plant layout - vsl steelssinter plant (under construction) 33 m2 blast furnace of 262 cubic meters...
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VSL STEELS LTD.
Plant Layout
VSL Steels Ltd.
VSL Steels Ltd is Flagship Company of VSL Group ( V S Lad &
Sons), the pioneer in Iron ore mining and one of the oldest mining
companies in the State of Karnataka. VSL Group, in its endeavour
to expand its business, is delighted to be part of the Core Iron &
Steel Industry.
We have established a Pig Iron Plant in the name of V.S.L. Steels
Ltd. in Paramenahally Village, Hiriyur Taluk, Chitradurga District,
Karnataka State capable of producing about 1.5 Lakh (0.15
Million) M.T. of Pig Iron per annum. V.S.L. Steels has a Mini
Blast Furnace of 262 M3 capacity, designed / technology by
MECON Ltd. The commercial production was started in January,
2007.
Major Facilities
Blast Furnace
262 M3
( Useful Volume) with
2 Nos. of PCM & SGP
Power Plant
( B F Gas Based)4 MW
Coke Oven Plant 100 MT / Day
Sinter Plant
(Under Construction)33 M2
BLAST FURNACE OF 262 CUBIC METERS
TAP HOLE DRILLING TO TAKE OUT HOT METAL
LANCING OF TAP HOLE
SHIFTING OF HOT METAL BY LRS CRANE
HOT METAL POURED IN TO THE PIG CASTING
MACHINE TO PRODUCE PIG IRON
CLOSING OF TAP HOLE BY MUD GUN MACHINE
BLAST FURNACE DETAILS :
Description Unit Value
Blast Furnace No 1
Volume M3 262
Productivity T/M3 ~ 2.0
HM Production Tons / Day 500
Coke Rate Kg/thm 650
Slag Rate Kg/thm 250
Slag Basicity CaO/SiO2 0.95
Hot Blast Temp. Centigrade 1000
Highlights of Blast Furnace Performance
Highest Hot Metal
Production519 MT (12th Feb 2010)
Lowest Coke Rate
( Net & Dry )593 Kg/THM ( 2nd Jul 2009 )
Highest Monthly Hot Metal
Production14,684 MT ( Jan – 2010 )
Highest Productivity 2.26 T/M3
Sl.
No.Material
No of
Bins
Effective
Volume
(cum)
Total Storage
Capacity in
Hours
1 Coke 2 140 12
2 Iron Ore 2 140 20
3 Nut Coke 1 110 80
4 Limestone 1 35 25
5 Dolomite 1 35 40
6 Quartzite 1 35 60
7 Manganese Ore 1 35 150
No. of Stoves 3 Nos.
Shell Height 28 M
Shell Diameter 5.3 M
Dome
Temperature1250 Deg. Cent.
Checker hole
diameter40 mm
Burner type Ceramic
Cold Blast
pressure1.5 Kg/cm2
Waste gas
Temperature350 Deg. Cent.
Hot Blast
Temperature1000 Deg. Cent.
HOT BLAST STOVE DETAILS
GAS CLEANING PLANT-THERMAX LTD
Gas volume at inlet 64000 nm3/hr
Gas pressure
at inlet4000 mmwc
Gas Inlet
Temperature300Deg
Gas out let
Temperature50 Deg mm
Dust content at
inlet10 gm/m3
Dust content at
outlet5 mg/m3
Water requirement
(Circulation)150 m3/hr
StagePressure
( mmwc )
Volume
( m3/sec )
1st 2300 8.25
2nd 4945 9.29
3rd 7985 10.5
4th 11425 11.99
5th 15275 13.57
SLAG GRANULATION PLANT
Slag Tapped per
day125 MT Approx.
Slag Flow Rate 1.5 – 3.0 T / min
Water Flow
( Circulation )450 m3/hr
Water Pressure 3.0 kg /Cm2
Special Features of Blast Furnace
1.RTDs:Resistance temperature detectors (RTDs) fixed in all tuyers inlet and outlet for quick judgment of performance of tuyers.
2. Thermocouples( Below the Tuyers):
Total 10 thermocouples fixed below each of the tuyers(to know the condition of the tuyers)
PACKAGE BOILER DETAILS
Make Thermax
Capacity 3 TPH
Working
Pressure15 kg/Cm2
TypeFire Tube
Boiler
CRANE & PCM Details
LRS Cranes Details:
1. M/s. Mukand Ltd.,
Capacity: 50/20 T
2. M/s. Globe Engineering
Capacity: 50/20 T
PCM Details:
1. M/s. METCO EngineeringCapacity: 500 T/Day No. of Moulds: 250Chain Length: 35 MtrSpeed: 6 – 12 Mtr/Min
2. M/s. METCO EngineeringCapacity: 500 T/Day No. of Moulds: 250Chain Length: 35 MtrSpeed: 6 – 12 Mtr / Min
With Ladle Hydraulic Tilting Device
CAPTIVE POWER PLANT - 4 MW
BOILER
MakeThermax
Babcock Wilcox
TypeBF Gas & Oil
Fired
Capacity 22 T/hr
Hydraulic test pressure
79.5 kg/cm2
Steam outlet pressure
44 kg/cm2
Steam outlet temperature
440 Deg. Cent.
TURBINE DETAILS
Make Triveni
Year of Mfg 2006
Power 4500 kw
Turbine gear boxTriveniGears
Gear ratio 5.519
Make BHEL
TypeSynchronous
Generator
Voltage 3.3 KV
RPM 1500
Capacity 4 .0 MW
ALTERNATOR
Air Cooled Condenser
Make Paharpur Ltd
Type Air Cooled
Fan Diameter
9.14 Mtr
Fan Speed 114 RPM
DG SET DETAILS
1. MAN B & W DG Set
Alternator
AVK Make, 11 KV, 750
RPM, 3.8 MW
2. Pilistick DG Set
Alternator
TDPS Make, 3.3 KV,
500 RPM, 2.5 MW
100 MT PER DAY COKE OVEN PLANT
SINTER PLANT
Capacity - 33 M2
Supplier – SSIT (China)
Type - Circular
Production/hr. - 59.40 T/hr.
Productivity - 1.80 T/M2/hr.
SINTER PLANT UNDER CONSTRUCTION
SINTER PLANT UNDER CONSTRUCTION
WATER RESERVOIR
We have created artificial lake in an area of about 25 Acres for
Rain Water Harvesting and recharging of Bore wells.
WATER RESERVOIR
Quality Assurance Lab
VSL Steels has setup a Quality Assurance Lab with modern
equipment along with well qualified staff. Raw materials are
checked to ensure their quality by the applicable Indian Standards
(IS) Methods. The Pig Iron produced is checked for its quality by an
Optical Emission Spectrometer. As the analysis reports are given
instantaneously by Spectrometer, it helps the Operation department
to take immediate corrective actions so as to control the quality of
Pig Iron being produced. The quality of Process Water and CPP
Water is checked by HATCH instrument.
VSL Steels Limited has been awarded ISO 9001:2008 & ISO
14001:2004 certificates by Perry Johnson Registers, INC.
Spectrometer
Quality Lab
Marketing
VSL Steels produces various grades of Pig Iron which are utilized by the foundry industry to produce
superior grade and high quality precision castings. We are catering to the needs of foundry industry
throughout India from Tamil Nadu to Punjab. Our quality is well accepted because of the consistency of
specification of the Pig Iron supplied.
Product Despatch:
Pig iron is analyzed by Spectrometer. Pig iron is heaped in batches according to the Heat Numbers
produced. Test certificates will be issued to every Heat produced indicating the grades of pig iron. Care is
taken to ensure that there is no mix-up of heaps.
We are moving our product by road and by rail. For Rail transhipment, the Pig Iron is first moved to
Chitradurga Railway Station, which is 55 Km, from our plant and there on to Customer destinations
through container rakes.
Pig Iron Specification:
The chart below depicts the various types of Pig Iron produced and their chemical composition. In addition
to standard specifications, VSL Steels can produce pig iron with chemical composition according to
customer needs.
PIG IRON LOADING INTO THE CONTAINER AT
RAILWAY STATION
VSL Steels Ltd plant location:
Nearest Town : Hiriyur - 10 Kms
Nearest Railway Station : Chitradurga - 55 Kms
Nearest Sea Port : New Mangalore Port – 325 Kms
Nearest Airport : Bangalore International AirPort – 170 Kms
Nearest State Highway : SH 19 – 1Kms
Nearest National Highway : NH 4 – 10Kms
Karnataka Industrial Areas Development Board (KIADB) Land : 99 Acres and 5 Guntas(Paramenehalli & Doddaghata Village,Hiriyur Taluk,Chitradurga)
Power Sanction : 5000 KVA from 66 KV State Grid (Hindusghatta Sub -Station,Hiriyur Taluk)
Water : Permission to use ground water of 1260 Cubic Meters per day and to draw 1 Lakh Cubic Meters per of water from Vedavathi River bed per annum.
Present Water consumption including domestic is 600 M3 / Day.
OTHER DETAILS RELATED TO PLANT
WATER SOURCES
1. Ground Water : a. Borewells within the Plant Area – 12 Nos,
( We can draw approx 500 M3/Day)b. Borewells in Farm House – 11 Nos,
( We can draw approx 800 M3/Day)
2. River Bed:We have permission to draw 1,00,000 M3 / Annum.
3. Rain Water Harvesting (Artificial Lake) 25 Acres Area:Presently we can collect and store 2,00,000 M3 of Runoff water during rainy season from catchment area of 900 acres. Holding / storage of water can be increased upto 4,00,000 M3 with further excavation
MAP SHOWING LOCATION OF BOREWELLS
Water Pipeline Route
Iron ore:a) Chitradurga District Mines (Sesa Goa,Mineral Enterprises ,R.Praveenchandra ) .These mines are about 60 Kms from the plant.
b) Tumkur District Mines (Balaji Produce, Tumkur Minerals etc) .These mines are about 50 to 70 Kms form the plant.
c) Bellary District Mines (NMDC ,SMIORE,Mysore Minerals Ltd,B.Kumar Gowda,MSPL,VESCO,SKME,Tiffins Baryets , etc . These mines are about 150 to 170 Kms from the plant.
LAM Coke: Import: Nearest Sea port: New Mangalore -325 Kms from the plant.
Domestic:Sl.No. Plant Name & Place Prod. Capacity ( MT/Monthly)Approx. Dist. From Plant1 Sathavana Ispat Pvt. Ltd., Bellary 30000 175 KM2 Gujarat NRE Coke, Dharwad 20000 300 KM3 Basudha Udyog Pvt. Ltd., Chennai 10000 550 KM4 Bhatia Coke Pvt. Ltd., Chennai 12000 550 KM5 SESA ( Sterlite ) Goa, Goa 50000 450 KM6 S F L, Mundra / Porbander, Gujarat 100000 1700 KM
All other flux (Lime Stone,Dolomite,Quartz & Manganese)
All the flux are available in Chitradurga & Tumkur district and the distance from the plant to the source is about 50 to 80 Kms.
RAW MATERIAL SOURCE
Land Details
❖ KIADB land : 99-05 Acres (Paramanahalli &
Doddaghatta Village,
Hiriyur Taluk, Chitradurga)
❖ Agriculture land adjacent to plant : 45-24 Acres (DoddaghattaVillage, Hiriyur
Taluk, Chitradurga)
❖ Agriculture land adjacent to SH-19 : 15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga)
UDUVALLI - GUEST HOUSE
15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga)
VSL Steels Ltd
(Details of Water, Land ,Railway Line and
Iron ore for expansion)
Water :
Details of Upper Bhadra Project,Karnataka.
29.90 TMC of Water to District of Chikkamagalore,Tumukr,Davangere & Chitrdurga Districts for irrigation ofabout 2,25 Lakhs Hectares..
According to the proposal, the Upper Bhadra lift Irrigation Scheme envisages lifting of 17.40 TMC of waterin Stage-I from Tunga river to existing Bhadra reservoir and lifting of 29.90 TMC of water in Stage-II fromBhadra reservoir to tunnel near Ajjampura in Tungabhadra sub-basin of Krishna basin. After tunnel, throughChitradurga Branch Canal and Tumkur Branch Canal, it is planned to irrigate 2,25,515 ha area by dripirrigation in the districts of Chikkamagalur, Chitradurga, Tumkur and Davanagere. This water would also fillup 367 tanks (157 through Chitradurga Branch Canal and 131 throughTumukurubranch).
Out of 29.90 TMC of water, 19.04 TMC of water is earmarked for irrigation and remaining 10.86 TMC isallocated for filling of 367 minor irrigation tanks. The entire water distribution will be automated andcontrolled by SCADA system. About 787 villages are likely to be benefitted under this project. The proposedproject requires 2,114 ha area land for construction of main canal and delivery chambers.
The project as per plan will have to complete by December 2017 and we expect about 6 months delay incompleting the project.
29.90 TMC of water to 4 Districts (Chikkamoagalore,Chitradurga ,Tumkur and Davangere ) out 4 DistrictChitradurga will get maximum share 11.96 TMC (Chitradurga Branch Canal) and 2 TMC for feeding water toVani Vilas Sagar Dam.
The Vani Vilas Sagar Dam is about 8 Kms from our plant and the Dam has capacity of hold 30 TMC of waterbut due to number of check dam & lakes in the catchment area few TMC of water reaches Dam at present(about 2 TMC) once Upper Badhra Project is commissioned directly 2 TMC water will be feed to V V S Damand also additional water reaches Dam due to filling of water body (check dam/lakes) totally about 5 to 6 TMCwater will be available.,
Land for Expansion:
Adjacent to the existing plant/land we have identified additional land of about 153 Acres- 28 Guntas.
Part- I (Government land)
a) Sy No 33 Doddaghata Village : 52 Acres 05 Guntas
b) Sy No 36 Doddaghata Village : 33 Acres 03 Guntas
c) Sy No 37 Doddaghata Village : 06 Acres 19 Guntas
d) Sy No 27 (part ) at Paramanahalli Village : 13 Acres 17 Guntas
Total : 105 Acres 04 Guntas
Part-II (Private land )
a)Sy No 34 & 35 (Doddaghata Village) - : 45 Acres 24 Guntas
b)Sy No 198 Paramanahalli Village : 03 Acres
Total : 48 Acres 24 Guntas
Grand Total : 153 Acres 28 Guntas
Note : 40 Guntas is 1 Acre.
Railway Line :At present the nearest Railway line is about 55 Kms (Chitradurga City Station for Pig Iron loading)and 80 Kms (Amruthapura Station for Raw Material).
The proposed new Railway Line will be at about 8 Kms from the plant.
List of working mines
Permissible Production (MMT)
Sl. No Name of the Mining Lease Category ML. no Revised MPAP
1 VESCO A 2296 1.100
2 B. Kumara Gouda A 2516 1.260
3 SMIORE A 2580 1.600
4 Zeenath Transport Company A 2547 0.480
5 P. Balasubbasetty & Sons A 2502 0.480
6 V.N.K Menon A 2543 0.100
7 Lakshmi Minerals A 2551 0.066
8 Tiffin Barytes A 2293 0.560
9 Nadeem Minerals A 2526 0.410
10 Allum Prasanth A 2352 0.046
11 Sri GaviSiddeshwara A 2552 0.260
12 R.B.S.S.N A-1 2682 0.1013
13 Allum Prashant A-1 2289 0.090
14 VIOM (MSPL) B 2416 1.800
15 Hanumantha Rao B 2505 0.100
16 Iyli Gurunath Iron Ore Mine (RMML) B 2593 0.320
17 Chowgule & CO B 2546 0.380
Sl. No Name of the Mining Lease Category ML. no Revised MPAP
18 G G Bros B 2522 0.140
19 H R Gaviyappa B 2483 0.105
20 H.N Premkumar B 2538 0.070
21 Jaisingpur Iron Ore Mine ( Ashwathnarayan Singh)
B 2531 0.120
22 S.V Srinivasulu B 2604 0.100
23 Zeenath Trasport Company B 2239 0.180
24 GG Bros B 2586 0.036
25 Narayanpur Manganese & Iron Ore Mine B 1602 0.626
26 H.G Rangan Goud B 2549 0.114
27 SKME B 2141 0.426
28 NMDC-KIOM A 1111 6.000
28 NMDC-DIOM A 2396 6.000
30 MML - TIOM A 2605 0.650
31 MML - SIOM B 2629 0.410
Total (Bellary Dist.) 24.1303
32 Sri R. Praveen Chandra A 2294 0.750
33 Mineral Enterprises A 2346 0.570
34 Garudadhri Impex Pvt Ltd., B 2583 0.008
35 Sesa Goa B 2677 2.29
Total (Chitradurga & Tumkur Dist. ) 3.618
GRAND TOTAL 27.7483
Note : Revised Iron ore production permissible limit as on November 2017
Iron Ore production permissible limit
Hon'ble Supreme Court has allowed total of 35 Million MT per annum Iron ore
extraction from State of Karnataka.
a) Bellary District : 28 Million MT
b) Chitradurga & Tumkur District : 07 Million MT
PROPOSED EXPANSION PLANVSL Steels Ltd has expansion plan to produce 0.3 Million MT finished steel.
Proposed Expansion Plan:
a) Modernizing existing Blast Furnace to increase the volume from 262 M3 to 325 M3, by retro fitting modern
facilities such as installation of Stave coolers, Bell Less top, Pulverized Coal Injection, Oxygen Enrichment
of Hot Blast, Preheating of Gas, Etc.
b) Setting up Steel Plant to Produce 0.3 MTPA Finished Steel (Flats,Bars & Rods)
In order to sustain the viability of the industry in the present competitive market, VSL Steels Ltd managementis of the view that we have to expand our existing Pig Iron plant into 0.3 Million MT Steels plant bymodernization of Blast Furnace and adding Steel making and Rolling facilities at the present existing facilitiesat Paramenahally and Doddaghatta Village, Hiriyur Taluk, Chitradurga District in the land adjacent to existingfacilities.
Additional Investment (Project Cost) : Rs. 393.25 Crs
Additional Land for expansion : 153 Acres-28 Guntas
Additional Water source : 0.034 TMC from Vani Vilas Sagara Dam
Additional Power : 20.00 MW
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