

This is provided the gap of 2-3 years is utilized for placement of order for the phase-2.

(6) While phase-1 facilities will have to be installed and commissioned together to get 1

million ton output of alloy and special steel long products, the phase -2 units can be installed in

phases. While the primary facilities like Coke oven n by product complex -2 (Battery Nos. 3 & 4);

Sinter plant No. 2, Blast Furnace No. 2, BOF-CC shop and Hot strip mill need to be completed

together to get a capacity of 2.5 million tons of hot rolled coils, the Hot rolled coil finishing

facilities, the cold rolling mill complex can be installed later depending on the market situation.

(7) Since the group is all ready having a 1.2 million ton pellet plant at the site owned by a

Group Company, the pellet plant under Phase-2 as envisaged in the PFR has not been

considered. Only a fine washing plant along with beneficiation of washery rejects with WHIMS

has been considered. It is envisaged that the fine benficiation unit will be installed at phase-1

with one set of equipment and the rest will come at Phase-2.

Table 24.2: Summary schedule of principal activities of the Plant construction

A. Phase-1: 1 million ton units

Sl. No. Activity Duration in months from Zerodate

1 Basic Engineering 0-32 Placement of orders for equipment, auxiliary and

services4-10

3 Detailed design and Engineering 3-19



4 Site preparation 0-45 Civil Works 4-216 Fabrication of steel structures 6-217 Erection of Steel Structures 9-238 Supply of equipments 6-199 Erection of plant & Equipment 9-2310 Erection of interplant pipe line 22-2511 Cold trials 26-2712 Testing & Commissioning 28-3013 Overall project Completion 30

Completion schedule of individual unitsCoke oven & By-product plant No. 1 1-26 (26 months)Sinter Plant No. 1 along with fine beneficiation 4-27 (23 months)Blast Furnace 3-27 (24 months)EOF complex 4-28 (24 months)Continuous Casting Units 4-28 (24 months)Hot Rolling mills (Bar & Rod Mill & Billet & bar Mill) 6-30 (24 months)Captive power plant No. 1 2-26 (24 months)

B. . Phase-2: 2.5 million ton units

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hexi#sj#tlewi05#1 Basic Engineering 0-32 Placement of orders for auxiliary and services 3-123 Detailed design and Engineering 4-224 Site preparation 0-45 Civil Works 4-226 Fabrication of steel structures 5-247 Erection of Steel Structures 9-258 Supply of equipments 6-259 Erection of plant & Equipment 9-3010 Erection of interplant pipe line 26-3111 Cold trials 32-3412 Testing & Commissioning 35-3613 Overall project Completion 36

Completion schedule of completion of erection ofindividual unitsCoke oven & By-product plant No. 2 1-26 (26 months)Sinter Plant No. 2 and expansion of fine beneficiationunit.

4-32 (28 months)

Blast Furnace N. 2 3-32 (29 months)BOF complex 4-32 (28 months)Continuous Casting Units 4-32 (28 months)Hot Strip mill 6-32 (26 months)Captive power plant No. 2 2-28 (24 months)CRM Complex Can come later



24.4 Construction methodology

24.4.1 A semi turnkey approach for construction management has been envisaged. As per this

approach, the technology and a few key equipment including key technology structures

will be supplied by the technology providers (Foreign or Indian). All other standard

equipment will be procured by Indian companies associated with the technology provider

who would erect all the equipment also. Civil work, structural work (fabrication and

erection), electrical work like power supply etc. will be carried out by a few selected

companies specializing in these areas, covering more than one unit.

24.4.2 Zero date

For successful completion of the plant erection and commissioning by the stipulated time

(30 months for 1 million ton facilities and 36 months for the phase-2 2.5 million ton

facilities) will require completion of all pre-zero date activities. These would be;

' Company Board approval for the capital expenditure

' Procurement of environment clearance for start of project activity

' Appointment of Project Consultant

' Finalization project execution methodology

' Clearance from statutory authorities n State Government as well central Government.

' Financial tie ups

' To ensure possession of the required land for the Phase.

' Completion of site survey and soil investigation for soil data

' Completion of enabling works like construction water, power sewerage lines, labour

camps, communication facilities.

' Placement of site preparation work order

' Finalization of Technical specification; Floating of tender inquiry, technical discussion

and negotiation with the major suppliers of plant & equipment

' Planning for construction material and tie up with suppliers of cement, steel and other

construction materials.

These activities require very little capital but completion of these activities which may

take 6-8 months time prior to the Zero date are essential for speedy execution of the

project.

24.4.3 Assumptions for the indicated construction schedule



The assumptions are summarized in the table below:

Table 24.3: Assumptions for the indicated construction schedule

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#


#


Chapter-25: Manpower Planning

25.1 General

This chapter deals with the manpower requirement of the integrated steel plant at both

for Phase-1: 1 million ton capacity facilities and Phase-2: 2.5 million ton capacity

facilities. The manpower requirement estimate has been made taking into account the

no. of units, type of equipment and capacity. Very large scale mechanization and

automation will be practiced reducing manpower requirement to the minimum. The

estimate considers 3 shift operations per day and continuous production round the year

except planned shutdown/break down period. The manpower requirement includes

personnel for operation and maintenance; services including production planning, quality

control, Research & Development; plant administration , finance, personnel, storage

and purchase/procurement.

Activities like Medical, security, horticulture, plant internal road transport, employee

transport and town ship facilities are likely to be out sourced and are not included in this

estimate. It is also expected that supply of large number of unskilled labour required for

periodic capital and other planned repairs will be sourced through contractual agencies

and is not also included. Routine repair activities like refractory repair, ladle relining,

removal of scrap and waste material etc. will be also sourced out.

The plant will be headed by the Chief Executive officer (CEO). He would be assisted by

Executive Directors (Works) one each for each phase of operation. The functions like

personnel, finance, purchase/procurement/stores and administration will be looked after

by officers at adequate levels all reporting to the CEO.

25.2 Man power estimate

The manpower estimates for both Phase-1: 1 million ton capacity facilities and Phase -2:

2.5 million ton capacity facilities are given in the tables below:

Table-25.1: Man power estimate for the Integrated Steel plant of AISL, Hospet

Phase-1: 1 million ton facilities

Unit Managerial Executive Supervisor Skilled Semi-Skilled

Un-Skilled

Clerical Total

Raw materialyards

1 4 4 10 20 10 1 50

Coke battery,Coal & coke

1 10 12 40 100 40 4 207

#


#


handlingPlants (Twinbattery)Coke By-product Plant

1 4 4 24 30 26 1 90

Coke DryCooling

1 4 4 8 8 - 25

Blast Furnace& PCI

2 10 21 30 36 29 2 130

Sinter plant 1 6 18 21 32 24 1 103

Steel making(EOF)

2 4 18 40 36 27 3 130

Continuouscasting units

1 4 15 30 35 22 3 110

Billet & Bar Mill 1 3 15 44 6 15 4 87Bar & Rod Mill 1 3 8 35 14 25 8 95CPP & TBB 2 6 15 35 30 25 4 117Oxygen Plant 1 4 6 9 9 9 2 40Laboratories 1 4 6 15 5 - 2 33Water supply 1 6 8 24 24 21 2 86Fire, Safetyandenvironmentcontrol

2 6 9 15 21 18 1 72

Energymanagement &gas pipe line

1 3 6 12 12 12 1 47

Plant Centralmaintenance(Mech.)

1 5 10 20 20 10 1 67

Plant Centralmaintenance(Electrical)

1 5 6 10 10 10 1 43

CentralPurchase

1 4 4 4 13

Stores 2 6 6 6 2 22Repair Shops 1 1 6 12 18 15 1 54Personnel &Administration

1 2 4 9 9 2 3 30

Finance 1 4 3 9 6 2 2 27Misc.Departments

1 2 4 10 8 8 2 35

Total 26 103 202 464 495 368 55 1713

#


#


B. Phase-2: 2.5 million ton facilities

Unit Managerial Executive Supervisor Skilled Semi-Skilled

Un-Skilled

Clerical Total

Raw material yards(Expansion)

4 4 10 20 10 1 49

Coal Washing Unit 1 4 4 10 15 10 1 45Coke battery, Coal &coke handling Plants(Twin battery No. 2)

1 10 12 40 100 40 4 207

Coke By-productPlant

1 4 4 24 30 26 1 90

Coke Dry Cooling 1 4 4 8 8 - 25Blast Furnace & PCI 2 10 21 40 45 35 2 155Sinter plant 1 6 18 21 32 24 1 103New Pellet Plant 1 6 18 21 32 24 1 103Steel making (BOF) 2 4 18 40 36 27 3 130Continuous castingunits

1 4 15 30 35 22 3 110

Hot strip Mill 1 10 30 60 10 25 4 140Cold Rolling MillComplex

2 30 54 54 54 54 9 257

CPP & TBB 1 6 15 35 30 25 4 116Oxygen Plant 4 6 9 9 9 2 39Laboratories 1 4 6 15 5 - 2 33Water supply 1 6 8 24 24 21 2 86Fire, Safety andenvironment control

2 6 9 15 21 18 1 72

Energy management& gas pipe line

1 3 6 12 12 12 1 47

Plant Centralmaintenance (Mech.)

1 5 10 20 20 10 1 67

Plant Centralmaintenance(Electrical).

1 5 6 10 10 10 1 43

Central Purchase 1 4 4 4 13Stores 2 6 6 6 2 22Repair Shops 1 1 6 12 18 15 1 54Personnel &Administration

1 2 4 9 9 2 3 30

Finance 1 4 3 9 6 2 2 27Misc. Departments 1 2 4 10 8 8 2 35Total 26 147 295 560 600 403 58 2098

It may be seen the manpower required for phase -1 facility will be 1713 and at Phase-2

the manpower will be 2098 giving manpower productivity of 583 tons per man year and

#


#


1191 tons per man year respectively, in terms of rated crude steel production. The man

power productivity at the full implementation of the integrated steel plant is envisaged to

be 918 t crude steel per man year very close to international performance for a fully

integrated unit producing from iron ore and having both long and flat products.

It should be mentioned here that the figures given above is only for regular employees.

The plantnd operation and maintenance will need perhaps as many men m mostly semi

skilled and unskilled for various non perennial jobs. This manpower cost has been

included in the works cost estimate elaborated in the next chapter.

The above estimate has been based on the production technologies envisaged and the

type of mechanization and automation, the plant lay out and the number of units

proposed. The manpower includes maintenance requirement and leave reserves.

The above figure is meant for planning purpose. The exact man power requirement can

be finalized only with the final selected equipment and recommendations of the

technology/equipment suppliers.

25.3 Training needs

A steel plant as envisaged to be set up by AARESS Iron & Steel Limited requires men

with diverse specialized skills in both technical as well as managerial areas. The initial

recruitment of personnel for the steel plant will comprise of some persons already well

experienced in their respective areas, but the plant will have to take fresh young persons

also. Even experienced persons from steel industry may have to work in units or

processes in this plant where they had not been exposed earlier. So organizing a

structured training program for the operation/maintenance/management personnel

during the project construction time will be a must.

The training needs to be both in India and also at abroad. It is desirable that the

technical training is given in units similar to what will be installed at AARESS at least for

some period for operating and maintenance persons to get acclimatized. Some part of

this training should be organized by the equipment suppliers in steel plants outside India

while a large part of the training will be organized in India in the existing steel

Companies.

#


#


Chapter-26: Capital Cost and Economics

26.1 The proposed integrated steel plant at AARESS Iron & Steel Plant at Hospet, Karnataka

is planned for a total capacity of 3.5 million tons of crude steel. The plant is envisaged to

be installed in two phases.

26.1.1 The first phase will be of 1 million ton crude steel capacity and would be through

Coke-BOF-EOF (Energy Optimizing Furnace) route with an iron ore fine sintering plant

partly replacing lump ore use. The liquid steel made will be cast into blooms and billets

with continuous casting machines. These semi-products are envisaged to be rolled to

long products: Billets, bars, rounds, wire rods etc. Alloy and special steels will be the

predominant steel quality. A 70 MW Captive power plant backed up by 6 MW TRT

extracting power from blast furnace top pressure has also been envisaged. The main

product mix at the first phase-1 is envisaged to be:

Table-26.1: Product mix at Phase-1

(Tons per year)

1. Steel Products

(1) Cast Blooms/Billets for sale: 67,000

(2) Rounds, square and flats from Billet and bar mill: 250,000

(3) Wire rods in coils and bars in straight lengths: 600,000

Total alloy and special steel products: 917,000

2. Pig Iron for sale: 3, 02,201

3. Coke Oven By-Products: 59,394

Ammonium sulphate 15,126

Crude tar 42,628

Crude S 1,640

4. Granulated Blast Furnace slag: 3, 29,280 (Dry)

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#


26.1.2 The 2.5 million ton phase of the steel plant r called Phase-2 will be based on Coke-

Blast Furnace-Basic Oxygen Furnace (BOF) r Hot strip Mill route. The liquid steel will be

continuously cast to slabs which will be rolled to Hot rolled coils in a Hot strip Mill. The

hot rolled coils will be partly processed by cold rolling to thinner gauges. A part of the

cold rolled coils will be coated with Zinc/Zinc-Aluminum (Hot dip Galvanizing) and some

part of the cold rolled galvanized coils will be colour coated. Apart from some lower

quality slabs which would be sold out, the steel product mix will have Hot rolled

coils/sheets/plates; cold rolled coils/sheets, galvanized cold rolled coils, corrugated

sheets and colour coated coils/sheets. This phase envisages installation of sintering

plants to sinter iron ore fines. For use of lower grade sinter fines, Phase-2 envisages

installation of a fine beneficiation plant for enriching the sinter grade fines and also to

magnetically enrich the tailings from the first beneficiation process. Though this has been

envisaged in Phase-2, but it can be taken up partly in phase-1 also. This phase has a

Captive power Plant of 200 MW power capacity basically to meet the plant internal

power demand. The steel Product mix envisaged is:

Table-26.2: Product mix at Phase-2

Slabs for sale: 15,000

Hot rolled coils for sale: 990.000

Hot rolled sheets/narrow plates: 485,000

Cold rolled coils/sheets: 567,000

Galvanized products: 180,000

Colour coated coils: 190,000

Total steel products 2,427,000

The other products will be:

Coke Oven battery By-Products 63,404

Ammonium Sulphate: 16,110

Crude Tar: 45,548

Crude sulphur 1,746

Granulated Blast Furnace Slag: 7, 47,544 (Dry)

#


#


26.3 Capital cost envisaged for installation of the steel Plant

26.3.1 For Phase-1 of the steel plant an earlier estimate of 2007 was available from AISL. This

estimate has been adjusted for the differences in the scope and facilities planned now.

The individual cost elements have been adjusted by the differences of cost indices

prevalent in 2007 and as of now, as available from the open economic data base of

Government of India modified by the recent slump in global prices of engineering goods.

This estimate shows a capital cost requirement of Rs. Crores including contingency, IDC

and margin money. The break up is given in the table below:

Table-26.3: Capital Cost Estimate of Phase-1 (1 million ton facilities)

##

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The above estimate includes Rs. 100 Crores to be spent in pollution control equipments

specifically for ensuring environment protection. This expense however excludes

[gk_fc[djsi m^_Y^ Wh[ h[gk_h[Z \eh j^[ fheY[ii Xkj Wbie ^[bfi environment conservation.

.

#


#


26.3.2 Capital cost estimate for Phase-2 facilities

For estimating phase-2 (2.5 million ton facilities of the steel plant) a different approach

has been taken. Here most of the envisaged units of phase-2 of similar capacities have

been installed in the Indian steel industry. The project ordering values along with the

date of placement of order and other details including taxes and duties are available. An

estimate has been made for each major process complex by adjusting the scope of work

and applying indices of prices and Foreign exchange parity to arrive at the likely present

day cost of the units proposed in phase-2. This brings the estimated cost of the entire

facilities at Phase-2 including 200 MW power plant to Rs. 12,654 Crores. The broad

unit-wise breakup of the Phase-2 capital cost has been given in Annexure- 26.1. The

summarized estimated project cost of the phase-2 facilities as broken up in traditional

format is presented in the table below:

Table-26.4: Capital cost estimate for Phase-2 facilities

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Note: This estimate is based on actual ordered values adjusted to present market. So

contingency was not added. With contingency it would be INR 622 Crores more.

The estimated project cost of Phase-1 and 2 inclusive of IDC and margin money as per

the current market goings would be:

Phase 1: Rs. 5,325 Crores

#


#


Phase-2: Rs. 12,654 Crores

Total 3.5 million ton steel Plant: 17,979 Crores.

26.3.3 It may be pointed out that both the methods of arriving the capital cost as adopted for

Phase-1 and Phase-2 respectively are not likely to be very accurate for future in view of

the present global slump in the rates of capital goods and the depressed prices of steel

and other capital basic products. The estimates reflect the current market in India and

abroad. The more desirable method would be to seek current budgetary quotations from

the main suppliers as far as possible and make estimates for the balance scope of work

taking recent project rates. However this method takes time and should be adopted

before approaching for funds. For the purpose of feasibility, it is considered that the

above estimate provides to the management an adequate idea of the magnitude of funds

required and the subsequent economics of operation.

26.4 Estimation of Production cost and Profitability

26.4.1 Estimate of production Cost:

The total production costs at both the phases with full capacity utilization and at partial

capacity utilization of 60%, 80% and 90% have been calculated at Annexure-26.2. The

annexure also gives the basic rates of the different inputs envisaged in the calculations

for future references. The costs of employment including direct and contractual routes

are given in Annexure 26.3. The annexure envisages the minimum wage rates for

contractual employees in vogue in Karnataka at present and the general trend of

compensation to direct employees. These figures are inclusive of indirect cost of

employment also.

The estimated production cost at current prices is summarized below:

Table-26.5: Summary of production Costs at full capacity utilization

Sl. No. Item Production cost in INR LakhsPhase-1 Phase-2

1 Input materials 241,341 378,7302 Cost on employment 9,338 18,6243 Repair & maintenance 5,528 13,8304 Rent and taxes 1,000 3,0005 Administration 2,000 5,0006 Grid support charges 1,111 3,173

Total 260,318 422,357Cost in terms of per ton of crude steel(Rs.)

26,032* 16,894

#


#


*Note: In terms of per ton of crude steel the Phase-1 cost may look disproportionately

high since the raw material cost includes the production cost of 302,000 t of pig Iron and

328,514 t of BF Coke each year, till starting of Phase-2 when the surplus hot metal and

BF coke would not be there. These two products can generate an additional 932 Crores

turn over steel and other by-products which is reflected in the profitability of the Phase-1

working. If one takes out the cost of manufacture of these two additional items, then the

cost of production per ton of crude steel at phase-1 is about Rs.17,500/t.

26.4.3 For calculation of profitability of operation at both Phase-1 and Phase-2 the following

Basic Assumptions have been made:

1. Capital Cost

(1A) Capital Cost for phase-1 project including contingency, IDC and margin money is

taken as Rs. 5,225 Crores. (US $ 779.8 million). Please see summary estimated

project cost.

(1B) Capital Cost for phase-2 project including IDC and margin money is taken at Rs.

12,654 Crores. (US $ 1889 million). Please see summary estimated project cost.

If 5% contingency is added to the plant cost then the capital cost comes to Rs.

13276 Crores.(US $ 1.98 billion) .

However, for profitability calculations we have assumed the lower capital cost of

Phase-2 plant.

(2) Calculation of working capital has been made on the following basis:

Sl. Item No. of days Margin moneyA Current assets1 Raw materials 15 25%2 Stores & Spares 30 25%3 Work in progress 2 days 25%4 Finished goods 10 25%5 Administrative expenses including salary 30 100%6 Debtors 15 25%B Current liabilities1 Credit available on supply 7 days2 Stores & Spares 30 days

Net working capital requiredLess margin moneyMaximum working capital loan possiblefrom banks

The actual calculations of working capital required and margin money to be added to the

project cost have been given in Annexure 26.4.

#


#


3. Grid tariff for remaining connected to the grid has been taken as:

Charges for remaining connected to the grid on the basis of captive power plant

capacity have been assumed as: Mi, >KK >WfWY_jo 'FR(-.,7)53)/5.-cedj^s as

per Karnataka State Grid tariff rule .It has been further assumed that any power

drawn from the grid would be compensated by export of power to the grid from

the CPP.

4. Bank interest rates envisaged: Project loan - @ 9.5%

Working capital loan -@ 12%

5. Depreciation has been calculated @ 5% on a straight line basis

6 Capacity built up assumed: Year-1: 60%; year-2: 80%; Year-3 onwards -90%

7 Long term Loan repayment would be in 20 years in equal six monthly repayment

basis starting from second year of operation. .

8. Financing pattern: Debt equity ratio 60: 40. The loan and equity assumed for

working out the profitability projection is as given below in Rs. Crores:

Description Phase-1 Phase-2 TotalEquity 40% 2,129.6 5,061.71 7,191.31Project loan 60% 3,194.4 7,592.56 10,786.96Total Project funding 5,324 12,654.27 17,978.27

9. Corporate tax on profit taken @30%.

10. After one year of operation a fixed amount has been envisaged to be spent on

capital and other repairs to be capitalized.

11. The expenses include CSR expenses to the extent of 5% of the project cost

distributed over 10 years.

The Net sales realization envisaged for the prime products and by-products at

Phase-1 and Phase-2 are given in Annexure 26.5.

The year wise profitability statement based on the above assumptions is given in

Annexure 26.6. The summarized position is given in the Table below.

#


#


Table-26.6: Summarized 10 years cumulative profitability position of Phase-1 and

Phase-2

Sl. No. Item Phase-1 Phase-2Amount(Rs. Crores)

% of sales Amount(Rs. Crores)

% of sales

1 Net sales realization 32,852 - 74,771 -2 Gross Profit 10,295 31.3 38069 50.93 Profit before Tax 4728.45 14.4 24629 32.94 Profit after tax 3301 10.1 1724` 23.15 Net cash surplus 2258.1 6.9 1507.24 20.2

The profitability projection of combined Phase-1 and 2 has not been attempted due to

the uncertainty of the time period between commissioning of the two phases. It may be

seen that operation in both the phases as per the current market condition is favorable

and the phase-2 get the advantage of capacity. But running the plant at almost 100%

capacity is crucial for ensuring profitability and liquidity to service all liabilities.

#


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Erri|yvi0Gletxiv057#

######################

Annexure-24.1

List of major structural & civil buildings

A. Phase-1: 1 million ton facilities

Sl. No. Unit Name of the building Construction1 Raw material handling - Wagon tippler building Structural

- Junction houses Structural- Tunnels for conveyors Civil- Conveyor galleries Structural- Electrical control building Civil- Loco and wagon repair shop Structural- Raw material yard

administrative officecontaining laboratory andarea canteen

Civil

2 Coke Oven battery & By-product complex no. 1

- Coal crushing building Structural

- Conveyor galleries Structural- Coke quenching station Structural- Coke quenching Pump house Structural- Coke crushing plant Structural- Coke sorting plant Structural- COBPP administrative

building containing laboratoryand area canteen

Civil

- Coke dry quenching electricalcontrol room

Civil

- Coke oven area fire station Civil- Coke oven air compressor

houseCivil

- Water pump house Civil- By product exhauster house Civil- By product office Civil- By product electrical control

roomCivil

- Area repair post Structural

3 Sintering Plant No. 1144 m2

- Fuel and flux crushing unit Structural

- Flux screening unit Structural

- Proportioning section Structural

- Mixing & Nodulizing building Structural

- Main sinter machine building Structural

#


#



######################

Sl. No. Unit Name of the building Construction

- Cooler fan hose Structural

- Process fan building for mainmachine

Structural

- Exhaust fan building for theauxiliary ESP for de-dusting

Structural

- Sinter screening building Structural

- Sinter conveyors gallery Structural

- Conveyor junction house Structural

- Circulating water pumphouse

Civil

- Sintering plant No. 1administrative office withsintering plant laboratory andarea canteen.

Civil

- Stock house building Structural

4 Blast Furnace No. 11680 m3 useful volume

- Blast furnace cast house andtuyere platform

Structural

- Slag granulation plant Structural

- Turbo blower house No. 1 Structural

- PCI building Structural

- Coal Injection building Structural

- Pig casting machine Structural

- BF gas cleaning pump house Structural

- De-dusting unit for the casthouse area

Structural

- Air compressor station Civil /structural

- Blast furnace cooling waterpump house

Structural

- Electrical motor controlrooms

Civil

- Blast Furnace No. 1administrative building witharea canteen

Civil

- Blast furnace expresslaboratory adjoining Blastfurnace cast house

Structural & civil

- Blast furnace area repair post Structural

- BF & Sintering plant area firestation

Civil

5 EOF shop and the casters - The EOF & CCP shopbuilding with 8 Nos. of bays

Structural

- GCP pump house Civil

#


#



######################

- Circulating water pumphouse for the EAF units

Civil


- Circulating water pumphouse for the LF/VD units

Civil

- Circulating water pumphouse for the casters

Civil

- Scale pit pump house Civil

- Water treatment plants Structural

- Electrical control rooms Civil

- MCC rooms Civil

- Repair post Structural

- EOF shop express laboratorynear shop stage

Structural/civil

- EOF shop administrativebuilding with area canteen

Civil

6 Rolling mill complex atphase-1

-

Bar & Rod mill - Main mill and finishing bays Structural

- Roll and repair shop Structural

- Motor room Civil

- Electrical control room Civil

- Water pump house for bar &Rod mill

Structural/civil


Billet & bar mill - Main mill and finishing baysincluding product storage andheat treatment facilities

Structural


- Motor room Civil


- Water pump house for Billetand bar mill

Structural/civil


Common facilities for hotrolling mills

- Administrative office forPhase-1 hot rolling millsincluding area canteen

Civil

- Hot rolling mill laboratorybuilding

Civil

- Fire station common withEOF shop

Civil

#


#



######################

7 75MW captive power PlantNo. 1

- Main power station buildingincluding central control room

Civil


- Junction houses Structural


- Coal handling system switchgear and control room

Civil

- ESP & ash handling systemswitch gear and control room

Civil

- WTP & DM Plant Structural

- Main pump house for turbineand boiler

Civil

- DG house Structural

- Fire station Civil

- Switchyard control room Civil

- CPP administrative officewith laboratory and areacanteen

Civil

- Fuel oil pump house Civil

8 Electrical facilities - MRSS building Civil

- Substation buildings Civil

- Cable tunnels Civil

- Security and reception atmain gate

Civil

9 General plant facilities - Main administrative office Civil

- Central laboratory building Civil

- Central canteen building Civil

- Central fire station Civil

- Central time office Civil

- Parking sheds Structural

A. Phase-: 2.5 million ton facilities

Sl. No. Unit Name of the building Construction1 Raw material handling - Junction houses (Expansion) Structural

- Tunnels for conveyors(Expansion)

Civil

- Conveyor galleries Structural- Electrical control building

(Expansion)Civil

#


#



######################

- Raw material yardadministrative office(Expansion)

Civil

2 Coke Oven battery & By-product complex no. 2

- Coal crushing building No. 2 Structural

- Conveyor galleries Structural

Sl. No. Unit Name of the building Construction- Coke quenching station No. 2 Structural- Coke quenching Pump house

No. 2Structural

- Coke crushing plant No. 2 Structural- Coke sorting plant No. 2 Structural- COBPP no. 2 administrative

building containing laboratoryand area canteen

Civil

- Coke dry quenching unit No.2 electrical control room

Civil

- Coke oven air compressorhouse No. 2

Civil

- Water pump house No. 2 Civil- By product exhauster house

No. 2Civil

- By product office No. 2 Civil- By product electrical control

room No. 2Civil

- Area repair post Structural

3 Sintering Plant No. 2360 m2

- Fuel and flux crushing unit Structural

- Flux screening unit Structural

- Proportioning section Structural

- Mixing & Nodulizing building Structural

- Main sinter machine building Structural

- Cooler fan hose Structural

- Process fan building for mainmachine

Structural

- Exhaust fan building for theauxiliary ESP for de-dusting

Structural

- Sinter screening building Structural

- Sinter conveyors gallery Structural

- Conveyor junction house Structural

- Circulating water pumphouse

Civil

#


#



######################

- Sintering plant No. 2administrative office withsintering plant laboratory andarea canteen.

Civil

- Stock house building Structural

4 Blast Furnace No. 23814 m3 useful volume

- Blast furnace cast house andtuyere platform

Structural

- Slag granulation plant Structural


- Turbo blower house No. 2 Structural

- PCI building No. 2 Structural

- Coal Injection building No. 2 Structural

- BF gas cleaning pump house Structural

- De-dusting unit for the casthouse area

Structural

- Air compressor station Civil /structural

- Blast furnace cooling waterpump house

Structural

- Electrical motor controlrooms

Civil

- Blast Furnace No. 2administrative building witharea canteen

Civil

- Blast furnace expresslaboratory adjoining Blastfurnace No. 2 cast house

Structural & civil

- Blast furnace No. 2 arearepair post

Structural

5 BOF shop and the casters - The EOF & CCP shopbuilding.

Structural

- GCP pump house Civil

- Circulating water pumphouse for the BOF units

Civil

- Circulating water pumphouse for the LF/RH units

Civil

- Circulating water pumphouse for the casters

Civil


- Water treatment plants Structural

- Electrical control rooms Civil

- MCC rooms Civil

#


#



######################

- Repair post Structural

- BOF shop express laboratorynear shop stage

Structural/civil

- BOF shop administrativebuilding with area canteen

Civil

6 Hot Strip Mill at phase-2 - Main mill and finishing baysincluding product storage.

Structural


- Motor room Civil



- Water pump house for Hotstrip Mill

Structural/civil


- Hydraulic oil room Civil/Structural

- Administrative office for Hotstrip mill including areacanteen

Civil

- Hot Strip mill laboratorybuilding

Civil

7 Cold Rolling Mill Complex -

The cold rolling Mill &Processing bays -10 Nos.

- The cold rolling Mill &Processing bays -10 Nos.

Structural

- CRMC Administrative officeand CRMC laboratory

Civil

- CRMC central store Civil

- CRM lubricant Pump House Structural

- Water supply Pump house Structural/civil

- ECR CRM Civil

- Spent acid recovery unit Structural

- Utility facilities shed Structural

- ECR Tandem mill Civil

- MCR Tandem mill Civil

- ECR galvanizing line Civil

- ECR Colour coating line Civil

- Step Down transformer room Civil

8 CPP-2


- Junction houses Structural

#


#



######################

- Coal handling system switchgear and control room

Civil

- ESP & ash handling systemswitch gear and control room

Civil

- WTP & DM Plant Structural

- Main pump house for turbineand boiler

Civil

- DG house Structural

- Switchyard control room Civil

- CPP administrative office(Expansion0

Civil

- Fuel oil pump house Civil


9 Electrical facilities - MRSS building (Expansion) Civil

- Substation buildings(Expansion)

Civil

- Cable tunnels (Expansion) Civil

- Parking sheds (Expansion) Structural

-

10 Central facilities - Main administrative office(Expansion)

Civil

- Central laboratory building(Expansion)

Civil

- Central canteenbuilding(Expansion)

Civil

- Central fire station(Expansion)

Civil

- Central time office(Expansion)

Civil

- Parking sheds (Expansion) Structural

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apital

estim

ate

.

#


#



######################

Annexure-26.5

Sheet-1/2

Income from sale of Prime and By-products

Computation of Net sales realization

Phase-1 Operations

Products MarketPrice

AverageFreight

PricewithED

NSR Sales Amount

Rs/t Rs/t Rs/t Rs/t T Rs. Lakhs

Steel ProductsGevfsr#Gsrwxvygxmsr#Wxiip##

IR=2G78#

Vsyrh2Wuyevi#+4930683qq,# 40,000 500 39,500 35,205 30,000 10,561.5

Vsyrh2Wuyevi#+930533qq,# 40,500 500 40,000 35,651 55,000 19,607.84

Jpexw#+4930683qq,# 40,500 500 40,000 35,651 20,000 7,130.125

Fevw#+49093qq,# 42,000 500 41,500 36,988 100,000 36987.52

Epps}#Gsrwxvygxmsrep#wxiip##

49QrGv82IR4=#

Vsyrh2Wuyevi#+4930683qq,# 49,000 500 48,500 43,226 25,000 10,806.6

Vsyrh2Wuyevi#+930533qq,# 49,500 500 49,000 43,672 30,000 13101.6

Jpexw#+4930683qq,# 49,500 500 49,000 43,672 10,000 4367.201

Fevw#+49093qq,# 51,000 500 50,500 45,009 100,000 45,008.91

Fievmrk#Uyepmx}#Wxiip#

IR642WEI#85433#

Vsyrh2Wuyevi#+4930683qq,#

Vsyrh2Wuyevi#+930533qq,# 45,000 500 44,500 39,661 30,000 11,896

Jpexw#+4930683qq,# 45,000 500 44,500 39,661 10,000 3,966.132

Fevw#+49093qq,# 45,500 500 45,000 40,107 100,000 40,106.95

Hve{mrk#Uyepmx}#[mvi#Vshw# 32,000 500 31500 28,075 40,000 11,229.95

Fvmklx#Fev#Uyepmx}#[mvi#Vshw# 32,000 500 31500 28,075 40,000 11,229.95

Gsph#liehih#Uyepmx}#[mvi#vshw## 33,000 500 32,500 28,966 40,000 11586.45

Jvii#Gyxxmrk#Wxiip#[mvi#vshw##

IR#4#E# 34,000 500 33,500 29,857 40,000 11942.96

Wtvmrk#Wxiip##

IR#78E#

Vsyrh#+930533qq,# 35,000 500 34,500 30,749 30,000 9224.599

Jpexw#+4930683qq,# 36,000 500 35,500 31,640 10,000 3163.993

#


#



######################

Fevw#+49093qq,# 36,000 500 35,500 31,640 100,000 32,085.56

Qmwg1#kvehi#gewx#Fpssq2Fmppix## 26,000 500 25,500 22,727 67,000 15227.27

Wyf#Xsxep#+Tvmqi#wxiip#

Tvshygxw,#

8,77,000 294,006.2

Annexure-26.5

Sheet-2/2

Computation of Net sales realization b Phase-1 (Continued)


AverageFreight

PricewithED

NSR Sales Amount

Rs/t Rs/t Rs/t Rs/t T Rs. Lakhs

Tmk#Mvsr## 20,500 500 20,000 17,825 302,000 53,832.44

F}0Tvshygx#wepi##

Eqqsrmyq#Wyptlexi# 8000 15124 1,209.92

Gvyhi#xev# 20,000 42,628 8,525.6

Wyptlyv#Geoi## 10,000 1,640 164

Fpewx#Jyvregi#Kverypexih#wpek## 8000 328,280 26,262.4

Wyf#Xsxep#F}0Tvshygxw# 36,161.92

Gsoi#wepi#ex#Tlewi04# 12,500 500 12,000 328,514 39,421.68

Qmwg#wepi## 2,000

Xsxep#Wepiw#viziryi## 382,000.6

Phase-2 operations


AverageFreight

PricewithED

NSR Sales Amount

Rs/t Rs/t Rs/t Rs/t T Rs. LakhsSteel ProductsHot rolled coils 33,000 500 32,500 28,966 9,90,000 286,764.7Hot rolled sheets/Plates 35,000 500 34,500 30,749 4,85,000 149,131Cold Rolled coils/sheets 41,000 500 40,500 36,096 5,67,000 204,665.8Galvanized products 47,500 500 47,000 41,889 180,000 75,401.07Colour Coated sheets/coils 50,000 500 49,500 44,118 190,000 83823.53Slabs for sale 25,000 500 24,500 21,836 15,000 3275.4Sub Total Steel products 803061.5

F}0Tvshygx#wepi##

Eqqsrmyq#Wyptlexi# 8000 16,110 1,288.8

Gvyhi#xev# 20,000 45,548 9,109.6

#


#



######################

Wyptlyv#Geoi## 10,000 1,746 174.6

Fpewx#Jyvregi#Kverypexih#wpek## 8000 747,544 59,803.52

Wyf#Xsxep#F}0Tvshygxw# 70,376.52

Qmwg#wepi## 4,000

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Stack calculation for AISL 3.5 MTPA Steel Plant phase-1

Sr. No. Source Fuel Stack

Height

Stack

Diameter

PM10

Emission

Rate

g/s

SO2

Emission

Rate

g/s

NOx

Emission

Rate

g/s

1. COB#1-

cumbustion

Gas

120.00 3.5 0.5 4.9 6.11

2. COB#2-

cumbustion

Gas

120.00 3.5 0.5 4.9 6.11

3. coke guide

car ehaust-1

Gas

50.00 2.2 2.2 5.6 Trace

4. SP#1-

cumbustion

Gas

80.00 4.5 9.6 36.00 72.00

5. SP#1-DE 1

BF

Gad

50.00 4.5 5.0 Trace Trace

6. SP#1-DE 2 Gas 50.00 4.5 5.0 Trace Trace

7. BF#1CH-DE Coke 35.00 3.5 3.1 Trace Trace

8. BF#1Stove-C Coke 60.00 3.5 0.9 2.8 1.42

9. BF#1SH-DE Coke 35.00 3 2.2 Trace Trace

10. PCM de-

dusting stack

No fuel


11. EOF-1

exhaust stack

Electricity

50.00 1.5 0.6 0.83 2.08

12. EOF-2

exhaust stack

Electricity

50.00 1.5 0.6 0.83 2.08

13. EOF1-2-

common-DE

Electricity

35.00 3 2.2 Trace Trace

14. EOF-DE-bulk

material

conveyor

Electricity

35.00 3 2.2 Trace Trace

15. Rolling Mill-

1 RHF stack

Mixed

Gases 50.00 2 0.1 0.8 1.83

16. Rolling Mill-

1 DE stack

Mixed

Gases 35.00 2 1.1 Trace Trace

17. Rolling Mill-

2 RHF stack

Mixed

Gases 50.00 2.5 0.3 1.9 4.58

18. Rolling Mill-

2 DE stack

Mixed

Gases 35.00 2.5 3.3 Trace Trace

19. CPP 1 stack

70 MW

Waste

Gases 180.00 5 7.1 23.6 23.61

20. Coal mill DE

stack

No fuel

35.00 3 4.4 0.0 0.00

21. Boiler stack

for TB steam

Waste

Gases 50.00 2 1.3 3.3 3.33

Stack calculation for AISL 3.5 MTPA Steel Plant PHASE-2

Sr. No. Source Fuel Stack

Height

Stack

Diamet

er

PM10

Emission

Rate

g/s

SO2

Emission

Rate

g/s

NOx

Emission

Rate

g/s

1. COB#3-cumbustion Gas 120.00 3.5 0.5 1.2 6.11

2. COB#4-cumbustion Gas 120.00 3.5 0.5 1.2 6.11

3. coke guide car

ehaust-2

Gas 50.00 2.2 2.2 Trace Trace

4. SP#2-cumbustion Gas 80.00 6.5 22.2 75.00 166.67

5. SP#2-DE Gas 50.00 6 11.1 Trace Trace

6. SP#2-DE Gas 50.00 6 11.1 Trace Trace

7. BF#2CH-DE Coke 35.00 5.5 8.9 Trace Trace

8. BF#2Stove-C Coke 60.00 5.5 0.6 6.3 3.77

9. BF#2SH-DE Coke 35.00 4.5 11.1 Trace Trace

10. BOF-1flare stack * No Fuel 80.00 2.5 1.9 3.75 5.63

11. BOF-2 flare stack * No Fuel 80.00 2.5 1.9 3.75 5.63

12. BOF-1DE-1 NO

FUEL

No Fuel 45.00 5.5 8.0 Trace Trace

13. BOF-1 DE-2 No fuel 45.00 5.5 8.0 Trace Trace

14. BOF-2 DE-1 No Fuel 45.00 5.5 8.0 Trace Trace

15. BOF-2 DE-2 No Fuel 45.00 5.5 8.0 Trace Trace

16. HSM RHF-1

MIXED GAS

Mixed

Gases

60.00 3.5 0.6 5.0 9.19

17. HSM RHF-2 Mixed

Gases

60.00 3.5 0.6 5.0 9.19

18. HSM DE-1 Mixed

Gases


19. HSM DE-2 Mixed

Gases


20. CRM-ARPduct-DE

GAS

Gas 30.00 0.8 0.2 Trace Trace

21. CRM-Batch

Annealing furnace

Gas 45.00 1.2 0.1 1.1 2.67

22. Galv. Line fur stack Electrica

l Energy

and Gas

45.00 1.5 0.1 0.7 1.67

23. CPP 2 stack 100

MW

Waste

Gases

180.00 5.5 10.0 33.3 33.33

24. CPP 2 stack 100

MW

Waste

Gases

180.00 5.5 10.0 33.3 33.33

25. Coal mill DE stack No Fuel 35.00 3 4.4 Trace Trace

26. Boiler stack for TB

steam

Waste

Gases

50.00 2 1.0 3.3 3.33

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