pre-feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/10...project proponent n....

Project Proponent

N. N. Ispat Pvt. Limited 25, Ganesh Chandra Avenue, 4th Floor, Kolkata - 700 013

for Proposed expansion of existing Steel Plant by installation of 2x350 TPD DRI Kilns, 2x20 T and 2x16.5 T Induction Furnaces, 1x30 T Electric Arc Furnace with matching LRF & CCM, 10,000 TPA capacity Galvanization

Plant along with 26 MW Captive Power Plant (16 MW WHRB + 10 MW AFBC)

at Village: Diwandighi, P.O. & Mouza: Mirzapur,

Palitpur Road, P.S. & District: Purba Burdwan, West Bengal

PRE-FEASIBILITY REPORT

M/s N.N.Ispat Pvt.Limited

Proposed expansion of existing Steel Plant by installation of 2x350 TPD DRI Kilns, 2x20T and 2x16.5 T Induction Furnaces & Electric Arc Furnace (1x30 T) with matching LRF &CCM, 10,000 TPA capacity Galvanization Plant along with 26 MW Captive Power Plant

(16 MW WHRB + 10 MW AFBC) at village: Diwandighi, P.O. & Mouza: Mirzapur,Palitpur Road, P.S. & District: Purba Burdwan, West Bengal


CONTENTSSectionNumber

Description

1.0 Introduction2.0 N. N. Ispat Private Limited - An Overview3.0 Site Location4.0 RawMaterials & Supplies5.0 The Project6.0

6.16.26.36.46.5

Manufacturing ProcessSponge Iron PlantInduction FurnaceElectric Arc FurnaceGalvanising PlantCaptive Power Plant

7.0 Water Demand8.0 Power9.0 Plant General Layout10.0 Quality Assurance11.0 Environment Control12.0 Control of Fugitive Emissions at Various Auxiliary

Facilities Inside The Plant13.0 Fire Protection System14.0 Green Belt Development15.0 Manpower Requirement16.0 Project Period17.0 Estimated Cost


Proposed expansion of existing Steel Plant by installation of 2x350 TPD DRI Kilns, 2x20 T and2x16.5 T Induction Furnaces & 1x30 T Electric Arc Furnace with matching LRF & CCM,

10,000 TPA capacity Galvanization Plant along with 26 MW Captive Power Plant (16 MWWHRB + 10 MW AFBC) at village: Diwandighi, P.O. & Mouza: Mirzapur, Palitpur Road, P.S. &

District: Purba Burdwan, West Bengal

PRE-FEASIBILITY REPORT Page-1


1.0 INTRODUCTION INTRODUCTIONM/s N. N. Ispat Pvt. Ltd., a Private Limited company, was incorporatedon 28th February, 2003, having its registered office at 25, GaneshChandra Avenue, 4th Floor, Kolkata-700 013 in West Bengal.

As per the NOC obtained from West Bengal Pollution Control Board(WBPCB), the company is presently operating 2x8 T capacity InductionFurnaces for the production of 48,000 TPA billets at village: Diwandighi,P.O. & Mouza: Mirzapur, Palitpur Road, P.S. & district: Purba Burdwanin the state of West Bengal. The company also received anEnvironmental Clearance EC granted vide F. No. J-11011/280/2012-IA-II-(I), dated 5th February,2015) from Ministry of Environment, Forest& Climate Change (MoEF&CC), to operate a steel plant for production of90,000 TPA of Liquid Steel from 2x15 T Induction Furnaces, productionof 0.12 MTPA Structural Steels (Angels, Channels, TMT etc.) along with2x9 MVA Ferro Alloy Plant and Foundry within the existing plant area atthe same location. As per EC of MoEF&CC dated 5th February,2015,2x15 T capacity Induction Furnaces for the production of 90,000 TPAbillets and Rolling Mill for the production of 1,20,000 TPA StructuralSteels (Angels, channels, TMT etc.) are already under operation and 2x9MVA Submerged Arc Furnaces and Foundry consisting of 2x5 T CupolaFurnaces, 2x3 T Induction Furnace, 2x20 TPH Green Sand Plant and2x10 TPH Sand Reclamation Plant are not implemented.

Now, to make the project more viable, the company has also decided toinstall another (2x20 T + 2x16.5 T) Induction Furnaces & 1x30 T ElectricArc Furnace with matching LRF & CCM to produce 2,16,000 TPA billets,2x350 TPD DRI Kilns to produce 2,10,000 TPA Sponge Iron,Galvanization Plant to produce 10,000 TPA Galvanised Product alongwith 26 MW capacity Captive Power Plant (16 MW WHRB + 10 MWAFBC) within the existing plant area. The overall project scenario withrated capacity per annum are presented in Table-1.1.


Proposed expansion of existing Steel Plant by installation of 2x350 TPD DRI Kilns, 2x20 Tand 2x16.5 T Induction Furnaces & Electric Arc Furnace (1x30 T) with matching LRF & CCM,

10,000 TPA capacity Galvanization Plant along with 26 MW Captive Power Plant (16 MWWHRB + 10 MW AFBC) at village: Diwandighi, P.O. & Mouza: Mirzapur, Palitpur Road,



TABLE-1.1OVRALL PROJECT SCENARIO

Name of theUnits

Units underoperation

(as per EC fromMoEF&CC)

Units notimplementedas per EC fromMoEF&CC

Proposedunits

Total Units

Sponge Iron Plant - - 2x350 TPDDRI Kilns

(2,10,000TPA Sponge

Iron)

2x350 TPDDRI Kiln

(2,10,000 TPASponge Iron)

Induction Furnaceswith matching LRF& CCM

2x8 T + 2x15 T

(1,38,000 TPABillets)

- 2x20 T +2x16.5 T

(2,16,000TPA Billets)

2x8 T, 2x15 T,2x20 T &2x16.5 T

(3,54,000TPABillets)

Electric ArcFurnace

- - 1x30 T


1x30 T


Rolling Mill 1,20,000 TPAStructural Steels(Angels, Channels,

TMT etc.)

- - 1,20,000 TPAStructural

Steels (Angels,Channels,TMT etc.)

Galvanising Plant - - 10,000 TPAGalvanisedProduct

10,000 TPAGalvanisedProduct

Ferro Alloy Plant - 2x9 MVASubmerged Arc

Furnaces

(Ferro Manganese -20,460 TPA

orSilico Manganese -

14,850 TPAor

Ferro Silicon -6,600 TPA)

-

2x9 MVASubmergedArc Furnaces

(FerroManganese -20,460 TPA

orSilico

Manganese -14,850 TPA

orFerro Silicon -6,600 TPA)

Foundry Consistingof Cupola Furnace

- 2x5 T

(21,500 TPACast Iron)

- 2x5 T

(21,500 TPACast Iron)

Induction Furnace - 2x3 T

(18,000 TPA

- 2x3 T

(18,000 TPA






Ductile Iron) Ductile Iron)

Green Sand Plant - 2x20 TPH

(72,000 TPAMould)

- 2x20 TPH

(72,000 TPAMould)

Sand ReclamationPlant

- 2x10 TPH

(80,000 TPAfresh sand)

- 2x10 TPH

(80,000 TPAfresh sand)

Captive PowerPlant

- - 26 MW CPP

(16 MWWHRB + 10MW AFBC)

26 MW CPP

2.0 N. N. ISPAT PRIVATE LIMITED- An Overview

M/s N. N. Ispat Private Limited was incorporated on 28th February, 2003,having its registered office at 25, Ganesh Chandra Avenue, 4th Floor,Kolkata-700013 in West Bengal. The Group Companies under the namesof AIC Iron Industries (P) Ltd., AIC Metaliks (P) Ltd. and Bhagwati SpongePvt. Ltd. at Purulia and Jamuria respectively are producing Steel Ingots,Sponge Iron and Billets for Domestic market.

The present management has already set an example of operating theirexisting plant with modern management. The Company had/will adoptthe latest techniques of Manufacturing, Management, Inventory Control,Finance Management, Human Resource Relation and image building. TheManagement’s focus is on timely delivery of the product at an acceptablequality level at a competitive price to the customer. This shall be achievedthrough an enterprise-wide resource planning and development coupledwith online information systems for feedback from customers anddistributors. An emphasis shall be placed for good material & energymanagement and environment cleanliness. The overall affairs of theCompany shall be managed under the guidance of Sri Dinesh Adukia.The other professional team of Company Executives will lend the requiredexpertise in conducting all the major functions of this business house.The Board of the Directors of the Company is as under :

Sri Dinesh Adukia - Director Sri Vivek Adukia - Director Sri Gyan Adukia - Director






The Organizational Structure is detailed herein below:Director

General Manager

Production Finance Administration Marketing

Manager Manager Manager Manager

Laboratory Maintenance

3.0 SITE LOCATIONThe project site is located at village: Diwandighi, P.O. & Mouza:Mirzapur, Palitpur Road, District: Purba Burdwan in the state of WestBengal (refer Figure-1.0). Its graphical co-ordinates are latitude23˚17′18.43″N and longitude 87˚52′20.17″E with mean sea level as110 ft. Burdwan Railway Station is about 5.0 km from the project site.National Highway-2 (NH-2) is passing through the south direction,around 8.0 km from the project site. The nearest industriallydeveloped town Durgapur is situated at around 63 km in north-westdirection w.r.t. the project site. Important Town like Burdwan (DistrictH.Q) is about 5.0 km from project site. River Damodar are passingapprox. 8.5 km distance in south direction w.r.t the project site.

There is no National Park & Reserve Forest within 10 km radius of theProject Site. The aerial distance between boundary of project site andboundary of Ramnabagan Wildlife Sanctuary is 4.0 km.(refer Figure-2.0)






FIGURE 1.0 : SITE LOCATION MAP






FIGURE 2.0 : SITE & SURROUNDING

4.0 RAW MATERIALS & SUPPLIES

The raw material, which will be handled through the material handlingsystem consists of Iron Ore fines / Pellet, Sponge Iron, Pig iron, IronScrap, Ferro Alloys, Dolomite, Imported Coal etc. Raw materials will bereceived at plant site by rail/ road. All the trucks for raw material andfinished product transportation shall comply with the applicableenvironmental norms.

The annual requirement of raw materials, which will be required for theproposed project, is presented below.

LIST OF RAW MATERIALS

Raw Material Quantity(in TPA)

Source Mode ofTransportation

2x350 TPD DRI Kilns :Iron Ore Fines /Pellet

3,15,000 Local Market Rail / Road

Imported coal 2,10,000 Imported Rail / RoadDolomite 6,300 Local Market Road2x20 T + 2x16.5 T Induction Furnace :Sponge Iron 2,10,000 In House -Pig Iron 43,000 Local Market RoadScraps 34,500 Local Market RoadFerro Alloys 3,200 In House Road1x30 T Electric Arc Furnaces :Sponge Iron 1,90,000 Local Market Rail / RoadPig Iron 39,000 Local Market RoadScraps 31,000 Local Market RoadCaptive Power Plant (10 MW AFBC) :Imported coal 63,000 Imported Rail / RoadDolochar 63,000 In house -

5.0 THE PROJECT

The configuration of Proposed Project is as follows:

DRI Kilns (2x350 TPD) – 2,10,000 TPA Sponge Iron






Induction Furnaces (2x20 T + 2x16.5 T) with matching LRF & CCM–2,16,000 TPA Billets (considering 10 heats per day, 300 working daysin a year)

Electric Arc Furnace (1x30 T ) – 1,95,000 TPA Billets (considering 22heats per day, 300 working days in a year)

Galvanising Plant - 10,000 TPA Galvanised Product Captive Power Plant - 26 MW (16 MW WHRB + 10 MW AFBC based)

The proposed expansion project will be installed on the available landwithin the existing plant premises, comprising of total 8.38 hectares(20.7 acres) as well on the additional land of total 10.24 hectares (25.3acres) adjoining the existing plant premises. Thus, total land will be18.62 hectares (46 Acres). Most of the facilities are available for settingup of the proposed steel plant such as Electricity, Water,Transportation of raw materials and finished goods etc. skilled andunskilled workers are also easily available within the industrial area.

6.0 MANUFACTURING PROCESS

6.1 SPONGE IRON PLANT

M/s N. N. Ispat Limited is planning to install two (2) DRI kilns, each of350 TPD capacity for production of 2,10,000 TPA sponge iron in theexisting plant (considering 300 working days).

Manufacturing Process

The proposed plant uses the coal based process in which iron oxide inpellet will be reduced with non-coking coal in a rotary kiln to makesponge iron. The raw materials (Pellet, coal and dolomite), in desiredquantities and sizes, are fed into the rotary kiln from the feed end,after the rotary kiln has been fired and reaches the desiredtemperature. The rotary kiln is a refractory lined cylindrical vessel onwhich blowers and air pipes are mounted to provide combustion air tothe kiln. The rotary kiln has a downward slope and is mounted onrollers to enable rotation. The angle of inclination, rotational speed,and length of time the charge is exposed to the atmosphere andtemperature has important bearings on the quality of the end product.The rotary kiln has three functions as: It is a heat exchanger, Vesselfor chemical reaction, Conveyor for solids.

With the rotation of the kiln, the charge moves down the slope and thesurface of the material is exposed to heat. The heat exchange takesplace via the non-refractory lining of the kiln. The reduction from






oxide to metal occurs by gradual removal of oxygen at varioustemperatures giving rise to various intermediate oxides. Hot spongeiron is discharged from the kiln discharge end and taken into therotary cooler. The effluent gas that contains coal volatile matter, finecarbon particles, iron fines and sponge iron dust is treated separatelyin the waste gas handling system. The system consists of:(a) Dust settling chamber(b) After burner chamber(c) Waste heat recovery boiler(d) Electrostatic precipitator(e) ID fan(f) Chimney

Direct Reduced Iron/Sponge Iron Process (DRI)

The process of reduction takes place inside the rotary kiln, which ismounted on tyres and supported by support rollers. The transversemotion of the kiln is controlled with the help of hydro thruster andthrust rollers. The kiln is rotated at the rate of 0.35 rpm with the helpof a girth gear mounted on the kiln and connected with 1 piniondrives, which in turn are coupled with gear boxes and motors.

The direct reduction of iron oxides inside the kiln is held due to COgas, which is generated out of coal at nearly 950°C. Shell air fans aremounted on the kiln, which inject air in controlled manner into thekiln for creating reducing atmosphere. The CO reacts with Fe2O3 andreduces it to Fe. The kiln is lined with refractory for sustaining thehigh temperature.

The hot sponge iron is then cooled by indirect cooling inside a cooler.The rotary cooler is supported on tyres and support rollers. The cooleris rotated at the rate of 0.6 rpm with the help of a girth gear mountedon the cooler and connected with single pinion drive, which is coupledwith a gearbox and motor. The water is sprayed on the cooler shellwhile the sponge iron travels inside the cooler and hence, the materialgets cooled at outlet to 150°C while discharged on the productconveyor.

In the kiln, the iron oxide will be heated to the reduction temperatureof 1000-1050°C. The iron oxide of the ore will be reduced to metalliciron by carbon dioxide generated in the kiln from coal. The heatrequired for the reduction process will also be supplied by thecombustion of coal.

Thermocouple will be installed along the length of the kiln shell formeasurement of thermal profile of the kiln. The temperature will be






controlled by regulating the amount of combustion air admitted intothe kiln through no. of ports with help of fans mounted on the kilnwill have variable speed drive. Auxiliary drive is provided for slowrotation.

The cooler will be lined with refractory castable for about 4.0 m fromthe feed end. Bypass arrangement will be provided at discharge endof the cooler for emergency discharge of materials. The cooled productwill be conveyed to the product processing building by a system of beltconveyors.

The cooling water will be collected in the trough below the cooler andsent to the cooling tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system will be followed in the plant.

Product Separation

The sponge iron along with unburnt coal in the form of dolocharcomes out of the cooler. The sponge iron being magnetic is separatedout of the dolochar by passing it through a magnetic separator. Thesponge iron and char, recovered separately, are stored in the storagebunkers and discharged through trucks.

Off gas cleaning system

The off gases moving in counter current of material flow inside thekiln are at a temperature of 1000°C and carry coal dust, which ispassed through dust settling chamber and after burning chamber(ABC). Air is added into the ABC for converting CO to CO2. The hotflue gas stream is taken to the waste heat recovery boiler (WHRB) forutilization of the sensible heat for making steam. The off gases arethen allowed to pass through ESP for removal of dust so that theconcentration of dust is limited to below 50 mg/Nm3 before beingdischarged from the chimney.

In-plant de-dusting system

Reverse air bag filter shall be installed for catching the dust fromvarious conveyors, material handling equipment and-producthandling equipment. The dust collected from the bag filter shall beconveyed pneumatically to a distant location and discharged ontrucks in wet condition.

Raw Materials required for Sponge Iron manufacture

The main raw materials for sponge iron production are pellet, coal,and dolomite. The specific consumption and annual requirement ofthese raw materials for the proposed 2x350 TPD capacity sponge ironplant are presented below






Raw Materials for 2x350 TPD Sponge Iron (Dry & Net)

Preferred Raw Material Characteristics

The principal burden material will be used for production of steelmaking grade DRI in the sponge making process is pellet, non-cokingcoal and dolomite.

The pellet should be preferably high in Fe content (>65% Fe). Coalwith a high reactivity and high fusion temperature is preferred. Thecoal should also be non-coking.

A low ash fusion temperature is undesirable as it promotes formationof accretions in the kiln. The coal ash composition is also importantas a siliceous ash might react with ferrous oxide to form low meltingferrous silicate and interfere with the reduction to metallic iron.

Product characteristics of Sponge Iron are as follows:

Sponge Iron (coal based) characteristics

Fe (total) : 92% min

Fe (met) : 83 % max

Metallization : 90 % max

Carbon : 0.25 % max

S : 0.025% max

P : 0.06% max

Re-oxidation : Non-pyrophoric characteristics

Major plant facilities

The major plant facilities for the sponge iron plant envisaged are asfollows:1. Day bins

S. No. Raw material Quantity in TPA

1. Pellet 3,15,000

2. Imported Coal 2,10,000

3. Dolomite 6,300






2. Rotary kiln and cooler3. Off gas system including waste heat power generation4. Product processing and storage.

Day bins

There shall be a day bin building to cater to raw material requirementof the kiln. These bins will generally have storage of about one day’srequirement of pellet, feed coal (4-8, 8-18 mm) & dolomite (1-4 mm).Weigh feeders will be provided to draw the required quantity of variousmaterials in proportion from the bins and the same will be conveyedto the kiln feed and discharge end.

Rotary kiln and cooler

The rotary kilns with 10.5 m of diameter, 145 m length will beprovided for reduction of iron oxides into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion resistantrefractory castables throughout its length with damps at feed end anddischarge end.

The rotary kiln will be supported on four piers. A slope of about 2.5%shall be maintained. Then main drive of the kiln will be by A.C motorswith VVF drive control. The speed of the kiln will be in the range of0.3-0.9 & 1.05-3.15 rpm. The auxiliary drive of the kiln will be by A.Cmotors.

The other main components of the kiln will be as given below:

a. Feed end and discharge end transition housing of welded steelconstruction with refractory lining including feed chute.

b. Pneumatic cylinder actuated labyrinth air seal complete with autolubricating at feed end and discharge end.

c. On board equipments like fans, manifolds, ports, slip ring,instrumentation etc.

d. Cooling fans at feed end and discharge end.e. Feed end double pendulum valve & dust valves.

Product processing and storage

There shall be one product processing unit for handling the coolerdischarge. The product containing sponge iron, char and spent limefrom the cooler discharge end will be discharged to a set of conveyorsand sent to the product processing building. The kiln cooler systemshall have a separate surge bin. Product from surge bin can bewithdrawn through vibrating feeder and to the product will first bescreened in a double deck screen having 3 mm and 20 mm screens.






+20 materials shall be dumped as rejects. The screened product i.e.+3 – 20 mm and -3 mm fraction shall separately be sent to theproduct storage separation. Sponge iron lump (3 – 20) shall be sent tothe product storage building for storing in two no. of bunkers wherethree days storage has been proposed. The sponge ion fines (-3 mm)will be stored in the fines bunker in the product processing buildingitself where one day storage will be provided. The sponge iron lumpand fines will be further conveyed from the respective bunkers bytruck to the steel making unit as per the requirement. The char/non-magnetic shall be stored in a separate bin from where it will be sent tothe power plant through conveyors for its utilization for powergeneration in FBC boiler.

Indicative process flow diagram of Sponge Iron Plant is presentedbelow.

PROCESS FLOW DIAGRAM OF SPONGE IRON PLANT

6.2 INDUCTION FURNACEThe company has decided to install 2x20T & 2x16.5T InductionFurnace to produce 2,16,000 TPA billets (2,19,000 TPA Liquid steel).The manufacturing process for Steel Billets are through Induction






Furnace - Ladle Refining Furnace - Continuous Casting Machine isdiscussed herein below.

The plant will produce steel in the form of billets, TMT Bars and Strips& Structural products through IF-CCM-RM route. Steel making will bedone using induction furnaces. A brief description of the processes isdealt in subsequent paragraphs and the process flow sheet is givenbelow.

Steel Making by Induction Furnace

The greatest advantage of the Induction Furnace is its low capital costcompared with other types of Melting Units. Its installation isrelatively easier and its operation simpler. Among other advantages,there is very little heat loss from the furnace as the bath is constantlycovered and there is practically no loss during its operation. Themolten metal in an Induction Furnace is circulated automatically byelectromagnetic action so that when alloy additions are made, ahomogeneous product is ensured in minimum time. The time betweentap and charge, the charging time, power delays etc. are items ofutmost importance is meeting the objective of maximum output intones/hours at a low operational cost. The disadvantage of the






induction furnace is that the melting process requires usually selectedscrap because major refining is not possible.

The process for manufacturing steel may be broadly divided into thefollowing stages:

i) Melting the charge mixed of steel & Iron scrap,ii) Ladle teeming practice for Casting (OR), andiii) Direct teeming practice for billet Casting unladdable teeming

machine

The furnace is switched on, current starts flowing at a high rate and acomparatively low voltage through the induction coils of the furnace,producing an induced magnetic field inside the central space of thecoils where the crucible is located. The induced magnetic fluxes thusgenerated out through the packed charge in the crucible, which isplaced centrally inside the induction coil.

As the magnetic fluxes generated out through the scraps and completethe circuit, they generate and induce eddy current in the scrap. Thisinduced eddy current, as it flows through the highly resistive bath ofscrap, generates tremendous heat and melting starts. It is thusapparent that the melting rate depends primarily on two things (1) thedensity of magnetic fluxes and (2) compactness of the charge. Thecharge mixed arrangement has already been described. The magneticfluxes can be controlled by varying input of power to the furnace,especially the current and frequency.

In a medium frequency furnace, the frequency range normally variesbetween 150-10K cycles/ second. This heat is developed mainly in theouter rim of the metal in the charge but is carried quickly to thecenter by conduction. Soon a pool of molten metal forms in the bottomcausing the charging to sink. At this point any remaining chargemixed is added gradually. The eddy current, which is generated in thecharge, has other uses. It imparts a molten effect on the liquid steel,which is thereby stirred and mixed and heated more homogeneously.This stirring effect is inversely proportional to the frequency of thefurnace and so that furnace frequency is selected in accordance withthe purpose for which the furnace will be utilized.






The melting continues will all the charge is melted and the bathdevelops a convex surface. However, as the convex surface is notfavorable to slag treatment, the power input is then naturallydecreased to flatten the convexity and to reduce the circulation ratewhen refining under a reducing slag. The reduced flow of the liquidmetal accelerates the purification reactions by constantly bringingnew metal into close contact with the slag. Before the actual reductionof steel is done, the liquid steel which might contain some trappedoxygen is first treated with some suitable deoxidizer. When nopurification is attempted, the chief metallurgical advantages of theprocess attributable to the stirring action are uniformity of theproduct, control over the super heat temperature and the opportunityafforded by the conditions of the melt to control de-oxidation throughproper addition.

As soon as the charge has melted clear and de-oxidising ions haveceased, any objectionable slag is skimmed off, and the necessaryalloying elements are added. When these additives have melted anddiffused through the bath of the power input may be increased tobring the temperature of metal up to the point most desirable forpouring. The current is then turned off and the furnace is tilted forpouring into a ladle. As soon as pouring has ceased, any slag adheringto the wall of the crucible is crapped out and the furnace is readied forcharging again.

As the furnace is equipped with a higher cover over the crucible verylittle oxidation occurs during melting. Such a cover also serves toprevent cooling by radiation from the surface heat loss and protectingthe metal is unnecessary, though slags are used in special cases.Another advantage of the induction furnace is that there is hardly anymelting loss compared with the arc furnace.

CONTINUOUS CASTING MAGHINEThe molten steel from the IF is cast in a continuous casting machineto produce billets.

The process is continuous because liquid steel is continuously pouredinto a ‘bottomless’ mould at the same rate as a continuous steelcasting is extracted.






1) Before casting begins a dummy bar is used to close the bottom ofthe mould.

2) A ladle of molten steel is lifted above the casting machine and ahole in the bottom of the ladle is opened, allowing the liquid steel topour into the mould to form the required shape.

3) As the steel’s outer surface solidifies in the mould, the dummy baris slowly withdrawn through the machine, pulling the steel with it.

4) Water sprays along the machine to cool/ solidify the steel.

5) At the end of the machine, the steel is cut to the required length byon line PLC based hot shearing machine.

6) After cut, billet will directly go to market.

6.3 ELECTRIC ARC FURNACE

The company has decided to install 1x30T Electric Arc Furnace toproduce 1,95,000 TPA billets (1,98,000 TPA Liquid steel). In ElectricArc Furnaces, the electric energy is used to form an electric arc whichheats the metal by radiant heat evolved. This can be further sub-divided as: Direct Arc Furnace: Electric arcs are formed between the electrodesand metal being heated, which is thus a component of the electriccircuit and is heated by radiation from the arcs. They are used insteel making.

Submerged Arc Furnace: The arcsburn under a cover of solid chargewhich surrounds the electrodes.These are mostly used for oresmelting operations, in particularfor making Ferro-alloys.

A Modern EAF Schematic Diagram






An EAF is a furnace that heats charged material by means of anelectric arc. They range in size from small units of approximately onetonne capacity (used in foundries for producing cast iron products) upto about 400 tonne units used for secondary steel making. Arcfurnaces used in research laboratories and by dentists may have acapacity of only a few dozen grams. EAF temperatures can be up to1,800oC.

The furnace has a steel shell in the form of a tapered cylinder with aspherical bottom. The shell has a refractory lining inside. The reactionchamber of the furnace is covered from above by a removable roofmade of refractory bricks held by a roof ring. The furnace has a maincharging door and a tap hole with tapping spout. It is fed with a threephase alternating current and has three electrodes fastened inelectrode clamps which are connected by means of a sleeve with amovable electrode stand. Current is supplied via water cooled flexiblecables and water cooled copper tubes. The furnace rests upon twosupport sectors which can roll on the furnace stand to tilt the furnacetowards the main door and towards the tap hole for tapping, the tiltingmotion being affected by a rack mechanism.

The furnace is charged from the top by means of a pan. To open thereaction chamber for charging, the furnace roof which is suspendedfrom chains is raised up to the gantry. The latter together with the roofand electrodes, can be swung towards the tapping spout. A rotatingmechanism is provided to rotate the furnace shell through an angle of40 degrees in both directions from the normal position. The furnacealso has an electromagnetic stirring device for intermixing of moltenmetal.

Although electricity provides most of the energy for EAF steel making,supplemental heating from oxy-fuel and oxygen injection is used. Themajor advantage of EAF steel making is that it does not require molteniron supply. By eliminating the need for blast furnaces and associatedplant processes like coke oven batteries, EAF technology has facilitatedthe proliferation of mini-mills, which can operate economically at asmaller scale than larger integrated steel making. EAF steel makingcan use a wide range of scrap types, as well as DRI and molten iron(up to 70%). This recycling saves virgin raw materials and the energyrequired for converting them. The EAF operates as a batch melting






process, producing heats of molten steel with tap-to- tap times formodern furnaces of less than 60 minutes.

Arc furnace processSteel in arc furnace may be refined with or without oxidation.Oxidation may be dispensed where the metal ingredients of the chargeare close to the desired steel grade in analysis. In such case, areducing slag is used both in melting and refining (single refining orsingle slag practice). Usually, this process is used to smelt alloy wastesto alloy steel. In working with oxidation, the charge is melted andrefined under an oxidizing slag or ‘black slag’ (the slag is called ‘black’due to the colour it is given by the iron oxide), removing phosphorousand/or carbon almost completely; then the ‘black slag’ is removed anda reducing or ‘white slag’ containing lime, fluorspar, silica, carbonand/or ferrosilicon made up, giving a very high degree ofdesulphurization and good de-oxidation. Additions of the requiredferroalloys are made during this stage, or sometimes to the ladle.

The principal processes in the oxidizing period arei) Removal of phosphorousii) Oxidation of silicon and manganeseiii) Removal of sulphuriv) Removal of nitrogen and hydrogen,v) Removal of non-metallic inclusions,vi) Heating of the metal,vii) Reboil andviii) Carbonization of metal.

A modern development in arc furnace practice is the use of an oxygenlance for injecting high pressure oxygen into the bath, during theoxidation period. This removes carbon more rapidly than by ore alone.Lancing does not need an arc for heating. The use of oxygen lance hasspecial advantage in the manufacture of stainless steel. If oxygen isblown into the metal, exothermic reactions prevail in the bath, themetal is heated up quickly, and it is possible to switch off the currentas soon as the carbon begins to burn intensively.






The aims of the reducing period during the melt in a basic EAF are:

i) De-oxidation of the metalii) Removal of sulphur,iii) Adjustment of the steel composition to specifications,iv) Control of the bath temperature, andv) Preparation of well oxidized free running highly basic slag, which

can be used for off-furnace treatment of the metal in the ladle.

The reducing period can be shortened considerably if the metal istreated with argon or synthetic slag or deoxidized in the ladle.

6.4 GALVANISING PLANT

The company is planned to set up the Continuous Galvanising Line ofcapacity 10,000 TPA for production of galvanised (Zinc coated) Strips& Structural as a finished product.

Galvanizing consists of coating steel with zinc in order to protect itfrom corrosion. Before steel strips & Structural can be galvanized,they undergo a pre-treatment in order to ensure that the materials arefree from any surface oxides as they enter the molten zinc coatingBath. This is done by removing the oil from the materials (in thedegreasing unit) and then removing the rust from the surface (in thepickling unit).

The materials are then dipped into a zinc bath (450°C to 460°C) to begalvanized. The melting zinc on the strip surface will be cooled andsolidified through air cooling in the cooling tower.

Finally the galvanised product are dipped into a water quenching tankin order to further cool the sheets from about 150°C to 40°C.

It is possible to make galvanised steel more durable by chromating it.Approximately 50% of the galvanised steel production output willreceive chromate passivation treatment after quenching: thegalvanised steel sheets will be sprayed with a chrome solution.

After galvanizing and chromating, the steel sheets are cut to achievethe desired coil size and weight and transported to the storage yard.






The process flow diagram below illustrates the main stages of thegalvanizing process, and indicates the major inputs and outputs, aswell as the resulting effluent and atmospheric emissions.

6.5 CAPTIVE POWER PLANT

The company intends to set up a Captive Power Plant of 26 MWcapacity (out of which 16.0 MW will be based on WHRB Boiler utilizingwaste heat, generated from the DRI plant and 10.0 MW based onAFBC Boiler utilizing dolo-char, generated from the proposed DRIplant & imported coal).

Waste Heat Recovery Boiler will be installed behind the ABC ofproposed DRI kilns in bypass configuration. The flue gases after ABCwill be taken to unifired furnace chamber and then flow over banks ofsuper heater, convective evaporator and economizer before beingdischarged to atmosphere through ESP, ID fan and stack. In theproposed Fluidized Bed Combustion (FBC) boiler envisaged,combustion of fuel particles is achieved in suspension with an inertaggregate i.e. sand. Combustion air will be fed through air nozzlesfrom underneath into the sand fuel bed. Oil burner will be providedfor start-up and low load flame stabilization. The fuel proposed in FBCBoiler dolochar. The flue gases will pass over various heat transfer

PROCESS FLOW DIAGRAM FOR PROPOSED GALVANIZING PLANT






surfaces to ESP and then finally discharged into chimney by ID fan.Condensate extraction pumps will pump the condensate aftercondenser of STG to a common de-aerator. Feed water from the de-aerator will be pumped to the waste heat recovery boiler as well asFBC boiler by boiler feed pumps. The steam generated from both theWaste Heat Recovery boilers and CFBC boilers will drive the steamturbine through a common steam header.

Brief Description of Major Plant and Equipment

The proposed plant will comprise the following major systems: Fluidized bed combustion boiler with auxiliaries Steam turbine generator and auxiliaries De-aerator and feed water system Electrical systems Instrumentation and controls Compressed air system (service air and instrument air) Handling & hoisting facilities Plant communication system Ventilation and air conditioning Fire-fighting detection & alarm system

Waste Heat Recovery Boiler (WHRB)

After burning chamber (ABC) and Dust settling chamber (DSC) will belocated at the exit of DRI Kilns. Part of the dust carried by the wastegases will settle down at DSC. The DSC and ABC assembly will beconnected to the DRI Plant Kiln through refractory lined duct.

The combustibles in the waste gases are burnt in the After BurningChamber which will raise the waste gas temperature thus making thewaste gases free from carbon mono-oxide. Provision for spraying waterwill be made to control the temperature if required. From ABC outletthe WHRB will be connected through a refractory lined duct. Anemergency stack cap on the top of ABC will be provided for divertingthe waste gases to atmosphere when WHRB is under shutdown orbreak down. The boiler will be complete with evaporator steam drum,mud drum, bank of super heaters, economizer, atemperator, air fans,ESP, internal piping etc. Soot blowing and super heater atemperationsystem will be also provided. Boiler will be provided with blow downtanks (IBD, CBD etc), sample cooler.






Flue gas cleaning systemThe exhaust gases will be discharged from boiler to ESP and then intothe atmosphere through induced Draft fan and chimney. The pressuredrop in the boiler ducts and ESP will be kept to match with therequirement of ID fan. The boiler will be of semi out door type with aweather canopy and side covering of trapeze corrugated steel sheets orother suitable materials as available.

The gases passing out of WHRB will be passed through one multi-fieldElectrostatic Precipitator before escaping the gas, having hugequantity of dust particles, into the atmosphere. The ESP will beinstalled between the WHRB and the stack. The dust content in gasdown-stream of ESP shall be limited to 30 mg/Nm3. The ESP Unit willbe provided with transformers, rectifier and controls. The dustparticles will be collected below ESP in hoppers and conveyed bymeans of conveyors or pneumatically and stored in silos. This will besubsequently disposed by trucks.

AFBC BOILERIt is planned to install an 10.0 MW capacity captive power plant basedon AFBC Boiler, utilizing dolo-char, generated from the proposed DRIPlant. The AFBC boiler plant shall comprise of boiler and itsauxiliaries.

The BoilerBoiler will be completed with evaporated steam drum, mud drum,bank of super heater. Attemperation system will be also provided.Boiler will be provided with blow down tanks (IBD, CBD etc), samplecooler. The exhaust gases will be discharged from boiler to ESP andthen into the atmosphere through 1x100% induced Draft fan andchimney.

Steam Turbine generator:The board description of the steam turbine generator envisaged isindicated below:

The Steam turbine will be single, Horizontal, Singled bleed condensingtype. The set shall be complete with gear box, Barring gear box,condenser, air evacuation system condensate extract pumps,generator cooling systems, gland sealing with gland vent condenserand lube oil system. Condensing steam turbine generator with inletsteam parameter of 66 ata and 4655°C at emergency steam valveinlet is provided.






Conversion of Heat Energy in Steam to Mechanical work will be doneby expanding the same in Steam Turbine which shall providemechanical energy in the form of rotational torque. Steam whilepassing through various stages of Turbine will release both pressureand temperature and ultimately dumped to Condenser at nearvacuum condition. Low pressure steam will be condensed by Air in AirCooled Condenser. Condensed Water from the Air Cooled Condenserwill be fed back to Boiler through Air Ejector, Gland Steam Condenserand De-aerator for re-generative heating and air removal. Boiler FeedPump shall take suction from Deaerator and feed deaerated water toBoiler Economiser.

Deaerator and feed water system:There will be a deaerator with feed tank. 2 numbers boiler feed waterpumps with motors (1 working + 1 stand by) shall be provided alongwith common suction header, auto recirculation valve,suction/discharge valve, non-return valve, pressure gauge,temperature gauge etc.

Electrics:The electrics include generators, transformers, switchgear – main andauxiliary, battery room etc.

Instrumentation & Control:Effective control and measurement of process parameters along withdata acquisition system in the control room has been envisaged.

Auxiliary Services:Auxiliary service systems such as ash handling, EOT crane,telecommunication, air conditioning and ventilation shall beadequately envisaged.

Ash Handling:Ash handling plant system would be designed.The fly ash from theproposed boilers will be collected in economizer hoppers, air heaterhoppers, ESP hoppers and will be conveyed through dense phasepneumatic conveying system to silo. The fly ash to be disposed fromthe silo will be moistened to reduce the dust while collecting the ash.The system will be provided with telescopic chute and rotary feeder forloading the ash into covered trucks.

Bottom Ash:Bottom ash from proposed boilers will be carried through asubmerged belt conveyor to silo. From Silo it will be disposed to ash






dump area in covered trucks in moistened condition. Further itwill be used for Road Construction and land filling purposes.

7.0 WATER DEMANDAs per an initial estimate, water to the tune of 515 cu.m/day will berequired for the proposed expansion project. The raw water will besourced from borewells.

Raw water treatment plant will be installed for pre-treatment of rawwater and the clarified water will be pumped through MS pipeline tothe proposed units.

The estimated unit wise make up water requirement for the proposedas well as existing units are given below:

Sl. No. DescriptionDaily waterDemand

(in cu.m/day)1. Sponge Iron Plant

(2x350 TPD)100.0

2. Steel Melting Shop(Induction Furnaces (2x20 T & 2x16.5 T) +Electric Arc Furnace (1x30 T) Ladle Furnaces+ Continuous Billet Caster)

70.0

3. Continuous Galvanising Line 5.004. Captive Power Plant (26 MW) 320.05. Domestic (440 persons) 20.0

TOTAL 515.0

Drinking water systemRaw water after necessary clarification and filtration through gravityfilter will be disinfected and stored in the drinking water storage tankand will be pumped to an overhead tank. Drinking water from thisoverhead tank will be supplied to various consumers of the steel plantby means of a piping network, completed with valves, fittings andappurtenances.

Fire fighting water systemThe fire fighting water network will be provided with adequate numberof yard hydrants and in-shop landing valves to combat fire hazards inthe plant.

To ensure availability of water at designed pressure for fire fighting,electric motor driven and standby diesel engine driven pump sets willbe provided. Main electrical driven fire fighting pumps and diesel






engines driven standby fire fighting pumps will be provided forfirefighting purpose. In case of fire, the main firefighting pump willpump firefighting water to the hydrants. An independent pipingnetwork will be provided complete with pipelines, valves, hydrants,fittings and appurtenances for the said purpose.

8.0 POWERThe estimated power requirement of the proposed unit is around 49.5MW. The power required for the proposed plant will be sourced fromproposed 26 MW CPP and rest from Damodar Valley Corporation (DVC)supply. The unit wise power requirement for the proposed project is asfollows:

Sl.No. Description

PowerConsumption

(in MW)1. Sponge Iron Plant

(2x350 TPD)4.0

2. Steel Melting Shop(Induction Furnaces (2x20 T & 2x16.5 T) +Electric Arc Furnace (1x30 T) Ladle Furnaces+ Continuous Billet Caster

40.0

3. Continuous Galvanising Line 1.04. Captive Power Plant (26 MW) 2.55. Auxiliary & other loads 2.0

TOTAL 49.5

9.0 PLANT GENERAL LAYOUTThe plant general layout has been designed to provide a rationaldisposition of production facilities, material logistics facilities,auxiliary & ancillary facilities and plant utilities & services. The layouthas been developed in such a way that future expansion &diversification may be readily feasible. A properly designed layout isobviously essential for operational efficiency, plant economy andsaving of capital cost.

In developing the plant general layout, the factors which have beentaken into consideration for appropriate flow of process materials areindicated below:

i) Economical and uninterrupted receipt of major incomingmaterials, in plant movement of molten metal without hindrance






and minimum counter-flow of materials particularly inside theproduction shop in which major equipment is located.

ii) Logical locational arrangement of the proposed Units, supportingfacilities, plant services and ancillary facilities so as to ensureminimum capital and operating costs.

iii) Compactness of the plant layout minimizing inter plant buildingfor processing materials as well as adequate scope for futureexpansion.

iv) Maximum utilization of the available facilities / services.

A plant Layout of the proposed steel plant is presented in Figure-3.0.

10.0 QUALITY ASSURANCEThe process of developing the required quality in the manufacturedproduct transcends beyond the routine quality control measures andsystems. Towards this, quality is conceptually imagined and built intothe practical operations at the following steps.

QUALITYA. Pre-order stageB. Post Order stageC. Process design stageD. Raw material acceptanceE. Finished product testingF. Packaging and transportation

Needless to mention that quality assurance of a company is asustained effort in amalgamating the quality at all the above stagessuccessfully in such a way that there is a synergy in production,planning, manufacturing and testing – all meeting the customer need.

Quality assurance is an effective culmination of documentation,formats, measurement standards and methods, testing procedures,sampling and maintenance of plant data and records. Above all, theinvolvement of the personnel of the organization coupled with theright automization of the process is extremely important.






Quality System:The pre-order quality system basically comprises of formats anddocuments for making techno commercial offers, ably supported by adetailed application study and a good costing system. The idea offormalizing a pr-order quality system is to respond to the customer’squeries with a minimum lapse of time besides giving adequateproduct information to the customer. The various pre-order bids ofdifferent applications over a period of time shall be logged into thecomputer data for onward response.

The post order quality system refers to those formats and procedures,which effectively translates a customer’s purchase order. Techno –commercial requirements into a meaningful work order for onwardprocessing by the production, QA, Sales, commercial and otherconcerned department.

Process Quality:

The system starts with the assessment of the quality required by thecustomer and the quantity as well as the delivery period. This istranslated into a viable production planning, keeping in mind the plantcapacity availability, raw material inventory.

The raw materials which are coming as feed to the plant need to beassessed before acceptance and all incoming materials including allchemicals will be analyzed for, purity and chemistry.

Only the accepted and lab tested final product is packed inappropriate quantities for shipment to the final customer.

All the data so generated in the entire process stated above is loggedinto an online information system (QIS: Quality Information System)and monitored from time to time.To carry out the in line process andfinal product testing, a complete analysis of required parameters ofthe final Products is maintained under appropriate classification.

Process ControlThe monitoring of process parameters such as consistency,

freeness, temperature, pH, machine speed and several othervariables form the key controlling indicators of the production system.






These indicators are regularly monitored and analyzed in the lab forthe aid of the shop floor personnel in fine-tuning their operations.

Future thrust area:The company shall place a string emphasis on “ Total QualityManagement” (TQM) in order to bring process orientation amongst itsemployees rather than just result orientation.

The company places a great deal of importance to make “QUALITY’ away of living in M/s N. N. Ispat Private Limited. This shall enable thecompany to conceptualize, develop and install appropriate qualitysystems in all phases of its operations, ably supported by the rightdocumentation and information systems. These systems shallultimately benefit the customer.

11.0 ENVIRONMENT CONTROL

M/s N. N. Ispat Private Limited thrust for productivity shall be inharmony with its concern for a cleaner environment. Special attentionhas been given to the development of the plant in respect to creatingan eco-friendly design based on modern technology in all respects,which is for water, air and solid controls in the plant.

Water Control

All tanks, pits etc. shall be bottom sealed to avoid undergroundwater pollution due to percolation or seepage.

Extensive recycling has been adopted in the design of plantwater systems. Quality of circulating water will be maintainedthrough dosing of conditioning chemicals for controllingcorrosion, scale deposit and microbial growth. Treatedwastewater will be re-used in the plant. As such, the plant willadopt zero discharge concept.






Air Pollution Control:

Probable Pollution Sources Mitigation Measures

DRI Plant

Raw Material Handling System for DRI Plant Bag Filter

DRI Kiln off Gases ESPSteel Melting Shops (SMS)

Fumes from Furnaces (IF/EAF/LRF) Bag Filter

Captive Power Plant

Unloading of Raw Material Sprinkler / Fogging / Mist

Raw Material Handling System for Power Plant Bag Filter

Boiler Flue Gases ESP

Electrostatic Precipitator (ESP)






The discharge of flue gases from chimney shall confirm to thenorms of State Pollution Control Board.

Sound/Noise pollution

All the equipment, machineries and instruments are beingprocured from the reputed manufacturers whose products aremanufactured as per the National and International Norms andStandards. Further all are BIS (ISI) marked. As per the abovestandards and norms, the noise level would be maintainedbetween the stipulated standards of the concerned body.

Solid Waste Handling

Induction Furnaces / Electric Arc Furnace slag will be used asland filling / road construction purpose.

End cuts, scales, scraps from the CCM will be used in theInduction Furnaces.

Dolochar from Sponge iron plant will be used in AFBC Boiler. Fly ash from CPP will be used as a raw material for cement

production / brick manufacturing in the neighbourhood. Bottom ash from CPP will be used for land filling / road

construction purpose.






12.0 CONTROL OF FUGITIVE EMISSIONS AT VARIOUSAUXILIARY FACILITIES INSIDE THE PLANT

The fugitive emissions emanating from tapping point of SMS will becontrolled by high efficiency Bag Filters.

There will be Dust Suppression Systems to control fugitiveemissions at raw materials handling section.

Fugitive dust emissions from the areas like raw materialsstockpile, raw materials unloading and loading points, rawmaterials spillages from the conveyor system etc. will be arrestedby Dry Fogging (DF).

Water sprinkling system on the stockpiles, plant roads and othersarea will be maintained.

13.0 FIRE PROTECTION SYSTEMIn addition to the yard fire hydrant system, the fire protection systemsenvisaged for the plant are as follows:

- Internal fire hydrant for storied buildings to be tapped-off fromthe outdoor fire water header.

- Fire detection and alarm system for electrical rooms, cablebasements/cellars, cable tunnels, selected oil/hydraulic cellars.

- Portable fire extinguishers such as CO2, foam and dry chemicalpowder in all areas of the plant with fire hazard.

14.0 GREEN BELT DEVELOPMENT

The proposed expansion project will be installed on the available landwithin the existing plant premises, comprising of total 8.38 hectares(20.7 acres) as well on the additional land of total 10.24 hectares (25.3acres) adjoining the existing plant premises. Thus, total land will be18.62 hectares (46 Acres).

Trees filter particulates and are effective as sink of pollutants. Treealso reduces noise level and regulates the oxygen balance in the areaby consuming released carbon dioxide. Hence, green developmentshall be part of pollution control measure adopted in the open spacesin the plant area.






In order to enhance land use as well as to compensate for any loss inecology during construction, adequate plantation programmes in andaround the project site have been planned and shall be adopted withplantation of adequate number of trees.

Considering the need of open space for fire fighting and safetyrequirement, greenbelt has been planned along the periphery inaddition to small patches of green area in the unutilized open space,roadside tree plantation and grass lawns. The peripheral green beltvaries in width to suit the plant design requirement. The greenery isshown in the plant layout (refer Figure-3.0).

Green belt development shall be taken up starting from theconstruction phase of the proposed project.

15.0 MANPOWER REQUIREMENTOperation and maintenance of proposed plant require humanresources in different categories like managers, engineers of differentdiscipline like metallurgical, mechanical, electrical, electronics,computer, civil, structural, chemical, etc., highly skilled, skilled andsemi-skilled work force in different disciplines, commercial,accountants and financial managers, unskilled labour force, clerical,security personal, etc.

Factory human resourcesIn order to operate and maintain the plant facilities, including itstechnical and general administration needs, the estimated manpowerrequirement for the proposed project has been estimated to be 440persons.

The above estimate covers the top management, middle and juniorlevel executives and other supporting staff.

16.0 PROJECT PERIODThe installation of several production units along with utilities andservices require co-operation for procurement of equipment, equipmentfoundations, award of all contracts and supervision of all constructionjobs at plant site. The factors which are responsible for timelyimplementation of the project are:






i) Arrangement of proper finance for the project.ii) Finalization of layout of the proposed plant.iii) Design of utilities and services.iv) Placement of orders for plant and machinery.v) Arrangements for Govt. sanctions and supply of power.vi) Recruitment of personnel.

As per an initial estimate around 30 months will be needed forimplementation of the project.

17.0 ESTIMATED COST

As per initial estimate, the cost of the project works out to aroundRs. 138 Crores.

pre-feasibility reportenvironmentclearance.nic.in/writereaddata/online/tor/10...project proponent n....

Documents