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OF
PROPOSED EXPANSION PROJECT HAVING
Ferro Alloys Plant, Integrated Steel Plant,
Captive Power Plant & Cement Grinding Plant
IN
Village Nabagram, P.O.: Digha, Block: Neturia
Dist. Purulia, West Bengal
FOR
M/s Ispat Damodar Private LimitedM/s Ispat Damodar Private LimitedM/s Ispat Damodar Private LimitedM/s Ispat Damodar Private Limited 4444thththth Floor, 37, Shakespeare SaraniFloor, 37, Shakespeare SaraniFloor, 37, Shakespeare SaraniFloor, 37, Shakespeare Sarani
Kolkata, West Bengal; Kolkata, West Bengal; Kolkata, West Bengal; Kolkata, West Bengal; PINPINPINPIN ---- 700017700017700017700017
JANUARY 2017
PREPREPREPRE----FEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORT
Centre For Envotech and Management Consultancy Pvt. Ltd.
AN ISO: 9001: 2008 and BS OSHAS 18001: 2007 certified company,
Empanelled with OCCL, Govt. Of Odisha, OSPCB as Category “A” Consultant Organization,
Accredit ed b y NAB ET, Qual it y Counc i l of Ind ia f or EIA s tud ies
As Category “A” Consultant Organizat ion.
CONTENTS
Chapters Subject Page No.
1 Executive Summary 1-2
2 Introduction to the Project and Background Information 3-20
2.1 Identification of the Project 3-5
2.2 Brief Description of the Nature of the project 5
2.3 Need of the Project and Its Importance to the country and Region 5-10
2.4 Demand Supply Gap 11-18
2.5 Employment Generation 18
3 Project Description 19-96
3.1 Type of project including interlinked and interdependent project, if any 19-20
3.2 Location 20
3.3 Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental consideration gone into
should be highlighted
20-24
3.4 Size or Magnitude of Operation 25
3.5 Project Description with Process Details (a schematic diagram /flow
chart showing the project layout, components of the project etc.
should be given)
25-88
3.6 Raw Materials Required along with estimated quantity, likely source,
marketing area of final product/s, Mode of Transportation of raw
materials and Finished Product
89-99
4 Site Analysis 100-105
4.1 Connectivity 100
4.2 Land Form Land Use and Land Ownership 100-101
4.3 Topography (along with map) 101-104
4.4 Existing Infrastructure 104
4.5 Soil classification 104
4.6 Climate Data from secondary sources: Purulia Weather 105
4.7 Social Infrastructure Available 106-107
5 Planning Brief 108-109
5.1 Planning concept (type of industries, facilities, transportation, etc.)
Town and country planning/development authority classification
108-109
6 Proposed Infrastructure 110 - 111
6.1 Industrial Area (processing area) 110
6.2 Residential Area (non processing area) 110
6.3 Green belt 110
6.4 Social Infrastructure 110
6.5 Connectivity (Traffic & Transportation Road/Rail/Metro/Waterways etc.) 111
6.6 Drinking Water Management (Source & Supply of Water) 111
6.7 Sewerage System 111
6.8 Industrial Waste Management 111
6.9 Solid Waste Management 111
6.10 Power Requirement & Supply /Source 111
7 Rehabilitation and Resettlement (R & R) Plan 112
7.1 Policy to be adopted (central/state) in respect of the project affected
person including home oustees, land oustees and landless laborers (a
brief outline to be given)
112
8 Project Schedule & Cost Estimates 113
8.1 Likely date of start of construction and likely date of completion (Time
schedule for the project to be given)
113
8.2 Estimated project cost along with analysis in terms of economic
viability of the Project
113
9 Analysis of Proposal Final Recommendations 114
9.1 Financial and social benefits with special emphasis on the benefit to
the local people including tribal population, if any, in the area.
114
LISTS OF TABLES
Chapters Name of the Table Page No.
C2 - 1 Existing and Proposed Expansion Project 3
C2 - 2 Company Background 4
C2 – 3 Real consumption of Steel in Million tonnes 11
C2 – 4 Steel Imports and Exports 12
C2 – 5 Production of Different Ferroalloys 13
C2- 6 Domestic Consumption 13
C2 - 7 Estimated Requirement of Raw Materials for Steel plants 14
C2 - 8 Ferroalloy Capacity in India (2012 estimates) 14
C2 – 9 Ferro Alloy Export ( ‘000 MT) 14
C2 - 10 Growth of Imports of Ferroalloys in India (in ‘000 MT) 14
C2 - 11 Projected Production of Steel & Demand of Ferroalloys (in ‘000 MT) 15
C2 - 12 Pan India Cement Production and consumption figures 16
C2 - 13 Cement Production and consumption in Eastern Region 17
C2 - 14 Cement /clinker Production and Export (in Million Tonnes) 18
C3 - 1 Magnitude of Operation of Existing & Proposed Expansion Project 25
C3 - 2 Annual Production of various Bulk Ferroalloys on Campaign basis 29
C3 - 3 Raw materials for Fe -Mn and their chemical composition 30
C3 - 4 General Composition of Charge 31
C3 - 5 Typical Quality of Ferro- Manganese 31
C3 – 6 Grades of Silico Manganese 33
C3 – 7 Raw materials for Si -Mn and their chemical composition 33
C3 – 8 General Charge Composition in Ton per ton of finished product 34
C3 – 9 Quality of Silico-Manganese 34
C3 – 10 Raw materials for Fe- Si and their chemical composition 37
C3 – 11 General Charge Composition in Ton per ton of product 37
C3 – 12 Raw materials for Fe- Cr and their chemical composition 42
C3 – 13 Charge Composition and utility consumption 43
C3 – 14 Technical Specifications of Submerged Electric Arc Furnace- 7.5 MVA 48
C3 – 15 Induration Process Zone with Size, Reaction Area and Temperature 59
C3 – 16 Material and Energy Balance 8MW Power Plant 62
C3 – 17 Annual Requirement of Raw Materials 64
C3 – 18 Specification of Fuel for FBC Boilers 64
C3 – 19 Technical Specifications of Induction Furnace 2 X 15 T 69
C3 – 20 Chemical Analysis of EAF Slag 74
C3 – 21 Technical Specification of EAF Furnace 76
C3 – 22 Water Quality 82
C3 – 23 Raw Materials for PSC & PPC 84
C3 – 24 Specification of Quality of Clinker 84
C3 – 25 Specification of Quality of Slag 85
C3 – 26 Specification of Quality of Gypsum 85
C3 – 27 Proximate Analysis of Coal for Cement Grinding Plant 85
C3 – 28 Ultimate Analysis of Coal for Cement Grinding 86
C3 – 29 Specification of HFO 86
C3 – 30 Norms for operating hours, safety factors for plant & machinery 86
C3 – 31 Norms for Raw Material Storages 86
C3 – 32 Moisture Content in Raw Materials for cement Grinding 87
C3 – 33 Details of Storage Capacities for Grinding Unit 87
C3 – 34 Raw Materials Required, Likely source, Mode of Transportation 89-92
C3 – 35 Quantification of Product after Expansion, Marketing Area & Mode of
Transportation
92
C3 – 36 Water Requirement and its source 93
C3 – 37 Power Requirement and its source 94
C3 – 38 Waste Water Generation /Recycle and Reuse 96-97
C3 – 39 Quantity of solid waste to be generated and management/ Disposal
Scheme
97-98
C4 - 1 Location of Water bodies, reserve forests and hill from project site 101
C4 - 2 Land Use in the Buffer Zone 104
C4 - 3 Educational Facilities in Purulia District 106
C4 - 4 The Health Infrastructure Status of Purulia District 107
C5 - 1 Showing Existing and Proposed area of M/s IDPL 108
C6 - 1 Existing & Proposed Plantation 110
C6 - 2 CSR activities taken up during last four years 110
LISTS OF FIGURES
Figures Name of the Figure Page No.
C2 - 1 Consumption of Steel (in million tons) 12
C2 - 2 Graphical Representation of Steel Import & Export 12
C2 - 3 Graph Showing Si-Mn & HC Fe-Mn Production Vs Crude Steel Production 15
C2 - 4 Graph Showing Si-Mn and HC Fe-Mn Production Vs Total Exports 16
C3 - 1 Index Map 21
C3 - 2 Location Map 22
C3 - 3 Vicinity Map 23
C3 - 4 Google Earth Map 24
C3 - 5 Over All Process Flow Chart Showing Components of the Project 26
C3 - 6 Project Layout 27
C3 - 7 Process Flow Diagram of Ferro Manganese Plant 32
C3 - 8 Process Flow Diagram of Silico-Manganese Plant 35
C3 - 9 Process Flow Diagram of Ferrosilicon Plant 37
C3 - 10 Flow chart for making briquettes 40
C3 - 11 Process Flow Diagram of Metal Recovery Plant 45
C3 - 12 Schematic Process Flow Diagram of Ferrochrome Plant 47
C3 - 13 Process Flow Diagram of Ferrochrome Plant 47
C3 - 14 Process Flow Diagram for Sponge Iron (DRI) & Power Plant 52
C3 – 15 Process Flow Diagram of Iron Ore Beneficiation & Pelletization Plant 55
C3 – 16 Induration Process Description 58
C3 – 17 Induration Section 59
C3 – 18 Temperature Profile 59
C3 – 19 Process Flow diagram for manufacture of MS Billets 68
C3 – 20 Process Flow Diagram Electric Arc Furnace 75
C3 – 21 Process Flow Diagram Of Rolling Mill 79
C3 – 22 Process Flow Diagram Cement Grinding Plant 88
C3 – 23 Water Balance diagram 95
C3 – 24 Schematic Diagram of EIA Process of the Project 99
C4 – 1 Map showing the distance of the Project Site from the National Park /
Sanctuaries and Elephant / Tiger Reserve and their corridors
102
C4 - 2 Land Use Map 103
1
1. EXECUTIVE SUMMARY
The proposed expansion of Ferro Alloys Plant, Iron Ore Beneficiation/Pellet Plant Integrated
Steel Plant through secondary route of steel manufacture and Cement Grinding Plant will be
located at village Nabagram, PO: Digha, Development Block: Neturia, Dist: Puruliya, West
Bengal. Total land acquired for this project by M/s Ispat Damodar Pvt. Ltd. is 78 Acres in
which a Sponge Iron Plant with 2 X 100 TPD kilns, SMS Plant with induction furnace of 2 X 4
T & 1 X 8 T capacity, a Ferroalloy plant of 4 X 7.5 MVA capacity and a Waste Heat Recovery
based power plant of 8 MW capacity are already in operation. The existing plant has been
operating since 2006. The company proposes to further acquire 25 acres of land for the
expansion purpose. The acquisition will involve mostly private land.
The site is accessible by Sarbari – Panchet Road which connects SH-5 (Purulia to Asansol via
Dishergarh). Thus the site is having advantages of proximity to 2 Coalfields – i. e. Ranigunj
Coal field of ECL on one side and Dhanbad coalfields of BCCL on the other. Nearest Railway
station is Madhukunda on S.E. Railway which is about 10 Km. from the site. Nearest sea port
is at Haldia at aerial distance of170 KM from the project site. Nearest Air Port is at Andal at a
distance of 75 KM and Netaji Subhas Chandra Bose airport at Kolkota, at an aerial distance
of 270KM from project site.
The location of the project at Neturia, District- Purulia has the following advantages:
a. Proximity to Coal mines of ECL & BCCL which will ensure easy supply of coal at reduced
cost of carriage.
b. Iron Ore can be procured in rake loads from Barbil /Banspani, Odisha (S. E. railway) and
unloaded in nearby railway siding of S. E. Railway near Madhukunda.
c. Proximity to H. T. power line of DVC as well to sub-station at Panchet.
d. Location of the site near Chirkunda & Asansol will provide adequate social infrastructures.
e. Location of the site close to National Highway No. 1 (Delhi Road) gives easy access and
convenience for transportation.
f. Purulia district is categorized under Group ‘c’ of Incentive Scheme of Govt. of West
Bengal which provides for additional incentives.
g. Ready market for Sponge Iron in large number of Induction Furnaces currently under
operation in Howrah, Hooghly & Burdwan districts.
Proposed expansion project cost is estimated for Rs.190.00Crores. It has the potential to
engage about 11 persons in the permanent set up and 254 contractual persons. The
manpower requirement in the peak construction phase of the project may be as high as 200
persons per day.
The major raw material required for the proposed Ferro Alloys, Integrated Steel Plant, Coke
ovens and Cement Grinding Plant are Iron ore, Manganese Ore, Coal, Limestone, Quartz,
Chromites ore etc. Purulia district does not have mineral resources. Most of the minerals
including iron ore, chromite, limestone, etc will be sourced from neighbouring state Odisha
whereas coal (both coking and non-coking) will be sourced from neghbouring coal fields of
ECL and BCCL. The coal for the coke ovens plant will be imported from Australia/USA or
Indonesia. Cement Clinker for cement grinding plant will be sourced from nearby Cement
Factory at for which a MoU will be made in due time.
2
Technology adopted for various sections are up-to-date technology aiming at lower energy
consumption, less water consumption and zero effluent discharge, recycle and reuse of solid
wastes, etc.
The proposed Ferro Alloys, Iron Ore Beneficiation /Pellet Plant, Integrated Steel Plant and
Cement Grinding Plant will be an expansion project adjacent to existing project of M/s Ispat
Damodar Pvt. Ltd, inside the same factory premises. The iron ore pellets produced in the
pellet plant will be utilized in the sponge iron plant. Sponge iron produced in the existing
plant and the expansion project will be utilized in the Steel melting Shop for manufacture of
steel products. Similarly part of Ferro alloys produced in the expansion project will be utilized
in the production of special steel in the SMS and balance may be used in group companies.
Power will be generated by utilizing process wastes like DRI off gas as well as utilizing the
solid wastes like dolochar and coal fines.
The fly ash generated in the power plant will be utilized in the manufacture of Portland
Pozzolana Cement (PPC). The slag generated in Ferro-manganese plant will be used for
manufacture of silico-manganese. The slag generated in Ferro-Silicon and Silico-Manganese
may be used for manufacture of Slag Cement. The slag generated in Ferrochrome plants will
be subjected to TCLP test and subject to clearance of test will be utilized as road base
material. The fresh water requirement will be optimised by taking recycling and cascading
measures. The dust from Air Pollution Control devices of Ferroalloy Plant will be used in
briquette making.
Point source emissions from various manufacturing facilities as well as fugitive emissions will
be maintained within statutory limits by installation bag filters, ESPs and other pollution
control equipments. Fugitive dust will be controlled by providing suction hoods at all transfer
points followed by suitable ducts and pulse jet bag filters.
The existing infrastructure facilities will help in successful implementation of proposed
project. The proposed project will improve the viability of the existing sponge iron plant as
well as to contribute to better performance of group companies by way of supplying needed
input material.
Water requirement for the project will be sourced from Panchet Dam Reservoir on river
Damodar, which is at a distance of 7.5 Km from project site in north direction. Adequate
recycling and cascading measures will be taken to reduce fresh water consumption. Effluent
generated will be treated and used for green belt development and dust supression.
Green belt development is in progress. Suitable plant species will be planted all along the
internal roads, plant boundary, raw material storage & handling, ash/dust prone areas. It is
planned to plant saplings considering the parameters as type, height, leaf area, crown area,
growing nature, water requirement etc. Green belt will be progressively developed on land.
The various aspects of the Pre-Feasibility Report as per MoEF Guidelines vide O.M. J- 11013
/41/2006-IA.II(I) dtd. 30-12-2010 are given in the subsequent sections.
3
2. INTRODUCTION OF THE PROJECT /BACKGROUND INFORMATION
2.1 Identification of the Project: M/s Ispat Damodar Pvt. Ltd. incorporated under Indian Company’s Act 1956 having its
registered office at 37, Shakespear Sarani, Kolkata-700017 has a manufacturing facility at
village: Nabagram, PO: Digha, PS: Neturia, District: Purulia, West Bengal.
The company is presently operating a plant having the following facilities:
1. A ferroalloy plant of 4 X 7.5 MVA capacity for production of Ferrochrome/
Ferromanganese/ Silico Manganese/ Ferro Silicon.
2. A sponge Iron Plant of 2 X 100 TPD capacities for production of 60,000 TPA Sponge Iron.
3. A captive Power Plant for generation of 8MW electricity based on WHRB and AFBC
utilizing Flue gas and dolochar respectively of Sponge Iron Plant.
4. Steel Melting Shop with Induction Furnaces (2 X 8 MT per heat) with continuous Casting
Machine for billets and slab.
5. The existing plant has commenced operation in 2006.
The company proposes to expand the existing plant and set up new manufacturing facilities.
The configurations of existing plant as well as proposed facilities are given in the table below.
Table No. C2-1 : Existing and Proposed Expansion Project
Sl.
No.
Facilities
Existing
Capacity
Proposed
Capacity
Ultimate
Capacity
1. Ferro Alloys
(Ferro Chrome/ Ferro Manganese /
Silico Manganese/ Ferro Silicon) (SEAF)
4 x7.5MVA 2x7.5 MVA 6 x 7.5MVA
2. Sponge Iron Plant
60000 TPA
(2x100 TPD)
105000 TPA
(1x350 TPD) 165000 TPA
3. Iron Ore Beneficiation & Pelletisation Plant - 600000 TPA 600000 TPA
4. Captive Power Plant
(WHRB + Dolochar AFBC)
8MW (4MW
WHRB +
4MW AFBC)
40MW
(8MW WHRB +
2X16MW AFBC)
48MW
5. Steel Melting Shop & Continuous Casting
Machine for Billet & Slab :
Induction Furnace
Electric Arc Furnace (EAF)
Laddle Refining & Tilting Furnace (LRF)
VOD/VID/AOD
Continuous Casting Machine (CCM)
2x4T,1X8 T
-
-
-
--
2x15T
1x20T
1x20T
1x20T
1x 6/11 mtrs.
2x4T
1X8 T
2x15T
1x20T
1x20T
1x20T
1x 6/11 mtrs.
6.
Rolling Mill with Preheating Furnace (Coal
gasifier/Pulverized Coal / Oil fired) or
Direct feeding from CCM (Structurals/
Rebar /Round)
- 200000 TPA 200000 TPA
7. Cement Grinding Plant - 1x1000TPD 300000TPA
4
Proposed expansion will come up in the existing site. The company has 78 acres of land
in its possession and 25 acres will be acquired for the project. Neturia Block of Purulia is
an industrial centre of West Bengal. Further the industrial hubs like Durgapur, Asansole,
Bokaro, etc, are in the vicinity which will provide opportunity for marketing the products
of the company apart from using the same internally.
2.1.1 Identification of Project Proponent:
M/s Ispat Damodar Pvt. Limited is a company which is part of the well known industrial
house of India namely the Eurasia group and is promoted by them. The Eurasia group is
renowned manufacturer of Sponge Iron (DRI), Ferro Alloys, Steel Billets, Engineering
Steel Castings, Captive Power, TMT Rebars and Organic Darjeeling Tea since last three
decades in India. The group has following manufacturing facilities located at eastern
states of India. The group turnover is more than 20,000 million (INR) and employing
more than 3000 people. Mr. Vikash Bansal and Mr. Satpal Bansal are currently in the
Board of Directors of the company.
Table No. C2-2 : Company Background
NAME OF COMPANY PRODUCTS FACTORY LOCATION
Brand Alloys Ltd
(An ISO & BIS
Certified, RDSO
Approved “CLASS A”
Foundry & NABL
Accredited)
-Indian Railways Casnub Bogie
& Its Components.
-Indian Railways Cms
Crossing, Coupler Components.
-TMT Rebars.
-Steel, Alloy & Stainless Steel
Casting Upto 20 M.T Single
Piece,Machining & Assembling
As Per Customer Drawing,
Design & Specification.
-Steel, Alloy & Stainless Steel
Centrifugal Casting Upto 600
Dia & 3000 Mm Length.
-Steel Billets.
-Sponge Iron (DRI).
Factory: Unit – I
NH-2 Delhi Road
Post : Sreerampur, Hooghly
Pin-712223
West Bengal, India
Factory : Unit – II
Vill.: Murusuan,
Post :Palaspanga
Dist.: Keonjhar, Odrisha,
India
Haldia Steels Ltd
(An ISO & BIS
Certified Company)
-Ferro Alloys (Simn & Femn)
-Steel Billets
-Sponge Iron (Dri)
-Captive Power
Factory : Unit – I
Raturia Industrial Area
Angadpur, Durgapur
West Bengal, India
Factory : Unit – II
Raturia Industrial Area
Angadpur, Durgapur
West Bengal, India
ISPAT DAMODAR LTD
(An ISO & BIS
-Ferro Alloys (SiMn & FeMn)
-Steel Billets
Factory
Nabagram P.O-Digha, P.S-
Neturia, Purulia, West
5
2.2 Brief Description of the Nature of the project:
The proposed project will consume minerals mainly iron ore, iron ore fines, manganese
ore, chrome ore, lime stone, dolomite, quartz, coal /coke & cement clinker as raw
materials and produce Sponge Iron, Steel long products of different specifications,
Ferroalloys, and Ordinary Portland Cement/ Portland Pozzolana Cement/Slag Cement.
The waste gases and low calorific value solid wastes will be utilized for electricity
generation. All other solid wastes will be suitably used for various purposes. The
beneficiated iron ore concentrates will be used for the manufacture of Iron Ore Pellets;
the pellets in turn will be the feed material for the sponge iron plant. The sponge iron will
be used as feed material for Induction Furnace Steel making or EAF steel making. The
ferroalloys will be used in the steel making.
As per EIA Notification 2006 the proposed Ferro Alloy and Secondary Steel Plant fall
under Schedule in serial No. 3 (a) - Metallurgical Industry (ferrous & non- ferrous). The
Iron ore beneficiation and pellet plant fall under Serial 2(b). The cement grinding plant
falls under serial 3(b) Based on capacity specification and general conditions mentioned
in the schedule of EIA Notification, the project is categorized as Category A.
2.3 Need of the Project and Its Importance to the country and Region:
M/s Ispat Damodar Pvt. Ltd., Purulia, West Bengal envisages to expand existing capacity
of its plants located at Purulia, WB as well as propose to install new plants in the
expansion proposal. The existing capacity and proposed expansion and ultimate capacity
of various facilities are depicted in Table No. C2-1.
2.3.1 Need for Steel Plant through secondary route of Steel Manufacture:
Steel is the prime mover of a country’s progress. Steel industries in India are making
steady progress, since 2003 with growth of qualitative and quantitative crude steel
production. Steel has played a vital role in the development of a country’s economy.
Production of steel is an important index of measuring a country’s economic and
Certified Company)) -Sponge Iron (DRI)
-Captive Power
Bengal, India
Sonic Thermal Ltd
(An ISO Certified) -Ferro Alloys (SiMn & FeMn)
Factory
Ghutghoria, Barjora, Dist-
Bankura,
West Bengal, India
Brand Steel and
Power(P) Ltd Songr Iron Factory
Vill: Murusuan,
Po:Palaspanga,
Block: Keonjhar Sadar, Dist:
Keonjhar, Odisha
The Arya Tea Company
Ltd Since 1885
(An IMO Organic, DNV
& Fair Trade Certified)
Organic Darjeeling Tea
Garden Address
Arya Tea Estate
Darjeeling Railway Station
Darjelling (N.F.Railway) ,
West Bengal, India
6
industrial development. The demand for steel is correlated with development of country’s
Infrastructure like Roads, Railways, Ports, housing, drinking water, growth of
manufacturing and automobile industries. Indian construction sector is consuming about
10 million tons of steel annually with steel cement consumption ratio of 0.32:1 against
international standard ratio of 1:1 .This sector is likely to increase the steel consumption
for increasing quality construction and durability. Our per capita consumption of steel is
only 57.8 Kg per annum (World Steel Association figure for 2013) against the world
average of 225.2Kg. With “Make in India” approach propounded by the prime minister,
the country is poised to develop at a faster rate for which more steel would be needed.
The National Steel Policy 2012 has envisaged steel production capacity of 300 MTPA by
2025-26 as against the annual production 89.6 MTPA for the financial year 2014-15 India
has targeted 275 million tonnes of steel production by 2025-26 against the present
production capacity of 91 million tones. Indian population is expected to grow to about
1500 million by 2025-26. Presently only 35% constitute urban population. With economic
boom the urban population will rise and there will be more need for housing and other
infrastructural facility. With an average per capita steel consumption of about 200Kg;
the total demand will be around 300 million tones per annum. This shall lead to a short
fall of about 25 million tones. In spite of the rapid strides India may become net importer
of steel. Therefore it is of utmost importance to set up new steel plants. The present
steel production in India is growing at a rate of 7.3% with about 50% of the total
capacity in the secondary steel sector of DRI-scrap- Electric furnace route.
In view of the scarcity of coking coal and availability of non-coking coal steel production
through secondary route i.e. DRI, IF/EAF, LRF, AOD has become a viable option. The
secondary route used to utilize scrap as the input material for steel manufacture through
induction furnace and EAF route. However, the scarcity of scrap had posed hindrance to
the development of secondary steel industry which was overcome by the use sponge iron
in place of scrap either partly or fully. Sponge Iron being the important input for
production steel through secondary route the steel production can be enhanced by
increasing the production level of sponge iron. Hence, enhancement of capacity of
Sponge Iron plant has been necessitated.
Steel can be produced by Induction Furnace or Electric Arc Furnace. The bulk of
structural quality mild steel for long products is manufactured by Induction Melting
Furnaces. The EAF units have also installed Induction Melting Furnaces. There are several
reasons for the popularity of Induction Melting Furnaces for making steel. They consume
less power comparing EAFs. Expenditure on electrode is nil. They use lesser quantity of
refractory. Initial investment is less on plant and equipment. The production scheduling is
also flexible. Thus, there are economic advantages in making steel through Induction
Furnaces route. However, induction melting lacks refining capacity. Certain impurities like
phosphorous cannot be removed in induction steel making. Another important aspect of
induction steel making is that the charge materials must be clean of oxidation products
because these materials cannot be reduced as no reductant is used. Another limitation is
7
that low carbon steels cannot be produced in Induction furnaces. However, induction
melting offers a route for cheaper production of mild steel of good quality.
In order to tide over the limitations of the induction melting, the present approach of the
mini steel mill owners is to have EAFs where steel can be made and refining is possible.
Low carbon steels can also be produced in these furnaces. Keeping these points in mind
the proponents have proposed installation of Induction furnaces and Electric Arc furnaces
with backward integration with continuous casting machines, ladle refining furnaces, AOD
& rolling mills with reheating furnaces to cater to the demand of various types of steel
products.
Long products in India are produced mostly by major integrated steel plants and also by
secondary re-rolling mills. With an annual production capacity of about 12.5 million
tones, the secondary producers contribute about 65% of the total long product production.
The annual consumption of long products at about 24.5 million tonnes is around 51% of
the finished steel in India which is higher than even USA. The major consumers of long
product are the construction industries which are growing at a rate of about 8.8%.
Therefore, there is necessity for production of long products and hence installation of
Rolling mills with reheating furnaces.
2.3.2 Need for Iron Ore Beneficiation and Pelletisation Plant :
It has been briefed in the previous paragraphs that enhancement of steel production
capacity is a must for economic development of the country. Enhancement of steel
production through primary methods i.e. BF, BOF route is handicapped by inadequate
supply of coking coal which is mostly imported. Therefore, steel production through
secondary route i.e. sponge iron, IF/EAF is a must.
However, sponge iron production has suffered a setback in recent years due raw material
insecurity as direct outcome of government regulations i.e unavailability of good quality
iron ore and coal. The standard quality of Iron Ore for Sponge Iron manufacture should
comply to the specification as mentioned in section 3.5.2. Unavailability of calibrated
lump ore and B grade coal compelled many of the Sponge Iron Manufacturers to shut
down their plants as a result sponge iron production declined from a high of 24.8 MTPA in
2010 to a low of 14.6 MTPA. In order to tide over this impasse new sponge iron
industries are setting up iron ore beneficiation plants followed by pellet plants.
India is endowed with vast reserves of iron ore deposits. However, these deposits are fast
depleting in respect of good quality calibrated lump ores which are basic need for both blast
furnace route & sponge iron route of steel production due to higher rate of steel production.
In the process of iron ore mining almost 60% fines are generated, out of which almost
20% is dust (- 1mm), which generally goes waste or exported at substantially low prices.
There has been huge build ups of iron ore fines at mining sites which are being sold at
throw away price or are causing solid waste disposal problem. The Government has
taken initiative to promote the use of fines and encouraging entrepreneurs to
agglomerate the fines so that the fines can be effectively used for the manufacture of
8
steel. With a view to utilize this low cost item cost-effectively pelletization units are
coming up in large scale (more than 30 milliom MT capacity expected in the next 3-4
years with a planned outlay of Rs. 80 billion) to agglomerate the dust into sized lumps
having almost similar physical and chemical characteristics. Steep rise in the prices of
raw materials for DRI and pig iron production has led to large scale switch over to
pelletization process. Raw material for pelletization are of generally lower grade iron ore
dust with excessive tramp elements, which are either exported or could pose adverse
impact on the environment. Government policy of charging additional duty or banning
exports of low grade iron ore also could be intended to generate positive sentiment about
availability of raw material for pelletization of ore dust. Due to non-availability of
technology in India in the past, on the other hand easy availability of alternative better
grade ore, requirement of large capital expenditure and overall commercial viability was
pushing the investment so far but now all steel plants are finding opportunity in that
venture. In keeping with this trend M/s Ispat Damodar Pvt. Ltd. envisages to put up a
iron ore beneficiation and pelletisation plant of 600000 TPA. The pellets can make up for
the calibrated lump ore requirement in their sponge iron plant. Prior to pelletization
proper selection of ore and beneficiation of dust ore is a prerequisite so as to make
pellets of quality comparable to calibrated lump ore. Pellets being manufactured without
beneficiation of fine ore are not of good quality due to high content of gangue and lower
Fe content generally pose serious problems in steel making through IF and strong
objection from prospective users.
On the basis of 30% replacement of Calibrated Lump Ore (i.e. CLO) by pellet on
minimum side, the requirement of pellet would be 51 million TPA against installed
capacity of about 30-36 million TPA. Besides, the sponge iron plants in the country which
are in verge of closure due to non-availability of requisite CLO both in quantity and
quality will consume more than 60% of the pellet in the mix. Presently more than 400
Sponge Iron units are there in the country. The sponge iron production in the country
showed a rising trend from 2005 till 2010 when the production jumped from 15 million
TPA to 24.8 million TPA. However due to scarcity of calibrated lump ore, some of the
units faced closure. As a result the sponge iron production reduced to 14.6 million tonnes
in 2013. Assuming only 400 units may be in operation up to 2020 then these 400 units
can produce about 30 million tonnes of Sponge Iron and will require additional 20 million
tonnes and more of pellet. The installation of Iron Ore Beneficiation Plant and Pellet plant
is therefore needed. To sum up the following factors justify installation of the Iron Ore
Beneficiation and Pelletisation Project and the Captive Power Plant.
• Under existing mining scenario, a great amount of Iron Ore Reserves comprising of
low grade fines & lumps are available, which cannot be used directly for steel making.
• In line with Mineral Conservation & Development Rules’ 1988, and increasing global
demand, the low grade iron ores are to be upgraded through beneficiation followed by
Pelletization for DRI / BF usage.
9
• Beneficiation of iron ore reject and its onward use in Pelletization is a step towards
mineral conservation and waste reduction. More over these plants can act as a
additional source of raw material for DRI/BF.
• Pelletization of the iron ore concentrate is considered in view of high productivity, low
energy consumption and eco-friendly process.
• The Beneficiation and Pellet Plant will help cater the raw material requirement of the
Steel making industries.
Advantages of utilizing pellets
• Production of DRI increases by 10 -15% in rotary kilns
• Specific Coal Consumption is reduced by 10-15%
• Specific Power Consumption is Reduced by 10%
• Lumps & Fines Ratio is 90:10 as against 60:40 if Iron ore is used
• Magnetic particles in char are reduced from 2.5% to 1%
• Accretion formation in DRI rotary kiln is reduced by 50%
2.3.3 Need for Ferroalloy Plant:
Ferro alloys like Ferro Manganese, Ferro Chrome, Silico- manganese are additives which
impart special quality to the special quality steel. As the production of steel goes up the
need for various types of ferroalloys also are increasing. Ferroalloy production level and the
projected indigenous/ export demands of various types of ferroalloys are given in the Table
No. C2-5.
The proposed Ferro Alloys Plant will be part of an enlargement project i.e Integrated Mini
Steel Mill just adjacent to existing sponge iron plant of M/s Ispat Damodar Pvt. Ltd., village:
Nabagram, PO: Digha, PS: Neturia, District: Purulia, West Bengal. The sponge iron
produced in the existing plant will be utilized in the proposed project to manufacture steel
products which will need ferroalloys for making special steels and stainless steel. The
existing infrastructure facilities will help in successful implementation of proposed project.
The proposed project will improve the viability of the existing sponge iron plant. Similarly,
the group companies have secondary steel plants and consuming ferroalloys in substantial
quantity purchased from the market. M/s Ispat Damodar Pvt. Ltd. is planning to consume
ferroalloys produced in the proposed project and in group company to increase the economy
of group companies and to earn greater revenue by selling remaining ferro alloy.
2.3.4 Cement Grinding Plant
Cement is a vital input to the acceleration of economic development and closely linked with
the GDP growth. With an assumed growth rate of 8% GDP in future years the cement
market has growth potential. The central government liberalization policies and new
schemes for housing and road projects will push the demand of cement to increase by about
9 to 10%.
1 0
One of the major contributions of cement industry to society is in the form of absorption of
industrial waste generated by other sectors, particularly the power sector and plastics. The
power generation in India is coal intensive which generates huge amounts of ash and
enormous areas of land are used to store it. According to the 2007 report of a committee
constituted by the Central Electricity Authority to assess land requirements for power
plants, 196 million tonnes of ash would be generated every year by the end of 11th five year
plan. Assuming land requirement of 0.4 acre per Megawatt capacity, about 50,000 acres of
land would be required every year to store ash if it is not consumed. These numbers would
increase further with increasing power plants.
The ash ponds have adverse effect on water bodies and agriculture land. In order to
conserve top soil and prevent the dumping and disposal of fly ash from coal or lignite based
thermal power plants, Ministry of Environment & Forests has issued directions through
Gazette notification number S.O.763 (E), [14/9/1999] - Dumping and disposal of fly ash
discharged from coal or lignite based thermal power plants on land with two amendments,
one in 2003 and the other in 2009. The statute requires all coal and, or lignite based
thermal power stations and, or expansion units in operation before the date of this
notification to achieve a target of 100 per cent utilization of fly ash within five years of issue
of the notification. However, utilization of fly ash is still less than 60 per cent of generated
quantity. Cement industry with about 38 per cent share in utilization of fly ash plays an
important role in evacuation and fruitful utilization of this harmful waste.
There are different varieties of cement based on different compositions according to specific
end uses, namely, Ordinary Portland Cement, Portland Pozzolana Cement, White Cement,
Portland Blast Furnace Slag Cement and Specialised Cement. The basic difference lies in the
percentage of clinker used.
In view of the above facts there is urgent need for establishment of cement grinding plant
which not only shall be able to absorb the fly ash generated in the integrated mini steel mill
but also may utilize the slag produced in the mini blast furnace if designed for the purpose.
Further, the demand supply gap for cement in eastern region as presented in Table No. C2-
13 justifies the setting up of the Cement Grinding plant by M/s Ispat Damodar Pvt. Limited
at village: Nabagram, PO: Digha, PS: Neturia, District: Purulia, West Bengal. This plant will
be a backward integration as the fly ash which will be available from captive power plants of
the company will be used in the cement grinding facility.
2.3.5 Need for captive Power Plant
The mini steel mills consisting of Induction furnace, Electric Arc Furnace are power
intensive. The ferroalloy plants are also highly power intensive. The total power demand
may stress the state grid and the plant may suffer interruption of power supply. The
company therefore proposes to install power plants based on waste heat of flue gas
generated in the sponge iron kiln as well by utilizing the solid waste i.e. dolochar generated
in DRI Plant. Power Plant will not only to cater to the power demand of the plant but also will
utilize the wastes produced in the plant.
1 1
2.4 Demand Supply Gap
Being a core sector, steel industry tracks the overall economic growth in the long term.
Also, steel demand, being derived from other sectors like automobiles, consumer durables
and infrastructure, its fate is dependent on the growth of these user industries. The Indian
steel sector enjoys advantages of domestic availability of raw materials and cheap labour.
Iron ore is also available in abundant quantities. This provides major cost advantage to
the domestic steel industry.
The Indian steel industry is largely iron-based through the blast furnace (BF) or the direct
reduced iron (DRI) route. About 60% of the crude steel capacity is rests with integrated
steel producers (ISP). But the changing ratio of hot metal to crude steel production
indicates the increasing presence of secondary steel producers (non integrated steel
producers) manufacturing steel through DRI/ scrap route, enhancing their dependence on
imported raw material.
World crude steel production was 1622.8 million tonnes (MT) in 2015 down by -2.8% as
compared to 2014.India’s annual production of crude steel for 2015 was 89.6 MTPA which
was up by 2.6% as compared to 2014, as per World Steel Association (WSA). China
accounted for 49.6% of the world's total crude steel production in 2015, having 803.8 MT.
During 2015, India became the 3rd largest steel producing country in the world behind
China and Japan.
2.4.1 Demand of Steel and Consumption Figures:
In India steel demand has outpaced supply over the last five years:
• In the FY 2015 the consumption of finished steel grew to 76.99 MT with the CAGR
increased to 5.74% during FY 08-15.
• Demand by rising infrastructure development and growing demand for automobiles,
steel consumption is expected to reach 104 MT by 2017.
• It is expected that consumption per capita would increase supported by rapid growth
in the industrial sector and rising infra expenditure projected in railways, roads and
highways etc.
• For the financial year 2015-16, the per capita consumption of steel in India was 60
kg against world average of 222 kg.
2.4.1.1 Table No. C2 – 3 : Real consumption of Steel in Million tonnes
Year Consumption
FY 09 52 million tones
FY 10 52 million tones
FY 11 59 million tones
FY 12 66 million tones
FY 13 71 million tones
FY 14 74 million tones
FY 15 74 million tones
FY 16 77 million tones
(Source: JPC India, Ministry of Steel, JSPL presentation, Tech Sc Research March 2016)
Fig. No. C2
2.4.1.2 Imports and Exports of Steel:
Demand - supply gap resulted in increased imports:
With the growth in demand of steel outpacing
last few years, imports have increased.
• India was an importer of
in FY 14. In 2015 India imported 9.32 MT of steel while exports declined to 5.59
MT in FY 15 from FY 13
• During FY 11-15 imports of steel grew at a
at CAGR of 11.32%
• Total domestic demand of steel is estimated at 113.3 MTPA by 2016
Table No. C2
Year
FY 11
FY 12
FY13
FY 14
FY 15
FY 16
Fig. No. C2 - 2 : Graphical
5 2 501 02 03 04 05 06 07 08 09 0
F Y 0 9 F Y
024681 0
F Y 1 17 4Steel Import & Export
. C2- 1: Consumption of Steel, in million tons
Imports and Exports of Steel:
supply gap resulted in increased imports:
With the growth in demand of steel outpacing growth in domestic production over the
last few years, imports have increased.
India was an importer of steel till FY 2013 but turned a net exporter of the same
in FY 14. In 2015 India imported 9.32 MT of steel while exports declined to 5.59
MT in FY 15 from FY 13-14.
15 imports of steel grew at a CAGR 9.01% while exports increased
1.32%
Total domestic demand of steel is estimated at 113.3 MTPA by 2016
. C2 – 4 : Steel Imports and Exports
Imports Exports
7 million tonnes 4 million tonnes
7 million tonnes 5 million tonnes
8 million tonnes 5 million tones
5 million tonnes 6 million tones
9 million tonnes 6 million tones
5 million tonnes 2 million tones
: Graphical Representation of Steel Import & Export
5 2 5 9 6 6 7 1 7 4 7 4 7 7Y 1 0 F Y 1 1 F Y 1 2 F Y 1 3 F Y 1 4 F Y 1 5 F Y 1 6
C o n s u m p t i o n o f S t e ei n m i l l i o n t o n n e s
F Y 1 2 F Y 1 3 F Y 1 4 F Y 1 5 F Y 1 67 8 5 9 55 5 6 6 2
I m p o r t s i n m i l l i o n t o nE x p o r t s i n m i l l i o n t o nSteel Import & Export
1 2
million tons
growth in domestic production over the
steel till FY 2013 but turned a net exporter of the same
in FY 14. In 2015 India imported 9.32 MT of steel while exports declined to 5.59
AGR 9.01% while exports increased
Total domestic demand of steel is estimated at 113.3 MTPA by 2016-17
Representation of Steel Import & Export
e l
n n e sn e s
1 3
2.4.2 Demand and Supply of Ferroalloys:
The Ferroalloy industries in India not only cater to the demand of domestic steel plants
but also aim at earning foreign exchange by export. Capacity increase of the Ferro Alloy
Industry in general followed the course to meet the planned target levels of the Steel
Industry in the country, and to continue to remain potential exporters of Ferro Alloys in
the international market for earning substantial foreign exchange for the country. After
initiation of the liberalization programme, there has been a spurt in the export of Bulk
Ferro Alloys, like all other products. The present scenario indicates that the ferroalloy
production in the country is driven not only indigenous demand but also exports. Yearly
production and consumption figures of the Ferroalloy plants are given hereunder to show
the growth projectile of the industry.
2.4.2.1 Production of Ferroalloys in Kilo Tonnes:
Table No. C2 – 5 : Production of Different Ferroalloys
2010-11 2009-10 2008-09 2007-08 2006-07
Bulk Ferro Alloys
HC Ferro Manganese 390,000 341,883 372,286 364,908 281,013
MC Ferro Manganese 8,000 8,222 8,386 7,704 9,190
LC Ferro Manganese 6,000 6,018 5,775 3,905 6,523
Silico Manganese 1,250,000 1,066,485 889,434 886,325 738,314
MC Silico Manganese 24,000 24,108 24,087 27,106 29,581
LC Silico Manganese 25,000 25,454 22,368 33,576 15,067
Ferro Silicon 117,000 97,682 110,742 96,972 92,632
HC Ferro Chrome /
Charge Chrome
1,030,000 890,916 790,072 964,806 801,138
LC Ferro Chrome 2,000 2,007 1,352 235 230
Total Bulk
Ferroalloys
2,852,000 2,462,775 2,224,502 2,385,537 1,973,688
Noble Ferro alloys 33,360 30,858 27,235 29,185 27,763
Total 2,885,360 2,493,633 2,251,737 2,414,722 2,001,451
Growth percentage 15.70% 10.74% (-) 6.75% 20.65% 21.64%
Source: IFAPA
2.4.2.2 Domestic Consumption:
Table No. C2- 6 : Domestic Consumption In Kilo Tonnes
Ferro Alloy 2005-06 2008-09 2011-12
Si-Mn 443 589 700
Fe-Cr 375 311 403
Fe-Mn 233 277 292
Fe-Si 174 156 229
Others 83 91 115
1 4
2.4.2.3 Table No. C2- 7 : Estimated Requirement of Raw Materials for Steel plants
Input Materials Unit Estimated
Consumption
2011-12
Estimated
Consumption
2016-17
Additional
Requirement
by 2016
Coking Coal Million Tonnes 43.2 90.2 47.0
Non-coking Coal Million Tonnes 35.3 28.4 -
Iron Ore Million Tonnes 115.0 206.2 91.2
Ferro Alloys Million tonnes 2152 3673 1521
2.4.2.4 Installed Capacity and Export/Import Scenario:
Table No. C2- 8 : Ferroalloy Capacity in India (2012 estimates)
Ferroalloy Capacity in Million Tonnes
Mn Alloys 3.16
Chrome Alloys 1.69
Ferro Silicon 0.25
Noble Alloys 0.05
Total 5.15
Table No. C2 – 9 :Ferro Alloy Export ( ‘000 MT)
Category 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12
Export 517 640 961 960 863 1555 1533
Domestic 1308 1520 1558 1420 1819 1460 1740
Total 1825 2160 2519 2380 2682 3015 3273
Export % 28 30 38 40 32 52 47
• Ferroalloy Imports
Although India is a large exporter of Ferroalloys, due to uncertain economic conditions in
the developed world, many ferroalloy companies (mainly from the CIS, Russia and
Kazakhstan) which restricted themselves to supplying to customers in the developed world
(US, EU, Japan) and to China have started making inroads into India. This has led to stiff
rise in imports of ferroalloys (25% CAGR) for the years as reflected in the table below.
Table No. C2 - 10: Growth of Imports of Ferroalloys in India (‘000 MT)
Ferroalloy 2005-06 2008-09 2011-12
Fe-Si 74 83 149
Refined Alloys 44 42 66
Fe-Cr 1 2 34
Fe-Mn 5 6 10
Total 124 133 259
1 5
Table No. C2 - 11: Projected Production of Steel and Demand of Feroalloys (‘000 MT)
2012-13 2013-14 2014-15 2015-16 2016-17
Projected Crude
Steel Production
85.90 94.50 104.00 114.5 125.90
Projected Finished
Steel Production
75.30 84.6 94.10 105.10 115.30
Demand of
Ferroalloys
2.018 2.221 2.483 2.751 3.025
Source: Report of Working Group on Steel Industry 2012-17
In 2015, the combined capacity for SiMn and HC FeMn was estimated at 4.85 Mt,
equivalent to more than 90% of capacity of all ferroalloys. As depicted in the following
graph, the vast majority of Indian manganese ferroalloy production has been in the form
of SiMn.
Fig. No. C2 - 3: Graph Showing Si-Mn and HC Fe-Mn Production Vs Crude Steel
Production
As can be noted from the facts furnished above, India’s ferroalloy production is driven by
domestic market but also by international market. The import and export of ferroalloys is
susceptible to trade policies of ferroalloy manufacturing countries. Since 2008, India has
been the world's largest exporter of SiMn, ahead of Ukraine, and, in the past 5-6 years,
an increasing proportion of SiMn and HC FeMn production has been exported. A rising
share of Indi exports of SiMn has been shipped to Europe, despite the fact that they face
strong competition from Ukraine, Norway and South Africa. The main markets for HC
FeMn from India are other Asian countries and the Middle East, where Indian imports
face competition from South Korea and Australia.
1 6
Fig. No. C2 - 4: Graph Showing Si-Mn and HC Fe-Mn Production Vs Total Exports
Having said this, the steady rise in Indian exports came to an abrupt halt in 2014
primarily as result of the global slowdown that has substantially reduced demand for all
steelmaking raw materials, including ferroalloys. The ongoing slump has triggered a sharp
drop in ferroalloy prices and has also contributed to a rising number of trade actions.
2.4.3. Demand and Supply of Portland Cement:
Like steel cement is a vital building material for development of infrastructure, industry
and housing projects. The GDP growth rate of 7-8% necessitates growth in demand of
cement, its production and installed capacity. The following projections which was made
by CRISIL research group gives a picture that Demand for cement is expected to grow at
a healthy pace of around 7-8 per cent CAGR over the next 5 years to about 321 million
tonnes in 2016-17 from almost 225 million tonnes in 2011-12, primarily led by increased
consumption from the infrastructure segment. On the supply front, CRISIL Research
forecasts almost 70 million tonnes of cement capacity to get commissioned at the pan-
India level, over the next 5 years.
2.4.3.1 Production and Consumption
Table No. C2 – 12 : Pan India Cement Production and consumption figures
Financial year Production MT Consumption MT
2007-08 170 170
2008-09 181 182
2009-10 207 202
2010-11 218 212
2011-12 241 224
2012-13E 242 237
2013-14P 260 253
2014-15P 278 274
2015-16P 301 295
2016-17P 325 320
1 7
Between 2012-13 and 2016-17, the infrastructure segment is forecast to account for
around 23 per cent of the overall cement demand, up from almost 20 per cent in the
previous 5-year period. In terms of demand from the housing segment, an increase in
independent housing projects, particularly in the semi urban and rural areas, is expected
to further boost cement demand.
From 2006-07 to 2011-12, demand for cement grew at a healthy 8 per cent CAGR. While
demand remained robust during 2006-07 to 2009-10, it slumped in 2010-11, as
prolonged monsoons slowed down construction activity during the year. In 2011-12, as
construction activity revived, albeit moderately, growth in pan-India cement demand
stood at 6.6 percent.
Table No. C2 – 13 : Cement Production and consumption in Eastern Region
Financial year Production MT Consumption MT
2007-08 23 25
2008-09 26 28
2009-10 29 33
2010-11 30 35
2011-12 31 37
2012-13E 35 40
2013-14P 39 43
2014-15P 42 47
2015-16P 47 51
2016-17P 52 56
P-Projected, E-Estimated Source:CRISIL Research
Ordinary Portland Cement (OPC): OPC, popularly known as grey cement, has 95 per
cent clinker and 5 percent gypsum and other materials. It accounts for 70 per cent of the
total consumption.
Portland Pozzolana Cement (PPC): PPC has 80 per cent clinker, 15 per cent pozolona
and 5 per cent gypsum and accounts for 18 per cent of the total cement consumption. It
is manufactured because it uses fly ash/burnt clay/coal waste as the main ingredient.
Portland Blast Furnace Slag Cement (PBFSC): PBFSC consists of 45 per cent clinker,
50 per cent blast furnace slag and 5 per cent gypsum and accounts for 10 per cent of the
total cement consumed. It has a heat of hydration even lower than PPC and is generally
used in the construction of dams and similar massive constructions.
2.4.3.2 Imports/Exports of Cement:
Cement being a low value high volume output has a very limited international trade. In
2010, international trade was 151 million tonnes and just 5% of the global cement
output. Bangladesh, Nigeria, USA, Iraq, Afghanistan and Singapore were the major
importers. The major exporting countries of cement were Turkey, China, Thailand, Japan,
Pakistan, Germany and India. It is a commodity which is freely traded and there are no
restrictions on its trade in most of the key trading countries.
1 8
Table No. C2 - 14: Cement/clinker Production and Export (in Million Tonnes)
Year Production Export %age Share (export
/production)
Cement Clinker Cement Clinker Cement Clinker
2006-07 155.64 121.75 5.89 3.11 3.78 2.55
2007-08 168.31 129.73 3.65 2.37 2.17 1.83
2008-09 181.60 138.78 3.20 2.90 1.76 2.09
2009-10(*) 160.75 128.25 1.59 3.12 0.99 2.43
2010-11(*) 168.29 131.69 1.52 2.63 0.90 2.00
(*) – The data from 2009-10 onwards excludes two cement companies, who discontinued
the membership from CMA.
Though India has been an exporter, the share of exports in its domestic production in the
last five years has actually witnessed a decline. In the long run also, cement exports are
likely to remain range bound to around 2 to 3 percent of the domestic production. India,
however, could have advantages in terms of the current and likely demand - supply gap
that exists in Bangladesh. There is alsoContinuous demand for exports to China and
other South East Asian countries. The nearness of the market provides it with the
positive cost differential and it could be developed as a long term destinations of Indian
cement.
2.5 Employment Generation:
The project will be having employment potential of about 500 persons.
1 9
3. PROJECT DESCRIPTION
3.1 Type of project including interlinked and interdependent project, if any
The proposed expansion project would include the following facilities:
i) Expansion of Ferroalloys plant by installation of 2X7.5 MVA SEAFs for manufacture
of Fe-Cr/Fe-Mn/Si-Mn/Fe-Si.
ii) Expansion of Sponge Iron Plant by installation of 1X350 TPD DRI Kilns.
iii) Iron Ore Beneficiation Plant with Pellet Plant of capacity of 6,00,000 TPA
iv) Expansion of Captive Power Plant with installation of 8 MW using DRI off gas and 2
X 16 MW AFBC utilizing dolochar.
v) Expansion of Steel Melting Shop
a) With installation of 2X15 T IFs with continuous casting machine for billets and
slabs
b) With installation of 1X20 T EAF with matching capacities of LRF, VOD, AOD and
continuous casting machine for billets and slabs.
c) With installation of 1X20 T Ladle Refining and Tilting Furnace.
d) With installation of 1X20 T VOD/VID/AOD.
e) With installation of 1X6/11 meters Continuous Casting Machine
vi) Installation of Rolling Mill with Reheating Furnace (Coal Gasifier /Pulverised Coal
Fired/Oil fired or Direct Feeding from CCM) for production 2,00,000 TPA Structurals
/Rebar /Rounds.
vii) Installation of Cement Grinding Plant 1X1000 TPD for annual production of 3,00,000
TPA PPC.
The proposed plants will be installaed at the existing premises of M/s Ispat Damodar Pvt.
Ltd at their works at Village. Nabagrm, PO: Digha, PS: Neturia, Dist: Purulia (WB).The
Project aims at utilizing the output of Iron ore beneficiation plant and pellet plant in the
Sponge Iron Plant. The output of Sponge Iron Plant will be utilized for Induction
Furnace/EAF units, The product of IF will be processed through LRF and Reheating
furnace and Rolling mill.The product of EAF will be utilized in Rolling mill after necessary
treatment in VOD/VID/AOD.. The fly ash produced in the captive power plant shall be
utilized in the making of Portland Pozolana Cement /Ordinary Portland Cement in Cement
Grinding Plant. The ferroalloys manufactured in Ferroalloy plant will be utilized in the
making of steel in IFs/EAFs. Waste heat of Sponge iron plant will be utilized in captive
power plant for generation of power. The dolchar and Coal fines of Sponge iron plant will
be used to generate power in CPP. The power generated at the proposed CPP will be
consumed for operation of the proposed plant and shortfall, if any, will be purchased
from the DVC grid. The finished rolled steel products and cement will be sold in the
market. As such the proposed project will be an interlinked project.
The project shall come over an area of 103 acres of land. Presently the company has in
its possession 78 acres of land. Additional 25 acres of land will be required for the
expansion project.
2 0
3028KLD of water will be required for the project including 1019 KL for the existing plant.
Water will be sourced from Panchet Dam reservoir over river Damodar is at a distance of
7.5 KM in the north of project site. The project is power intensive in view of Ferroalloy
units, induction furnace and electric arc furnace. The power demand would be to the tune
of 77 MW. The captive power plant will generate 48 MW which will cater to the power
demand. Balance 29 MW will be sourced from DVC grid system.
3.2 Location:
The proposed expansion project will be located at adjacent plots to the existing factory
premises of M/s Ispat Damodar Pvt. Ltd. and the land is covered in Survey of India Topo
Sheet No. F45C14 (73I/4). The location maps viz. topographic location map and map
with project boundary marked on it are given below. The Coordinates are Latitude: 230
39’ 00” North and Longitude: 860 47’ 51”.
3.3. Details of alternate sites considered and the basis of selecting the proposed
site, particularly the environmental consideration gone into should be highlighted
The proposed expansion project will be located in adjacent plots to the existing industrial
complex consisting of Ferroalloys Plant, Sponge Iron Plant, Induction Furnaces and
Captive Power Plant of M/s Ispat Damodar Pvt. Ltd. The site is already developed and
connected to road and rail network. Adequate transportation facilities are available for
transportation of product to important destinations.
By installing proposed project in adjacent plots to existing factory premises, M/s Ispat
Damodar Pvt. Ltd. is planning to increase the economy of existing plants and to earn
greater revenue by selling remaining ferroalloys, alloy steel products, cement, structural
steel etc. Hence the proposed project will be beneficial and techno-economically feasible.
Hence, no alternative site is analyzed. Financial and social benefits with special emphasis
on environmental consideration and benefit to the local people will be kept as top priority
for the proposed project.
The site selection has been made in view of the fact that the company has existing
facility in the location, the location is well connected by road and rail network; proximity
to raw materials and water. Environmental pollution control measures will be suitably
undertaken to restrict the pollution below the limits stipulated by CPCB/ WBPCB/ MoEF &
CC.
2 1
Fig. No. C3 – 1 : Index Map
P R O J E C T S I T E
2 2 Fig. No. C3 – 2 : Location Map
Govt. of India Toposheet No.
F45C10 & F45C14
2 3 Fig. No. C3- 3 : Vicinity Map
Govt. of India Toposheet No.
F45C10 & F45C14
2 4
Fig. No. C3 - 4 : Google Earth Map
Is p a t D a m o d a rP l a n t S i te
2 5
3.4 Size or Magnitude of Operation:
The table below depicts the size of the plant and magnitude of operation;
Table No. C3-1: Magnitude of Operation of Existing & Proposed Expansion Project
Sl.
No.
Facilities
Existing
Capacity
Proposed
Expansion
Capacity
Ultimate
Capacity
1. Ferro Alloys
(Ferro Chrome/ Ferro Manganese /Silico
Manganese/ Ferro Silicon) (SEAF)
4 x7.5MVA 2x7.5 MVA 6 x 7.5MVA
2. Sponge Iron Plant
60000 TPA
(2x100 TPD)
105000 TPA
(1x350 TPD) 165000 TPA
3. Iron Ore Beneficiation & Pelletisation Plant - 600000 TPA 600000 TPA
4. Captive Power Plant
(WHRB + Dolochar AFBC)
8MW (4MW
WHRB +
4MW AFBC)
40MW
(8MW WHRB +
2X16MW AFBC)
48MW
5. Steel Melting Shop & Continuous Casting
Machine for Billet & Slab :
Induction Furnace
Electric Arc Furnace (EAF)
Laddle Refining & Tilting Furnace (LRF)
VOD/VID/AOD
Continuous Casting Machine (CCM)
2x4T,1X8T
-
-
-
1x 6/11 mtrs.
2x15T
1x20T
1x20T
1x20T
1x 6/11 mtrs.
2x4T, 1X8T
2x15T
1x20T
1x20T
1x20T
2x 6/11mtrs.
6.
Rolling Mill with Preheating Furnace (Coal
gasifier/Pulverized Coal / Oil fired) - 200000 TPA 200000 TPA
7. Cement Grinding Plant - 1x1000TPD 300000TPA
3.5. Project Description with Process Details (a schematic diagram /flow chart
showing the project layout, components of the project etc. should be given)
The project facilities, size and magnitude has been detailed above. This is basically an
integrated mini steel mill with all the facilities. The finished products would include Structural
steels and Rebar, Portland Pozzolana Cement. Feroalloys which may be surplus after internal
use will also be sold or used in sister companies. As mentioned the components of the
project are interlinked.
2 6
The project would require make up water to th tune of 3028KLD which would be sourced
from Panchet Dam reservoir over rive Damodar at a distance of7.5Km in north direction of
project site. The demand of power would be 77 MW which will be partly met from internal
generation from Captive Power Plants and balance will be sourced from DVC grid.
78 acres of land is in the possession of the company in the existing project site which will be
utilized for the expansion project. Further land measuring 25 acres will be acquired. Project
Layout depicting the location of various facilities are given below.
Iron Ore Fines Coke Fines Bentonite
Lime Stone Washed Coal Dolomite
DoloChar
Iron Ore Conc. Pellets
Coal fines
Fly Ash
Tailings Sponge Iron
Dust Pig Iron Pig Iron
Dust Dust
Mn Ore Oxygen
Ferroalloy
Lime Stone
Dolomite
Slag
Furnace Oil /Producer Gas
Billet/slab
Cement Clinker Gypsum
Fly Ash
Rolled Product Portland Pozzolana Cement
Fig. No. C3 – 5: Over All Process Flow Chart Showing Components of the Project
I r o n O r eB e n e f i c i a t i o nP l a n t P e l l e t P l a n t S p o n g e I r o nP l a n tF e r r o a l l o y sP l a n t I n d u c t i o nF u r n a c e E l e c t r i c A r cF u r n a c e
L a d l e R e f i n i n gF u r n a c e V O D / V I D / A O DR e f i n i n gC o n t i n u o u s C a s t i n gR e h e a t i n gF u r n a c e
R o l l i n g M i l l C e m e n t G r i n d i n gP l a n t
2 7
Fig. No. C3- 6: Project Layout
2 8
Process details of various manufacturing facilities are given below.
3.5.1 Ferroalloys Plant:
Two numbers of 7.5 MVA capacity submerged electric arc furnaces will be installed in the
ferroalloys plant which already operates four numbers of 7.5 MVA SEAFs. The submerged
electric arc furnaces are designed to produce various types of bulk ferroalloys like Fe-Cr,
Fe-Si, Fe-Mn, and Si-Mnn . The submerged arc process is a reduction smelting operation.
The reactants consist of metallic ores (ferrous oxides, silicon oxides, manganese oxides,
chrome oxides, etc.) and a carbon-source reducing agent, usually in the form of coke.
Limestone may also be added as a flux material. Raw materials are crushed, sized, and in
some cases, dried, and then conveyed to a mix house for weighing and blending.
Conveyors, buckets, skip hoists, or cars transport the processed material to hoppers
above the furnace. The mix is then gravity-fed through a feed chute either continuously
or intermittently, as needed. At high temperatures in the reaction zone, the carbon
source reacts with metal oxides to form carbon monoxide and to reduce the ores to base
metal.
Smelting in an electric arc furnace is accomplished by conversion of electrical energy to
heat. An alternating current applied to the electrodes cause current to flow through the
charge between the electrode tips. The furnace shell is water cooled to protect it from the
heat of the process. A water-cooled cover and fume collection hood are mounted over the
furnace shell.
Normally, three carbon electrodes arranged in a triangular formation extend through the
cover and into the furnace shell opening. Pre-baked or self-baking electrodes are
typically used. Raw materials are sometimes charged to the furnace trough feed chutes
from above the furnace.
The surface of the furnace charge containing both molten material and unconverted
charge during operation is typically maintained near the top of the furnace shell. The
lower ends of the electrodes are maintained at about 1 to 2 meters below the charge
surface. Three-phase electric current arcs from electrode to electrode, passing through
the charge material. The charge material melts and reacts to form the desired product as
the electric energy is converted into heat. The carbonaceous material in the furnace
charge reacts with oxygen in the metal oxides of the charge and reduces them to base
metals. The reactions produce large quantities of carbon monoxide which passes upward
through the furnace charge. The molten metal and slag are removed (tapped) through
one or more tap holes extending through the furnace shell at the hearth level. Feed
materials may be charged continuously or intermittently. Power is applied continuously.
Tapping is intermittent based on production rate of the furnace.
The molten alloy and slag that accumulate on the furnace hearth are removed at one to
five hour intervals through the tap hole. Tapping typically lasts 10 to 15 minutes. In
some cases, tapping is done continuously. Tap holes are opened with pellet shot from a
gun, by drilling or by oxygen lancing. The molten metal and slag flow from the tap hole
2 9
into a carbon-lined trough, then into a carbon-lined runner which directs the metal and
slag into a reaction ladle, ingot molds, or chills (chills are low, flat, iron or steel pans that
provide rapid cooling of the molten metal). After tapping is completed the furnace is
resealed by inserting a carbon paste plug into the tap hole.
After cooling and solidifying, the large ferroalloy castings may be broken with drop
weights or hammers. The broken ferroalloy pieces are then crushed, screened (sized)
and stored in bins until shipment. In some instances, the alloys are stored in lump form
in inventories prior to sizing for shipping.
Production Capacity
The product profile and the production capacity proposed are presented in Table No. C3–1.
Submerged Electric Arc Furnace shall be used for the manufacture of any one of the four
alloys. It may be noted that the annual production capacity mentioned for individual
alloys is the maximum capacity possible on campaign basis.
Table No. C3-2: Annual Production of various Bulk Ferroalloys on Campaign basis
Sl.
No.
Description Capacity/
furnace in Tons
Existing
Capacity in Tons
Proposed
Capacity in Tons
Total Capacity
in Tons
1. Ferro Silicon
(Fe Si) *
7000 28,000 14,000 42,000
2. Silico Manganese
(Si Mn) *
14,850 59400 29,700 89,100
3. Ferro Manganese
(Fe Mn) *
19,800 79200 39600 1,18,800
4. Ferro Chrome
(Fe-Cr) *
13,500 54000 27,000 81,000
* It is proposed to manufacture the above alloys on campaign basis.
3.5.1.1 Ferro Manganese:
High carbon Ferro-manganese is commercially produced by carbothermic reduction of
manganese ores, primarily in electric submerged arc furnaces (SAF). The produced metal
typically contains around 78% Mn, 7% Carbon and around 40% MnO (high MnO slag
practice). An increasing part of the metal is refined to medium or low carbon manganese.
Electric furnaces used in the production of manganese alloys are generally circular and
have three electrodes, each connected to a separate electrical phase. The electrodes are
submerged in the burden & the electric current runs through the area below the
electrode tip where electrical energy is converted to heat. Produced slag & metal may be
tapped simultaneously from the sample tap-hole or separately in different slag and metal
tap holes arranged at a vertical distance of 0.5-1m. The Fe-Mn is smelted in electric
submerged arc furnace of rating 12000 KVA.
Coke is the common source of carbon for the ore reduction & the commonly used fluxes
are limestone & dolomite. These basic fluxes are added to give the slag suitable chemical
3 0
properties, smelting temperature and viscosity in order to secure good furnace operation
and a high manganese yield. The manganese ores vary widely in their content of
manganese, iron, silica, alumina, lime, magnesia and phosphorus. One important
parameter is the manganese to iron ratio.
One of the principal impurities in manganese ore is phosphorus. This is of critical concern
since most of the phosphorus enters the alloy on smelting rather than entering the slag.
Sulphur is not a problem since it is mainly dissolved & removed with the slag. The oxide
of iron, manganese, silicon, phosphorous etc. contained in the ore is reduced by coke
carbon in a submerged electric arc furnace.
As the raw materials move down in the furnace the higher oxides of manganese are pre-
reduced in the solid state to Mn3O4 and preferably further to MnO by CO gas formed in
the crater zone. The extent of the simultaneously running Boudouard reaction
(CO2+C=2CO) is responsible for the variation in carbon and electrical energy
consumption.
Then CO-rich gas from the furnace is used to heat the raw materials. Contrary to iron
production, separate pre-reduction units are not used in production of ferromanganese
due to its high investments & operating costs. After further heating, the reduced ore and
added fluxes start melting at temperature of 12500 C to 13000 C. The coke remains solid,
so below this area there is a permanent coke bed. The melting together of ores & fluxes
and reduction of MnO dissolved in the slag phase take place in the furnace. Limestone
and dolomite are common fluxes providing necessary CaO & MgO to the slag phase. The
metal will be collected in the bottom of the furnace from where it is tapped together with
the slag. The coke bed starts approximately at the tip of the submerged electrodes. It
constitutes a permanent reservoir of coke. The relative amount of coke in the charge mix
determines whether the coke bed increases, decreases or stable in size. In addition to
being the chemical reduction agent it is also the heating element of the process where
the electric current runs and Ohmic energy is produced. The electrical feature of coke bed
is of great importance as it determines the energy and temperature distribution. The
production rate, product quality and stability of the furnace operation are mainly
determined by parameters in the coke bed.
Table No. C3 – 3 : Raw materials for Fe -Mn and their chemical composition
Sl. No. Constituents Mn Ore Dolomite Coke
1 MnO 46 - 48% -- --
2 CaO + MgO -- 55% --
3 Al2O3 5% -- --
4 Fe2O3 5 - 15% -- --
5 Ash -- -- 20%
6 Fixed Carbon -- -- 60%
7 Volatile Matter -- -- Balance
3 1
Charge Composition:
Charge composition for production of one ton of ferromanganese would include the following;
Table No. C3 - 4: General Composition of Charge:
The main objectives of the ferromanganese furnace operation are:
• To operate on a stable & high load
• To minimize coke & energy consumption
• To produce metal and slag of required composition
• To secure a high yield of manganese
• To minimize emission of greenhouse gases and noxious compounds
Optimum operation of a ferromanganese furnace occurs when the power consumption is
low and furnace is operated on a stable and high load. Maintaining control of the addition
and consumption of carbon is perhaps the most important issue for an operator of a
submerged arc reduction furnace, whether the product is ferromanganese, Silico-
Manganese or any other alloy. In principle, a furnace must receive and consume the
same amount of carbon. The objective of the carbon control is to feed the furnace with
exactly the right quantity of reductant required for the intended work of reduction in
process. Quality of Ferro manganese is given in table below.
Table No. C3 - 5: Typical Quality of Ferro- Manganese
Constituent Composition %
Manganese 65-70
Silicon 2.50 Max
Carbon 6-8
Phosphorous 0.55 Max
Sulphur 0.50 Max
Size 10 - 150 mm
Packing In HDPE Bags of 1.0 MT each or as per customers requirement
The slag contains considerable amount of manganese (38%-42%) and negligible amount
of phosphorous. This slag can be used as feed material in production of Silico Manganese
and low carbon Ferro Manganese. As such the alloy produced has less phosphorous.
Ferro Manganese thus produced has 76-78% Mn. The process description and flow sheet
is given below.
Input Material Amount in Ton /Ton
of Finished Product
Mn Ore 2.30 T
Dolomite 0.35 T
Low Ash Met Coke 0.60 T
3 2
Fig. No. C3 – 7 : Process Flow Diagram of Ferro Manganese Plant
Manganese Ore Flue Dust
Dolomite
Low Ash Gaseous Emissions Coke
Metal and Slag
3.5.1.2 Silico-manganese:
Silico-manganese (Si-Mn) is also produced by carbothermic reduction of oxidic raw
materials in electric submerged arc furnaces. The same type of furnace is used for
production of high carbon Ferro-manganese (HC Fe-Mn). Operation of Silico-manganese
process is often said to be more difficult than the FeMn process. The main reason is
probably that a higher process temperature is needed to attain the wanted Si
specification of the metal.
Silico Manganese is also employed as a complex de-oxidant in steel making and melting
(upon melting together with aluminum) to produce a complex Manganese silicon
aluminum (M-S-A) de oxidant. The composition of some, grades of Silico-Manganese
grades Si-Mn 17, Si-Mn 14 & Si-Mn 10 may be delivered with a phosphorous content up
to 0.5%.
Standard Silico-manganese with 18-20% Si & 70% Mn is typically produced from a blend
of MnO rich slag from the HC Fe-MN process with 35-45% MnO, manganese ores,
quartzite, (Fe) Si-remelts or off grade qualities and coke. Usually about one-quarter of
the manganese is supplied as ore, since this gives a better furnace operation than Fe-
Mnslag as the only source of MnO. The supplies of MnO –rich slag may also be limited.
Sometimes minor amounts of MgO-containing minerals are added e.g. dolomite [CaCO3.
MgCO3] or olivine [2MgO.SiO2].
The economy of Silico-manganese smelting is enhanced by minimizing the loss of
manganese as metal inclusions and MnO dissolved in the slag. The discard slag from the
Si-Mn process normally contains 5% to 10% MnO. In order to reduce the overall losses of
the processes, any amount of metal fines and remelts from the production process are
usually recycled to the furnace. The HC Fe-Mn slag is a very pure source of manganese
P r o p o r t i o n i n ga n d M i x i n g S u b m e r g e dA r c F u r n a c eT a p p i n g o fM o l t e n M e t a lB r e a k i n g &C l e a n i n gP a c k i n g o fF i n i s h e d F e - M nM e t a l R e c o v e r yP l a n t T e s t i n g S t o r a g ea n d D e s p a t c h
3 3
because the easily reduced impurities in the ores have been taken up by the HC Fe-Mn
metal in the preceding process step. The content of impurities in Si-Mn metal, especially
phosphorus, is therefore controlled, not only by the selection of manganese ore but also
by the relative amount of manganese ores and HC Fe-Mn slag in the raw material mix.
Table No. C3 - 6: Grades of Silico Manganese
Grade Si % Mn at Least %
SiMn26 26.00 60.00
SiMn20 20.00-25.9 65.00
SiMn17 17.0-19.9 65.00
SiMn14 14.0-16.9 60.00
SiMn10 10.0-13.9 62.00
SiO2 is reduced along with MnO in the Si-Mn process. As the former oxide is far more
stable than the latter, a process temperature of 16000C to 16500C is needed to produce
an alloy with 20% Si and discard slag low in MnO. Fe-Mn slag has a relatively low melting
temperature compared with Mn-ores. Accordingly, a high share of Fe-Mn slag will tend to
give lower process temperatures. The Si-level that can be achieved by carbothermic
reduction of the oxidic raw materials seems to be limited to 20% Si.
Low carbon Silico-manganese (LC Si-Mn) with 14-17% Si is produced by upgrading
standard Si-Mn alloy by the addition of silicon wastes from the ferrosilicon industry. Such
wastes are relatively cheap sources of silicon, so this practice can even be favorable for
production of Standard Si-Mn since it greatly reduces the specific energy consumption
and consequently increase the production capacity of furnace.
The specific power consumption for production of standard Si-Mn from a mixture of
Mnore, HC Fe-Mn slag & Si-rich metallic remelt is typically 4000 kWh/ton of metal,
dependent primarily on the amount of metallic added to the feed. The power
consumption will increase with the Si-content of the metal produced, and also with the
produced amount of slag per ton of metal. Each additional 100 Kg of slag produced will
consume 50kWh of electric energy. Approximately 100kWh per ton of metal & some coke
will be saved if the ore fraction of the charge is reduced to MnO by the CO gas ascending
from the smelt reduction zone.
Table No. C3 - 7: Raw materials for Si -Mn and their chemical composition
S. No. Constituents Mn Ore Quartz Coke
1 MnO 38-40% -- --
2 SiO2 3% 97% --
3 Al2O3 5% 1% --
4 Fe2O3 17% 0.5% 0.5%
5 Ash -- -- 20%
6 Fixed Carbon -- -- 60%
7 Volatile Matter -- -- Balance
3 4
Charge Composition:
Table No. C3 – 8: General Charge Composition in Ton per ton of finished product
Input Material Amount in Ton /ton
of finished product
Mn Ore 1.80 T
Fe-Mn Slag 0.60 T
Dolomite 0.35 T
Low Ash Met Coke 0.60 T
Casing Sheet 0.01 T
Silico manganese is more stable compounds than manganese carbides. Therefore the
higher the Si content in the Silico manganese less is its carbon content. 20% Silico
manganese is used for smelting of medium carbon Ferro manganese and 30% used for
production of metallic manganese.
Silico Manganese is an alloy of silicon, manganese, iron and some other elements in
small percentage. Silicon and manganese are the principal de-oxidants in steel making.
Silico Manganese is used on a large scale as an alloying element in the manufacture of
spring /Alloy steel/ stainless Steel/ tool steel. Silicon has positive effect on mechanical,
physical and chemical properties of steel and is widely used in manufacture of structural,
tool grade and special steel.
The production process of transformer grade steel also requires silicon. Manganese has
the additional property of controlling the effect of sulphur by forming Manganese
Sulphide, which floats out of liquid steel. The quality of silico manganese produced is
given in following table.
Table No. C3 - 9: Quality of Silico-Manganese
Constituents Composition %
Manganese 60 - 65 %
Silicon 14 -17 %
Carbon 2.50% max
Phosphorous 0.35 % max
Sulphur 0.04 % max
Size 10 - 150 mm
Packing In HDPE Bags of 1.0 MT each or
as per customers requirement
3 5
Fig. No. C3- 8: Process Flow Diagram of Silico-Manganese Plant
Manganese Ore Ferro manganese Slag Flue Dust
Dolomite Gaseous Emissions Low Ash
Coke
Metal and Slag
Silicomanganese
3.5.1.3 Ferro-Silicon
Silicon is a metalloid having an atomic mass of 28.086, density of 2.37 gm/cm3, melting
point of 1414°C & boiling point of 2287°C. In its electric properties, silicon is a semiconductor.
Silicon reacts with oxygen to form silica (SiO2), whose melting point is 1710°C. Silica can
exist in several modifications: quartz, tridymite, cristobalite, and silica glass. Ferro-silicon is
made in submerged arc provided with three-phase transformers having power rating of
7,500-9,000 kVA operating at a voltage of 145-175 V. Generally, Semi- Closed-type
stationary or tilting furnaces are mainly used for manufacturing ferro alloys.
The physical state of the charge is of prime importance for successful operation of a furnace.
The charge materials must have constant moisture content and lumps of coke breeze and
quartzite should have only slightly varying size. The process of making Ferro-silicon
produces little slag; this is tapped together with the metal through the same tap hole.
Physico-chemical Conditions of the Process:
The reaction of reduction of silicon from silica occurs with solid carbon:
SiO2l + 2COg 2CO2g + Sil
2CO2g + 2Cs 4COg
SiO2l + 2C Sil + 2COg
A typical reaction producing ferro-silicon is shown below:
Fe2O3 + 2SiO2 + 7C 2FeSi + 7 CO
During the course of the reaction of silicon reduction is determined by the applied
pressure of carbon monoxide.
S u b m e r g e dA r c F u r n a c eT a p p i n g o fM o l t e n A l l o yB r e a k i n g &C l e a n i n gP a c k i n g o fF i n i s h e d F e - M nM e t a l R e c o v e r yP l a n t T e s t i n g , S t o r a g ea n d D e s p a t c h
3 6
In an industrial furnace for smelting ferro-silicon, the pressure at the top is equal to
atmospheric and the partial pressure of carbon monoxide that is established in the
reduction zone is slightly above atmospheric pressure. With a constant value of P2CO,
the equilibrium constant for a 45 per cent alloy is lower than that for 75 per cent alloy,
which means that a lower temperature is required for making the former.
During a melt for ferro-silicon, the iron dissolves the reduced silicon thereby removes it
from the reaction zone and thus causes the reaction to be proceeded from left to right.
The mechanism of reduction of silica is not described exhaustively in the above resulting
reaction. An intermediate oxide – silicon dioxide, and silicon carbide can also form in the
process. Carbon causes final reduction of silica. The latter reacts with carbon both at the
surface of lumps of coke breeze and in their core upon having penetrated through pores
and fissures.
Samples taken from lower levels in the furnace usually contain much silicon carbide.
According to P. V. Geld, the formation of SiC from the elements can only occur with large
kinetic difficulties and requires a high mobility of atoms, which can only be achieved at
temperatures above 1700°C. On the other hand, the reaction is thought to be probable.
Thus, silicon carbide forms as an intermediate product. Solid inclusions of silicon carbide,
if present in the slag, can impair the fluidity of already tough siliceous slags.
At corresponding temperatures, silicon carbide can be destroyed by metals and oxides,
its destruction by iron following the reaction SiCs + Fel = FeSil + Cgr
At high temperatures and in the presence of a solvent (iron with silicon) the aluminium
and calcium, if present in the charge, are reduced by carbon and silicon. Industrial
grades of ferro-silicon can thus contain up to 2 per cent Al and up to 1.5 per cent Ca.
Under the reducing conditions, a great amount of phosphorus from the charge and ash
pass to the melt, while sulphur is volatilized in the form of SiS2.
In operation with rich quartzites, the process occurs with little slag, only 2-6 per cent of
the mass of melt. The slag is formed from the alumina, calcium oxide and magnesia that
are present in quartzite and coke breeze. A typical composition of slag is 35-39 per cent
Al2O3, 22-26 per cent SiO2, 9-18 per cent CaO, 7-13 per cent BaO, 1-3 per cent MgO, 7-
14 per cent SiC, and 0.2-2.0 per cent FeO. The melting temperature of slag is 1650-
1700°C, i.e. low enough to cause slagging of the hearth. In practice, a trend is to operate
with silica-rich quartzite and low-ash reducer in order to minimize the bulk of slag of this
composition.
The charge materials, prepared as indicated earlier, should be stored separately in
furnace bay bins. Before supplying to the furnace, they should carefully be weighed and
mixed. A dosing carriage is loaded first with coke breeze, then with turnings and
quartzite, and finally with graphitization wastes.
3 7
Table No. C3 – 10: Raw materials for Fe- Si and their chemical composition
S . No. Constituents Quartz (%) Charcoal (%) Iron scrap (%)
1 Si O2 98 --- ---
2 Al2O3 1 -- --
3 Fe 0.6 -- 94
4 S & P 0.05 -- 0.05
5 Ash -- 20 --
6 Fixed carbon -- 60 --
7 Volatile matter -- Balance --
Charge Composition:
The general composition of a charge in ton, may be as follows:
Table No. C3 – 11 : General Charge Composition in Ton per ton of product
Material FS45 FS75
Quartzite 3.00 3.00
Coke breeze 1.41 1.44
Iron turnings/ Mill Scale 170 kg 38 kg
Fig. No. C3 - 9: Process Flow Diagram of Ferrosilicon Plant
Quartzite Iron Turning/Mill scale Flue Dust
Coke breeze Gaseous Emissions
Metal and Slag
Silico-Ferrosilicon
3.5.1.4 Ferrochrome:
More than 80% of the world production of ferrochromium is used in stainless steel
making. There are four grades of ferrochromium produced commercially, characterized
broadly in terms of their carbon and chromium contents;
• High carbon ferrochromium (Cr : >60%, C : 6-9%)
• Charge chrome (Cr : 50-60%, C : 6-9%)
P r o p o r t i o n i n ga n d M i x i n g S u b m e r g e dA r c F u r n a c eT a p p i n g o fM o l t e n A l l o yB r e a k i n g &C l e a n i n gP a c k i n g o fF i n i s h e d F e - M nM e t a l R e c o v e r yP l a n t T e s t i n g , S t o r a g ea n d D e s p a t c h
3 8
• Medium carbon ferrochromium (Cr : 56-70%, C : 1-4%) and
• Low carbon ferrochromium (Cr 56-70%, C : 0.015-1.0%)
The demand for low-carbon ferrochromium, produced by reacting Fe-Cr-Si alloy with a
Cr2O3CaO based slag, has decreased dramatically during the last two decades mainly due
to the commercial development of AOD and VOD processes which allow removal of
carbon from stainless steels with acceptable loss (oxidation) of chromium"'. These low
and ultra-low carbon ferrochromium grades are used mainly for final adjustments of
composition and for super alloys which are melted in coreless induction furnaces. The
ultra-low ferrochromium, produced by auminothermic reduction of chrornite, is relatively
pure but very expensive and consequently, not widely employed in the steel industry.
As a result the high-carbon ferrochromium/Charge chrome has become the most widely
produced and consumed grade of chromium-containing ferroalloys. The production of
high carbon ferrro-chromium is based on reduction smelting of chromite ore with coke in
the presence of silica in a submerged arc furnace.
M/s Ispat Damodar Pvt. Ltd proposes to set up 2 X 7.5 MVA in addition to the existing 4
X 7.5 MVA capacity high carbon ferro chrome plant keeping in view the present market
demand. The process description is as below.
The process of Ferrochrome manufacture involves the following principal steps:
i) Agglomeration of Chrome ore fines to form briquettes or pellets.
ii) Blending of the Charge
iii) Preheating of the Charge
iv) Smelting
v) Tapping of molten metal and slag
vi) Gas Cleaning
• Pelletization/Briquetting
The electric smelting process necessitates the use of a highly permeable lumpy charge
for easy dissipation of reaction gases and smooth functioning of furnaces. Therefore the
concentrates and fines are agglomerated first, since they cannot be utilised directly. Out
of the several agglomeration process, available as alternatives like modulizing, sintering,
pelletizing and briquetting, the last is mostly used in by Indian manufacturers.
Pelletization route is also most used, so far, in other countries of the world.
The briquetting process of agglomeration is used by many ferrochrome plants in India
prominent among them being FACOR, IMFA, and ICCL plants. In this process the chrome
ore fines and the concentrates (grain size preferably upto 1 mm, or still better, to 0.5
mm) are mixed with suitable binders and/or lime, and fed into a double roll briquetting
press, to be moulded into shapes, usually pillow like shapes of 50 x 40 x 25 mm or 76 x
46 x 22 mm in dimensions by the application of external pressure on to the material. In
Indian plant Moalsses is the usual binder used*. A schematic description of a briquttingn
process is given below. Briquetting plant having 2X25 TPH has been envisaged in the
proposed project
3 9
As explained in Figure No. C3-10 below, the chrome ore fines received from mines are
first dried in dryer. The dry ore is mixed with bentonite, hydrated lime and molasses, and
the green mix is then fed to the briquetting presses. The presses compact the mixture at
high pressure to form green briquettes. The green briquettes are stored in the storage
yard for curing. After curing at ambient temperature for 24- 48 hrs, the briquettes
become stronger and are fed into Submerged Arc Furnaces.
Making of Briquettes:
Converting fines or ore concentrates in to briquettes is necessary due to the following
reasons;
• Direct use in the furnace is hazardous.
• It decreases porosity and causes eruptions
• Cr2O3 loss through slag is extremely high.
• Reduces effective volume of the furnace.
• Yield & productivity comes down considerably.
• Creates unstable condition for operation.
Process employed for making briquettes:
• Feeding of dry fines / concentrate & binders.
• Batching in desired proportions.
• Thorough mixing in pan mixer.
• Pressing in briquette press using roller segments.
• Storage and curing.
Binders used
• Hydrated lime
• Molasses
Specification of hydrated lime
Ca (OH) 2 : 65 % min
SiO2 : 8 % max
Al2O3 : 7 % max
MgO : 3 % max
Size : 200 mesh
Specification of molasses:
Sp. Gravity : 1.38 min
Brix : 800 min
Fig. No. C3
Major Raw Material Handling Equipments:
The briquetting plant shall be layed out in two streams; each stream with a capacity of
25 TPH. Equipments for one stream are listed below
Fig. No. C3-10: Flow chart for making briquettes
Major Raw Material Handling Equipments:
The briquetting plant shall be layed out in two streams; each stream with a capacity of
25 TPH. Equipments for one stream are listed below 4 0Flow chart for making briquettes
The briquetting plant shall be layed out in two streams; each stream with a capacity of
4 1
• 2 dryers of capacity 15TPH.
• One Pan Mixture of capacity 25TPH.
• One Press of capacity 25 TPH each.
• One air compressor.
• Two vibrating screens.
• Molasses lifting pump.
• Lime hoist.
• Nos of conveyors shall be put to match the flow circuit.
Raw material requirement
1- Chrome fines 183 TPD.
2- Hydradeted Lime Powder 8 TPD.
3- Molasses 12 TPD.
Pollution control measures at Briquetting Plant
Only fugitive emission will be generated in briquetting plant while drying chrome fines at
dryer & at different transfer points of fines. M/s Ispat Damodar Pvt. Ltd. proposes a
separate bag filter dry fog system for its briquetting plant to control fugitive dust
emission. M/s Ispat Damodar Pvt. Ltd. assures to maintain particulate emission level as
per government statutory norms fixed by State Pollution Control Board, West Bengal.
Smelting:
The raw materials will be taken in proper proportion in accordance with a charging table
specifying the charge composition through furnace charging conveyor and the mixed
charge will be taken in the furnace top bunker locate in the furnace bay. The charge
materials will be fed to the furnace with the help of vibrating feeder followed by a
discharge chute arrangement through a number of feed openings at the furnace top.
Charging will be done periodically after allowing the previous charge to melt. The
following measures are essential for normal and smooth operation of the furnace.
1. The charge should always have the specified composition;
2. The charge should be given evenly to each electrode;
3. The top of the melt should not be allowed to overheat as this will increase the
consumption of electrical energy;
4. Charge cones should be pierced periodically.
Disturbance in the furnace run may be caused by various factors. Most often they are
linked with an inappropriate composition of the slag and with a deficiency or excess of
reducer in the charge.
In a melt for high carbon Ferro-chrome, much slag forms in the hearth that is why there
is single large pool of molten metal under the electrodes, instead of individual pots as is
the case with slag less process for smelting siliceous alloys. A great part of the energy is
lost in the slag to raise its temperature above that of the molten metal.
4 2
During smelting, electrodes are slipped from time to time to take care of the electrode
consumption due to arcing or burning. The rate of electrode slipping is about 2 Cm in two
hours. The electro thermal process is generally used for the production of Charge
Chrome, through now there are quite a few plants with PLASMA technology. And quite a
few other electrical power saving technologies like Kawasaki, Inmetco, Krupp Codir, etc.
process are in the final stages of commercialization. In fact Kawasaki process is already
being economically operated in Japan.
In the generally used electro thermal process, the furnace is either a closed-top or semi-
closed one, operated on a continuous basis. In which the chrome ore is reduced by
carbon, with electric power producing the high temperature necessary for the reactions.
The stationary type submerged arc smelting furnace is provided with three electrodes,
Soderberg continuous self-baking type, having a variable pitch circle. The smelting
operation aims at reducing the Iron and Chromium Oxides, while major portion of the
other constituents of the ore go into the slag. The slag volume is generally 1.2 to 1.4
times, in weight of the metal produced.
In India, the reductant generally used in Charge Chrome production, are coke and coal, a
judicious mixture of which is decided purely from tech no-economic reasons, in spite of
the high ash contents of these reductants leading to higher slag volumes & higher
phosphorous in the metal. However, economics permitting, imported coke or low-
phosphorous Giridih coke or similar suitable reducing agent is made a constituent of the
reductant mix for charge chrome furnace, in order to control the total input of impurities.
Table No. C3 -12: Raw materials for Fe- Cr and their chemical composition
Sl.
No.
Constituents Chromite
Ore hard
lump (%)
Chromite
Ore fines
(%)
Quartz
(%)
Dolomite
(%)
Magne
site
Coal % Coke
(%)
1 Cr2O3 40-44 min 52-52 max -- -- -- -- --
2 FeO (Total) 11 max 13 max 0.6 2.0-2.5 -- -- --
3 Al2O3 10 max 10 max 1 0.8-1.5 -- -- --
4 SiO2 12 max 5 max 98 4.5-5.8 -- -- --
5 CaO 4-6 4-6 0.3 28-30 45 -- --
6 MgO 15-18 10-12 0.2 18-20 -- -- --
7 Sulphur (as SO3) 0.005 0.005 -- -- -- -- --
8 Phosphorous
(as P2O5)
0.01 max 0.01 max -- -- -- 0.01 max 0.015 max
9 Cr:Fe 1.8:1 - 2:1 --
10 Ash -- -- 12 max 14 max
11 Fixed Carbon -- -- 50 min. 84 min
12 Volatile matter -- -- 38% max 2 max
13 Moisture 10 max 8 max
4 3
Table No. C3 - 13: Charge Composition and utility consumption:
Raw Material and Utilities Consumption per tonne of charge
chrome (Salable Product)
Chromite ore hard lump (+ 50 mm size) 0.381 T
Chromite ore briquettes 1.9 T
Chromite ore friable lumps 0.127 T
Quartize 0.279 T
Magnesite 0.05 T
Coal 0.293 T
Coke 0.501 T
Electricity 1. Around 3050 KWH to 3200 KWH
(preheating facilities)
2. Around 3800 KWH to 4000 (with only
briquetted charge without preheating)
The slag volume for production of every tone of Ferro-chrome is expected to be about
1.25 tones and chromium recovery about 85% from charge to molten metal.
It may be mentioned, however, the above charge composition is only representative,
applicable for the analysis of the raw materials considered and any change in the
composition of the raw materials will correspondingly affect the charge composition.
The following steps are involved in the production process of charge chrome:
(i) Removal of volatiles & moisture from the charge thru heating of the charge by the
latent heat of the off gases of the furnace,
(ii) Reduction of Iron & Chromium oxides, with simultaneous formation of Iron &
Chromium carbides.
(iii) Melting of the reduced elements, resulting in formation of molten ferro-chrome.
(iv) Formation and melting of slag.
(v) Reduction of chromium and silicon from the slag.
The principal reactions taking place in the furnace are:
2/3Cr2O3 + 18/7 C = 4/21Q7C3 + 2 CO
FeO + C = Fe + CO
1/3 Cr7C3 +1 /3Cr2O3 = 3Cr + CO
The melting temperature maintained in charge chrome is around 1600°C. The operating
voltage for the process varies between 150V to 260V, averaging at around 200V.
Tapping of Molten Metal and Slag
The metal and slag will be tapped simultaneously, on an average, in every alternate two
hours, or in larger intervals depending on availability of power, into refractory lined ladles
mounted on ladle cars. Since it is desired to hold the slag & metal in a ladle, use of top
pouring type ladles has been contemplated.
4 4
Ladles used for tapping of metal or slag are to be suitably lined with refractory like high
alumina to make them withstand the high working temperature and thermal shock. Such
refractory linings require certain amount of patch repair after every use of the ladles and
also are to be completely changed with a total relining of the ladle after a number of
uses. The checking and repair/relining of ladle refractory will be done in ladle preparation
bay where the ladles will also be heated to make them moisture free and also avoid the
chilling of molten metal during tapping. Ladles will be heated in vertical position by a
ladle pre-heater.
The properly lined and preheated ladle will be taken to the furnace tapping region with
the help of transfer cars and placed below the tap holes. The tap hole will be opened with
the tap hole opening device using oxygen. After the tapping is over the tap hole will be
closed again with the help of mud gun. The filled up ladle will be lifted by crane and
taken to the casting area where the slag is removed and cast. The slag is then manually
broken and removed to the slag yard. The empty transfer car will be sent back to ladle
preparation bay for loading of the next ladle for the tap.
After the slag is removed, the ladle containing the metal will be taken to the casting area
and cast into ingots adopting floor casting method. The empty ladle will be sent to the
ladle preparation bay by transfer car. Substantial losses take place during slag removal,
casting and breaking of cast ingots to finished products. The metal loss to be considered
during this stage is 2% of the molten metal and this to be considered while arriving at
the saleable tonnage of Ferro-chrome.
Product & Slag Handling
After cooling down of the metal, they are removed to the finished & packing bay where
they will be broken down to small pieces by pneumatic hammers/chisels to pieces of size
100 to 150 mm.
• Metal Handling:
Metal cakes are handled with the aim of removing slag contamination and meeting the
size specification. The moulds are broken manually to serve both the purpose. Manual
sorting is done to separate out slag. In certain cases chipping is necessary to separate
out sand and slag contamination from the metal surface. As a result of the metal
handling process the following out puts are generated.
Sized pure metal shifted to sales yard for dispatch after confirmatory analysis. Slag &
metal contaminated mixture shifted to Metal Recovery Plant (MRP) for further processing.
Undersized metal particles containing small quantity of slag particles (sifted to MRP for
further processing). The cakes will be transported to the finishing & storage area with the
help of transfer cars. A 10 TPH Metal Recovery (Jigging Plant) has been envisaged for
recovery of Fe-Cr from the slag in the proposed expansion in order to obviate safe
disposal of ferrochrome slag
• Metal Recovery from Slag and Mixture:
Some quantity of mixtures gets generated at various point of handling of molten metal &
slag. Manual separation of metal and slag from the mixture is not economical beyond
certain level. So such mixtures are processed in the Metal recovery plant for metal
recovery. In the Metal recovery plant the mixture is crushed to smaller size with the h
of a jaw crusher followed by cone crusher in order to ensure better liberation of metal.
The mixture is subjected to gravity separation in water medium in the jigs. The liberated
metal is separated which contains still some amount of slag mix and nonme
They are separated out by screening and manual picking.
The same process is repeated for processing of pure slag. Pure slag is not actually pure.
It contains metal content to the extent of 4
entrapments. Undersize metal particles are processed in the jigs only to remove the
small quantity of nonmetallic content present in them.
After making the fines and chips sized output from metal recovery plant free from non
metallic contents or reducing it to
for dispatch after confirmatory analysis.
4-4.2% of saleable metal (Ferro Alloys). The entrapped metal is recovered from the slag
in the metal recovery plan
� Feed Hoppers
� Drizzly Feeder
� Jaw Crusher
� Cone Crusher
� Vibrating Screen
� Storage Hopper
� Jig Feed Hopper
� Hydraulic Jig
� Other accessories such as Motors, conveyors etc.
Fig. No. C3-11
Metal Recovery from Slag and Mixture:
Some quantity of mixtures gets generated at various point of handling of molten metal &
slag. Manual separation of metal and slag from the mixture is not economical beyond
certain level. So such mixtures are processed in the Metal recovery plant for metal
recovery. In the Metal recovery plant the mixture is crushed to smaller size with the h
of a jaw crusher followed by cone crusher in order to ensure better liberation of metal.
The mixture is subjected to gravity separation in water medium in the jigs. The liberated
metal is separated which contains still some amount of slag mix and nonme
They are separated out by screening and manual picking.
The same process is repeated for processing of pure slag. Pure slag is not actually pure.
It contains metal content to the extent of 4 – 4.2 % mainly in the form of nodules and
Undersize metal particles are processed in the jigs only to remove the
small quantity of nonmetallic content present in them.
After making the fines and chips sized output from metal recovery plant free from non
metallic contents or reducing it to the desired level, they are handed over to sales yard
for dispatch after confirmatory analysis. The slag generated from the furnaces contains
4.2% of saleable metal (Ferro Alloys). The entrapped metal is recovered from the slag
in the metal recovery plant (MRP). The metal recovery plant consists of:
Feed Hoppers
Drizzly Feeder
Jaw Crusher
Cone Crusher
Vibrating Screen
Storage Hopper
Jig Feed Hopper
Hydraulic Jig
Other accessories such as Motors, conveyors etc.
11: Process Flow Diagram of Metal Recovery Plant 4 5
Some quantity of mixtures gets generated at various point of handling of molten metal &
slag. Manual separation of metal and slag from the mixture is not economical beyond
certain level. So such mixtures are processed in the Metal recovery plant for metal
recovery. In the Metal recovery plant the mixture is crushed to smaller size with the help
of a jaw crusher followed by cone crusher in order to ensure better liberation of metal.
The mixture is subjected to gravity separation in water medium in the jigs. The liberated
metal is separated which contains still some amount of slag mix and nonmetallic portion.
The same process is repeated for processing of pure slag. Pure slag is not actually pure.
4.2 % mainly in the form of nodules and
Undersize metal particles are processed in the jigs only to remove the
After making the fines and chips sized output from metal recovery plant free from non-
they are handed over to sales yard
The slag generated from the furnaces contains
4.2% of saleable metal (Ferro Alloys). The entrapped metal is recovered from the slag
t (MRP). The metal recovery plant consists of:
Metal Recovery Plant
4 6
Gas Cleaning:
There would be 1 Nos. dry type pollution control system. The system uses Gas Cooler
and Bag Filter for the gas cleaning purpose. The high gas temperature after combustion
above melt level is mostly absorbed by the charge mix above melt zone and further
cooled by dilution in air at the gap between furnace and gas hood. After cooling, the gas
is transported to FD gas cooler by means of gas ducts. From the gas cooler, the gas
enters a Bag Filter unit via the ID Fan. This is a positive pressure type bag filter unit. The
ID Fan creates a positive pressure inside the filter bags, which does not allow dusts to go
out. The cleaned gas finally passes out to the atmosphere through a stack attached to
the Bag House.
However, the promoters of the proposed project have already taken up initiatives to
make an assessment of environmental impact.
Major Capital Equipments
The equipments for a typical charge-chrome industry is broadly classified into the
following groups on the basis of the functional requirements:
(i) Raw material storage, handling and preparation.
(ii) Agglomeration
(a) Pelletizing Route :
The system will include grinding and filtering facilities, Disc Pelletizer, shaft type sintering
furnace, etc.
(b) Briquetting Route:
It will include Double Roll press, in addition to other supporting facilities:
(iii) Raw Materials Handling for Smelting:
This will include, in addition to the common facilities for such systems for dosing &
charging, preheating Kiln (in plants using hardened pellets as the feed), etc.
(iv) Smelting Furnace and Auxiliaries:
This will include furnace of circular design having a stationary hearth and semi-closed or
closed top design, with three phase self-baking continuous soderberg electrodes;
electrode holder assembly, as well as the electrode slipping mechanism; copper contact
clamps holding the electrodes; copper bus bars; water cooled copper bus-tubes;
connector terminal and copper flexibles.
(v) Tapping & Finishing:
The cast house is generally equipped with mud-gun for closing the tap holes, Oxygen
lancing system for opening of tap holes, refractory lined ladles for holding the taped out
metal and slag, slag granulation plants, suitable overhead cranes, crane weighers, mobile
breaker, crusher, etc.
4 7
Clean gases
Fluxes Chromo ore briquettes
Bag filter
Coke
Flue Dust
Metal and Slag
Granulated Slag
Fig. NO. C3-12: Schematic Process Flow Diagram of Ferrochrome Plant
Fig No. C3 – 13: Process Flow Diagram of Ferrochrome Plant
B l e n d i n g S m e l t i n gF u r n a c eT a p p i n g o f m o l t e na l l o y a n d s l a gB r e a k i n g a n dC l e a n i n gP a c k i n g o f F i n i s h e dF e r r o c h r o m eM e t a lR e c o v e r y P l a n t T e s t i n g , S t o r a g ea n d D e s p a t c hS l a gg r a n u l a t i o n
4 8
Table No. C3-14: Technical Specifications of Submerged Electric Arc Furnace- 7.5 MVA
S. No. Parameters Unit Value / Features
1. Installed capacity t/yr 13500
2. Nominal tap weight T 7.1
3. Tap to tap time Min 90
4. Heat size with hot heel T 35
5. Type of furnace High power AC arc furnace with eccentric
bottom tapping water-cooled sidewall
panels and roof, cooling electrodes with
water spray, oxygen-lancing facility
6. Transformer rating MVA 7.5 MVA (with 20% over-loading)
7. Furnace charge-mix Ores, Reductants, etc
8. Method of charging Continuous charging through skip, telfer
hoist and charging chutes.
9. Alloy making practice Single slag hot heel and foamy slag.
Slag-free tapping
10. Fume collection & cleaning Bag filters
3.5.2 Sponge Iron Plant:
Sponge iron, also known as "Direct Reduced Iron" (DRI) and its variant Hot Briquetted
Iron (HBI) have emerged as prime feed stock which is replacing steel scrap in EAF/IF as
well as in other steel-making processes. It is the resulting product (with a metallization
degree greater than 82%) of solid state reduction of iron ores or agglomerates (generally
of high grade), the principal constituents of which are metallic iron, residual iron oxides,
carbon and impurities such as phosphorus, sulphur and gangue (principally silica and
alumina). The final product can be in the form of fines, lumps, briquettes or pellets.
M/s Ispat Damodar Pvt. Ltd is already operating a Sponge Iron Plant having 2X100 TPD
kilns. In the expansion proposal, they propose to include 1X350 TPD DRI kiln. The
process description and the process flow diagram are given below.
Direct reduction processes available can be broadly grouped under two categories based
on the type of reductant used. These are:
- Solid based processes
- Gas based processes
The DRI technology to be followed at M/s Ispat Damodar Pvt. Ltd. will be solid base
process. The principal processing steps would include the following i ) Raw Material Preparation and feeding of measured amount to the Kiln i i ) Operation of the Kiln and formation of Direct Reduced Iron(DRI) i i i ) Product cooler i v ) Product Separation v ) Off gas cleaning system v i ) In-plant de-dusting system
4 9
• Raw Material Preparation and feeding to the Kiln
The charge into the kiln consists of a mixture of iron oxide lump /pellet, fluxes such as
limestone and/or dolomite (amount depending of sulfur content of the coal) and medium
volatile non-coking coal. The feed size of the solids is closely controlled to expedite
separation. Raw materials are metered into the high end of the inclined kiln. Iron oxide
pellets may be used in place of lumps. A portion of the coal is also injected pneumatically
from the discharge end of the kiln. The burden first passes through a pre-heating zone
where coal de-volatilization takes place & iron ore is heated to pre-heating temperature
for reduction.
• Operation of the Kiln and formation of Direct Reduced Iron (DRI)
Generally in any sponge iron process, reduction is conducted in a refractory lined rotary
kiln. The kiln of suitable size, generally inclined at 2.5 % slope rest on two-four support
stations, depending on the kiln size. The transport rate of materials through the kiln can
be controlled by varying its slope and speed of rotation. There are inlet and outlet cones
at opposite ends of the kiln that are cooled by individual fans. The kiln shell is provided
with small sampling ports, as well as large ports for rapid removal of the contents in case
of emergency or for lining repairs. The longitudinal positioning of the kiln on its riding
rings is controlled hydraulically.
Temperature and process control in the kiln are carried out by installing suitable no. of
air injection tubes made of heat-resistant steel spaced evenly along the kiln length and
countercurrent to the flow of iron ore. Tips of the air tubes are equipped with special
internal swirlers to improve uniformity of combustion.
A central burner located at the kiln discharge end is used with LDO for heating the cold
kiln. After initial heating, the fuel supply is turned off and the burner is used to inject air
for coal combustion.
The kiln temperatures are measured with fixed thermocouples and Quick Response
Thermocouples (QRT). Fixed thermocouples are located along the length of the kiln so
that temperatures at various sections of the kiln can be monitored. Fixed thermocouples,
at times may give erratic readings in case they get coated with ash, ore or accretion. In
such cases QRT are used for monitoring the kiln temperatures.
The product (DRI) is discharged from the kiln at about 1000°C. An enclosed chute at the
kiln discharge end equipped with a lump separator and an access door for removing
lumps transfers the hot DRI to a rotary cooler.
• Product Cooler
The cooler is a horizontal revolving cylinder of appropriate size. The DRI is cooled
indirectly by water spray on the cooler upper surface. The cooling water is collected in
troughs below the cooler and pumped to the cooling tower for recycling along with make-
up water.
Solids discharged to the cooler through an enclosed chute are cooled to about 100°C.
without air contact. A grizzly in the chute removes accretions that are large to plug up or
damage the cooler discharge mechanisms.
5 0
• Product Separation:
The product is screened to remove the plus 30mm DRI. The undersize – a mix of DRI,
dolo char and coal ash are screened into +/- 3mm fractions. Each fraction passes
through a magnetic separator. The non-magnetic portion of the plus 3mm fraction is
mostly char and can be recycled to the kiln if desired. The non-magnetic portion of –
3mm fraction mostly spent lime, ash and fine char is discarded. The magnetic portion of
each fraction is DRI. The plus 3mm fraction can be used directly for steel making and the
finer fraction can be briquetted /collected in bags.
• Off Gas Cleaning System:
The kiln waste gases moving in counter current of material flow inside the kiln are at a
temperature of about 10000C and carry coal dust which passes through a dust settling
chamber where heavier dust particles settle down due to sudden decrease in velocity of
gases. The flue gases then pass through an after burning chamber (ABC) where un-burnt
combustibles are burnt by blowing excess air. Air is added to ABC for converting CO to
CO2.The hot flue gases are then led to the Wate Heat Recovery Boiler (WHRB) for
utilization of sensible heat for making steam. The off gases then pass through pollution
control equipment namely ESP /Bag filter/ scrubber where balance dust particles are
separated. Then the gas is let off into the atmosphere through stack via ID fan.
• In-Plant De-dusting System:
Reverse air bag filter shall be installed for catching the dust from various conveyors,
material handling equipment and product handling equipment. The dust collected from
the bag filter shall be conveyed pneumatically to a distant location and discharged on
trucks in wet condition.
• Reaction mechanism
There are two major temperature zones in the kiln. The first pre-heat zone is where the
charge is heated to 900 – 1000°C. The second metallization zone is held fairly constant
at 1000-1050°C.
The charge into the kiln consists of a mixture of iron oxide lump, fluxes such as limestone
and/or dolomite (amount depending of sulfur content of the coal) and medium volatile
non-coking coal. In the pre-heating zone, the moisture is driven off first, and then the
hydrocarbons and hydrogen evolve by thermal decomposition of the coal.
As the combustible gases rise from the bed of solid material, a portion of the gases is
burnt in the free board above the bed by controlled quantities of air introduced through
the air tubes. As the kiln rotates, the primary mode of heat transfer is by radiation to the
tumbling charge and subsequently by internal solids mixing and renewal of the exposed
bed surface.
In the pre-heat zone, the reduction of iron oxide proceeds only to ferrous oxide (FeO)
(Equation I).
Fe2O3 + CO = 2 FeO + CO2 ............................ (I)
5 1
Final reduction to metallic iron occurs in the metallization zone by reaction of CO with
FeO to form CO2 and metallic iron (Equation II).
FeO + CO = Fe + CO2 ........................... (II)
Most of the CO2 reacts with the excess solid fuel in the kiln and is converted to CO
according to the Boudouard reaction (Equation III).
CO2 + C = 2 CO ............................ (III)
Coals with higher reactivity are preferred as they provide rapid conversion of CO2 to CO,
thereby maintaining reducing conditions in the kiln metallization zone. The highly
endothermic reaction of coal with CO2 prevents the bed from overheating and attaining
high temperature that could lead to melting or sticking of the charge.
High coal reactivity decreases the reduction zone bed temperature but increases the
relative capacity. Desired bed and gas temperature in the freeboard can be achieved with
high reactivity fuels even with very high throughput rates. Air admitted to the ports
below the bed in the pre-heat zone will burn some of the gases that otherwise leave the
kiln unburnt to improve fuel consumption.
TYPICAL RAW MATERIAL CHARACTERISTICS
i) Iron ore lump
Fe 65 % (min.)
SiO2 + Al2O3 3.5 % (max.)
S 0.02 %(max.)
P 0.035%(max.)
Size 5-20 mm
ii) Coal (dry basis)
Fixed C 42.5 % (min.)
Ash 27.5 % (max.)
VM 30 %
S 1.0 % (max.)
Moisture 7 % (Max.)
Reactivity 1.75 cc of CO/gmC/sec
Caking index 3 max.
Size 0 - 20 mm
iii) Limestone
SiO2 8 % (max.)
CaO 46 % (min.)
MgO 8-10
iv) Dolomite
SiO2 5 % (max.)
CaO 28 % (min.)
MgO 20 %
5 2
Typical Product Characteristics
The typical sponge iron (coal based) characteristics are as follows:
Fe (total) 92 % (min.)
Fe (Met.) 83 % (min.)
Metallization 90 % (min.)
Carbon 0.25 % (max.)
S 0.025 % (max.)
P 0.06 % (max.)
Re-oxidation characteristics Non-pyrophoric
Waste Heat Recovery Boiler:
After burning chamber (ABC) and dust settling chamber (DSC) will be located at the exit
of DR plant kilns. Part of the dust carried by the waste gases will settle down at DSC. The
DSC and ABC assembly will be connected to DR plant kilns through refractory lined duct.
The combustibles in the waste gases are burnt in After Burning Chamber which will raise
the waste temperature thus making the waste gases free from carbon monoxide.
Provisions for spraying water will be made to control the temperature if required. From
ABC outlet the WHRB will be connected through a refractory lined duct. An emergency
stack cap on the top of ABC will be provided for diverting the waste gases to atmosphere
when WHRB is under shut down or break down.
Fig. No. C3 - 14: Process Flow Diagram for Sponge Iron (DRI) & Power Plant
W e i g h i n g R o t a r yk i l n C o o l e r C o o l e r D i s c h a r g eA f t e r B u r n e rC h a m b e r P r o d u c t H o u s e I n t e r m e d i a t eS t t o r a g eW H R B M a g n e t i c S e p a r a t o r M a g n e t i c S e p a r a t o rS p o n g e I r o n C h a r S p o n g e I r o nF i n e D o l o c h a rA F B CB o i l e rE S PS T G S T GC o a l
I r o nO r e C o a l L i m e s t o n e /D o l o m i t e F i n e c o a l
E l e c t r i c i t y f o r I n t e r n a lc o n s u m p t i o nI D F a n S t a c k
5 3
3.5.3 Iron Ore Beneficiation Plant:
General:
To meet the input requirement of the pellet plant, it is proposed to set up an
beneficiation plant to produce 0.66 million Ton/year of concentrate. The average grade of
iron ore fines (-10mm) will be Fe-55-60%, SiO2 & Al2O3-10%, which will be beneficiated
to produce ore concentrate of average quality about 64% Fe. The concentrate so
produced will be carried to the pellet plant ground hopper for feeding.
Operating Regime
The operating regime of the proposed Iron Ore Beneficiation plant has been given below;
Working days per year 300
Number of hours per shift 8
Number of shifts per day 3
Number of effective hours per day 24
Feed and Product Quality
The pellet grade fines will have minimum 64% Fe to meet the requirement of DR grade
pellet. Quality requirement for concentrate product
ROM feed
Quantity 8,25,000 t/yr
Sizes, mm - 10
Parameters Qualities
Fe % 55-60 %
Bulk Density 2.26 t/m3
Product
Quantity 660,000 t/yr
Size -300 #
Fe % 64%
Process Flow:
Beneficiation process mainly involves grinding of ore and separation of gangue to the
extent possible within the required operational limits. Grinding of ore can be done in two
alternatives viz. wet grinding and dry grinding. Considering the beneficiation process, wet
grinding system is a preferred option. It is envisaged that the beneficiation process will
consist of primary grinding, hydro-cycloning, two stage spiral classification, single stage
high gradient magnetic separation, regrinding and thickening of concentrate received
from both spirals and magnetic separators. The thickened concentrate at approximately
64% solids by weight will be pumped to storage tank of the Pellet Plant. Tailings from the
beneficiation plant will be transported through pipeline and discharged to a tailing pond.
The iron ore fines from the Joda-Barbil area will be transported by road /rail to the
Beneficiation plant at NAbagram. Trucks carrying the Iron ore fines from other sources
are tippled in the truck unloading hopper and stockpiled by means of slewing boom
stacker. The iron ore fines from the stockpile is reclaimed through reclaimers and
5 4
transported to silos and filled with the help of a shuttle conveyor. The ball mill's
discharge is collected in pump sump for pumping to Hydro Cyclone clusters. The over
flow from the cyclone is sent to slime thickener. The cyclone under flow is fed to a bank
of rougher spirals. The concentrate from the rougher spirals will be processed in cleaner
spirals.
The tailing from the rougher and cleaner spiral is fed to intermediate slime thickener. The
concentrate from cleaner spiral is pumped to secondary hydro cyclone. The under flow
from cyclone is fed to regrinding mills for further grinding to required product size
whereas, the over flow from the cyclone is fed to concentrate thickener. The under flow
from the concentrate thickener is pumped to two slurry storage tanks and from there it is
pumped to Pellet Plant Site. The under flow from intermediate slime thickener is pumped
to a linear screen. The over size from the screen is to primary grinding mill. The under
size from the screen is fed to High Gradient Magnetic Separator (HGMS) for recovery of
concentrate from slimes. The concentrate from HGMS is further ground in the same
regrinding mill, which is close circuited with secondary hydro cyclone. The concentrate
over flow from hydro cyclone is thickened in concentrate thickener before pumping to
slurry storage tanks provided with agitators. The tailing from HGMS is fed to a tailing
thickener. The tailing thickener underflow is pumped to a tailing pond. The overflow from
the tailing thickener is sent to process water tank for re-circulation in the process. Slime
generated from the process is 1,85,000 TPA.
Service Facilities
Beneficiation plant will be provided with the following facilities for smooth operation.
i.) Water Supply Facility
Makeup water will be supplied from the centralized storage tank of the proposed project
at the rate of 784m3/Day. Inside the plant there will be a storage facility. From the
storage tank the pumping & water distribution systems has been proposed to cater the
need of water on all screens and sumps.
ii.) Electrical Facility
The power requirement of 2.75 MW will be sourced from the centralized MRSS and will be
distributed up to the MCC room. From there the power will be distributed to all drives &
motors.
iii.) Instrumentation & Telecommunication Facility
The entire beneficiation plant from the ball mill feeding conveyor to the product
conveyors will be interlocked and operated from the control room by PLC control system.
Proper instrument control like density control, pressure gauge, weigh to meter etc. has
been envisaged for smooth running of the plant.
iv.) Fire Detection & Alarm System
The plant shall be microprocessor based analog addressable type automatic fire detection
and alarm system which shall comprise of detectors, fire alarm panel, manual call point,
etc.
5 5
v.) AC & Ventilation System
To ensure the proper working environment for men and machines and to maintain
necessary environmental conditions adequate ventilation, air conditioning & dust
suppression system has been envisaged.
vi.) Computerization Facility
For greater visibility into operations and improve day to day high level information
among the shop/offices an off line computer and data communication systems has
been proposed for the plant. The proposed system will cover key functions and operation
of plant that enables the management to exercise better control over the resources.
vii.) Repair, Maintenance & Store Facility
To cater the day to day repair and maintenance need of plant and conveying system, a
field repair shop with stores have been envisaged in plant. However the major
maintenance of the equipment will be carried out by the centralized work shop.
Iron Ore Fines
825000 TPA Size: -10 mm
-100 mesh
O/F
Iron Ore Fines
660000 TPA U/F
Tailings
Concentrate
Nonmag Tailings O/F(-325 mesh) Magnetic Concentrate +18 mm
5-18mm
Iron Ore Beneficiation Plant Pelletization Plant
Fig. No. C3- 15: Process Flow Diagram of Iron Ore Beneficiation & Pelletization Plant
C o k e f i n e s : 1 2 0 0 0 T P AB e n t o n i t e : 4 2 0 0 T P AL i m e S t o n e : 1 2 0 0 0 T P A
T a i l i n gT h i c k e n e r1 8 5 0 0 0T P A( D i s p o s e )
P r i m a r y G r i n d i n g P r i m a r y H y d r o c y c l o n eR o u g h e r S p i r a lC l e a n e r S p i r a lS e c o n d a r y H y d r o -c y c l o n eH G M SB a l l M i l l
C o n c e n t r a t eT h i c k e n e r C o n c e n t r a t eS t o r a g e B i nC o n F e e d B i nM i x e rG r e e n P e l l e t i z e rD o u b l e R o l l S c r e e nS c r e e nI n d u r a t i o n F u r n a c e
P e l l e t s : 6 0 0 0 0 0T P A . S i z e : 5 - 1 8 m m
5 6
3.5.4 Pellet Plant
It is envisaged that the proposed pellet plant facilities shall be of travelling grate type
having capacity of 0.6 MTPA. It shall consist of shops like Raw Material Preparation,
Mixing and Pelletisation, In-duration Furnace, Product Screening & Storage. The
operating days of the plant will be 300 days per year.
Plant & Process Description
This project is for an Iron-ore Pelletising Plant of capacity 0.6 MTPA. The process of
pelletising of iron bearing ores is to utilize fines by agglomeration in blast furnace and
direct reduction shaft and rotary kiln furnaces. Also hitherto unused wastes, such as
sludge and similar waste materials and fines can be brought to use by the palletizing
process after beneficiation.
The manufacturing process is divided into four stages:
1. Raw material preparation
2. Mixing and Pelletisation
3. In-duration
4. Product Screening & Storage
Raw Material Preparation
Iron ore Fines of about 58 % Fe content will be upgraded to 64 % Fe Concentrate by Iron
Ore Beneficiation Plant. The carbon carrier (coke, anthracite), bentonite and flux
(limestone, dolomite) are stored in the bins (optional arrangement) equipped with de-
dusting unit. The additives are transported to the mixer via loss-in-weight-feeders.
Mixing & Pelletising
All the additives will be added by weigh feeder to a common conveyor belt going to feed
the chute of the mixer. In the mixer, the ore concentrate is mixed with the controlled
addition of process water and filter dust which mainly consists of iron from the de-
dusting systems. The moisture content of the material is controlled to approximately 9 –
10 %. After the intensive mixing, the mixed material is transferred by belt conveyors to
the silo provided above the each of three pelletisation disc.
The production of green pellets is performed in three closed palletizing disc circuits.
Pelletising discs were selected over palletising drums because of their minor space
requirements and their self-classifying effect.
The mixed material is received into the mixed material bins with a storage capacity of
approximately 40m3 each, installed directly above the three discs. The material discharge
from each mixed material bin is done by a vibrating mouth and controlled by weigh
feeders equipped with variable speed drivers, thus feeding the required amount of mixed
material onto the corresponding palletizing disc. The charging is done automatically in
accordance with a pre-set time schedule. A control loop, governed by the filling degree of
the bins, is superimposed on this schedule for determining the destination of feed. The
bins filling degree is measured by load cells.
5 7
The weigh feeder discharges into the disc feeding chutes are equipped with fluffier for a
disintegration of any compacted material as well as for distribution of the mixed material
on the pelletising disc.
The green pellets are formed in the discs with a diameter of 6m each, with simultaneous
and variable addition of water. The inclination of each disc is variable and optimum
setting will be determined during start-up, according to mixed material properties,
desired green pellet diameter and feed-rate. The rotary speed of the disc can also be
varied during operation by means of frequency-controlled motors, depending on the
palletising characteristic of the concentrate mixtures.
The green pellets produced are discharged into a reversible belt conveyor. In case of
emergency and also during start – up of a disc when the green pellets do not have the
required properties, the disc discharge can thus be recycled or discharged to an
emergency stockpile by means of another reversible belt conveyor.
During normal operation the green pellets are discharged to the green pellet collecting
belt conveyor, which ensures the smooth handling of the green pellets. A belt weigh
feeder is installed in this belt conveyor for weighing the total amount of green pellets
discharged from the pelletising discs. This belt weigh feeder is used for mass balancing
and services as a standby signal for the speed control of the induration machine.
Green pellets are distributed into the wide belt conveyor by the reciprocating head of belt
conveyor Head pulley of this conveyor is supported in a reciprocating carriage, which
moves the head pulley over the width of the downstream perpendicular – arranged wide
belt conveyor. The forward velocity of the carriage with the heady pulley is identical to
the belt speed and during the backward stroke the green pellets are discharged onto the
wide belt conveyor.
The wide belt conveyor discharges the green pellets into the double deck roller screen
which consists of an upper and a lower roller deck. The upper deck screens the oversize
green pellets (> 16 mm) and the lower deck has the function to screen out undersize
green pellets of < 6 mm. On – space green pellets 6 – 16 mm are re-rolled on the lower
deck and evenly distributed over the width of the pallets of the induration machine.
Undersize and oversize green pellets are recycled by belt conveyors back to the green
palletizing area. Belt weigh feeder will measure the amount of green pellet under and
over size.
Pellet Induration
The pellets are completely heat hardened and cooled on one strand, thus not requiring
any intermediate pellet strength. By this the addition of binder can be reduced with a
positive effect of the product pellet quality. Dust and spillage creation in the hot phase of
traveling grate process is practically negligible.
Traveling grate system pellets are uniformly cooled since the total pellet layer remains
undisturbed while being transported through the total in-duration and cooling stages.
This avoids the creation of larger clusters, which would diminish the effect of cooling.
Properly heated and cooled pellets are of superior quality.
5 8
The Traveling Grate Process assures that during the preheating and firing stage always
sufficient oxygen is available in the hot gasses for proper oxidation. The Traveling Grate
machine on which the green pellets will be heat treated, in-durated and cooled has a
reaction area of 108 m2 (3m wide and 36 m long). This traveling grate consists of an
endless chain, which continuously revolve. One of the process pre-requisites for
obtaining a uniform product quality is a uniform bed height. This is ensured by
automatic control of the Traveling Grate speed as a function of the ultrasonic level
measuring devices installed after green pellets are charged to traveling grate. Grate
speed control by ultrasonic replaces the old concept of speed control by green pellet -,
hearth- and side layer quantity, because of significantly reduced response times and thus
improved pellet bed level on the indurating machine.
A stand-by input data for the grate speed control system is the actual feed rate (t/h) of
green pellets (difference of mass flows on belt weigh feeders and to the travelling grate).
Thermal attack on the pallets and grate bars, which would lead to excessive wear, is
avoided by using a hearth and side layer of indurated pellets. Side layer is used for
protecting the side walls of pellets and avoiding the so called “side wall effects”.
A storage bin for hearth – and side layer is arranged at the feed-end of the traveling
grate. A motor – driven discharge gate can adjust the height of the hearth layer on the
pallets. The standard height for this application is 10 cm.
The three components are fed onto the pellets in the following order:
� Hearth layer
� Side layer
� Green pellets
The hearth and side layer bin is equipped with an emergency chute which permits
additional filling of the pallets with hearth layer in case of failure in the green pellet
feeding system and thus protecting the pallets and grate bars from overheating. The
complete pellet in-duration process is given below.
Fig. No. C3-16: Induration Process Description
5 9
Fig. No. C3-17: Induration Section
Fig. No. C3 - 18: Temperature Profile
Table No. C3 – 15: Induration Process Zone with Size, Reaction Area and Temperature
Process Zone Size Reaction Area Process Gas Temp.
Updraft Drying 3m x 3m 9m2 300 0 C
Downdraft Drying 3m x 6m 18 m2 320 0 C
Preheating 3m x 5m 15m2 400 – 1280 0 C
Firing & After Firing 3m x 12m 36 m2 1350 – 1050 0 C
Cooling 1 & 2 3m x 10m 30 m2 1050 - 100 0 C
TOTAL 3m x 36m 108 m2
6 0
Hot combustion gases enter the firing zone by the direct recuperation principle, which
means that hot gases from the cooling zone 1 are recuperated. Burners are arranged
opposite to each other on the longitudinal sides of the preheating and firing zone. The
arrangement and sizing of the burners ensures a uniform hot gas temperature over the
width of the pellet bed.
Since the burners are divided in several control zones, an optimum temperature profile
can be adjusted thus permitting an optimum heat treatment of the pellets. The burners
are of the self-inspirator type and operate with mixed gas. The temperatures in the
individual control zones of the preheating and firing zone are measure with
thermocouples and indicated by the central control system. They serve as control
variables for the automatic supply of fuel to the burners.
Intake and circulation of the air and gas required for the process is ensured by the
application of various fans. The in-duration process is characterized by the recovery of
maximum heat from cooling of the hot pellets by applying the direct recuperation principle,
which means transportation of recovered hot air from the first cooling zone to the
preheating- and firing zone without a fan. The cooling air fan sucks in ambient air through
a silencer and forces this air through an air duct into the wind boxes of cooling zones.
The cooling air, which becomes heated after passing through the hot pallets and the hot
pellet bed, is collected in the first and second cooling hood. These hoods are installed
directly above and sealed against the travelling grate. The heated air streams are
recycled to the process as a “heat carrier”. Hot air collected in the second cooling hood
and hot process gas from the wind box recuperation system (supplied via bypass) is
extracted by the updraft-drying fan and forced through duct into the wind boxes of the
updraft-drying zone and through a duct and damper into the hood above the preheating
zone. Wind box pressure in the updraft-drying zone is automatically controlled by a
damper, which leads excessive air to the hood exhaust gas system.
The hot gases of the downdraft-drying, preheating and firing zone are sucked in “down-
draft” through the pellet charge by fans. The wind boxes of the downdraft drying zone
and the preheating zone are connected to the wind box exhaust fan & will be recycled to
the process after re-slurring. All clean gases will be released via one common stack to
the atmosphere.
The hot combustion gases from the last section of the firing- and the after-firing zone
serve as drying gases in the downdraft-drying zone. They are sucked through the pellet
bed by the wind box recuperation fan and then forced via gas ducts into the hood above
the downdraft-drying zone.
An appropriate temperature profile in the preheating zone is essential for the production
of high quality oxide pellets. This temperature profile can be adjusted easily by mixing
controlled quantities of second cooling air / wind box recuperation air, supplied by up-
brought drying fan by-pass between the wind box recuperation and the up-draft drying
system allows the passing of heat from the one to the other system.
6 1
The hood exhaust fan sucks off the humid exhaust air from the updraft-drying hood. Hot
excess gas from the recuperation fan is added in order to raise the temperature of this
air and to control the pressure in the downdraft hood. The exhaust gas is cleaned in the
electrostatic precipitator and direct to atmosphere together with the waste gases via the
common waste gas stack. A grate bar cleaning device is located near the lowering station
on the return track of the traveling grate.
Screening and Product Handling
The indurated and cooled pellets are discharged from the indurating machine into the
discharge bin, mounted on load cells. The Product belt conveyors is equipped with a
water spray system, which is used to cool down hot pellets > 120 0C in case of
emergency only. The cooling zone of the indurating machine is designed to cool down
fired pellets in normal operation to temperatures of 100 – 120 0C.
The vibrating product screen finally screens out undersize material from the product
pellets and to separate a certain quantity of fired pellets which will be recycled as hearth
layer to the indurating machine.
A product screen mainly consists of vibrating screen decks and four chutes to further
convey 4 size fractions of fired pellets:
� Undersize pellets < 5 mm
� Product pellets 5 – 10 mm
� Hearth layer pellets 10 – 16 mm
� Oversize pellets > 16 mm
The fines < 5 mm will be transported via a conveyor to a stockpile.
Sized pellets are used as hearth layer to avoid clogging of side layer chutes and improve
the permeability of the heart layer and thus reduce pressure drop and energy
consumption of this system.
Screened hearth and side layer is transported by belt conveyors to the hearth layer bin at
the feed end of the indurating machine. Conveyor is equipped with a variable speed
drive. The belt speed is controlled by the level of the hearth and side layer bin. Belt
weigh feeder registers the production rate of the plant. A sampler is installed in the
discharge chute of product conveyor, which takes samples for pellet quality control.
3.5.5 CAPTIVE POWER PLANT
Waste heat recovery power plant in Sponge Iron Plants is very common these days. The
waste heat of a sponge iron kiln can be effectively utilized in steam generation which in-
turn can generate power. In the existing plant there is an 8 MW power plant which
utilizes the waste heat of 2X100 TPD DRI. In the expansion proposal it is envisaged to
install waste heat boilyer for recovery of waste heat of flue gases of 1X350 TPD DRI kiln
which can generate 8MW of power. The total off-gas from the proposed DRI kilns shall be
around 1, 24,250 Nm3/hr at a temperature of about 950-1000 °C. The same is proposed
to be utilized to produce steam of 36TPH. Steam at a Pressure of 65 Kg/Cm2 and
temperature of 485+ /- 5 0 C
6 2
The waste char generated from the existing and proposed DRI Plant will amount to
45,850TPA, part of which will be utilized along with coal fines for generation of 32MW
power through FBC boiler. Purchased coal fines/Coal will also be utilized in FBC Boiler to
produce 2 X 16 MW. The boilers each of 70 T generation capacity will produce steam at
65 kg/cm2 and 485+ /- 5 0 C.
WHRB & FBC Boiler Based Power Plant
The proposed plant will comprise the following major system.
i. Waste Heat recovery steam generation plant and auxiliaries.
ii. FBC Boiler & auxiliaries
iii. Steam turbine generator.
iv. De-aerator and feed water system.
v. Electrics.
vi. Water supply system.
vii. Instrumentation and controls.
viii. Ash handling system.
ix. Compressed air system.
x. Fire fighting.
xi. Tele-communication.
Waste Heat Recovery Boiler
The waste heat recovery steam generation plant will comprise of two no of natural
circulation semi-outdoor type twin drum waste heat boiler & its auxiliaries .The salient
technical particulars of the boiler are given as follows.
The steam generation capacity of the WHR boiler shall be 36 TPH and FBC boiler of
capacity 70 TPH. The stream shall be generated at 65 ata and 485± 5°C. The boiler will
be complete with evaporator steam drum, bank of super heaters economizer, air heater,
air fans, ESP, internal piping etc. Soot blowing and super heater will be also provided.
The exhaust gases will be discharged in to atmosphere through existing ID fan and
chimney. The Pressure drop in the boiler ducts and ESP have to match with the
requirement of existing fan. The boiler will be of semi outdoor type with a weather
canopy and side covering of trapezoidal corrugated steel sheets
Table No. C3 - 16: Material and Energy Balance 8MW Power Plant
Material in Material out
Material Qty, TPH Energy,
MCal/hr
Material Qty,
TPH
Energy,
MCal/hr
Off gas from ABC of DRI Kiln
82.00 23057.75 Exit Gas 82.00 2952.00
Water 36.00 3960.00 Steam 36.00 23880.49
Air Radiation heat loss 185.26
Total 102.56 27017.75 Total 102.56 27017.75
6 3
FBC Boiler Power Plant:
Power Generation Potential:
i) Dlochar:
Calorific value of Char=1600 K cal/Kg
Power generation potential of FBC boiler with char as fuel =45,850 X 1600X 1000/
2750 = 26676363.636 KWH/annum
Considering 300 days of operation, the power generation potential is calculated as:
26676363.636 /300 /24 /1000 =3.70 MW
ii) Coal fines:
During crushing and screening of coal in DRI plant coal fines are produced which
along with coal will be utilized in Fluidized bed combustion boiler to produce power.
Coal fines generated will be 14850 TPA
Calorific value of Coal fines = 3900 K cal/Kg
Considering heat required per unit of generation as 2750 Kcal/KWH
Power generating potential of coal fines =14850 X 3900 X 1000 /2750 = 21060000 KWH
Considering 300 days of operation, power gen potential =21060000 /300 /24 /1000
=2.925 =2.93 MW
iii) Coal
Calorific Value of Coal=3600 Kcal/Kg
Considering heat required per unit of generation as 2750Kcal/KWH
The total coal required for generation of 33.37 MW (32 - 3.70 - 2.93) will be : 25.37
X 24 X 300 X 1000 X 2750 /3600 /1000 = 139535 T
The total power generated from dolochar, coal fines and Coal will work out to
Char = 3.70 MW
Coal fines = 2.93
Coal =25.37
Total = 32 MW
It is proposed to install 2 X 70 TPH Fluidized bed combustion boiler for power generation.
Char and coal fines along with fresh coal shall be used as fuel for FBC.
Specifications for Fluidized Bed Boilers:
Type of Boiler : Bi /Single Drum Top /Bottom Supported
Natural circulation, Balance draft Furnace with
fluidized Bed combustion.
Steam Generation Capacity of Boilers: 70 TPH
Steam Generation Pressure : 65 kg/cm2 (at MSSV outlet) at 485± 5°C
Feed water temperature : 126°C for MCR at Economizer inlet.
6 4
The boiler will be complete with evaporator steam drum, bank of super heaters
economizer, air cooled condenser, air heater, air fans, ESP, internal piping etc. Soot
blowing and super heater will be also provided. The exhaust gases will be discharged in
to atmosphere through ESP and chimney. The boiler will be of semi outdoor type with a
weather canopy and side covering of trapezoidal corrugated steel sheets.
Annual Requirement of Raw Material
The FBC Boiler shall be designed to utilize char and coal fines. The annual requirement
of raw materials for FBC Power generation is as tabulated in the Table No. C3-17.
Table No. C3 - 17: Annual Requirement of Raw Materials
Sl. No. Raw Material Annual Qty, t/yr
1 Char 45,850
2 Coal Fines 14,850
3 Coal 1,39,535 T
The specification of fuel is tabulated below.
Table No. C3 – 18: Specification of Fuel for FBC Boilers
Proximity Analysis Coal Fines Char Coal
Fixed Carbon 28 -30 % 13 -18% 27
Volatile Matter 24- 26% 2 – 5 % 22
Ash Content 40 -45% 75– 80% 39
Moisture 8 - 10% - 12
Average GCV Kcal/kg 2800 – 3900 1300-1800 3600
Steam Turbine generator
The broad description of the 20 MW steam turbine generator envisaged indicated below:
The Steam turbine will be single, Horizontal, Single bleed condensing type. 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
condenser and lube oil system. Condensing steam turbine generator with inlet steam
parameter of 65 ata and 465±5°C at emergency steam valve inlet.
De-aerator and feed water system
There will be a de-aerator with feed tank. 2 numbers boiler feed water pumps with
motors (1 working + 1 stand by) shall be provided along with common suction header,
auto recirculation valve, suction/discharge valve, non return valve, pressure gauge,
temperature gauge etc.
Electrics
The electrics include Generators, Transformers, Main and auxiliary Switchgears, power
distribution arrangement, battery room etc.
Instrumentation & Control
Effective control and measurement of process parameters along with data acquisition
system in the control room has been envisaged.
6 5
3.5.6 Steel Melting Shop & Continuous Casting Machine for Billet and Slab (IF)
3.5.6.1 Steel making by Induction furnace
The greatest advantage of the Induction Furnace is its low capital cost compared with
other types of melting units. Its installation is relatively easy and its operation is very
simple. Among other advantages, there is very little heat loss from the furnace as the
bath is constantly covered and there is practically no noise during its operation. The
molten metal in an Induction Furnace is circulated automatically by electromagnetic
action so that when alloy additions are made, a homogeneous product is ensured in
minimum time. The time between tap and charge, the charging time, power delays etc.
are items of utmost importance in meeting the objective of maximum output in tons
/hour at a low operational cost.
The disadvantage of the Induction Furnace is that the melting process requires usually
selected scrap because major refining is not possible.
Manufacture of MS Billets
The process for manufacture of MS Billets may be broadly divided into the following
stages - Melting the charge mixed of steel & Iron scrap, Ladle teeming practice for
Casting (OR), Direct teeming practice for Ingot Casting unladdable teeming machine.
i) Melting the charge
The furnace is switched on, current starts flowing at a high rate and a comparatively low
voltage through the induction coils of the furnace, producing an induced magnetic field
inside the central space of the coils where the crucible is located. The induced magnetic
fluxes thus generate out through the packed charge in the crucible, which is placed
centrally inside the induction coil.
As the magnetic fluxes generate out through the scraps and complete the circuit, they
generate and induce eddy current in the scrap. This induced eddy current, as it flows
through the highly resistive bath of scrap, generates tremendous heat and melting starts.
It is thus apparent that the melting rate depends primarily on two things (1) the density
of magnetic fluxes and (2) compactness of the charge. The charge mixed arrangement
has already been described. The magnetic fluxes 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 varies between 150- 10K
cycles/second. This heat is developed mainly in the outer rim of the metal in the charge
but is carried quickly to the center by conduction. A pool of molten metal forms causing
the charge to sink to the bottom. At this point any remaining charge mixed is added
gradually. The eddy current, which is generated in the charge, 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 the
furnace, so that furnace frequency is selected in accordance with the purpose for which
the furnace will be utilized.
The melting continues till all the charge is melted and the bath develops a convex surface.
However as the convex surface is not favorable to slag treatment, the power input is then
naturally decreased to flatten the convexity and to reduce the circulation rate when refining
under a reducing slag. The reduced flow of the liquid metal accelerates the purification
6 6
reactions by constantly bringing new metal into close contact with the slag. Before the
actual reduction of steel is done, the liquid steel which might contain some trapped oxygen
is first treated with some suitable deoxidizer. When no purification is attempted, the chief
metallurgical advantages of the process attributable to the stirring action are uniformity of
the product, control over the super heat temperature and the opportunity afforded by the
conditions of the melt to control de-oxidation through proper addition.
As soon as the charge has melted clear and de-oxidizing ions have ceased, any
objectionable slag is skimmed off, and the necessary alloying elements are added. When
these additives have melted and diffused through the bath of the power input may be
increased to bring the temperature of metal up to the point most desirable for pouring.
The current is then turned off and the furnace is tilted for pouring into a ladle. As soon as
pouring has ceased, any slag adhering to the wall of the crucible is crapped out and the
furnace is readied for charging again.
As the furnace is equipped with a higher cover over the crucible very little oxidation
occurs during melting. Such a cover also serves to prevent cooling by radiation from the
surface heat loss and protecting the metal is unnecessary, though slag is used in special
cases. Another advantage of the induction furnace is that there is hardly any melting loss
compared with the arc furnace. The technical specifications of Induction Furnace are
presented in Table No. C3 -19.
Description for Medium Frequency Induction Furnace
Each Induction Furnace comprises of:
a. Furnace: The furnace consists of sturdy steel structure fabricated from rolled steel
sections and plates. The furnace is provided with a tilting stand, which is grouted;
to the foundation. Mounted on the tilting stand are two spherical bearings. Crucible
structure or furnace frame is pivoted on these bearings. The furnace frame consists
of columns with dished bottom. The platform is integral with the crucible structure.
b. Water Cooled Induction Coil: The induction coil is made of water-cooled hollow
copper conductor. The coil is insulated between the turns with high quality segment
insulation. Inside of the coil is grouted with coil lining cement of high strength. The
coil is sectionalized for water flow with different feed points. The ends of the coil are
connected to water-cooled cables by means of copper tubes. The coil is radically
supported by means of magnetic yokes.
c. Water Cooled Magnetic Yokes: The magnetic yokes serve the purpose of guiding
the flux and shielding the steel structure against stray field effects. Yokes are
pressed on to the coil by means of radial bolts with lock nuts. The yokes can be
dismantled without breaking of the lining, if necessary.
d. Water Cooled Cables: Power is fed to the crucible (induction coil) by means of
flexible water cooled cables. These cables are made of high conductivity copper
strands. Necessary cable guides are provided on the furnace end as well as on the
foundation side. Protection cover is provided to prevent accidental touch of live parts.
e. Tilting Cylinders: The furnace is tilted by means, of hydraulic cylinders, which are
of sturdy single acting type. Backpressure valves are provided such that in the event
of hose failure the furnace returns in a controlled manner. High-pressure hoses
connect the hydraulic pipeline to the tilting cylinders allowing radial movement.
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f. Lining Formers: Formers for coil grouting, bottom cementing, top cementing and
one former for crucible lining are included.
g. Oil Hydraulic System: High-pressure oil needed for tilting is derived from a self-
contained hydraulic power pack. This consists of factory built assembly, comprising of
• Oil tank
• Pump and motor
• Strainer
• Check valve
h. Gauge and gauge selector: The common control desk for two crucibles is
provided on the furnace platform, which houses the directional valves for tilting.
One rotary switch is provided for switching ON the hydraulic pump. Furnace power
can be switched ON/OFF through push buttons located 'on the control desk. Lamps
indicate the status of these operations.
i. Cooling water System-1: This system will take care of cooling water requirements
of induction coil, magnetic yokes and water-cooled cables.
This system consists of the following:
Section-I of plate type heat exchanger made of stainless steel plates (mounted on
common MS frame) for handling furnace coil cooling water. Two mono block pumps
with their bases are supplied for recalculating the closed circuit water.
j. Out of two pumps, one pump shall be standby: One expansion vessel is
supplied which also serves to make up lost water in the closed circuit system. This
is provided .with a drain and make up water connection towards cooling water
requirements of induction coil, magnetic yokes and water cooled cables following
instrumentation are included:
• Pressure gauge for pump
• Pressure switch Flow switches
• Thermostats
The MS pipes & fittings with header, valves etc. for coil cooling system shall be
provided by you in accordance with our schematic.
k. Cooling Water System-2 (For De-ionised water)
This system consists of:
• One monoblock pump is provided suitable for handling deionised water and
equipped with mechanical seal.
• Section-ll of plate type heat exchanger made of stainless steel plates (mounted on
common MS frame) for handling deionised water.
• Suction shut-off and delivery control valve is included.
• One stainless steel expansion vessel will be provided which serves as the make-up
point for deionised water.
Capacitor Rack of angle iron construction, housing the following:
• Water cooled shunt capacitors
• Water headers of copper
• Polyurethane hoses and SS hose clips
• Mounting materials, busbars, connecting jumpers, etc.
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Fig. No. C3-19: PROCESS FLOW DIAGRAM FOR MANUFACTURE OF MS BILLETS
He a tEx c h a n ge r
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Table No. C3-19 : Technical Specifications of Induction Furnace 2 X 15 T
Sl.
No.
Parameters Unit Value/ Features
1. Installed capacity t/yr 96,000
2. No. of units Nos 2
3 Heats per day No. 8 (each)
4. Nominal tap weight T 15
5. Tap to tap time Min 90
6. Heat size with hot heel T 35
7. Type of furnace High power induction furnace with
eccentric bottom tapping water-cooled
sidewall panels and roof, cooling of
electrodes with water spray
8. Transformer rating MVA 7.2 MVA (with 20% over-loading)
9. Furnace charge-mix approx.
Sponge Iron /scrap % 68-70 & Return scrap
Hot Metal / scrap % 21-22
10. Method of charging
> Metal/scrap Continuous charging through roof with
system of overhead bin, conveyor,
chute, etc.
> Lime - Lime will be charged manually.
> Ferro-alloys/ deoxidizers - Manual chargin
11. Steel making practice Single slag hot heel and foamy slag.
Slag free tapping. Alloying in ladle
during tapping and also at ladle furnace
12. Steel refining - In ladle furnace
13 Fume collection &
Cleaning
- Swiveling hood for fume extraction
- Bag filters are common for induction
furnace and ladle furnace
3.5.6.2 Steel making by Electric Arc Furnace:
The melting of the Hot metal, direct reduced iron and steel scrap is done in electric arc
furnace using the electricity due to heat generated by the arc between the three graphite
electrodes. The oxides of silicon, manganese, aluminium etc. form slag. The molten slag
being lighter than steel, is removed from the top of the furnace.
The carbon content in the hot metal is reduced by oxygen blowing. The exhaust gases
are cooled and cleaned in gas cleaning plant. Cooled and cleaned gases are released to
atmosphere through 43 m height forced draft chimney. The liquid metal is poured in
refractory lined ladles and transferred to ladle heating furnace for further refining.
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Both Induction furnaces (IF) and Electric Arc Furnaces (EAF) are used for smelting steel.
The major difference between the two processes is the ability to use differing quality of
charge material. Oxidation and reduction reactions take place within and above the melt
zone during electric steel making which allows for highly oxidized and low quality waste
material. Induction furnaces are sensitive to low quality charge materials and
contaminants resulting in premium scrap cost. A reductive atmosphere is not present in
induction melting and therefore iron oxide will not be reduced. This increases iron loss
through slag.
Following paragraphs detail the operation of an electric arc furnace.
FURNACE OPERATIONS
The electric arc furnace operates as a batch melting process producing batches of molten
steel known "heats". The electric arc furnace operating cycle is called the tap-to-tap cycle
and is made up of the following operations:
• Furnace charging
• Melting
• Refining
• De-slagging
• Tapping
• Furnace turn-around
Modern operations aim for a tap-to-tap time of less than 60 minutes. Some twin shell
furnace operations are achieving tap-to-tap times of 35 to 40 minutes.
Furnace Charging
The first step in the production of any heat is to select the grade of steel to be made.
Usually a schedule is developed prior to each production shift. Thus the melter will know
in advance the schedule for his shift. The scrap yard operator will prepare buckets of
scrap according to the needs of the melter. Preparation of the charge bucket is an
important operation, not only to ensure proper melt-in chemistry but also to ensure good
melting conditions. The scrap must be layered in the bucket according to size and density
to promote the rapid formation of a liquid pool of steel in the hearth while providing
protection for the sidewalls and roof from electric arc radiation. Other considerations
include minimization of scrap cave-ins which can break electrodes and ensuring that
large heavy pieces of scrap do not lie directly in front of burner ports which would result
in blow-back of the flame onto the water cooled panels. The charge can include lime and
carbon or these can be injected into the furnace during the heat. Many operations add
some lime and carbon in the scrap bucket and supplement this with injection.
The first step in any tap-to-tap cycle is "charging" into the scrap. The roof and electrodes
are raised and are swung to the side of the furnace to allow the scrap charging crane to
move a full bucket of scrap into place over the furnace. The bucket bottom is usually a
clam shell design - i.e. the bucket opens up by retracting two segments on the bottom of
the bucket. The scrap falls into the furnace and the scrap crane removes the scrap
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bucket. The roof and electrodes swing back into place over the furnace. The roof is
lowered and then the electrodes are lowered to strike an arc on the scrap. This
commences the melting portion of the cycle. The number of charge buckets of scrap
required to produce a heat of steel is dependent primarily on the volume of the furnace
and the scrap density. Most modern furnaces are designed to operate with a minimum of
back-charges. This is advantageous because charging is a dead-time where the furnace
does not have power on and therefore is not melting. Minimizing these dead-times helps
to maximize the productivity of the furnace. In addition, energy is lost every time the
furnace roof is opened. This can amount to 10 - 20 kWh/ton for each occurrence. Most
operations aim for 2 to 3 buckets of scrap per heat and will attempt to blend their scrap
to meet this requirement. Some operations achieve a single bucket charge. Continuous
charging operations such as CONSTEEL and the Fuchs Shaft Furnace eliminate the
charging cycle.
Melting
The melting period is the heart of EAF operations. The EAF has evolved into a highly
efficient melting apparatus and modern designs are focused on maximizing the melting
capacity of the EAF. Melting is accomplished by supplying energy to the furnace interior.
This energy can be electrical or chemical. Electrical energy is supplied via the graphite
electrodes and is usually the largest contributor in melting operations. Initially, an
intermediate voltage tap is selected until the electrodes bore into the scrap. Usually, light
scrap is placed on top of the charge to accelerate bore-in. Approximately 15 % of the
scrap is melted during the initial bore-in period. After a few minutes, the electrodes will
have penetrated the scrap sufficiently so that a long arc (high voltage) tap can be used
without fear of radiation damage to the roof. The long arc maximizes the transfer of
power to the scrap and a liquid pool of metal will form in the furnace hearth At the start
of melting the arc is erratic and unstable. Wide swings in current are observed
accompanied by rapid movement of the electrodes. As the furnace atmosphere heats up
the arc stabilizes and once the molten pool is formed, the arc becomes quite stable and
the average power input increases.
Chemical energy is to be supplied via several sources including oxy-fuel burners and
oxygen lances. Oxy-fuel burners burn natural gas using oxygen or a blend of oxygen and
air. Heat is transferred to the scrap by flame radiation and convection by the hot
products of combustion. Heat is transferred within the scrap by conduction. Large pieces
of scrap take longer to melt into the bath than smaller pieces. In some operations,
oxygen is injected via a consumable pipe lance to "cut" the scrap. The oxygen reacts with
the hot scrap and burns iron to produce intense heat for cutting the scrap. Once a molten
pool of steel is generated in the furnace, oxygen can be lanced directly into the bath.
This oxygen will react with several components in the bath including, aluminum, silicon,
manganese, phosphorus, carbon and iron. All of these reactions are exothermic (i.e. they
generate heat) and supply additional energy to aid in the melting of the scrap. The
metallic oxides that are formed will end up in the slag. The reaction of oxygen with
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carbon in the bath produces carbon monoxide, which either burns in the furnace if there
is sufficient oxygen, and/or is exhausted through the direct evacuation system where it is
burned and conveyed to the pollution control system. Auxiliary fuel operations are
discussed in more detail in the section on EAF operations.
Once enough scrap has been melted to accommodate the second charge, the charging
process is repeated. Once the final scrap charge is melted, the furnace sidewalls are
exposed to intense radiation from the arc. As a result, the voltage must be reduced.
Alternatively, creation of a foamy slag will allow the arc to be buried and will protect the
furnace shell. In addition, a greater amount of energy will be retained in the slag and is
transferred to the bath resulting in greater energy efficiency.
Once the final scrap charge is fully melted, flat bath conditions are reached. At this point,
a bath temperature and sample will be taken. The analysis of the bath chemistry will
allow the melter to determine the amount of oxygen to be blown during refining. At this
point, the melter can also start to arrange for the bulk tap alloy additions to be made.
These quantities are finalized after the refining period.
Refining
Refining operations in the electric arc furnace have traditionally involved the removal of
phosphorus, sulfur, aluminum, silicon, manganese and carbon from the steel. In recent
times, dissolved gases, especially hydrogen and nitrogen, have been recognized as a
concern. Traditionally, refining operations were carried out following meltdown i.e. once a
flat bath was achieved. These refining reactions are all dependent on the availability of
oxygen. Oxygen was lanced at the end of meltdown to lower the bath carbon content to the
desired level for tapping. Most of the compounds which are to be removed during refining
have a higher affinity for oxygen than the carbon. Thus the oxygen will preferentially react
with these elements to form oxides which float out of the steel and into the slag.
In modern EAF operations, especially those operating with a "hot heel" of molten steel &
slag retained from the prior heat, oxygen may be blown into the bath throughout most of
the heat. As a result, some of the melting and refining operations occur simultaneously.
Phosphorus and sulfur occur normally in the furnace charge in higher concentrations than
are generally permitted in steel and must be removed. Unfortunately the conditions
favorable for removing phosphorus are the opposite of those promoting the removal of
sulfur. Therefore once these materials are pushed into the slag phase they may revert
back into the steel. Phosphorus retention in the slag is a function of the bath
temperature, the slag basicity and FeO levels in the slag. At higher temperature or low
FeO levels, the phosphorus will revert from the slag back into the bath. Phosphorus
removal is usually carried out as early as possible in the heat. Hot heel practice is very
beneficial for phosphorus removal because oxygen can be lanced into the bath while its
temperature is quite low. Early in the heat the slag will contain high FeO levels carried
over from the previous heat thus aiding in phosphorus removal. High slag basicity (i.e.
high lime content) is also beneficial for phosphorus removal but care must be taken not
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to saturate the slag with lime. This will lead to an increase in slag viscosity, which will
make the slag less effective. Sometimes fluorspar is added to help fluidize the slag.
Stirring the bath with inert gas is also beneficial because it renews the slag/metal
interface thus improving the reaction kinetics.
In general, if low phosphorus levels are a requirement for a particular steel grade, the
scrap is selected to give a low level at melt-in. The partition of phosphorus in the slag to
phosphorus in the bath ranges from 5 to 15. Usually the phosphorus is reduced by 20 to
50 % in the EAF.
Sulfur is removed mainly as a sulfide dissolved in the slag. The sulfur partition between
the slag and metal is dependent on slag chemistry and is favored at low steel oxidation
levels. Removal of sulfur in the EAF is difficult especially given modern practices where
the oxidation level of the bath is quite high. Generally the partition ratio is between 3 and
5 for EAF operations. Most operations find it more effective to carry out desulfurization
during the reducing phase of steelmaking. This means that desulfurization is performed
during tapping (where a calcium aluminate slag is built) and during ladle furnace
operations. For reducing conditions where the bath has a much lower oxygen activity,
distribution ratios for sulfur of between 20 and 100 can be achieved.
Control of the metallic constituents in the bath is important as it determines the
properties of the final product. Usually, the melter will aim at lower levels in the bath
than are specified for the final product. Oxygen reacts with aluminum, silicon and
manganese to form metallic oxides, which are slag components. These metallics tend to
react with oxygen before the carbon. They will also react with FeO resulting in a recovery
of iron units to the bath. For example:
Mn + FeO = MnO + Fe
Manganese will typically be lowered to about 0.06 % in the bath.
The reaction of carbon with oxygen in the bath to produce CO is important as it supplies
a less expensive form of energy to the bath, and performs several important refining
reactions. In modern EAF operations, the combination of oxygen with carbon can supply
between 30 and 40 % of the net heat input to the furnace. Evolution of carbon monoxide
is very important for slag foaming. Coupled with a basic slag, CO bubbles are tapped in
the slag causing it to "foam" and helping to bury the arc. This gives greatly improved
thermal efficiency and allows the furnace to operate at high arc voltages even after a flat
bath has been achieved. Burying the arc also helps to prevent nitrogen from being
exposed to the arc where it can dissociate and enter into the steel.
If the CO is evolved within the steel bath, it helps to strip nitrogen and hydrogen from
the steel. Nitrogen levels in steel as low as 50 ppm can be achieved in the furnace prior
to tap. Bottom tapping is beneficial for maintaining low nitrogen levels because tapping is
fast and a tight tap stream is maintained. A high oxygen potential in the steel is
beneficial for low nitrogen levels and the heat should be tapped open as opposed to
blocking the heat. At 1600 C, the maximum solubility of nitrogen in pure iron is 450 ppm.
Typically, the nitrogen levels in the steel following tapping are 80 - 100 ppm.
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Decarburization is also beneficial for the removal of hydrogen. It has been demonstarted
that decarburizing at a rate of 1 % per hour can lower hydrogen levels in the steel from 8
ppm down to 2 ppm in 10 minutes. At the end of refining, a bath temperature
measurement and a bath sample are taken. If the temperature is too low, power may be
applied to the bath. This is not a big concern in modern melt shops where temperature
adjustment is carried out in the ladle furnace.
De-Slagging
De-slagging operations are carried out to remove impurities from the furnace. During
melting and refining operations, some of the undesirable materials within the bath are
oxidized and enter the slag phase.
It is advantageous to remove as much phosphorus into the slag as early in the heat as
possible (i.e. while the bath temperature is still low). The furnace is tilted backwards and
slag is poured out of the furnace through the slag door. Removal of the slag eliminates
the possibility of phosphorus reversion.
During slag foaming operations, carbon may be injected into the slag where it will reduce
FeO to metallic iron and in the process produce carbon monoxide which helps foam the
slag. If the high phosphorus slag has not been removed prior to this operation,
phosphorus reversion will occur. During slag foaming, slag may overflow the sill level in
the EAF and flow out of the slag door.
The following table shows the typical constituents of an EAF slag:
Table No. C3 - 20: Chemical Analysis of EAF Slag
Component Source Composition Range
CaO Charged 40 - 60 %
SiO2 Oxidation product 5 - 15 %
FeO Oxidation product 10 - 30 %
MgO Charged as dolomite 3 - 8 %
CaF2 Charged - slag fluidizer
MnO Oxidation product 2 - 5%
S Absorbed from steel
P Oxidation product
Tapping
Once the desired steel composition and temperature are achieved in the furnace, the tap-
hole is opened, the furnace is tilted, and the steel pours into a ladle for transfer to the
next batch operation (usually a ladle furnace or ladle station). During the tapping process
bulk alloy additions are made based on the bath analysis and the desired steel grade.
De-oxidizers may be added to the steel to lower the oxygen content prior to further
processing. This is commonly referred to as "blocking the heat" or "killing the steel".
Common de-oxidizers are aluminum or silicon in the form of ferrosilicon or
silicomanganese. Most carbon steel operations aim for minimal slag carry-over. A new
slag cover is "built" during tapping. For ladle furnace operations, a calcium aluminate
slag is a good choice for sulfur control. Slag forming compounds are added in the ladle at
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tap so that a slag cover is formed prior to transfer to the ladle furnace. Additional slag
materials may be added at the ladle furnace if the slag cover is insufficient.
Furnace Turn-around
Furnace turn-around is the period following completion of tapping until the furnace is
recharged for the next heat. During this period, the electrodes and roof are raised and
the furnace lining is inspected for refractory damage. If necessary, repairs are made to
the hearth, slag-line, tap-hole and spout. In the case of a bottom-tapping furnace, the
taphole is filled with sand. Repairs to the furnace are made using gunned refractories or
mud slingers. In most modern furnaces, the increased use of water-cooled panels has
reduced the amount of patching or "fettling" required between heats. Many operations
now switch out the furnace bottom on a regular basis (2 to 6 weeks) and perform the
hearth maintenance off-line. This reduces the power-off time for the EAF and maximizes
furnace productivity. Furnace turn-around time is generally the largest dead time (i.e.
power off) period in the tap-to-tap cycle. With advances in furnace practices this has
been reduced from 20 minutes to less than 5 minutes in some newer operations. H e a t E x c h a n g e r B a g F i l t e r C h i m n e yT h r e e p h a s e e l e c t r i c P o w e r
Fig. No. C3 – 20: Process Flow Diagram Electric Arc Furnace
C o n t i n u o u s C a s t i n g
P r e p a r a t i o n o fC h a r g e : S p o n g eI r o n , P i g I r o n a n dS c r a pE l e c t r i c A r c F u r n a c e :M e l t i n gR e f i n i n gD e s l g g i n gT a p p i n g
L i m e a n d F e r r o a l l o yO x y g e n L a n c i n gP o u r i n g
C h a r g i n g o f t h eF u r n a c e
R e f i n i n g i nL a d d l e / A O D / V O D
M u l t i -C y c l o n eI D F a n
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EAF Furnace Specification:
One no. EAF of 18 ton capacity with transformer rating of approx. 12 MVA is proposed to
be installed for producing carbon steel as well as alloy and stainless steels. Provision of
high powered transformer and oxygen assisted melting facility would reduce the melting
time considerably
Table No. C3- 21: Technical Specification of EAF Furnace
S. No. Parameters Unit Value/ Features
1. Installed capacity t/yr 86,400
2. No. of units Nos 1
3 Heats per day No. 22
4. Nominal tap weight t 18
5. Tap to tap time Min 65
7. Type of furnace High Power Electric Arc furnace
8. Transformer rating MVA 12
9. Furnace charge-mix approx.
Sponge Iron /scrap % 45
Hot Metal / scrap % 52
Return Scrap % 3
10. Method of charging
> Metal/ scrap Batch Process
> Lime
> Ferro-alloys/ deoxidizers
11. Steel refining Oxygen lancing
12. Fume collection & cleaning Bag filters
3.5.6.3 Ladle furnace (LF):
The liquid steel in the ladle is further refined and the desired chemistry of steel is
obtained by adding alloying elements. For homogenizing the liquid steel inert gas argon
is purged through the liquid steel and the flue gases are removed from the top of the
ladle through cooled ducting, bag filter and released to atmosphere after cooling and
cleaning the gases for particulate matter through chimney.
It is proposed to provide one no matching capacity LF i.e. 20 tons equipped with arc
heating, inert gas stirring and alloy addition facilities to treat the heats tapped from EAF.
All the 22heats produced per day per EAF can be conveniently be treated at one LF with
an average treatment cycle time varying between 40 to 50 minutes per heat depending
on the extent of treatment required. Hence, one no. of LFs will suffice the shop
requirement.
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3.5.6.4 Vacuum Oxygen Decarburization (VOD):
This process is based upon the fact that under vacuum and oxidizing conditions
decarburization is favoured against the scorification of chromium, Therefore, this process
is exclusively applied to stainless steel grades and other Chromium bearing steels.
Vacuum Oxygen Decarburization (VOD) is carried out in several steps as follows:
1. Melting
2. Oxygen pre blowing at atmospheric pressure for preliminary decarburization and the
scorification of Si (As well as Al, Ti, and V if any).
3. Vacuum treatment under oxidizing conditions by introducing gaseous oxygen into the
vacuum chamber.
4. Vacuum treatment under reducing conditions
5. De-sulphurisation
3.5.6.5 Stainless Steel Refining in AOD Converter
SSR process is advantageously used for refining speciality steels & alloys and it is the
most significant advance in the manufacture of these materials. In the case of electric arc
furnace (EAF), five to six hours/ heat are required to produce final carbon content below
0.03% whereas routine production of extra low carbon (ELC) can be achieved in Stainless
Steel Refining Converter in less than two hours. Similarly, even 0.001% sulphur is
feasible with Stainless Steel Refining Converter.
Stainless Steel Refining Converter accepts molten metal transfer not only from EAF but
also from Induction Furnaces, LD or BOP converters and Submerged Arc Smelting
Furnaces. On an intermittent basis, metal from hot metal sources including Blast
Furnaces (BF) and Cupolas can be refined in Stainless Steel Refining Converter.
Stainless steel production from stainless steel refining process comprises of three phases
which are indicated below together with key parameters of each phase;
• Decarburisation
Once the heat has been transferred to the SSR vessel, bath temperature is observed.
Based on the starting temperature, chemistry and weight, a series of calculations to
guide the process is made.At some point prior to the end of the decarburisation period, a
sample is subjected to carbon analysis. This is used to verify and fine-tune the original
end point calculations. Based on this updated oxygen requirement, a precise
determination of reduction additions and fluxes is made.
• Reduction / Desulfurisation
After attaining the aimed carbon level, alloys and fluxes which promote recovery of any
oxidised metallics are added (in batch) to the Stainless Steel Refining Converter. Since
the amount of oxygen consumed by metallic oxidation is determined precisely, the
amount of reduction material (usually silicon ferro alloys or aluminium) is determined
accurately. The reduction mix is stirred with inert gas for a period sufficient to allow
completion of oxidation/reduction reactions and slag formation.
If the initial sulphur content is high, desulfurisation slag (CaO/SiO2 >2) is added after the
original reduction slag is decanted. Stirring is provided for promoting slag formation.
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• Trim
Small adjustments in composition are made based on the after reduction chemistry.
Temperature adjustments are also possible within 5OC in view of predictability of the
process. Modern SSR practice is characterised by rapid heat times, achieved through the
use of a top lance and occasionally a sublance for sampling and long refractory
campaigns resulting in high productivity and low refining costs.
3.5.6.5 Continuous Caster
The continuous caster is a machine that converts liquid steel to solidified billets of size
and shape suitable for a rolling mill. The liquid steel is brought to the caster in a
refractory lined vessel called a ladle. The machine receives the ladle by two steel arms,
called a turret, which can revolve and swing the ladle to the casting position. The turret
can carry two ladles at one time and thus facilitate a complete sequence of ladles that
permits continuous casting as long as the ladles can be exchanged in time.
At the casting position a preheated intermediate vessel called a turndish is brought under
the ladle. The function of the turndish is to hold a reservoir of metal for casting and
permit exchange of ladles without interrupting casting. The turndish also serves to
remove inclusions and is also therefore a necessary metallurgical tool. The turndish has a
stopper rod, which sits on the nozzle. The stopper rod lifting controls the steel flow
through the nozzle and is in turn controlled by measuring the level of steel in the mould.
The liquid steel is let into a water-cooled vertical curved mould and starts solidifying
inside the mould. The solidifying bar of steel is pulled out by a dummy bar to start the
process and after wards by the solid bar itself. The extraction is accomplished by a set of
rolls, which are driven by a variable speed drive. During extraction of the steel bar, the
solidifying bar is sprayed by a set of nozzles, which deliver water at a controlled rate.
The bar takes distance to solidify and a time depending on the size of the billet (the solid
is called a billet or bloom depending on the actual size.). The billet is cut to the desired
length after complete solidification and then lifted from the roller table to a turnover
cooling bed or pusher cooling bed (If slow cooling is desired).The billets are now marked
inspected and made ready for rolling.
3.5.7 Rolling Mill
Technology and Process Description
The re-heating furnace of capacity 30 TPH will be installed to produce rolled product (TMT
bars/ structurals/ rounds) of 200000 TPA. 208000 TPA steel billets will be utilized as raw
material to produce billets.
The process involves the re-heating of the steel billets to a temperature of almost 10500C
to get them into malleable shape where after it shall be possible to roll them into bars of
the required diameter. Apart from the re-heating furnace, the rolling mill comprises of a
number of roll bearing stands. These rolls are grooved so that bypassing through every
consecutive groove, the steel piece reduces in cross-section and increasing in length.
This process continues until the bar reaches its required diameter.
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RAW MATERIALS ( BILLETS )
WEIGHMENT, RECEIVING, UNLOADING & STACKING
CUTTING(GAS/CHISEL)
[AS PER REQUIREMENT SECTION TO BE ROLLED]
HEATING IN FURNACE(CHARGING IN OIL FIRE PUSHER TYPE REHEATING FURNACE)
ROLLING
INTERMEDIATE HEAD & TAIL OF THE BARS ARE CUT THROUGH ROTARY SHEAR
THERMO MECHANICAL TREATMENT
END CUTTINGS (SHEAR CUT / GAS CUT)
INSPECTION / TESTING
BENDING/BUNDING
STACKING
WEIGHMENT & DESPATCH
Earlier, the process of transferring the bar from one rolling stand to another used to be
carried out manually. Technological developments in steel processing have made it now
possible to automatically transfer the steel piece from one stand to another with the help
of what is known as a ‘repeater’ thereby making manual rolling mills automatic. The steel
piece in final shape bears appropriate rib design, which gives it bonding strength with
concrete during construction. This bonding strength ad tensile strength is added to the
bar by the cold twisting process done with the help of bar twisting machines. Recent
technological advancements in steel processing have now given birth to what is
commonly advertised as the TMT Bar which has metallurgical qualities than the
conventional CTD (Cold Twisted) bar.
Fig. No. C3 - 21: Process Flow Diagram of Rolling Mill
TMT Bar: The production of rolled steel reinforcing steel bar required the attainment of
high yield strength typically around 500 N/mm2. There are, basically, three ways of
producing this high yield strength.
8 0
• By micro alloying (V, Nb) precipitation of carbides and carbonitrides.
• By cold working, drawing, cold rolling
• By thermo-mechanical treatment, quenching the barn directly after hot rolling
followed by self-tempering.
The rolled bar yield strength can also be increased by modifying the chemical
composition by adding small quantities of dispersoid forming elements such as vanadium
or Niobium. This provides an increase in the yield strength while maintaining good weld
ability, but use of alloy additions in an expensive process route to follow.
The installation of an in-line quenching process can produce steel reinforcing bars with
high and very stable yield strength good weld without the addition of expensive alloys.
This process route provides the best and most economical solution.
The TMT process exposes the bar to an intense cooling after the last rolling pass,
providing excellent strength combined with good toughess. The fast cooling of the core
leads to a very fine ferritic – pearlitic structure. Hence the mechanical properties required
by several technical standards like ABNT, BSI, AFNOR, ASTM, JIS, DIN etc. regarding
high strength bars may safely reach, even for analysis levels, which normally apply to
low resistance material only, as follows:
• C : 0.20 to 0.30 %
• Si : 0.10 to 0.30 %
• Mn : 0.60 to 0.90 %
• Ceq : 0.30 to 0.50 %
Thus high strength material may be produced combined with weld ability characteristics.
(C = 0.24, Ceq = 48%)
Advantages
• Provides optimal physical properties to the bars and other product
• One chemical analysis range only for all sizes of rebars
• Zero discards by Quality Control
• Operationally safe and presenting no restriction of rolling mill productivity
• Matches high strength with excellent ductility and ensure good weld ability
The TMT process consists of a set of cooling elements in series, located after the last
rolling pass. Every cooling element is provided with water inlet, which allows the
homogenous cooling of the bar. The water undergoes intensive turbulence caused by a
series of circular grooves perpendicular to the bar axis. The turbulence eliminates the
steam from the bar surface which leads to improved heat transmission. This provides an
advantage over existing configuration in both the current drilled hole and slot designs are
typically prone to contamination. The amount of spring gap and the number of spring
coils (spring gaps) is determined after an iterative of the specific cooling requirement and
the resulting water flow rates.
8 1
Technical Description
A TMT post cooling system comprises of different number of cooling elements located in
series after the last finishing pass, a water supply system. The cooling elements and
spray pipes are housed in modular freestanding enclosed water box. Each cooling
elements is provided with an individual shut off valve for precise cooling water control.
The cooling train length consists of the required number of TMT nozzles back to back in
modular arrangement. The TMT nozzles consists of a common spring coil compressed
between two guides bushings. Its overall length depends on the cooling applications.
Cooling water enters the nozzles through the successive circular channels or gaps formed
by the compressed spring coil. The spring coil used in the TMT nozzles is essentially a
combination of the drilled holes and slotted type cooling nozzles. The entry spring is
instrumental in achieving high cooling rates as it causes the initial water contact to
contain a very high kinetic energy and impact perpendicular to the product axis. The high
kinetic energy prevent the initial steam jackets from forming around the bar surfaces.
Laminar water flow, with high heat transfer characteristics, then occurs inside the guide
bushings. Experimental data shows that the cooling effectiveness quickly diminishes after
approximating 4-6 inches of travel (steam boundary layer formation), where in the
system, the water is quickly and efficiently vented. In determining a solution to a
particular cooling application, an iterative analysis evaluates the desire temperature
drop, the cooling time available (i.e. nozzle or train length) the required water quantities
and range of product grades. The optimized solution takes in account the implication of
the long nozzle with a nominal amount of water. A long nozzle with relatively small
amounts of water may promote the premature formation of steam (through Leidenfrost
phenomena), and dramatically reduces the heat transfer co-efficient while potentially
including severe vibrations in the rolled product. This results in not only product waviness
but can lead co cobbles. Water Supply Systems-Water supply systems for cooling
consists of centrifugal. Water pumps, water control valves and flow feedback devices.
TMT cooling trains, for either rod or bar mills are arranged with parallel water supply
feed, one per water box, which ensures optimum control of the water. The water supply
for each box contains a throttle valve and flow meter feedback. The water is then further
sub-divided to each cooling nozzle via a header located in or near the cooling box. When
required, a return flow control valve is utilized to maintain the water inertia in the header
or quick response situations. In TMT installations, each nozzle is equipped with
independent control i.e. shut off valve; throttle valve and flow meter feedback. A Diverter
valve is an option when quick response is required.
Electrical Control
TMT Cooling trains are equipped with electrical control systems which permit precise
product cooling and variable monitoring. The TMT water box has entry and exit
pyrometer, which provides feedback to regulate the water floor. Similarly, a bar mill
Turbo Quench cooling train utilizes pyrometer, which provides feedback (both entry and
exit) for water regulation.
8 2
The water flow rates are regulated via the pyrometer feedback over the length of the bar
these shall be noted in the Control Desk. A pulpit operator controls the water flow
regulation manually on the control desk.
General Cooling System Performance
Billets material, which will be used for commissioning, will be at constant analysis and
will fall within the range of :
C : 0.20 to 0.30 %
Si : 0.10 to 0.30 %
Mn : 0.60 to 0.90 %
Ceq : 0.30 to 0.50 %
The steel bar should have an entry temperature into the cooling box of approximately
9500C. The quenching system is capable of achieving all the specified property
requirements to IS 1786-1985, on bending, elongation and AGT.
Grade 460 mean value 500 N/mm Sq Standard deviations 18 N/mm Sq. grade 500 mean
value 540N/mm Sq. Standard deviation 18 N/mm Sq. The maximum variation of yield
strength, and ultimate strength on any part of bar length under uniform temperature and
constant speed, with uniform water temperature conditions will be 25N/mm Sq. which
equates to a standard deviation of approximately 13N/mm Sq.
The quenched molten site layer will be concentric and of a suitable depth to comply with
the requirements of the yield stress quoted in the standard. The variation of temperature
at the equalization point will be within + 15 deg. C when cooling uniformly heated billets
under same conditions mentioned above.
Supply of water must be kept at a constant temperature, preferably not greater than
280C.
Table No. C3- 22: Water Quality
Measuring of floating substances : 0.2 mm
Total Hardness : 50 to 300 ppm as CaCo3
Turbidity : Max 5 NTU
Alkalinity : 150 to 500 ppm as CaCo3
Temperature : Max 30 (35) deg. C
Iron Content : Max 2 ppm as Fe
Chlorides Max 100 ppm as SO4
Sulphates Max 200 ppm as SO4
Fuel Requirement: Furnace oil will be used as fuel in the re-heating furnace, the
requirement of furnace oil will be about 7000-10000 litters/day. Storage capacity of 100
KL envisaged for the project.
8 3
3.5.2.9 Environmental Management:
Air:
a. Raw material storage and handling area: As the raw materials to be used in plant
are only billets, no fugitive emissions will be generated during material handling.
b. Furnace: The exhaust gas emits to atmosphere from the furnace containing only
sulphur dioxide, oxides of Nitrogen, carbon dioxide.
c. Stack: The unit has proposed to set up a stack of adequate height 30.0 m.
3.5.9 Cement Grinding Plant:
The proosed integrated steel plant complex will consist of captive power plants based on
waste heat of DRI kilns, a FBC boiler based on dolochar. The total generation capacity
would be 48 MW. The CPP is designed to produce 403 T/h tones of fly ash which can be
effectively be utilized in the manufacture of portland pozzolana cement (PPC) which
contains abou 35% of fly ash. The company will be receiving required amount of cement
clinkers from neighboring cement manufacturing units for sustained production of 1000
tonnes per day from one number of grinding mill that it proposes to install. In the
absence of PPC or when the main plant is idle the cement grinding plant will be utilized to
produce Ordinary Portland Cement. Provision also will be made to produce Portland Slag
Cement (PSC) by utilsing the blast furnace slag from nearest steel mills.
3.5.9.1 Manufacturing Process:
Clinker, Slag and Gypsum are the raw materials used in the manufacture of Portland Slag
Cement (PSC). Requisite quantity of clinker will be supplied from neighboring cement
manufacturing units to the factory site by railway wagons. Clinker received by rail shall
be stored in suitable clinker storage silo. Slag, which is a waste material generated in the
process of steel making will be received by rail/road and stored. Gypsum which is a by-
product of the fertilizer industry will be received from the fertilizer plants at Paradeep by
rail and stored in a covered storage yard. Clinker, fly ash and gypsum are the raw
materials for the manufacture Portlant Pozzulana Cement. The fly ash to the tune of
1,05,000 TPA will be required for cement grinding unit.
For cement grinding, appropriate imported Cement Vertical Roller Mill (CVRM) will
installed. Clinker is fed into Cement Vertical Roller Mill along with requisite quantity of
gypsum, where it is ground to a fine powder to produce Ordinary Portland Cement (OPC).
Portland Slag Cement (PSC) is normally manufactured by grinding clinker with gypsum at
suitable proportion and grinding granulated slag separately and thereafter mixing them
together intimately in a paddle mixer. Alternatively, all the above raw material i.e clinker,
gypsum and slag can be ground together. The mill has been provided with a dynamic
classifier internally which allows only the fine particle of requisite blaine to pass to the
bag filter where the fine particles is settled and collected in the hopper in the bag filter.
The collected cement in the hopper is transported by enclosed air slide to the elevator
and is stored in the Reinforced Cement Concrete silo called cement silo. In case of
separate grinding the material is stored in the multi compartment silo from where the
ground clinker and slag is extracted, blended in proper proportion in a mixer and then
8 4
send to cement storage silo. In case of inter grinding of clinker, gypsum and slag
together the material from bag filter hopper is directly sent to cement storage silo. In
case of manufacture of PPC, clinker, fly ash (extracted from the Fly ash storage
compartment) and gypsum are inter ground and stored in the identified cement silo
Cement Packaging: Cement extracted from silos is conveyed to the automatic
electronic packers, where it is automatically packed in 50 kg HDPE bags and dispatched
in trucks/wagons The plant is well automated and operated from central control room
and the control system is based on PLC/DCS. Manufacturing Process Flow is presented in
following Fig. No. C3 – 20.
Quality Control:
All the raw materials in process and products are tested out by means of XRF and XR.
The preventive measures are taken to ensure the consistence and best quality is
achieved. Material testing is undertaken on calibrated instruments for both physical and
chemical parameters all the time. The people involved in this stream are highly qualified
and experienced and quality conscious.
3.5.9.2 Mix composition of Raw Materials for Various Products
Table No. C3 - 23 : Raw Materials for PSC & PPC
Sl.
No
Raw Materials Proportion by wt %
PSC (PPC)
1 Clinker 55 62
2 Gypsum 3 3
3 Slag 42 --
4 Fly Ash --- 35
3.5.9.3 Specification of Raw Materials
a) Table No. C3 - 24: Specification of Quality of Clinker :
Parameters % age
LOI 0.60
IR 0.26
SiO2 20.36
Al2O3 5.56
Fe2O3 3.56
CaO 63.24
MgO 4.83
SO3 0.67
F-CaO 1.28
LSF (Lime Saturated Factor) 0.95
SM (Silica Modulous) 2.23
AM (Alumina Modulous) 1.56
8 5
C3S (Tri-calcium Silicate) 53.10
C2S (Di-calcium Silicate) 18.33
C3A (Tri-calcium Aluminate) 8.71
C4AF (Tetra calcium alumino feerite) 10.83
b) Table No. C3 - 25: Specification of Quality of Slag
Parameters % age
%LOI 0.59
%IR 0.65
%SiO2 34.11
%Al2O3 20.85
%Fe2O3 0.83
%CaO 32.16
%MgO 9.16
%Sulphide 0.67
%MnO 0.58
(CaO+MgO+Al2O3)/SiO2 1.82
%Glass Content 95
c) Table No. C3 – 26: Specification of Quality of Gypsum
Parameters % age
% IR 1.59
%SiO2 1.89
%Al2O3 1.11
%Fe2O3 0.62
%CaO 31.88
%MgO 0.6
%SO3 43.86
%P2O5 0.8
%Purity 94.299
d) Quality of Coal-
i) Table No. C3– 27: Proximate Analysis of Coal for Cement Grinding Plant
Sl. No. Parameters % (wt/wt)
1 Ash content 38
2 Moisture content 07
3 Volatile Matter 25
4 Fixed carbon 30
8 6
ii) Table No. C3 - 28 : Ultimate Analysis of Coal for Cement Grinding
Sl. No. Parameters % (wt/wt)
1 Carbon 40.73
2 Hydrogen 2.82
3 Sulphur 0.42
4 Nitrogen 1.16
5 Ash content 38.65
6 Moisture Content 6.75
7 GCV 3920 K Cal/Kg
e) Specifications for Auxiliary Fuel
Table No. C3 - 29: Specification of HFO
Specific gravity @ 150C 0.950
Gross Calorific Value, Kcal/kg 10280
Flash point, 0C max 66
Sulphur, % max 4.5
K. Viscosity in Centistokes @ 500C max 169
Ash by wt, % 0.1
Water & Sediment Vol. Max. % 1.25
Capacity of HFO Storage Tank 1Nos. X 22 KL
3.5.9.4 Norms for Main Machinery & Storages (Cement)
Operating hours per day (hr/day) and safety factors for plant and machinery are given in
following Table:
Table No. C3– 30: Norms for operating hours, safety factors for plant & machinery
Sn Department Operating, hr/day Safety factor
1 Cement mill 22 -
2 Packer 15 1.25
Norms for storages for raw materials, additives and final product is given below;
Table No. C3 -31: Norms for Raw Material Storages
Sl. No. Material Storage, days
1 Clinker 5
2 Cement 6
3 Gypsum 15
4 Slag 6
For the purpose of plant machinery design, calculation of equipment capacities and
material storages, the moisture content of the raw materials are indicated in the
following Table No. C3 - 32.
8 7
Table No. C3- 32: Moisture Content in Raw Materials for cement Grinding
Sl. No. Department Moisture content, %
1 Gypsum 15
2 Slag 15
3 Clinker < 1
4 Fly Ash < 1
3.5.9.5 Equipment and Storage Capacities
The storage capacities for various materials required for enhanced capacity including
existing is given in the following Table 2.10.
Table No. C3 - 33: Details of Storage Capacities for Grinding Unit
Description Days of storage Capacity (Tonne)
Recommended
Clinker silo 5 2 X 25,000
Gypsum stock pile (covered) 15 2 X 2,500
Cement Silos 3 4 X 7,500
Slag Stock pile 12 2 x 12,500
Coal Stock pile 10 4,000
Fly Ash Silo 4 2x2000
8 8
Fig. No. C3 – 22: Process Flow Diagram Cement Grinding Plant
G y p s u mS t o c k p i l e S l a gS t o c k p i l e F l y a s h S i l o C l i n k e rS i l o C o a lS t o c k p i l eS e r v i c eB u n k e r S e r v i c eB u n k e r S e r v i c eB u n k e r S e r v i c eB u n k e r C r u s h e rB a l l M i l lH o t G a sG e n e r a t o rV e r t i c a lR o l l i n gM i l l
B a gF i l t e rM u l t iC o m p .S i l oC e m e n tS i l oP a c k e r sT r u c k / W a g o n
I D F A N
8 9
3.6 Raw Materials Required along with estimated quantity, likely source, marketing area
of final product/s, Mode of Transportation of raw materials and Finished Product/s.
3.6.1 Table No. C3– 34: Raw Materials Required, Likely source, Mode of Transportation
Sl.
No.
Raw Material Consumption
in tonnes per
ton of product
Amount
in tonnes
Likely Source Mode of
Transport
Iron Ore Beneficiation Plant (8,25,000 T throughput)
1 Iron Ore Fines 0.8 8,25,000 Mines in Barbil/
Joda of Odisha
By Rail
Pellet Plant(6,00,000 TPA)
1 Iron Ore Concentrate 1.1 6,60,000 Own production --
2 Coke Fines 0.15 (150kg) 9,000 Durgapur Steel
Plant/ Coking
Plant of
Durgapur
Project Ltd.
By Road in
covered trucks
3 Bentonite 0.05 (50kg) 3,000 Local Market By Road
4 Limestone 0.15 (150kg) 9,000 Biramitrapur,
Sundargarh,
Odisha
By Road in
covered trucks
Sponge Iron Plant (1,65,000 TPA)
1 Iron Ore/Pellets 1.6 2,64,000 Mines in Barbil/
Joda of Odisha
By Rail /Road in
covered trucks
2 Washed Coal 1.3 2,14,500 Nearby Coal
Mines of ECL
and BCCL
By Rail /Road in
covered trucks
3 Dolomite 0.05 (50kg) 8,250 Biramitrapur,
Sundargarh,
Odisha or Mines
in North Bengal
By Rail /Road in
covered trucks
Ferroalloy Plant-Ferro chrome (81,000 TPA)
1. Chromites Ore Hard
Lump
0.32 25,759 Sukinda, Jajpur
dist., Odisha
By rail /road in
covered trucks
2. Chromite Ore
Briquettes
1.9 1,53,900 Own plant --
3. Chromite Ore Friable
Lump
0.13 10,287 Sukinda, Jajpur
dist., Odisha
By rail /road in
covered trucks
4. Quartzite 0.28 22,599 Mines in
Bankura W.
Bengal and
Chhatisgarh
By rail /road in
covered trucks
5. Coke 0.5 40,582 Own production --
9 0
6. Coal 0.3 23,734 Nearby Coal
Mines of ECL
and BCCL
By rail /road in
covered trucks
7. Electrode Paste 0.025 2,025 Maharastra
Carbon Ltd.,
Graphite India,
Durgapur
By rail /road in
covered trucks
Ferroalloy Plant-Ferro Manganese (1,18,800 TPA)
1. Manganese Ore 2.3 2,72,918 OMC
Manganese
mines in Odisha
By Rail /Road
in covered
trucks
2. Dolomite 0.35 41,630 Biramitrapur,
Sundargarh,
Odisha
By Rail /Road
in covered
trucks
3. Low Ash Met Coke 0.6 71,280 Durgapur Steel
Plant /Coking
Plant of
Durgapur
Projects Ltd.
By Rail /Road
in covered
trucks
4. Electrode Paste 0.015 1,782 Maharastra
Carbon Ltd.,
Graphite India
Ltd., Durgapur
By Rail /Road
in covered
trucks
Ferroalloy Plant-Ferro Silicon (42,000 TPA)
1. Quartz 0.5 84,000 Mines in
Chhatisgarh,
Odisha
By Rail /Road
in covered
trucks
2. Charcoal 1.5 63,000 Local Market By Rail /Road in
covered trucks
3. Iron Scrap 0.35 14,700 Local Rolling
Mills and own
production
By Rail /Road
in covered
trucks
4. Electrode Paste 0.06 2520 Maharastra
Carbon Ltd,
Graphite India
Ltd, Durgapur
By Rail /Road
in covered
trucks
5. Cashing Sheet 0.005 210 Steel Plants Of
SAIL/TISCO
By Road
6. MS Rounds 0.027 1,140
Ferroalloy Plant-Silico Manganese (89,100 TPA)
1. Manganese Ore 1.79 1,59,442 Manganese
Mines in Odisha
/Chhatisgarh
By Rail /Road
in covered
trucks
2. Dolomite 0.35 31,185 Mines in Odisha, By Rail /Road in
9 1
Chhatisgarh covered trucks
3. Fe-Mn Slag 0.6 53,460 Own
Production
--
4. Low Ash Met coke 0.6 53,460 Imported coal From Australia
by Ship & then
by Rail /Road
5. Electrode Paste 0.025 2228 Maharastra
Carbon Ltd.,
Graphite India
Ltd., Durgapur
By Rail /Road
in covered
trucks
6. Cashing Sheet 0.01 891 Steel Plants Of
SAIL/TISCO
By Road
SMS - Induction Furnace (Annual Production-1,38,000 TPA)
1. Sponge Iron 0.806 1,11,350 In Plant
Production
--
2. Pig Iron /Iron Scrap 0.35 48,300 Local Market By Road in
covered trucks
3. Ferroalloys 0.02 2,760 In plant
production
--
SMS- Electric Arc Furnace (96,000 TPA)
1. Iron Scraps 0.556 53,400 Local Rolling
Mills
By Road in
covered trucks
2. Sponge Iron 0.456 43,770 --
3. Graphite Electrode 0.009 860 Maharastra
Carbon Ltd.,
Graphite India
Ltd., Durgapur
By Road in
covered trucks
4. Lime 0.071 6,880 Biramitrapur,
Sundergarh,
Odisha
By Road in
covered trucks
5. Coke 0.013 1,260 In plant
production
By Road in
covered trucks
Reheating Furnace/Rolling Mill (2,00,000 TPA)
1. Billets 1.07 2,14,000 In plant
production from
IFs and EAFs
--
2. Furnace Oil
/Pulverised Coal
0.042 8400 KL Local Oil
Terminals
By Road in
Tankers
Cement Grinding Plant (3,00,000 TPA)
1. Cement Clinker 0.6 1,80,000 From
neighbouring
cement units
Rail /Road by
covered trucks
2. Fly Ash 0.35 1,05,000 In plant
generation
--
9 2
3. Gypsum 0.05 15,000 IFFCO and PPL,
Paradeep
By Rail /Road in
covered trucks
Captive Power Plant based on WHRB (8 MW)
1. DRI Flue gas 1,05,000
Nm3/hr at
950-10000C
In plant
Production
Duct
2. Water 36 t/hr. Panchet
Reservoir on
river Damodar
Pipe Line
Captive Power Plant based on FBC (2 X 16 MW)
3. Dolochar 4,585 In plant
production
--
4. Coal fines 14,850 In plant
production &
purchase from
open market
By Rail /Road
in covered
trucks
5. Coal 1,83,535 From nearby
Coal fields of
ECL and BCCL
By Rail /Road
in covered
truck
3.6.2 Table No. C3 - 35: Quantification of Product after Expansion, Marketing Area &
Mode of Transportation
Sl.
No.
Product Amount,
TPA
Market Mode of
Transport
1 Sponge Iron 1,65,000 Used in the plant in IF/EAF steel
making. In case not used in the plant
will be sold to steel manufacturers
By Road in
covered trucks
2 Ferroalloys 1,18,800 Partly used in the plant and balance
will be sold to steel manufacturers
in West Bengal
By Road in
covered trucks
3 MS Billets 1,38,000 Partly used in the plant and balance
will be sold to Steel Rolling Mills in
West Bengal
By Road in
covered trucks
4 MS/ Special
Steel/ Stainless
steel Billets
96,000 Partly used in the plant and balance
will be sold to steel Rolling Mills in
West Bengal
By Road in
covered trucks
5 Structural
steel /Rebar
2,00,000 Sold in open market By Road in
covered trucks
7 Portland
Pozzolana
Cement
3,00,000 Sold to Wholesalers in the state By Road in
covered trucks
9 3
9 Iron Ore
Pellets
6,00,000 Will be partly used in Sponge Iron
plant and partly sold to sponge iron
plants /Blast furnaces in the state
By Road in
covered trucks
3.6.3 Resource optimization/recycling and reuse envisaged in the project, if any,
should be briefly outlined
• The process selected envisages recycling all the materials collected in the pollution
control equipments thereby ensuring no generation of solid waste.
• The waste water generate from the boiler blow down of power plant and the waste
water generated from the regeneration of anion and cation exchanger of DM plant will
be utilized for green belt development and dust suppression.
• The coke breeze & coal breeze generated in coke ovens will be recycled in Coke ovens.
• The fines collected in bag filters of cement grinding plant will be mixed with the
ground cement before packaging.
• The waste heat in flue of the Sponge Iron Plant will be fully recovered through
installation of Waste heat recovery boiler to generate power.
• The coal fines and dolochar generated in Sponge Iron Plant will be utilized in FBC
Boiler to generate power.
• The waste heat in flue of the Coke Ovens Plant will be fully recovered through
installation of Waste heat recovery boiler to generate power.
• Ferro manganese slag generated in Ferro alloy plant and mill scale generated in
secondary steel manufacturing will be recycled in the manufacture of ferroalloys.
• No waste water is generated in cement plant.
• The fly ash recovered from the WHRB and CFBC boilers will be used for making
Portland Pozzolana Cement.
3.6.4 Availability of water its source, energy /power requirement and source
36.4.1 Water requirement and its source:
Table No. C3 - 36: Water Requirement and its source
Sl.
No.
Facility Quantity (cu. m/day)
Exiting Proposed Total
1 Make-up water for DRI kilns 60 90 150
2 Make-up water for SMS (Induction Furnace & LRF)
• Cooling Water
• Soft water regeneration
20
05
40
10
60
15
3 Make-up water for SMS
• Electric Arc Furnace/ VOD/AOD/VID
• Soft Water Regeneration
--
54
6
54
6
4 Make up water for Rolling Mill -- 90 90
5 Make up water for Ferroalloys
• Cooling Make up
120
60
180
9 4
• Soft water Regeneration 10 05 15
6 Make up water for Iron Ore Beneficiation 784 784
7 Make up water for Pellet plant
• Process Make up
• Cooling Make up
--
50
30
50
30
8 Make up water for power plant 748 610 1358
1. Cooling tower make up 648 100 748
2. Boiler feed water 90 486 576
3. DM Plant Regeneration 6 18 24
4. Floor Washing 4 6 10
9 Cement Grinding (cooling make up) -- 40 40
10 Raw Water treatment (losses through clarifier,
under flow and filter backwash)
16 70 86
11 Domestic use 40 50 90
Total 1019 2009 3028
3.6.4.2 Table No. C3 - 37: Power Requirement and its source:
Sl.
No.
Plant Facility Power Requirement
per Tonne of
Product (Kwh)
Annual
Production
(Tonnes)
Total Power
Requirement
(MW)
1 DRI 80 1,65,000 01.84
2 SMS (IF) 850 1,38,000 16.50
3 SMS (EAF) 500 96,000 07.00
4 Iron Ore Beneficiation 30 6,60,000 02.75
5 Pellet Plant 70 6,00,000 06.00
6 Ferroalloy Plant 3200 79,200 35.00
7 Rolling Mill 30 2,00,000 0.833
9 Cement Grinding Plant 50 3,00,000 2.00
10 Power Plant 10% generation 48 MW 4.8
Total
76.723 say
77 MW
The Ferroalloys plant, the induction furnace steel melting and the EAF steel melting are energy
intensive processes. As such the total estimated demand of power for the entire project after
expansion is estimated to be 77MW. M/s Ispat Damodar Pvt. Limited proposes to generate 48
MW from its captive power plant by installation WHRBs and FBC boilers utilizing the processes
wastes. Balance power will be drawn from the DVC grid.
9 5
3 0 2 8 m 3 / d a y 2 8 7 8 m 3 / d a yR i v e r w a t e r F i l t e r b a c k w a s h
2 9 4 2 m 3 / d a y
7 8 4 m 3 / d a y 5 0 m 3 / d a y
3 6 m 3 / d a y
5 0 m 3 / d a y
8 0 m 3 / d a y
2 4 m 3 / d a y 2 4 m 3 / d a y L o s s : 4 m 3 / d a y 1 5 0 m 3 / d a y
7 5 m 3 / d a y
1 5 m 3 / d a y
1 5 m 3 / d a y
8 0 m 3 / d a y
8 m 3 / d a y 8 m 3 / d a y
9 0 m 3 / d a y
8 m 3 / d a y 8 m 3 / d a y
1 9 5 m 3 / d a y
1 5 m 3 / d a y 1 5 m 3 / d a y 1 5 m 3 / d a y1 3 5 8 m 3 / d a y
2 4 m 3 / d a y 2 4 m 3 / d a y 2 4 m 3 / d a y
1 0 m 3 / d a y 1 0 m 3 / d a y 1 0 m 3 / d a y 2 4 m 3 / d a y
2 4 m 3 / d a y
4 6 m 3 / d a y 4 6 m 3 / d a y
4 0 m 3 / d a y 6 m 3 / d a y9 0 m 3 / d a y D o m e s t i c 7 2 m 3 / d a y 7 2 m 3 / d a y
Fig. No. C3 – 23: Water Balance diagram
R W T P C l a r i f i e r F i l t e rS e t t l i n g p o n dP e l l e t i z a t i o n p l a n t S e t t l i n g t a n kD R II F & L R F S o f t w a t e r S e t t l i n gE A F , V D ,V I D / L R F S o f t w a t e r S e t t l i n gR o l l i n g m i l l O i l s e p a r a t i o nF A P S o f t w a t e r S e t t l i n gt a n kC P P D M P l a n tR e g e n e r a t i o n N e u t r a l i z a t i o np i tF l o o r w a s h O i l s e p a r a t i o nB o i l e r B l o w d o w nC T b l o w d o w nC e m e n tg r i n d i n g S o f t w a t e rD o m e s t i c S T P G r e e n b e l t
G U A R DP O N D3 3 8 m 3 / d a y D u s ts u p p r e s s i o n1 7 0 m 3 / d a yA s hC o n d i t i o n i n g1 1 6 m 3 / d a yF i r e f i g h t i n g5 2 m 3 / d a y
I r o n o r e b e n e f i c i a t i o np l a n t
9 6
3.6.5 Quantity of waste to be generated (liquid and solid) and scheme for their
management/ disposal
The plant will be designed for a zero effluent discharge. Effluent generated in various
units will be undergo treatment so that it can be used for secondary purposed like toilet
flushes, floor washing, green belt development dust suppression etc. In the table below
tentative disposal amount and their treatment and reuse scheme is furnished.
Table No. C3 - 38 : Waste Water Generation/Recycle and Reuse
Sl.
No.
Facility Waste water generation/Recycle/Reuse
1 Iron Ore
Beneficiation
24KLD waste water generated from filter press and hydro-cyclone
will be recycled back to the process with fresh make-up water.
2 DRI Plant There will be no process effluent. Cooling water will be completely
recycled with makeup water in a closed loop. 12 KLD generated
from wet scrubber will be reused for dust suppression.
3 SMS-IF There will be no process effluent. Cooling water will be completely
recycled in closed loop with makeup water. 30 KLD waste water
generated from soft water plant will be taken to guard pond after
treatment in settling pond and reused in dust suppression/ green
belt development.
4 SMS-EAF There will be no process effluent. Cooling water will be completely
recycled in closed loop with makeup water. 8 KLD waste water
generated from soft water plant will be taken to guard pond after
treatment in settling pond and reused in dust suppression/ green
belt development.
5 Ferroalloy
Plant
There will be no process effluent. Cooling water will be completely
recycled in closed loop with makeup water. 15 KLD waste water
generated from soft water plant will be taken to guard pond after
treatment in settling pond and reused in dust suppression/ green
belt development
6 Rolling Mill 8 KLD effluent will be generated from cooling water blow down
contaminated with oil during cooling of motors/equipment. Same
will be treated in oil separator and taken to guard pond for reuse.
7 Captive Power
Plant
i) Coolling Tower
Blowdown
46 KLD will be taken to guard pond after settling and reused for
dust suppression and green belt development
ii) Boiler Blow don 24 KLD will be taken to guard pond and reused for dust
suppression and green belt development
iii) DM Plant-
regeneration ion
exchangers
24 KLD will be taken to neutralization tank and from there to
guard pond and will be used for dust suppression and green belt
development.
9 7
iv) Raw Water
treatment & floor
wash of CPP area
10 KLD-Settling Pond, guard pond and reuse in dust suppression
and green belt development.
8 Clarifier-Back
wash
24 KLD
Clarifier
Underflow
16 KLD
9 Cement
Grinding Plant
No process effluent. Cooling water blow down will be completely
recycled with makeup water. Soft water regeneration of 6 KLD will
be treated in settling tank then reused for dust suppression &
green belt development.
10 Domestic
effluent
72 KLD will be treated in STP and reused for green belt
development.
3.6.5.2 Table No. C3 - 39: Quantity of solid waste to be generated and management/
Disposal Scheme:
Sl.
No.
Description of
Solid Waste
Quantity in TPD Disposal Practice
Existing
EC
Proposed
Expansion
Total
I. Iron Ore Beneficiation Plant
1 Tailings from Iron
ore Beneficiation
Plant
-- 550 TPD 550 TPD Will be removed from
tailing pond and disposed
off in solid waste yard
II Pellet Plant
1 Dust from APC
device
-- 30 30 Will be recycled back to
the process
III DRI Plant
1 Dolo Char 60 105 165 Used in FBC Boiler for
power generation
2 Coal fines 18 31.5 49.5 Used in FBC Boiler
3 Dust from ESP and
Bag filters of DRI
20 35 55 ESP dust used in Fly ash
brick making & Bag filter
dust used in low land filling
4 Kiln Accretion 13.5 24 37.5 Will be used for road
making
IV Induction Furnace
1 Slag 16 30 46 Sold to cement
manufacturers
2 Dust from bag filters 1.6 3 4.6 Sent to pelletisation plant
V Electric Arc Furnace
1 Slag -- 49 49 Filling low lying areas
9 8
2 Bag Filter Dust -- 2.8 2.8 Sent to pelletisation plant
VI. Ferroalloy Plant
1 * Slag from ferroalloy plant
Fe-Mn slag 221 110 331 Used as raw material for
Si-Mn
Si-Mn slag 182 91 273 Used as road construction
material
Fe-Si Slag 13 6.5 19.5 Used as road construction
material
Fe-Cr Slag 234 117 351
2 Dust from APC
devices
0.6 0.4 1 Sold to brick
manufacturers
VII. Captive Power Plant with WHRB and FBC Boilers
1 Fly Ash 66 282 348 Used in cement making
2 Bottom Ash 9 31 40 Sold to fly ash brick
manufacturers
VIII. Cement Grinding Plant
1 Dust from bag filters -- 15 15 Mixed with the product
2 Sludge from
neutralization pit
1 TPA 1 TPA Impervious Pit
IX. Hazardous Wastes
1 Used Oil/Used
Lubricants
0.2 1.0 1.2 Will be sold to authorized
Re-processors
2 DM Plant Resin 200 kg
in 5
years
500 Kg in
5 years
700 kg
in 5
years
Will be disposed off in
impervious pit
3 Sludge from
neutralization pit
0.2 T 0.5 T 0.7 T Disposed off in
impervious pit
4 Waste Oil/Used
Cotton Wastes
100 kg 500 kg 600 kg Will be disposed off in
impervious pit.
* The ferroalloy furnaces can be inter alia used for manufacture of Fe-Mn, Si-Mn,Fe-Si, or
Fe-Cr. In that case the maximum of the slag produced has been shown.
* All the solid wastes will be subjected to TCLP test to ascertain that they are non-
hazardous before their disposal.
9 9
Fig. No. C3 - 24: Schematic Diagram of EIA Process of the Project
M/s Ispat Damodar Pvt. Ltd.
Village: Nabagram, PO: Digha, PS: Neturia, District: Purulia, West Bengal
FACILITIES:
Iron ore beneficiation
& Pellet plant.
Sponge Iron plant.
Steel melting shop
Ferroalloys Plant
Captive power plant ,
Cement grinding plant
WATER
REQUIRED:
Amount:
Source: Ground
Water/River
Damodar
Land:
15 acres-
existing, Total
land 125 acres
already
acquired
RAW MATERIALS:
- Iron Ore fines
- Non coking Coal
- Met Coal
- Dolomite
- Chromites Ore
- Mn Ore
- Quartzite
- Iron Scrap
- Pig Iron
- Furnace Oil
– Cement Clinker
-Gypsum
ENVIRONMENTAL IMPACT ASSESSMENT-ATTRIBUTES
Air:
Process
emission,
Fugitive
emissions,
Vehicular
emossions.
PM2.5,
PM10,
SO2, NOx
Water: CT
blow down,
Boiler Blow
down, DM
water
regenerati
on, pH,
TDS, TSS
Noise:
Noise
generatin
g
Machines,
Vehicles
Soil:
Excavation,
Seepage/
drainage
from
material
storage
area and
ash pond
Bio-
diversity:
Impact due
to noise, air
pollution,
water
pollution
and loss of
habitat
R&R:
Evacuati
on due
to land
acquisiti
on
Solid Waste:
Iron ore tailings,
dolochar, fly ash,
bottom ash,
ferroalloy slag,
SMS slag, Bag
filter dust,
Cement dust
HAZ WASTE:
Used Oil, Used
Resin, Batteries
AIR:
ESP
Bag
Filter
WATE
R: ETP,
STP,
Recycle
and
Reuse
NOISE:
Green Belt,
Pads,
Insulation,
Silencers,
Enclosures,
PPE
SOIL:
Plantation,
Water
Sprinkling
BIO-
DIVERSITY:
Conservation
of Flora and
fauna. No Wild
life sanctuary
within study
area
R&R:
Land
already
procured.
No R&R
action plan
SOLID WASTE:
Disposal in solid
waste dump
yard, reused/
recycled.
Haz waste
disposed in
secured land fill,
used oil sent to
authorized re-
processers
ENVIRONMENTAL MANAGEMENT PLAN
1 0 0
4. SITE ANALYSIS
4.1 Connectivity:
a. The expansion project is proposed to come up at village Nabagram in Naturia Block on
Sarbari – Panchet Road which connects SH-5 (Purulia to Asansol via Dishergarh). The
site is having advantages of proximity to 2 Coalfields – i. e. Ranigung Coal field of ECL
on the side and Dhanbad coalfields of BCCL on the other side.
b. Nearest Railway station is at Madhukunda on S.E. Railway which is about 10 Km. from
the site.
c. H.T. power line of DVC is running over the subject plot of land. Nearest sub- station of
DVC is Panchet which is about 3 Km from the site.
d. Nearest sea port is at Haldia at a crow-fly distance of170 KM from the project site.
e. Nearest Air Port is at Andal at a distqance of 75 Km and Netaji Subhas Chandra Bose
Airport at Kolkotai s at an aerial distance of 270KM from project site.
Location Advantages
The location of the project at Neturia, District- Purulia has the following advantages:
a. Proximity to Coal mines of ECL&BCCL which will ensure easy supply of coal at reduced
cost of carriage.
b. Iron Ore can be produced in rake load from Barbil /Banspani, Orissa (S E railway) and
unloaded in nearby railway siding of S E Railway near Madhukunda.
c. Proximity to H. T. power line of DVC as well to sub-station at Panchet.
d. Location of the site near Chirkunda & Assansol will provide for adequate social
infrastructures.
e. Location of the site close to National Highway No. 1 (Delhi Road) gives easy access and
convenience for transportation.
f. Purulia district is categorized under Group ‘c ‘of Incentive Scheme of Govt. of West
Bengal which provides for additional incentives.
g. Ready market for Sponge Iron in large number of Induction Furnaces currently under
operation in Howrah, Hooghly & Burdwan districts.
4.2 Land Form Land Use and Land Ownership:
The study area is comprised of different land forms like river bodies, reserve forests,
hills, water reservoir etc. The distance of such land forms from project site are mentioned
below;
1 0 1
Table No C4- 1: Location of Water bodies, Reserve Forests & Hill from Project Site
Location Distance Direction
From Project Site
Rivers
Damodar River 3.6km N
Khudiya River 5.7km N
Barakar River 5.7km N
Uttala River 3.3 km NW
Water Reservoir
Panchet Water Reservoir 7.5 km NW
Reserve/Protected Forests
Panchet Reserve Forest 3.0km SW
Muktipur P.F 2.5 km SW
Bheti P.F 8 km S
Dhurajpur P.F 9.1 km S
Dandihit P.F 9.5 km SE
Hills
Panchkot Hill 4.5 Km SW
4.3 Topography (along with map)
The topography of the area is an undulating terrain. It has number of rivers like River
Damodar, River Barakar, River Uttala and river Khudiya. The Panchet Reservoir on river
Damdar is also located partly in the study area. Panhet reserve forest and Panchkot
(Pachet Hill) also covers a large chunck of the study area. Except for Panchkot hill which
has highest elevation of 643 m other land forms vary fron 140m to 100 m above MSL
slopping from West to East. The existing and the proposed expansion plant of M/s IDPL
is having an altitude of 140m. The topography map is provided at Fig. No. C2 – 2.
4.3.1 Existing Land use pattern (agriculture, non-agriculture, forest, water bodies,
(including area under CRZ), shortest distance from the periphery of the project
to periphery of the forests National Parks, wild life sanctuary, eco sensitive
areas, water bodies(distance from HFL of the river), CRZ. In case of Notified
Industrial Area a copy of the notification should be enclosed
No forest land is involved in the Plant area. The land use pattern of the Plant area is
given in Table No. C5-1. The wildlife map showing the distance of the project site from
the National Park / Sanctuaries and Elephant / Tiger Reserve and their corridors is given
in Fig. No. C4- 1
The land use map of 10km radius of the project area also given below, which shows the
land use pattern in the surrounding of the plant area.
1 0 2
Fig. No. C4 -1: Map showing the distance of the Project Site from the National
Park / Sanctuaries and Elephant / Tiger Reserve and their corridors
1 0 3Fig. No. C4 -2: Land Use Map
1 0 4
Table No. C4 - 2: Land Use in the Buffer Zone
Landuse/cover Type Area (in sq.km.)
Agricultural Land 200.84
Dense Forest 14.41
Industrial Area 0.19
Land with/without Scrub 3.9
Mining & Allied Activity 0.47
Open Forest 6.74
Plantation 0.41
Water body, River & Sandy Bed 31.65
Settlement 55.67
Total 314.28
4.4 Existing Infrastructure:
i) The site is accessible by Sarbari – Panchet Road which connects SH-5 (Purulia to
Asansol via Dishergarh). Thus the site is having advantages of proximity to 2
Coalfields – i. e. Ranigunj Coal field of ECL on one side and Dhanbad coalfields of
BCCL on the other.
ii) Location of the site close to National Highway No. 1 (Delhi Road) gives easy access
and convenience for transportation.
iii) Nearest Railway station is Madhukunda on S.E. Railway which is about 10 Km. from
the site.
iv) Proximity to H. T. power line of DVC as well to sub-station at Panchet has the
advantage of connecting to DVC grid.
v) Location of the site near Chirkunda, Hijuli, Saltora & Asansol will provide for
adequate social infrastructures.
4.5 Soil Classification:
The soil of Purulia district is undulating tract of high ridges and low valleys. The major
part of the district is plain. The alluvial areas are found in very narrow strips along the
rivers. The valleys are steep along the rivers. Alluvial fans are found in the fringe areas of
Ajodhya hills. The soils of the district are mostly sedentary in nature. Colluvial soil is
found only in valley bottom. Soils of undulated uplands are shallow, gravelly, coarse
having low water holding capacity. These lands are either severely eroded or very
susceptible to erosion.
The whole district is a network of number of rivers. The principal rivers of the district are
Damodar, Kansabati, Kumari, Darakeswar and Subarnarekha. All the rivers have an
easterly and South easterly courses, only the Subarnarekha flows south and receives
west and south west flowing tributaries. All the tributaries of these rivers are non-
perennial and subject to flash floods. The Kansabati is the master stream of the district.
1 0 5
4.6 Climate Data from secondary sources: Purulia Weather
Location: West Bengal
Altitude: 748 feet
Summer Temperature: Max: 45º C; Min: 23º C
Winter Temperature: Max: 20º C; Min: 3º C
Average Rainfall: 1100 mm - 1500 mm
Located in the central-west of West Bengal, Purulia is one of the important districts of the
state. It is located just north of the Kasai River and has a town under the same name,
which forms its headquarters as well. Purulia is a major road and rail junction of West
Bengal and the region’s major agricultural distribution centre. Situated at 22.600 to
23.500 north latitudes and 85.750 to 86.650 east longitudes, with an average elevation of
228 meters, Purulia is one of the drought prone districts of West Bengal. It has a sub
tropical climate nature and is characterized by high evaporation and low precipitation.
Temperature is very high in summer and low in winter which varies from 2.80 in winter to
520 in summer thus causes dryness in moisture. But in hot summer it comes down to
25% to 35%. Purulia has hot & dry summers, pleasant & cool winters and rainy
monsoons.
Summers
Just like the other districts in West Bengal, Purulia also experiences three prominent
seasons, of which summer is one. The summers in Purulia are extremely hot and dry.
The mercury rises to a maximum of about 45°C, with the minimum being 23°C. Record
highest temperature is 54 degrees in 2011, which is the second highest temperature ever
recorded in Asia, following Jacobabad's record 55.7 degrees. The level of humidity in the
region is somewhere between 55% and 65%. Summers usually start from March and last
till the month of June. While scorching heat characterize the day time, the nights are
usually warm.
1 0 6
Monsoon
The coming of June marks the arrival of monsoon in Purulia. The rainy season in the
district is characterized by heavy rainfall, making it the extremely wet and damp time of
the year. Monsoons last till about the mid of September. Though rainfall definitely lowers
the temperature and provides relief from the scorching heat.Rainfall defines the climate
of the district. South west monsoon is the principal source of rainfall in the district.
Average annual rainfall varies between 1100 and 1500 mm. The relative humidity is high
in monsoon season, being 75% to 85%.
Winters
The winters in Purulia vary from being pleasant to cool. Starting from the middle of
November, the mercury starts dropping in the region. While the maximum temperature
lies somewhere around 20°C, mercury drops to about 3°C at night, making the place
chilly and cold. The winter season lasts till about the mid of February and is deemed as
the most favorable time for tourists and visitors, who want to explore this fine district in
West Bengal. In short, Purulia experiences dry and cool winters.
4.7 Social Infrastructure Available:
The study area has 50 villages. As per census 2011 the study area has a population of
54719 of which male and female were 28,097 and 26,621respectively. The density of
population of the study area as per 2011 is 174 per Sq. Km people per sq. km. With
regards to Sex Ratio of the area it stood at 947 per 1000 male. Percentage of S.C and SC
population stood at 24.15% and16.60% respectively. Percentage of Literates stood at 53.17%
Location of the site near Chirkunda & Assansol will provide for adequate social
infrastructures.
The expansion project will be coming up within the premises of existing plant which is
located in village Nabagram within Neturia Block. The site is in the proximity of towns like
Chirkund and Asansol, which are having adequate social infrastructures like hospitals,
schools, colleges, community halls, places of worship, cemetery, crematory etc. Location
of the site close to National Highway No. 1 (Delhi Road) gives easy access for
transportation.
4.7.1 Educational Facilities
The educational facilities available in the district are given in the
Table No. C4-3 : Educational Facilities in Purulia District
Sl. No. TYPE OF FACILITIES NUMBER
1 Primary School 2975
2 Junior High School 73
3 High School 148
4 No. of M.S.K. 139
5 No of S.S.k. 416
6 Higher Secondary School 122
1 0 7
7 High Madrasa 4
8 General college 11
9 Degree College 35
10 Polytechnic Col lege 1
11 Engineering College 1
Source-: www.purulia.nic.in
The educational facilities in the district are good due to the presence of good
infrastructure for basic education like primary schools and high schools, colleges for
higher education.
4.7.2 Health Facilities
Table No. C4-4 : The Health Infrastructure Status of Purulia district
Sl. No. Type of Health Centre Nos.
1 District Hospital 1
2 Sub-divisional Hospital 1
3 Dental Hospital 1
4 Jail Hospital 1
5 Rural Hospita l5
6 Block Primary Health Centre 15
7 Primary Health Centre 53
8 Panchayat Primary Health Centre 2
9 Sub Centre 485
10 Family Welfare Center 501
11 Blood Bank 3
Source-: 2011 census
Due to industrialization & various income generating activities the socio -economic
condition of the people has been increased in last few years. Large percentage of
household’s depends upon agricultural activities. Some households depend on business,
trade and other occupation, small scale household industries and some even depend on
cultivation as farm labour.
1 0 8
5. PLANNING BRIEF
5.1 Planning concept (type of industries, facilities, transportation, etc.) Town and
country planning/development authority classification
The proposed expansion project will be located in the existing project site at Village:
Nabagram, PO: Digha, Neturia Development Block, Dist: Purulia, WB. Already a steel
complex with 2X100 TPD sponge iron plant, a 4X7.5 Ferroalloy plant, a 2X4 T & 1X8 T
induction furnace and a captive power plant of 8 MW capacity is operating at the site.
The proposed expansion project would include an iron ore beneficiation plant, a
pelletisation plant, SMS with induction furnace and Electric Arc Furnace, Non-Recovery
type coke ovens, Ferroalloys plant, cement grinding plant and a captive power plant
based on WHRB from waste flue of DRI Plant and Coke ovens and CFBC utilizing dolochar
and coke fines of DRI plant. As the project proponent has a steel complex operating in
the existing premises and other plants like it has advantage of putting integrated steel
plant, ferroalloy plant, coke ovens and steel melting shop, cement grinding plant etc,
adjacent to existing steel complex. Main raw material like iron ore, manganese ore,
chrome ore, Lime stone etc will be brought in rake loads from the neighboring state
Odisha. Non coking coal will be brought from ECL or BCCL coal fields which are very
nearby. Infrastructure facilities in the area are well developed and the sight has well
connectivity by road and rail. The nearest town Parbeliya, Hijuli & Saltora are 3.5km to
5km away and easily accessible by road where all facilities such as schools, collages,
hospitals and markets are available. Asansole and Dhanbad are bigger industrial towns
located at 17km and 40km respectively, which have all basic social infrastructure
educational institutions, hospitals, markets, etc.
(ii) Population Projection
In the area, trained manpower is already available and in the proposed project local
workers will be given priorities for employment. There will not be significant increase in
population due to proposed project. The additional people influx due to the proposed
project can be easily accommodated in the nearby towns and villages. The development
of new residential facility is not contemplated.
(iii) Land use planning (breakup along with green belt etc.)
The proposed project will be constructed with well developed green belt all around the
boundary of the plots as well as all around the various units. The land use breakup of the
proposed project is given below.
Table No: C5 – 1 Showing Existing and Proposed area of M/s IDPL
Sl.
No.
Item Existing Area
in acres
Proposed
area in Acres
Total Area
in Acres
1 Plant Built Up area 6.00 36.00 42.00
2 Raw Material and Finished
Product-Storage Yard
2.00 10.00 12.00
1 0 9
3 Ash and Solid Waste Disposal 1.00 4.00 5.00
4 Other Ancillary Area -- 2.00 2.00
5 Water Reservoir & Rain water
harvesting
-- 4.00 4.00
6 Internal Roads and Adm. Building 1.0 3.00 4.00
7 Green Belt 5.00 29.00 34.00
Total Land 15.00 85.00 103.00
Total land of the proposed project is 103 acres and about 34 acres land will be converted
to Green Belt. It is proposed to plant 5000 saplings every year. Suitable plant species will
be planted all along the internal road, raw material storage & handling, ash/dust prone
areas. It is planned to plant saplings considering the parameters as type, height, leaf
area, crown area, growing nature, water requirement etc. Green belt will be
progressively developed on land earmarked for the purpose.
(iv) Assessment of Infrastructure Demand (physical & social)
The road and rail infrastructure are already well developed in the area which are required
for the transport of the raw material from and finished goods to the various part of the
country. The manpower will be mostly sourced from the locality and their social
infrastructure is also developed. The inflow of money in terms of taxes to gram
panchyats and salaries to the manpower will further improve the physical and social
infrastructure.
(v) Amenities/Facilities
The following facilities shall be provided in the project site:
a. Administrative Building, Service Building
b. Construction offices and stores
c. Time and security offices
d. First Aid and fire fighting station
e. Canteen and welfare centre
f. Toilets and change rooms
g. Car parks and cycle/ scooter stands
h. Training centre
i. Communication facility.
j. Emergency vehicle for shifting the workers during accident etc.
Office space has been provided as per good practice and canteens, toilets and restrooms
according to norms laid down in relevant factories act. The above facilities shall also be
adequately furnished and equipped.
1 1 0
6. PROPOSED INFRASTRUCTURE
6.1 Industrial Area (processing area)
The infrastructural facilities are already developed in the premises of the unit as per the
requirement and additional facilities for the expansion purpose will be provided as per the
requirement.
6.2 Residential Area (non processing area)
The local peoples will be employed for the proposed project. The development of
residential area is not needed.
6.3 Green belt
Green belt development work will be undertaken on area of 34 acres. About 600 saplings
will be planted per acre. The details of existing Green Belt and Development of Green
Belt Plan for the proposed project are given below. The existing plantation has been done
alongside the boundary wall and in the vacant land earmarked for the purpose. The
plants in the existing green belt include Devil Tree (Alstonia scholaris), Mahaneem
(Melia azadiracta), Gulmohar (Delonix regia), Acasia (Acacia auriculiformis), Am
(Mangifera indica), Silk Tree (Albizia procera) with survivility of 65%. The future
development will also include avove local species.
Table No. C6 – 1 : Existing & Proposed Plantation
Sl.
No.
Year of Plantation Area (in
acres)
No of
Saplings
Cumulative
Area
% of Total
Area
1 Existing Plantation 8.4 9800 8.4 3.3
2 1st year of proposed
Expansion
5.0 3000 13.4 8.1
3 2nd year 6.5 3900 19.9 15.4
4 3rd year 6.5 3900 26.4 23.7
5 4th year 7.6 4600 34.0 33
6.4 Social Infrastructure
The social infrastructure in the region is well developed due to the proximity of the
location to Asansole and Dhanbad. Further development will be undertaken through CSR
activities. Details of CSR activities already done and proposed to be carried out are
detailed below.
Table No. C6 - 2: CSR activities taken up during last four years
Sl.
No. CSR Activity Taken up Year Expenditure
1 Pond Renovation of Namodigha,
Nimdanga, Manpur & Nabagram villages
2014-15 Rs.4,00,000.00
2 Modernisation of Library in Namodigha
village
2015-16 Rs 20,000.00
1 1 1
3 Supply of drinking water in summer
months to the villages under Shabari
GP, Digha GP and Bamunia GP
2013-14, 2014-
15 1015-16 and
2016-17
Rs.5,00000.00 @
Rs. 1,25,000.00
per year
4 Renovation of BDO Office in Neturia 2015-16 Rs.1,00,000.00
The company will continue to do CSR activities in future. It is proposed to install tube
wells in the water scarcity areas in future. CSR activities will be finalized after
consultation with the villagers as per demand in public hearing. The annual budgetary
provision will be made as per MoEF norms
6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.)
The connectivity in terms of traffic, transportation road is already developed and good.
There are well connected roads in the area. The nearest railway station and railway
siding is at Parjanpur.
6.6 Drinking Water Management (Source & Supply of Water)
The water for the factory will be sourced from river Damodar. Part of the same water will
be use for sanitation and drinking purpose after proper treatment. For the adjoining
areas in the buffer zone of 10 km radius, tube wells will be dug in water scarcity areas.In
summer the drinking water is being supplied in tankers to the villagers whenever
required. The same practice will be continued to meet temporary scarcity conditions
6.7 Sewerage System
Sewage treatment plant will be provided for the treatment of domestic effluent and
treated effluent will be utilized for green belt development.
6.8 Industrial Waste Management
Industrial effluent generated from proposed project will be treated in Settling Pond and
ETP. The treated effluent will be utilized for Green Belt development.
6.9 Solid Waste Management
Dusts collected in pulse jet bag filters will be reused in pellet manufacture. Majority of
solid wastes will be utilized for pellet manufacture. The fly ash generated in the power
plant will be utilized in the manufacture of Portland Pozzolana cement (PPC). The
dolochar the solid waste generated in Ferromanganese plant will be used for silico
manganese. Slag generated in SMS will be utilized for the construction of the roads and
balance quantity will be disposed off by landfill.
6.10 Power Requirement & Supply/Source
The power requirement will be fulfilled from proposed Captive Power Plant to maximum
extent and as and when required power will be purchased from DVC Grid.
1 1 2
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN
7.1 Policy to be adopted (central/state) in respect of the project affected person
including home oustees, land oustees and landless laborers (a brief outline to
be given)
The rehabilitation and resettlement (R&R) is not required for the proposed project as it
will be constructed on the land acquired by the company after giving due compensation
1 1 3
8. PROJECT SCHEDULE & COST ESTIMATES
8.1 Likely date of start of construction and likely date of completion (Time schedule
for the project to be given)
The board of directors of the company has vast experience in steel manufacturing
business. All necessary statutory permissions will be obtained. The construction of the
expansion project will be started after getting Environment Clearance from MoEF & CC. It
is expected that the construction will be started from the date of environmental clearance
and shall be completed within 2 and half years.
8.2 Estimated project cost along with analysis in terms of economic viability of the
Project
The estimated gross capital investment of the proposed expansion project is about 190
Crores. The economic viability is still good due to availability of raw materials, market
and infrastructural facilities.
1 1 4
9. ANALYSIS OF PROPOSAL FINAL RECOMMENDATIONS
9.1 Financial and social benefits with special emphasis on the benefit to the local
people including tribal population, if any, in the area.
The proposed expansion project will have good financial and social benefits to the local
people.
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