PRE-FEASIBILITY REPORT FOR CAPACITY EXPANSION...

PRE-FEASIBILITY REPORT

FOR

CAPACITY EXPANSION OF INTEGRATED

IRON & STEEL PLANT TO 1.5 MTPA

AT BELHA, DISTRICT BILASPUR, CHHATTISGARH

TO

NOVA IRON & STEEL LIMITED

NOVEMBER 2014

M. N. DASTUR & COMPANY (P) LTD CONSULTING ENGINEERS

KOLKATA

NOVA IRON & STEEL LTD M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh

Pre-Feasibility Report

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TABLE OF CONTENTS

Page

1 −−−− INTRODUCTION Background .. 1-1 Authorisation .. 1-2 Structure of the report .. 1-2 Acknowledgement .. 1-2

2 −−−− PLANT LOCATION AND LAYOUT Location of proposed site .. 2-1 Features .. 2-3 Infrastructural facilities .. 2-3 Transport linkages .. 2-3 Water .. 2-4 Power .. 2-4

3 −−−− RAW MATERIALS Major raw materials .. 3-1 Iron ore fines .. 3-1 Coal .. 3-2 Limestone .. 3-3 Dolomite .. 3-3 Quartzite .. 3-4 Pyroxenite .. 3-4 Iron ore pellet .. 3-4 Coke .. 3-4

4 −−−− MAJOR PLANT FACILITIES Raw materials handling and storage system .. 4-1 Requirement of raw materials .. 4-1 Unloading and storage facility .. 4-1 Base-mix preparation system .. 4-4 Despatch of raw materials to the consuming units .. 4-5 Charge-mix feed to the DR kiln .. 4-7 Product handling system .. 4-7 Facilities associated with the raw material handling systems .. 4-8 Coal washery .. 4-8 Design basis/consideration .. 4-9



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TABLE OF CONTENTS (Continued)

Page

4 −−−− MAJOR PLANT FACILITIES (cont’d) Direct reduction (DR) plant .. 4-10 Design basis .. 4-10 Product quality .. 4-10 Raw materials .. 4-10 Major facilities .. 4-10 Sinter plant .. 4-11 Production programme .. 4-11 Design basis .. 4-11 Raw materials .. 4-11 Consumption of input materials .. 4-12 Sinter quality .. 4-12 Major facilities .. 4-13 Blast furnace .. 4-13 Production programme .. 4-13 Design basis .. 4-13 Analysis of raw materials .. 4-14 Coal for PCI application .. 4-14 Input materials quantity .. 4-14 Hot metal quality (typical) .. 4-15 Facilities in blast furnace .. 4-15 Steelmelt shop-1 (SMS-1) .. 4-16 Design basis .. 4-16 Requirement of raw materials and supplies .. 4-17 Equipment and facilities for steelmelt shop-1 .. 4-18 Steelmelt shop-2 (SMS-2) .. 4-20 Design basis .. 4-20 Requirement of raw materials and supplies .. 4-22 Equipment and facilities for steelmelt shop-2 .. 4-22 Calcining plant .. 4-26 Wire rod mill (WRM) .. 4-27 Design basis .. 4-27 Major equipment .. 4-28 Medium merchant mill (MMM) .. 4-29 Design basis .. 4-29 Major equipment .. 4-30 Light merchant mill (LMM) .. 4-31 Design basis .. 4-31 Major equipment .. 4-32



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Page

4 −−−− MAJOR PLANT FACILITIES (cont’d) Captive power plant .. 4-32 Technical profile of the captive power plant .. 4-33 Top recovery turbines (TRT) .. 4-33 Air separation plant (ASP) .. 4-33 Oxygen .. 4-33 Nitrogen .. 4-34 Argon .. 4-34 Facilities proposed .. 4-34 Plant materials flowsheet .. 4-34

5 −−−− UTILITY AND SERVICE FACILITIES

Power distribution system and electrics .. 5-1 Plant power requirements .. 5-1 Characteristics of plant loads .. 5-1 Source of power .. 5-2 Power distribution philosophy .. 5-2 Instrumentation and automation systems .. 5-3 Structure of proposed automation system .. 5-3 Instrumentation and level-1 automation .. 5-4 Process automation (level-2) system .. 5-6 Supervisory control and data acquisition system (SCADA) .. 5-6 Manufacturing execution (level-3) system .. 5-7 IT infrastructure .. 5-7 Plant communication system .. 5-8 Plant telephone system .. 5-8 Loudspeaker intercommunication (LSIC) system .. 5-8 Closed circuit television (CCTV) system .. 5-8 Wireless communication system .. 5-8 Plant optical fiber cable (OFC) backbone .. 5-9 Fire detection and alarm system .. 5-9 Water system .. 5-9 Water requirement .. 5-9 Source of water .. 5-11 Plant water system .. 5-11 Waste water and effluent treatment management .. 5-15 Distribution pipework .. 5-15



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Page

5 −−−− UTILITY AND SERVICE FACILITIES (cont’d) Utility system .. 5-16 Fuel system .. 5-16 Availability of by-product gases for power generation .. 5-16 LPG/propane manifold .. 5-17 Process steam .. 5-17 Plant and instrument air system .. 5-17 Air pollution, ventilation and air conditioning .. 5-18 Chilled water plants .. 5-18 Overhead yard pipework .. 5-19 Central utility monitoring and control .. 5-19 Auxiliary facilities .. 5-19 Laboratories .. 5-19 Repair shops and stores .. 5-19 Ancillary facilities .. 5-20 Drainage and sewerage system .. 5-20 Roads .. 5-21

6 −−−− ENVIRONMENTAL POLLUTION CONTROL MEASURES Review of pollution potential .. 6-1 Proposed mitigation measures .. 6-2 Air pollution mitigation measures .. 6-2 Water pollution control measures .. 6-4 Zero Discharge Concept .. 6-5 Work Zone Pollution control measures .. 6-5 Solid waste generation and utilisation .. 6-6 Plant safety .. 6-6 Plant greenbelt and landscaping .. 6-7 Design targets for APC and WPC measures .. 6-7 Environmental Monitoring .. 6-8

7 −−−− IMPLEMENTATION SCHEDULE Implementation schedule .. 7-1



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Page

8 −−−− CAPITAL COST ESTIMATE Capital cost estimate .. 8-1 Plant cost .. 8-1 Interest during construction .. 8-2

TABLES Table 3-1 – Major raw materials .. 3-2 Table 4-1 – Annual consumption of various raw materials and mode of receipt .. 4-2 Table 4-2 – Requirement of wagon tippler .. 4-3 Table 4-3 – Base-mix and trimming materials .. 4-4 Table 4-4 – Specific consumption of raw materials for the DR plant .. 4-10 Table 4-5 – Design basis of sinter plant .. 4-11 Table 4-6 – Typical analyses of raw materials for sinter production .. 4-11 Table 4-7 – Consumption of input materials .. 4-12 Table 4-8 – Design basis of blast furnaces .. 4-13 Table 4-9 – Typical raw materials analysis (dry basis).. 4-14 Table 4-10 – Input material quantities .. 4-14 Table 4-11 – Requirement of major raw materials and supplies .. 4-17 Table 4-12 – Requirement of major raw materials and supplies .. 4-22 Table 4-13 – Estimated power generation capability .. 4-33 Table 4-14 – Technical profile of CPP .. 4-33 Table 5-1 – Make-up water requirement .. 5-10 Table 5-2 – Major water systems .. 5-13 Table 5-3 – Generation of by-product gas .. 5-16 Table 5-4 – Surplus by-product gas availability .. 5-16

FIGURES

Fig. 2-1 – Location map of existing plant .. 2-2 Fig. 7-1 – Implementation schedule .. 7-2

DRAWINGS

Dwg. 11330-02-0001 – Plant general layout Dwg. 11330-04-0001 – Plant materials flowsheet Dwg. 11330-05-0001 – Schematic water flow diagram

NOVA IRON & STEEL LTD

M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh Pre-Feasibility Report

- 1 -

SUMMARY

1. Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron

plant of capacity 500 tons per day (TPD) adopting coal based

rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state.

NISL is now contemplating expansion of the above mentioned

sponge iron plant to 1.5 million tons per annum (MTPA)

integrated steel plant along with a 260 MW power plant. The

area of the existing plant is 370.2 acres out of which the

existing facilities occupy only 30 acres and the rest of the

land is vacant. In addition to the above, BPSL has purchased

412.03 acres of land. Accordingly, total land area available

for the project will be 782.23 acres.

2. After expansion, the plant would produce saleable products

consisting of wire rods, billets, beams, channels, rounds,

squares, angles and flats, as listed below:

Rounds .. 675,000 Beams .. 245,000 Squares .. 50,000 Channels .. 280,000 Angles .. 200,000 Flats .. 100,000

Apart from above finished products, about 514,700 tons per

annum pig iron would be used for sale.



Summary (Cont’d)

- 2 -

3. Based on the BF-DRI-EAF-IF process route following major

plant facilities have been envisaged for the proposed

expansion plan.

Sinter plant .. 1 x 248 sqm

Blast furnace .. 1 X 1008 cum

.. 1 X 550 cum

DR Kiln .. 4 X 500 tpd

Calcining Plant .. 2 x 600 tpd

Steelmaking .. IF - 3 x 15 ton LF – 1 X 15 ton EAF – 2 X 90 ton LF – 2 x 90 ton VD - 1 x 90 ton

Casting and Rolling .. Light Merchant Mill .. Medium Merchant Mill .. Wire rod mill

Captive Power Plant .. 2 x 130 MW (CPP-1) .. 2 x 7.5 MW (CPP-2)

4. Nova Iron and Steel Limited (NISL) is located at Belha tehsil

of Bilaspur district in the State of Chhattisgarh, between

latitudes 22°53'N to 22° 55' N and longitudes 82° 00' E to 82°

05' E and 268 m above mean sea level (MSL). The site is

approximately 40 km from Bilaspur town. The site is located

on the eastern side of national highway NH-130 and

connected with the bypass road from NH-130. The bypass

road is connecting NH-130 and village Belha at the northern

side of proposed plant. The NH-130 is about 9 km away from

the site. The nearest railway station is Dagori, situated

about 6 km. on the north-east side of the plant.

5. Requirement of some of the major raw materials considered

for the production viz. anthracite coal and PCI coal would be

met through import. Iron ore fines, coke, non-coking coal,

iron ore pellet, BF & SMS grade limestone, dolomite, quartzite



Summary (Cont’d)

- 3 -

and pyroxenite would be procured from indigenous sources.

Wagon tipplers/truck tipplers are envisaged for unloading of

the raw materials and mechanised systems are considered for

storage and distribution of various raw materials.

6. Requirement of fuel, power and other utilities viz. plant and

instrument grade compressed air, steam, industrial gases

(oxygen, nitrogen & argon), chilled water would be fulfilled

through installation of new facilities. Blast furnace gas would

be available as by-product gas inside the plant for various

process needs and heating applications of the plant, besides

being a source of power generation. Total make-up water

requirement for the plant after full implementation would be

about 2,040 cu m per hour, which would be drawn from the

Sheonath river.

The requirement of power for the expansion would be

1,288 Million KWh, which would be met partly through

captive power generation from coal & gas fired captive power

plant and from TRT of blast furnace.

7. In view of the aforementioned plant facilities, there would be

pollution load, for which adequate mitigation measures would

be adopted to keep the pollution load within the stipulated

norms.

8. It is envisaged that the project would be completed within 36

months from the ‘Go-Ahead date’.

9. The estimate of capital cost includes plant cost, preoperative

expense, working capital margin and interest during

construction. The plant cost comprises the costs of plant &

equipment (as erected) together with the cost of pollution



Summary (Cont’d)

- 4 -

control, design, engineering, consultancy & administration

during construction and contingency. The capital cost is

estimated to be Rs. 10,834 crore approximately. About

7 - 9 per cent of the total plant cost has been kept for

environment management measures.



1−1

1 – INTRODUCTION

BACKGROUND

Nova Iron & Steel Ltd. (NISL) presently owns a sponge iron

plant of capacity 500 tons per day (TPD) adopting coal based

rotary kiln unit at Dagori in Bilaspur of Chhattisgarh state. NISL

is now contemplating expansion of the above mentioned sponge

iron plant to 1.5 million tons per year (MTPA) integrated steel

plant along with a 260 MW power plant.

M/s Bhushan Power & Steel Limited (BPSL) has taken over

NISL in 2011. BPSL is a leading manufacturer of flats, rounds

and long products including value added products with billets, HR

coils, pig iron, CR coils, GP/GC, precision tubes, black pipe/GI

Pipe, cable tapes, tor steel, wire rod and special alloy steel.

BPSL has successfully commissioned a greenfield steel and

power plant in Odisha with hot rolled coil making facility - first in

private sector in the state of Odisha. BPSL is selling its value

added range of products in secondary steel sector through a large

distribution network in India (comprising more than 35 sales

offices) and abroad.

The area of the existing plant is 370.2 acres out of which the

existing facilities occupy only 30 acres and the rest of the land is

vacant. In addition to the above, BPSL has purchased 412.03 acres

of land. Accordingly, total land area available for the project will be

782.23 acres.



1 – Introduction (cont’d)

1−2

AUTHORISATION

NISL, vide its letter No. NISL/WO/BSP/RKG/RNY/14-

15/166 dated 02.07.2014 commissioned M. N. Dastur & Company

(P) Ltd. (CONSULTING ENGINEERS), Kolkata, for preparation of an

Environmental Impact Assessment (EIA) study for its 1.5 MTPA

integrated steel plant. According to the Ministry of Environment

and Forests (MoEF) regulations, this Pre-Feasibility Report (PFR)

has been prepared as an appendage to the EIA study for the

proposed project. This PFR, along with Form I, needs to be

submitted to MoEF for obtaining prior environmental clearance for

the project.

STRUCTURE OF THE REPORT

The Pre-Feasibility Report is presented in eight chapters.

Following this introduction, the project concept and site conditions

are discussed in Chapter 2. Chapter 3 describes annual

requirements of major raw materials and their availability for the

project. Major plant facilities envisaged for the project including

plant layout are discussed in Chapter 4. Chapter 5 describes

various utility services, like power system, instrumentation,

automation and plant communication systems, water and utility

systems and auxiliary facilities, like laboratories, workshops, and

stores, etc. Environmental pollution control measures proposed

are indicated in Chapter 6. Chapter 7 describes plant construction

schedule and volume of construction. The capital cost estimate is

indicated in Chapter 8.

ACKNOWLEDGEMENT

CONSULTING ENGINEERS gratefully acknowledge the

co-operation and assistance extended by the officials of NISL and

BPSL during the site visit and the preparation of the Pre-Feasibility

Report.

NOVA IRON & STEEL LTD. M. N. DASTUR & COMPANY (P) LTD Integrated Steel Plant in Chhattisgarh P re −−−− Fe as i b i l i t y Rep or t

2-1

2 – PLANT LOCATION AND LAYOUT

This chapter presents the location of proposed plant site, its

features and briefly reviews the infrastructure facilities available at

site.

LOCATION OF PROPOSED SITE

Total land area available for the project will be 803.05 acres.

The location map of the existing plant is shown in Fig. 2-1 on the

next page. The plant general layout of the proposed plant is given

in Drawing No. 11330-02-0001. The site is approximately 40 km

from Bilaspur town. The site is located on the eastern side of

national highway NH-130 and connected with the bypass road from

NH-130. The bypass road is connecting NH-130 and village Belha

at the northern side of proposed plant. The NH-130 is about 9 km

away from the site. The nearest railway station is Dagori, situated

about 6 km. on the north-east side of the plant.

River Sheonath is flowing by the southern boundary of the

proposed site. It is a perennial river. It is envisaged that the

requirement of water will be fulfilled from this river for expansion

project.


2 – Plant location and layout (cont’d)

2-2



2-3

FEATURES

The acquired additional area for plant comprises

predominantly barren/single crop agricultural land. The village

Dagori is located at the northern side of the proposed plant.

The finished ground level of the existing plant is RL+268.0

m. The land at its northern side is higher than the existing plant

which varies from RL+268.0 m to RL+269.5 m. Land is fairly plain

with small undulations for developing a good layout. The soil

predominantly consists of moorum, clay, slit and sand. There are a

few rocks outcrops within plant site.

INFRASTRUCTURAL FACILITIES

Transport linkages

Rail: The nearest railway station, Dagori, located in Bilaspur

–Raigarh railway line, is situated about 6 km away from the plant

site. Dagori railway station is located in between Belha and

Nipania Railway Stations.

Major raw materials will be transported by rail. Anthracite

coal will be imported through Paradip port and then will be

transported by rail to the plant site. Suitable rail link has been

envisaged from the proposed railway siding at Dagori station to the

plant site for receipt of raw materials, as well as for despatch of

finished products.

Road: Nearest national highway NH-130 is about 9 km away

from plant approach. There is a bypass road connecting NH-130

and village Belha at the northern side of proposed plant. The

condition of approach road from the existing plant to the bypass

road needs to be improved under expansion project.



2-4

Port: Paradip port is situated about 640 km from proposed

site. Imported raw materials will be handled through Paradip port.

Suitable interaction with the port authorities will be necessary to

finalise this arrangement.

Water

To meet the make-up water requirement, it is necessary to

have a reliable water source. The main source of make-up water is

river Sheonath which is about 100 m from the existing southern

boundary of the plant. The river is a perennial source of water.

The river Sheonath has been considered as a probable source

of water. To ensure an uninterrupted supply of water, a reservoir of

14 days storage capacity has been considered within the plant

premises. However, suitable study on impounding arrangements in

the form of a pick-up weir at the river source and intake facilities

will have to be assessed at an appropriate time to meet the plant

water requirements.

Power

The nearest 220 kV sub-station is located at 20 km away

from the proposed plant site. The plant power requirement will be

met from the captive power plant as well as from the grid.



3-1

3 – RAW MATERIALS

This Chapter discusses the annual requirement of major raw

materials, reviews their availability, quality and probable sources

of supply.

MAJOR RAW MATERIALS

The major raw materials required for the proposed project

are iron ore fines, coal, limestone, dolomite, etc. Estimated gross

requirement of raw materials to be procured annually on net and

dry basis are given in Table 3-1 in the next page.

Iron ore fines

Iron ore in the form of fines will be required for use in sinter

plant. The entire requirement of iron ore fines will be met from the

mines located in Madamnar region, Narayanpur district of

Chhattisgarh. The procurement size of iron ore fines and their

likely chemical analysis are as follows:

Size Fe SiO2 Al2O3 LOI

mm % % % %

-10 63.07 2.65 2.04 2.24



3 – Raw materials (cont’d)

3-2

TABLE 3-1 – MAJOR RAW MATERIALS

Consuming unit

Raw materials

Indicative source

Net & dry requirement

Gross procurement

tons/year tons/year(1)

Iron ore fines Narayanpur, Chhatisgarh

1,653,511 1,834,000

Limestone fines

Keonjhar, Odisha

218,678 136,910 (2)

Dolomite fines Baradwar, Chhattisgarh

17,230 - (3)

Pyroxenite Local 69,056 74,180

Sinter plant

Anthracite coal Australia 34,569 37,200

Non-Coking coal

Jharsuguda , Odisha

592,746 230,400 (4)

Dolomite Baradwar, Chhattisgarh

18,480 19,300

Injection coal Jharsuguda , Odisha

254,034 281,800

DR plant

Pellet Local 991,320 1,120,900

Quartzite Local 21,964 23,340 PCI coal Australia 175,715 190,750 Coke Local 696,300 773,700

Blast furnace

Pellet Local 480,300 543,000

Coal washery

Non-Coking coal

Jharsuguda , Odisha

1,500,000 1,663,710

Power plant Thermal coal Jharsuguda , Odisha

770,880 855,020

Limestone Keonjhar, Odisha

606,880 686,170 Calcining plant

Dolomite Baradwar, Chhattisgarh

114,660 129,640

Notes:

(1) Includes moisture, handling and screening losses as applicable. (2) Excludes about 91,220 tons of limestone fines generated in calcining

plant, which is to be utilized in sinter plant. (3) Excludes about 17,230 tons of dolomite fines generated in calcining

plant, which is to be utilized in sinter plant. (4) Excludes about 385,050 tons of washed coal produced in coal washery,

which will be used as a non-coking coal in DRI plant.

Coal

Anthracite: Anthracite coal will be used in sinter plant. As

such coal is not available in India, the same will be met through

imports from Australia.

Pulverized coal injection: Coal with low volatile matter

and ash content will be used for pulverized coal injection (PCI) in

blast furnace. As such coal is not readily available in India,

requirement of the same is planned to be met through imports from

Australia.




3-3

Non-coking coal: Raw non-coking coal will be sent to coal

washery and the entire washed coal will be used in the DR plant.

To meet the balance requirement of coal in the DR plant, suitable

grade of non-coking coal will be procured from collieries of IB

Valley region, Jharsuguda, Odisha. The middling from coal

washery and char from DR plant will be used in the thermal power

plant. The balance requirement of suitable grade thermal coal will

be procured from collieries of IB Valley region, Jharsuguda,

Odisha.

Limestone

BF grade limestone will be used in the sinter plant and SMS

grade limestone will be used in the calcining plant. It is envisaged

that, the total requirement of limestone for use in sinter plant and

calcining plant will be procured from Banspani region within a size

range of (+) 40 to (-) 80 mm. A typical chemical composition of

limestone considered for this report is tabulated below:

SiO2 Al2O3 CaO MgO LOI

% % % % %

0.99 0.52 52.27 1.98 42.34

Dolomite

It is envisaged that the entire requirement of dolomite for use

in sinter plant, DR plant and calcining plant will be met from

Baradwar region in Chhattisgarh. Size of the dolomite to be

procured will be in the range of (+) 40 to (-) 80 mm. The typical

analysis of Baradwar dolomite considered is as follows:

SiO2 Al2O3 CaO MgO LOI

% % % % %

0.86 0.29 30.80 19.12 46.05




3-4

Quartzite

Quartzite will be used in the blast furnace. It is envisaged

that the entire requirement of quartzite will be procured from

local sources in the size of (+)10 to (-)40 mm. A typical chemical

analysis of quartzite considered for this report is as follows:

SiO2 Al2O3

% %

96.92 0.92 Pyroxenite Pyroxenite will be used in the sinter plant. It is envisaged

that the entire requirement of pyroxenite will be procured from

local sources. A typical chemical analysis of pyroxenite considered

for this report is as follows:

SiO2 Al2O3 CaO MgO

% % % %

47.0 0.83 0.80 32.0

Iron ore pellet

It is envisaged that, the entire requirement of pellet for use

in blast furnace and DR plant will be procured from local sources.

Coke

It is envisaged that, the entire requirement of coke for use in

blast furnace will be procured from local sources.



4−1

4 – MAJOR PLANT FACILITIES

The major production facilities of the steel plant will

comprise coal washery, direct reduction plant, sinter plant, blast

furnaces, steelmelt shops and long product mills. The plant will

also have captive air separation plant on Build-Own-Operate (BOO)

basis to meet the plant oxygen requirement. Power generation

units are also envisaged utilising surplus blast furnace gas and

in-plant char and middlings. Additionally, boiler coal will be used

in the power plant. This chapter describes the major facilities

envisaged for the project.

RAW MATERIAL HANDLING AND STORAGE SYSTEM

Requirement of raw materials

The annual consumption of various raw materials and mode

of receipt is indicated in Table 4-1 in the next page.

Unloading and storage facility

All rail-bound materials viz. pellet, iron ore fines, non-coking

coal for power plant and coke will come in an open top BOXN

wagon. These materials will be unloaded by crescent type rotary

wagon tippler. Materials unloaded by wagon tippler will be drawn

by apron feeder/belt feeder located below the wagon tippler

hoppers and fed to the conveyor system for its onward

transmission to the storage yard.

The tippling rate of wagon tippler will be 25 tips per hour

and the same will be designed as per Research Designs and

Standards Organisation (RDSO) stipulated norm G-33, May 2010.

Handling of DFC wagons is not envisaged in this Report.



4 – Major plant facilities (cont’d)

4−2

TABLE 4-1 – ANNUAL CONSUMPTION OF VARIOUS RAW MATERIALS AND MODE OF RECEIPT

Sl. No.

Material

Receipt

size

Gross (1) annual

quantity

Gross daily(2)

quantity

Mode of receipt

mm ton ton A. For Sinter Plant

Iron Ore Fines (IOF)

(-)10

1,834,000

5,558

Rail Limestone 40-80 136,900 415 Road Pyroxenite 40-80 74,200 225 Road Anthracite (-)20 37,200 113 Road

B.

For Blast Furnace

Iron Ore Pellet 5-18 543,000 1,552 Rail Quartzite 10-40 23,300 67 Road PCI Coal (-)50 190,800 545 Road Coke 10-80 797,600 2,211 Rail

C.

For DR Plant

Iron Ore Pellet 5-18 1,120,900 3,397 Rail Non-coking coal 5-20 512,200 1,552 Road Dolomite (-)8 19,300 58 Road

D.

For Coal Washery

Raw coal (-)600 1,663,700 5,455 Road

E.

For Calcining Plant

Limestone 40-80 686,200 2,079 Road Dolomite 40-80 129,600 393 Road

F.

For Power Plant

Boiler coal 0-100 855,000 2,375 Rail

G.

For SMS-1

Ferro-alloy - 2,400 7 Road

H.

For SMS-2

Ferro-alloy - 25,500 80 Road Direct reduced iron - 235,500 736 Road

Note: (1) Above figures are derived based on the following losses:

- 2 per cent handling loss - 5 per cent screening loss - 5-10 per cent moisture loss

(2) Above figures are derived based on the following operating day/year:

- 330 days for Sinter plant - 350 days for BF - 330 days for DR plant - 305 days for Coal washery - 330 days for Calcining plant - 360 days for Power plant - 330 days for SMS-1 - 320 days for SMS-2




4−3

The number of rakes to be handled per day and requirement

of wagon tippler are given in Table 4-2.

TABLE 4-2 – REQUIREMENT OF WAGON TIPPLER

Material

Daily quantity

No. of rakes(1)

No. of rakes(2) at peak load

ton

Iron Ore Fines 5,558 1.46 1.95 ≈ 2 Pellet 4,949 1.30 1.69 ≈ 2 Coke 2,211 1.05 1.40 ≈ 2 Boiler coal for power plant

2,375 0.63 0.83 ≈ 1

Note:

(1) A rake load of 2,100 ton for coke and 3,800 ton for other materials has been considered.

(2) Bunching factor of 1.33 for indigenous and 1.5 for imported materials have been considered for finding out peak load.

Based on number of rakes to be handled per day at peak

load and keeping in view the contamination of materials for process

requirement, two (2) nos. ‘C’ type rotary wagon tipplers have been

envisaged.

Road-bound materials will be unloaded in the ground hopper

in the storage yard and the same will be stored in the respective

storage yard by stacker/reclaimer. (-)600 mm raw coal required for

coal washery will be brought to the site by 130-ton dumper and the

same will be stored in the storage yard. Unloading of all road-

bound materials will be done by external agency.

Purchased coal for DR plant having size of 5-20 mm will be

unloaded in the ground hopper and will be stored in an overhead

bunker and then fed to the day-bin of DR plant through conveyor

system.




4−4

Materials unloaded by wagon tippler will be stored in the

respective storage pile with the help of stacker/reclaimer with

by-pass facility. Open storage piles system has been considered

for all material except PCI which will be kept under the covered

storage.

PCI coal delivered by road will be unloaded to a separate

ground hopper. PCI will be stored in the covered store by using

travelling tripper.

A storage capacity of seven (7) days for indigenous materials

and fifteen (15) days storage for imported materials has been

considered.

Base-mix preparation system

A base-mix yard has been envisaged to get good quality of

sinter. Base-mix and trimming materials required to be despatched

to the sinter plant and their respective quantities are indicated in

Table 4-3 below:

TABLE 4-3 – BASE-MIX AND TRIMMING MATERIALS

Estimated daily gross quantities

tons

Constituents of base-mix:

Iron ore fines .. 5,558 Limestone (purchased) .. 322 Limestone fines from LCP .. 221 Dolomite fines from DCP .. 52 Pyroxenite .. 180 Coke breeze/Anthracite .. 302

Total .. 6,635

Trimming materials:

Limestone (purchased) .. 83 Limestone fines from LCP .. 55 Pyroxenite .. 45 Coke breeze/Anthracite .. 76

Total .. 259




4−5

Twin boom stacker has been considered for stacking of

base-mix.

Seven (7) days storage with 2 nos. of pile of base-mix have

been considered, one (1) under stacking mode and the other on

reclaim mode.

Despatch of raw materials to the consuming units Despatch of coke, pellet, sinter and quartzite to BF:

Material (one at a time) will be reclaimed by stacker/ reclaimer in

reclaim mode and dispatched to the bins at blast furnace stock

house through series of conveyors. Sinter received from sinter

plant will be fed to the BF stock house through conveyor system.

Despatch of PCI to BF: PCI from covered shed will be

reclaimed by pay loader and fed to the yard hopper. Materials from

yard hopper will be withdrawn by vibrating feeder located below

and fed to the hammer mill for sizing of (-)10 mm. This (-)10 mm

material will be then fed to the bunker for its onward pulverization

suiting the requirement for injection system to BF.

Despatch of base-mix to sinter plant: Base-mix will be

reclaimed by barrel reclaimer and fed to the bunkers at the

proportioning bin of sinter plant for its onward transmission to the

sinter machine after final adjustment of chemistry of the sinter-

mix.

Transfer car has been considered to transfer barrel reclaimer

from one bay to the other.

Despatch of limestone to LCP: Limestone will be reclaimed

by stacker/reclaimer in reclaim mode and fed to screening station

through conveyor system.




4−6

(-)40 mm size fraction separated out will be dumped to the

ground. 40-80 mm will be fed to the respective bins at LCP area.

Despatch of lime and DRI to SMS: Lime received from LCP

will be stored in a bin having storage capacity of 600 ton. Lime is

then fed to the bins at SMS building through conveyor system.

DRI will be fed to the bins at SMS by conveyor system.

Additional DRI purchased for SMS will be transported to SMS by

conveyors.

Despatch of raw coal to washery: Raw coal (- 600 mm)

stored at storage yard by dumper (by external agency) will be

reclaimed by pay-loader and fed into the dumper (35-ton).

Dumper will dump the coal into the hopper. Material drawn

by apron feeder located below the hopper will be fed into the

primary sizer to crush down (-) 120 mm.

Secondary sizer will be used to crush down further upto (-)20

mm. (-)20 mm size will be stored in bunker through series of

conveyors. Six (6) nos. bunkers, each having 1,000-ton capacity,

have been envisaged to store 6,000 ton of coal, which is the daily

requirement for the coal washery. Material drawn by belt feeder

will be then transported to top of de-sliming screen.

Despatch of middling char and boiler coal to power

plant: Middlings (0.5 to 6 mm) stored at ground will be reclaimed

by pay-loader and fed into the conveyor system for its onward

transportation to the bins at Power Plant.

Char generated in the DR plant will be transported to the

stock yard and stored beside boiler coal stock pile. It will be




4−7

transported to the power plant from the yard by means of conveyor

system.

Boiler coal will be reclaimed by stacker/reclaimer on reclaim

mode and fed to the crushing unit to size down into (-) 25 mm with

the help of hammer mill. Then, (-) 25 mm boiler coal is fed to the

bins at power plant through conveyor system. Necessary grinding

arrangement of coal will be kept in the power plant, to suit the feed

requirement of boiler.

Despatch of raw materials to DR Plant: The following raw

materials will be despatched to the DR Plant:

Despatch of pellet: Pellet will be reclaimed by stacker

/reclaimer in reclaim mode and after screening, (+) 5 mm to (-) 18 mm size will be stored in the day-bin. (-)5 mm iron ore of pellet separated out after screening, will be stored in the ground and disposed off from time to time (by external agency).

Non-coking coal: Coal generated in the coal washery will be

stored on ground in coal washery plant. The size fractions of coal will be +5-20 mm and (-) 5 mm to 0.5 mm. Different size of coal will be reclaimed by pay-loader and stored in the respective bins at day-bin building.

A mixture of two (2) fractions of coal will be used for

injection system. Dolomite: Dolomite will be reclaimed by pay loader and fed

to the yard hopper for onward transmission to the day-bin. Charge-mix feed to the DR kiln

Raw materials namely pellet, coal and dolomite will be drawn

from the respective storage bunkers of day-bins as required by

weigh feeders in pre-determined proportion and conveyed to the

kiln inlet buildings as co-current feed.

Product handling system

Cold DRI will be discharged at 100 0C and screened to

separate out magnetic and non-magnetic materials.




4−8

An emergency bypass system will also be provided for

intermediate storing and handling of cooler discharge material in

the event of temporary break down of finish product screening and

separation system.

Electromagnet belt scale and mechanical hoist will be

provided in the system as required for DRI conveyor also.

Adequate facilities will be provided for dust extraction and

suppression system to minimize the dust level.

Facilities associated with the raw material handling system

The following facilities have also been provided:

- Belt weighing facilities - Belt charging facilities - Maintenance facilities - Air-conditioning and ventilation facilities - Dust suppression facilities

COAL WASHERY

A coal washery of 1.5 million tons per annum (mtpy)

throughput capacity will be installed. The washed coal will be

consumed in DR plant. The plant will be operated at rated capacity

of 250 tons per hour (tph).

In order to achieve the raw coal throughput rate of 250 tph,

the washery will be designed with single stream process. Heavy

media cyclone process will be used for optimizing the yield. The

products are clean coal and middling. Tailings generated from disc

filter will be dumped via conveyors to the designated area of

washery. The clean coal will be sent to DR plant. Due to higher

requirement of washed coal in DR plant, NISL will purchase clean

washed coal from different sources for continuous feeding to DR




4−9

plant. The middlings will be used in power plant for power

generation.

Design basis/consideration

Capacity: The main washery plant will have a throughput

capacity of 1.5 mtpy. The coal washing plant will be designed for

throughput rate of 250 tph based on 6000 effective working hours

per year. However, 20% design margin will be considered for

selection of the plant equipment. The washing plant will be

designed for washing crushed raw coal of size -20 mm.

Coal feed: Raw coal (0-20 mm) will be brought from coal

handling plant via conveyor and fed into a desliming screen with

throughput capacity of 250 tph.

The raw coal is expected to have characteristics as given

below:

Top size of raw coal .. -20 mm

Raw coal ash .. 52 to 55%

Angle of repose .. 35 to 40 degrees

HGI of raw coal .. 40 to 60

Size of coal to be fed to the washery .. (-) 20 mm

Desired product characteristics: The washery will be

designed to produce clean coal with an ash content of 32-35% on

dry basis for feeding to DR plant. Two types of washed clean coal is

generated from washery circuit one is washed fines (-5 +0.5 mm)

and the other one is clean coal coarse (-20+5 mm).

Middling have a size fraction of -6mm to 0.5 mm. Middling

with ash content about 70-72 % (on dry basis) will be used in

power plant.




4−10

DIRECT REDUCTION (DR) PLANT

Design basis

The DR plant will have four numbers of 500 tpd rotary kilns,

out of which one 500 tpd kiln is already present and three new 500

tpd kilns will be installed at the plant site. Each DR kiln will be

based on rated production of about 500 tons of direct reduced iron

(DRI) per day. The annual production from all four number of kilns

will be about 660,000 tons of DRI based on 330 days operation

using iron ore pellets. Commercially established coal based rotary

kiln process will be adopted for the DR plant.

Product quality

It is expected that the DRI produced will contain about

88 per cent of Fe (total), around 0.15 per cent carbon and the

degree of metallization will be about 88.5 per cent.

Raw materials

The rotary kiln charge will consist of iron ore pellets, non

coking coal and dolomite. The specific consumption of various raw

materials are indicated in Table 4-4.

TABLE 4-4 – SPECIFIC CONSUMPTION OF RAW MATERIALS FOR THE DR PLANT

Raw materials Specific consumption (1) Kg/ton DRI

Iron ore pellets .. 1,502 Non-coking coal .. 1,283 Dolomite .. 28

NOTE: (1) Net and dry basis. Major facilities

The facilities within the DR plant will comprise the following

major units:

- Raw materials feeding system - Rotary kiln




4−11

- Rotary cooler - Product (DRI) handling system - Waste gas system

SINTER PLANT

Production programme

One sinter machine of about 248 sq m will be installed to

produce 1.918 mtpy charge sinter, which will be adequate for 80

per cent sinter feed in BF-1 & BF-2.

Design basis

The design basis considered for sinter plant is given in

Table 4-5 in the next page.

TABLE 4-5 - DESIGN BASIS OF SINTER PLANT Product sinter, tons/year .. 2,256,700 Charge sinter, tons/year .. 1,918,200 Screening at BF stock house, % .. 15 Operating days/year .. 330 Daily product sinter, tons/day .. 6,840 No. of strand .. 1 Approx. suction area, sq m .. 248 Product sinter size, mm .. 5 - 50 Temperature of sinter at cooler discharge, oC .. 100

Raw materials

The typical analyses of input raw materials (dry basis) for

sinter production are given in Table 4-6 in the next page.

TABLE 4-6 – TYPICAL ANALYSES OF RAW MATERIALS FOR SINTER PRODUCTION

Fe SiO2 Al2O3 CaO _MgO LOI % % % % % %

Iron ore fines .. 63.07 2.65 2.04 - - 2.24 Limestone .. 0.24 0.99 0.52 52.27 1.98 42.34 Coke breeze .. 1.74 7.02 3.64 0.80 0.45 85.00 Flue dust .. 36.30 9.75 1.55 6.20 1.60 37.50 Mill scale .. 51.10 0.90 0.30 0.68 0.25 5.00 Lime .. - 3.00 2.50 83.00 3.20 4.00 Dolomite .. 0.22 0.86 0.29 30.80 19.12 46.05




4−12

Pyroxenite .. 5.00 47.00 0.83 0.80 32.00 14.00

Consumption of input materials

The annual input material consumption for production of

1.918 mtpy charge sinter is given in Table 4-7 in the next page.

Sinter quality

The expected chemical analysis of sinter production from

sinter plant is as follows:

Fe FeO SiO2 Al2O3 CaO MgO CaO/SiO2

% % % % % % ratio 56.25 8.0-9.0 4.70 2.15 8.00 1.70 1.70

Physical and metallurgical properties of sinter will be as

follows:

ISO tumbler index (+6.3 mm) .. 76% (min) Reducibility index .. 65% (min) RDI (-3.15 mm) .. 28% (max)

Sinter size range .. 5−50 mm Sinter mean size .. 18 mm

TABLE 4-7 – CONSUMPTION OF INPUT MATERIALS Annual Materials consumptions(1) tons/year Iron ore fines .. 1,653,500 Limestone .. 218,700 Dolomite .. 17,300 Calcined lime .. 35,500 Pyroxenite .. 69,100 Flue dust .. 17,300 Mill scale .. 40,800 Coke breeze and anthracite .. 124,700

NOTE: (1) Quantities are approximate net input for




4−13

sinter plant on dry basis. Major facilities

The sinter plant will comprise:

- Proportioning section - Mixing and nodulizing section - Sinter machine section - Sinter cooler section - Sinter stabilizing section - Sinter storage and despatch - Waste gas cleaning section - Plant dedusting system - Cranes, hoists and elevator - Plant electrics - Instrumentation and Level-1 automation system - Plant communication system - Utility system - Air-conditioning and ventilation system - Fire fighting system

BLAST FURNACE

Production programme

Two (2) blast furnaces (BF-1 and BF-2) of useful volume

(U.V.) of about 1008 cu m and 550 cu m respectively will be

installed to produce 1.464 mtpy of basic grade hot metal in a year.

Design basis

The design basis of blast furnaces is given in Table 4-8.

TABLE 4-8– DESIGN BASIS OF BLAST FURNACES

Item Blast furnaces

Hot metal production, mtpy .. 1.464 Daily production capacity, thm/day (avg) .. 4,184 No. of furnaces .. 2 Useful volume, cu m (approx) .. 1008 and 550 Productivity, t/(useful volume)/day (approx.) .. 2.65(1008 cu m BF) 2.75 (550 cu m BF) Operating days .. 350 Burden: Sinter, % .. 80 Pellet, % .. 20 Top gas pressure, kg/sq cm (g) .. 1.5 (1008 cu m BF) 1.2 (550 cu m BF) O2 enrichment, % .. 3 to 4 Coke rate (including nut), Kg/thm .. 414 Coal rate, Kg/thm .. 120




4−14

Slag rate, Kg/thm .. 310 Coke ash, % .. 12.5 Hot blast temperature, 0C .. 1150 Si in metal, % .. 0.6-0.8

Analysis of raw materials

The major raw materials for blast furnaces comprise sinter,

pellet, additives and coke. Pulverised coal will be injected through

tuyeres as auxiliary fuel in furnaces. The typical analysis of raw

materials envisaged is given in Table 4-9.

TABLE 4-9 – TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS)

Fe SiO2 Al2O3 CaO MgO % % % % % Sinter .. 56.25 4.70 2.15 8.00 1.70 Pellet .. 65.00 2.50 1.75 0.40 0.30 Quartzite .. 0.50 96.92 0.92 - -

Ash

basis Moisture CSR

CRI % % % %

Coke .. 12.5 5.0 62 (min) 21-23

Coal for PCI application

Ash, % (dry basis) : 10-11 Fixed carbon, % : 78-78.5

Input materials quantity

The annual input materials required for the envisaged hot

metal production of 1,464,300 mtpy from blast furnaces are given

in Table 4-10.




4−15

TABLE 4-10 – INPUT MATERIAL QUANTITIES

Material

Annual Consumption

tons/year(1)

Fluxed sinter (charge) .. 1,918,200 Pellet .. 480,300 Quartzite .. 21,950 Charge coke (hard+nut) .. 606,200 Injection coal .. 175,700

NOTE:

(1) All quantities are approximate net input to blast furnaces on dry basis. Hot metal quality (typical)

The expected hot metal quality is as follows:

Facilities in blast furnace

The blast furnaces will comprise of the following facilities:

- Stock house and charging system - Blast furnace proper - Cast house and cast house equipment - Hot blast stoves - Gas cleaning system - Slag granulation plant and dry slag pit - Blowers - Pig casting machine and hot metal ladle repair shop - Coal dust injection system - Electrics, instrumentation and automation - Plant communication system - Utility system - Water system - Top gas recovery turbine - Cranes and hoists - Fire fighting system

- Air-conditioning and ventilation system

Si S P

% % %

0.6-0.8 0.045 (max) 0.15 (max)




4−16

STEELMELT SHOP–1 (SMS-1)

Design basis

Steelmelt shop–1 (SMS-1) will be designed with IF route with

installation of induction furnace (IF), ladle furnace (LF) and

continuous casing machine (CCM) for production of about 130,300

tons per year of billets. Balance requirement of billets for mills will

be met with production from SMS-2.

Induction furnace (IF): (3) nos. 15 ton/7.2 MVA capacity Ifs

are envisaged in the project. The estimated quantity of liquid steel

from the IFs works out to be around 133,700 tpy as per detailed on

the next page. Consent to establish is already available for the

manufacturing of 30,000 tpy.

No of furnaces .. 3

Capacity of IF .. 15T/7.2 MVA

Net operating days .. 330

Charge mix .. 70% DRI 20% Pig Iron 10% return scrap

Tap–to–Tap time, mins .. 140

Average number of heats possible from one (1) IF

.. 10

Average number of heats/day from 3 IFs

.. 30

Average number of heats/day considered from 3 IFs (1)

.. 27

Liquid steel, tons / year .. 133,700 NOTE: (1) Although 30 heats/day can be produced from 3 IFs

(each IF will be capable to produce 10 heats/day), taking combined availability of logistics, furnaces, caster and other variables into account, consideration of 27 heats/day from three (3) furnaces to be cast for 330 days will be rational.




4−17

Ladle furnace (LF): It is proposed to provide one no.

matching capacity LF i.e 15 tons equipped with arc heating, inert

gas stirring and alloy addition facilities to treat the heats tapped

from IF.

All the 27 heats produced from IFs will be conveniently

treated at one LF with an average treatment cycle time varying

between 35-45 minutes per heat depending on the extent of

treatment required.

Continuous casting machine: It is proposed to install one

(1) no. 2-strand billet continuous casting (CC) unit in order to cast

the envisaged liquid steel production. A casting time of 45-46 mins

will be adopted to match with the three IFs being operated in

staggered way of 46 mins considering each IF tap-to-tap time of

140 mins, thus making one heat available in every 46 minutes for

casting sequence. One (1) no. 2-strand billet caster will be able to

cast the entire quantity of 133,700 tpy of liquid steel on the basis

of casting 27 heats/day. Assuming a yield of 97.5 % from liquid

steel to cast billets, the annual quantity of billets will be 130,300

tpy.

Annual production from SMS-1: The annual production

of SMS-1 will be as below:

Liquid steel, tpy .. 133,700

Semis (Billets), tpy .. 130,300

Requirement of raw materials and supplies

The requirement of the raw materials and major supplies for

annual production of 130,300 tons of billets is presented in the

Table 4-11.




4−18

TABLE 4-11- REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES Raw materials and supplies Annual consumption,

tons/year DRI .. 112,700 Pig .. 32,200 Scrap (return) .. 16,100 Ferro alloys .. 2,000 Burnt lime .. 2,700 Fluorspar .. 330 Electrode .. 60 Pet coke .. 700 Oxygen, N cu m/yr .. 0.27 x 106 N2/Ar, N cu m/yr .. 0.06 x 106 Propane/LPG, N cu m/yr .. 0.07 x 106

Equipment and facilities for steelmelt shop-1

The major equipment and facilities proposed to be installed

in the steelmelt shop-1 are briefed below:

Induction Furnace (IF): Three (3) nos. 15 ton capacity IFs

consisting of two (2) crucibles each are envisaged for melting DRI,

pig iron and return scrap. Major technical parameters are given as

follows:

No. of units .. Three (3)

No of crucibles .. Two (2)/furnace

Capacity .. 15 tons

Transformer rating .. 7.2 MVA

IF and LF gas cleaning system: A common system for

collection and cleaning of fumes from IFs and LF is proposed to be

provided.

Fume collecting hood dedicated for two crucibles of each IF

will be provided. This will be of swinging type and is operated on




4−19

the crucible which is under operation. Fumes from each IF will be

joined in one common duct. Fume from LF will also be collected

through a water cooled hood, sleeve and ductwork. The ducts

carrying fumes from the LF and the duct carrying fume from IFs

will join in the mixing chamber, from where the gases will be led to

the bag house, by means of ID fans. Clean gases having less than

50 mg per N cu m dust content will be exhausted through a stack.

Ladle furnace (LF): The relevant parameters of the LF are as

follows:

No. of units .. One (1)

Nominal capacity .. 15 tons

Heating rate .. 4-5 deg C/min

Transformer rating .. 3.6 MVA

Type of unit .. Lift/lower roof type

This unit will also be utilized to hold the heats for an

extended period of time, should it be necessary for any reason,

such as, sequencing of casting in CC machine, hold up in CC

machine, etc. All the required features including both top and

bottom rinsing, multi-strand wire feeding, automatic temperature

measurement and sampling facilities will be provided.

Billet casting machine (CCM): The salient features of the

CCM are indicated below:

No. of machines .. One (1)

No. of strands .. Two (2)

Type of machine .. Conventional billet caster, radial bow type

Mould .. Tubular mould

Casting practice .. open/closed

Ladle capacity, ton .. 15

Billet Size .. 130 sq mm & 150 sq mm




4−20

The continuous casting machine will be inclusive of ladle

turret, ladle shroud manipulator, tundish preparation facilities,

mould and segment assembly, testing and storage facilities, etc.

Necessary automatic control system for casting speed,

primary/secondary cooling water system and billet transfer system

up to the end of cooling bed will also be provided. Provision of

emergency water supply to caster in case of power failure will be

provided.

Shop auxiliary and maintenance facility: Suitable shop

auxiliary equipment will also be considered. Facilities for

debricking/relining/drying of refractory for ladles & tundishes,

slide gate nozzle and porous plug setting, tundish nozzle setting,

mould preparation, testing and assembly will be provided.

STEELMELT SHOP–2 (SMS-2)

Design basis

Steel melt shop-2 (SMS-2) will be designed with installation

of electric arc furnace (EAF), ladle furnace (LF), vacuum degasser

(VD) and continuous casting machine (CCM) for production of

about 1,460,200 tons per year of billets/blooms. The EAF has

been designed considering use of DRI, hot metal and scrap as

metallics. A hot metal pretreatment facility (hot metal

desulphurization plant) is also envisaged in the shop. The billet

quantity per year of 1,460,200 tpy is considered with optimum

number of heats produced from two (2) EAFs that can be cast

through two (2) nos. 4-strand billet cum bloom caster. The total

quantity of semis produced from both SMS-1 and SMS-2 meets the

mill production requirement.

Electric arc furnace (EAF): In order to achieve the

required production of billets, it is proposed to install two (2) nos.




4−21

90ton/70 MVA capacity EAFs. The estimated quantity of liquid

steel from the EAFs works out to be around 1,497,600 tpy as per

the basis detailed below.

No of furnaces .. 2

Capacity of EAF .. 90 tons/70MVA

Number of operating days .. 320

Charge mix .. 52% hot metal 45% DRI 3% return scrap

Tap-to-Tap time, mins .. 55

Average number of heats/day/EAF .. 26

No of heats from 2 EAFs .. 52

Liquid steel, tons/year .. 1,497,600

Ladle furnace (LF): It is proposed to provide two nos

matching capacity LFs i.e 90 tons equipped with arc heating, inert

gas stirring and alloy addition facilities to treat the heats tapped

from EAF. All the 26 heats produced per day per EAF can be

conveniently 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, two (2) nos LFs will suffice the

shop requirement.

Vacuum degassing (VD): While the LFs will be adequate to

produce almost all the steel grades, certain special grades

requiring low gas levels need to be degassed to obtain the required

quality. These heats after LF treatment will be transferred with

adequate superheat to VD unit for degassing. Minor additions may

be required at VD unit as well. It is proposed to install one no. of

VD unit, in case if all the heats are required to be processed

through VD. Normally, the refining cycle time will be 20-40

minutes.




4−22

Continuous casting machine: It is proposed to install two

(2) nos. 4-strand billet cum bloom continuous casting units in

order to cast the envisaged liquid steel production. The product

sizes of the billet caster include 130 mm to 200 mm square billets.

The speed will be adjusted for different billet sections according to

steel grades and facilitating sequence casting operation. A casting

time of 54-55 mins is adopted to match with EAF tap-to-tap time of

55 mins. Two (2) nos. 4-strand billet cum bloom caster will be able

to cast the entire quantity of 1,497,600 tpy of liquid steel on the

basis of casting 26 heats/day/caster. Assuming a yield of 97.5 %

from liquid steel to cast billets, the annual quantity of billets will

be 1,460,200 tpy.

Annual production from SMS-2: The annual production of

SMS-2 will be as below.

Liquid steel, tpy .. 1,497,600

Semis (Billets/Blooms) .. 1,460,200

Requirement of raw materials and supplies

The requirement of the raw materials and major supplies for

annual production of 1,460,200 tons of billets is presented in the

below Table 4-12.

TABLE 4-12 - REQUIREMENT OF MAJOR RAW MATERIALS AND SUPPLIES

Raw materials and supplies Annual consumption tons/year

Hot metal (after HMDP) .. 905,500 DRI .. 782,800 Return Scrap .. 53,000 Ferro alloys .. 40,000 Additives .. 7,500 Burnt lime .. 97,400 Burnt dolo .. 22,500 Fluorspar .. 3,700 Pet coke .. 4,500 Steam .. 8,100




4−23

Electrode .. 3,600

Oxygen, N cu m /yr .. 54.8 x 106 Ar/N2, N cu m/yr .. 0.77 x 106 Propane/LPG, N cu m/yr .. 0.75 x 106

Equipment and facilities for steelmelt shop-2

The major equipment and facilities proposed to be installed

in the steelmelt shop-2 are described below:

Hot metal desulphurization plant: The sulphur content in

hot metal will be 0.045 percent (max). In order to meet the

requirement of low sulphur content in steel, desulphurisation of

hot metal will be installed prior to feeding the hot metal into EAF.

Hot metal will be desulphurised by deep injection of a combination

of desulphurising reagent (calcium carbide and magnesium) in

charging ladle by injection lances. Provision for mono-injection

(CaC2) and co-injection (CaC2 +Mg) as well as deslagging will be

provided.

Electric arc furnace (EAF): The salient features of the EAF

are indicated below:

Number of furnaces .. Two, EBT type

Furnace capacity .. 90 tons

Furnace transformer .. 70 MVA

Metallic charge, approx .. 52% Hot metal, 45% DRI + 3% return scrap

Method of charging .. Continuous charging of DRI/flux, and charging of hot metal by charging crane or via a launder

Hot metal will be charged to EAF by means of hot metal ladle

held with shop EOT cranes either by opening the furnace roof or

via a hot metal launder through the slag door. Water cooled side

panels and water cooled roof have been envisaged.




4−24

EAF and LF gas cleaning system: A common system for

collection and cleaning of fumes from EAF and LF and dust from

the raw material handling system of the steelmelt shop is proposed

to be provided.

Fumes and dust will be evacuated directly from EAF roof

through water cooled elbow, movable sleeve, combustion chamber,

water cooled ducting, forced air cooler and mixing chamber to the

bag house. The secondary fumes arising during hot metal charging,

deslagging, tapping, etc. and those escaping from the annular

spaces around electrodes will be collected through a canopy hood

located in the building roof above crane level.

The fume from LF will also be collected through a water

cooled hood, sleeve and ductwork. The ducts carrying fumes from

the LFs and from the roof canopy, as well as ducts carrying dust

from the dust extraction points of the raw material handling

system will join the mixing chamber, from where the gases will be

led to the bag house, by means of ID fans. Clean gases having less

than 50 mg per N cu m dust content will be exhausted through a

stack.

Ladle furnace (LF): The relevant parameters of the LF are as

follows:

No. of units .. One (1)

Nominal capacity .. 90 tons

Heating rate .. 4-5 deg C/min

Transformer rating .. 14 MVA

Type of unit .. Lift/lower roof type

This unit can also be utilized to hold the heats for an

extended period of time, should it be necessary for any reason,




4−25

such as, sequencing of casting in CC machine, hold up in CC

machine, etc. All the required features including both top and

bottom rinsing, multi-strand wire feeding, automatic temperature

measurement and sampling facilities will be provided.

Vacuum degassing (VD) unit: VD unit will primarily be used

for ladle degassing to reduce the entrapped as well as the dissolved

gases in steel such as hydrogen, nitrogen and oxygen to desired

levels, and chemical homogenization.

The salient features of the VD unit are given below:

No. of units .. One

Ladle capacity, tons .. 90

Type of unit .. Stationary vacuum vessel with cover lift and travel car

Vacuum system .. Multi-stage stream ejector with

boosters and condenser units

Billet cum bloom casting machine (CCM): The salient

features of the CCM are indicated below:

No. of machines .. Two (2)

No. of strands .. Four (4) Type of machine .. Conventional billet cum bloom

caster, radial bow type Mould .. Tubular mould Casting practice .. open/closed Ladle capacity, ton .. 90 Billet Size: .. 130 sq mm to 200 sq mm

The continuous casting machine will be inclusive of ladle

turret, ladle shroud manipulator, tundish preparation facilities,

mould and segment assembly, testing and storage facilities, etc.




4−26

Necessary automatic control system for casting speed,

primary/secondary cooling water system and billet transfer system

up to the end of cooling bed will also be provided. Provision of

emergency water supply to caster in case of power failure will be

provided.

Raw material handling and conveying: Facility for DRI

conveying from DR plant to SMS storage bunker and further

conveying and charging to EAF will be considered. Lime will be

either conveyed from lime plant or brought by transport vehicle

and stored in storage bunkers for further charging to EAF. Ferro

alloys will be brought by transport vehicle from stores and stored

in storage bunkers for further charging to EAF & LF. Facility for

storage and charging of lime and ferro alloy will be provided.

Shop auxiliary and maintenance facility: Suitable shop

auxiliary equipment will be provided. Facilities for debricking/

relining/drying of refractory for ladles & tundishes, slide gate

nozzle and porous plug setting, tundish nozzle setting, mould

preparation, testing and assembly will be provided.

CALCINING PLANT

The production of calcined lime & burnt dolomite has been

considered based on the following requirements:

Calcined product

Net requirement for steel melt

shop

Net requirement for other

plant/sale tpa tpa tpa

Calcined lime 100,000 150,900

Burnt dolomite 22,500 22,500 In view of the above, total net production of calcined lime

and burnt dolomite is estimated as around 250,900 tpa and 45,000

tpa respectively. In case of future expansion, the calcined materials

for other plant/sale will be used to meet the in-plant requirement




4−27

first and then the excess calcined products, if any, will be sent to

the Odisha plant or sold out in market.

The calcined product will be screened before dispatch to the

steel melt shop or other plant and the undersize fraction of

calcined products will be used in sinter plant. Considering

handling and screening losses as well as fluctuation in the specific

consumptions of calcined lime and burnt dolomite, the daily peak

production requirement is estimated as 984 tons for calcined lime

and 176 tons for burnt dolomite based on 330 days working

annually. The installation of a separate dolomite kiln for the above

requirement will make non uniform kiln size in comparison with

other plants. Hence, it is proposed to install two (2) Nos. each of

600 tpd capacity vertical shaft kilns for the production of calcined

lime and burnt dolomite in separate campaign.

The high grade limestone and dolomite in the size range of

40 – 80 mm is proposed to be used. The annual net requirement of

limestone and dolomite in the size range of 40-80 mm has been

estimated at about 606,880 tons and 114,660 tons respectively.

The calcining plant will comprise raw materials storage and

handling, kilns with kiln feed building, calcined product handling

and storage facilities. Various utilities, such as fuel, electric power,

water, compressed air, etc., will be made available to the plant.

The plant will be provided with kiln waste gas cleaning

system and dedusting system for raw material and product

handling facilities.

WIRE ROD MILL (WRM)

It is proposed to install a wire rod mill of 500,000 tpy

capacity under the 1.5 mtpy expansion plan.




4−28

Design basis

Product-mix: The finished product will be produced in

following sizes:

Rounds .. 5.5 – 20 mm

Coil weight (max.) .. 2 ton

The grades of steel for wire rods considered are low &

medium carbon steel, spring steel, welding rod, tyre bead, cold

heading quality (CHQ) steel, ball bearing steel.

The size-wise and grade-wise product-mix for the proposed

single strand 0.5 mtpy capacity wire rod mill (WRM) is given in the

next page.

Product-mix, size in mm

Description 5.5 6.0-7.5 8.0-16.0 17.0-20.0 Total

tpy tpy tpy tpy tpy Low carbon 45,000 35,000 25,000 25,000 130,000

Medium carbon

30,000 30,000 30,000 30,000 120,000

Spring steel 15,000 15,000 25,000 15,000 70,000

Tyre cord 35,000 - - - 35,000

Welding rod 40,000 30,000 - - 70,000

Ball bearing 15,000 10,000 10,000 - 35,000

Cold head quality

- - 40,000 - 40,000

Total 180,000 120,000 130,000 70,000 500,000

Billet requirements: It is proposed to use 150 mm sq (with

a provision for 160 mm sq) and 12 m long billets which would give

a coil weight of about 2.114 tons. However, the wire rod mills will

be capable of rolling 130 & 160 sq mm.




4−29

Yield: Material losses in the production of wire rods arise

due to scale, shear, cropping, trimming, cobbles, etc. In a modern

mill, average yield is 97 per cent. Hence an yield of average 97%

has been considered. Thus total billet requirement will be 515,500

ton for a annual production of 500,000 tpy wire rods.

Reheating furnace capacity: A 150 tph walking beam type

furnace has been selected for the wire rod mill.

Major equipment

Continuous cast (CC) billets from the Steel Melt Shop will

be transferred through roller table of caster bay or cross transfer

(cold billet) to storage bay of this shop. The mill will comprise of

the following major facilities:

- Billet charging and discharging equipment - Walking hearth type reheating furnace (150 tph) - Descaler - Roughing train - Intermediate train - Prefinishing blocks - Finishing blocks - Post Finishing blocks (optional) - Water boxes before & after finishing blocks - Shears - Pinch rolls - Laying head - Air cooling conveyor - Reform station - C-hook conveyor - Coil compacting, trimming and strapping machine - Weighing device - Unloading stations

The mill will be provided with its own roll/rings and guide

shop, express laboratory, recirculating water treatment facilities,

etc.




4−30

MEDIUM MERCHANT MILL (MMM)

A medium merchant mill (MMM) of 650,000 tons per year

capacity will be installed. It will roll continuous cast (CC) billets

received from the steel melt shop. The CC billets will be stored,

inspected and conditioned in the continuous cast billet storage

aisles, and then transferred and stocked in the finished billet

storage aisles.

Design basis

Product-mix: Low, medium and construction grade steel of

following sizes will be rolled in this mill:

Size Quantity

mm tons/year Beams (ISMB, ISJB, ISLB) .. 100-175 195,000 Channels (ISMC, ISJC, ISLC) .. 75-175 205,000 Rounds .. 45-90 25,000 Squares .. 45-80 25,000 Angles .. 55-100 125,000 Flats .. 70-180 x 12,15 75,000

Total .. 650,000

Billet requirements: The billet size and requirement is given

below:

Billet size .. 200 mm sq, 12 m long,

Yield .. 95%

Billets required .. 684,200 tons

Mill characteristics: MMM will be designed to roll at a

maximum speed of 16 meters per second.

The mill stands are divided into three groups – roughing,

intermediate, finishing groups. The finishing group will have

convertible stands for rolling beams.




4−31

Reheating furnace capacity: A walking beam type furnace

of 180 tph has been selected for MMM.

Major equipment

Continuous cast (CC) billets from the Steel Melt Shop will be

transferred through roller table of caster bay or cross transfer (cold

billet) to storage bay of this shop. The mill will comprise of the

following major facilities:

- Billet charging and discharging equipment - Walking hearth type reheating furnace (180 tph) - Descaler - Roughing train - Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers

and fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - weighing and collecting station

LIGHT MERCHANT MILL (LMM)

A light merchant mill (LMM) of design capacity 400,000 tons

per year capacity will be installed. However, the plant will produce

371,300 tons of finished product. It will roll continuous cast (CC)

billets received from the steel melt shop. The CC billets will be

stored, inspected and conditioned in the continuous cast billet

storage aisles, and then transferred and stocked in the finished

billet storage aisles.




4−32

Design basis

Product-mix: Low, medium and construction grade steel of

following sizes will be rolled in this mill:

Size Quantity

mm tons/year Rebars & Rounds .. 10-40 150,000 Squares .. 22-50 25,000 Channels .. 25-100 75,000 Angles .. 25-75 75,000 Beams .. 75-120 50,000 Flats .. 25x5-75 x 12,15 25,000

Total .. 400,000

Billet requirements: The billet sizes and requirement is

given below:

Billet size .. 130 & 150 mm sq, 12 m long Yield .. 95% Billets required .. 390,800 tons Mill characteristics: LMM will be designed to roll at a

maximum speed of 22 meters per second for rolling of rebars and

round of size 10 to 40 mm.

Reheating furnace capacity: A walking beam type furnace

of 100 tph has been selected for LMM.

Major equipment

Continuous cast (CC) billets from the Steel Melt Shop will be

transferred through roller table of caster bay or cross transfer (cold

billet) to storage bay of this shop. The mill will comprise of the

following major facilities:

- Billet charging and discharging equipment - Walking hearth type reheating furnace (100 tph) - Descaler - Roughing train




4−33

- Intermediate train - Finishing blocks - Water boxes before & after finishing blocks - Shears - Pinch rolls - Cooling bed with straightening, grids, aligning rollers and

fixed & movable rakes, layer forming - Straightening machine - Multi-strand cold saws - Automatic stacker - Strapping machine - Weighing and collecting station CAPTIVE POWER PLANT The following captive power plants have been envisaged to

generate the electrical power in the plant:

- 2 x 130 MW power plant (CPP-1) - 2 x 7.5 MW in-plant gas based power plant (CPP-2). This

plant will also generate 20 MW mechanical power for BF blowers.

The power demand of the steel plant facilities are indicated

in Chapter 5. The installed capacity, average power and energy

generation, etc. are given in Table 4-13 in the next page.

TABLE 4-13 – ESTIMATED POWER GENERATION CAPABILITY

Sl. No.

Description

CPP-1

CPP-2

TRT

1. Installed capacity, MW 2 x130 2 x 7.5 4.5 2. Average electrical power

generated, MW 260 15 4.5

3. Send out power, average, MW 234 13.5 3.6 4. Send out energy, MU, yearly 1,638 94.5 25.2

Technical profile of the captive power plant

The technical profile of the CPP-1 and CPP-2 are indicated in

Table 4-14.




4−34

TABLE 4-14 – TECHNICAL PROFILE OF CPP

Sl. No.

Description

CPP-1

CPP-2

1. Nos. and size of boilers

4 Nos. coal fired boilers (AFBC) of 250 TPH each and 4 Nos. Waste heat recovery boilers of 50 TPH

2 Nos. by-product gas fired boilers 80 TPH each

2. Nos. and size of turbines

2 Nos. x 130 MW 2 Nos. x 7.5 MW

TOP RECOVERY TURBINES (TRT)

The TRT has been envisaged to recover energy from the top

gas of blast furnace and convert to power. Around 4.5 MW of power

will be available from top recover turbine of blast furnace.

AIR SEPARATION PLANT (ASP)

The industrial gases viz. oxygen, nitrogen and argon are

envisaged to be received through pipeline supply at Battery Limit

from the ASP.

Oxygen

Oxygen (99.5% purity) will be required in EAF, cutting

operation in caster, scrap and for other general purpose usage.

Low purity oxygen will be required in blast furnace for enrichment

purpose.

Nitrogen

Nitrogen (99.9% purity) will be required for gas line purging

process purpose and general purpose (e.g. instrumentation, etc.)

applications in blast furnace, sinter plant, EAF, casters and rolling

mills, etc.




4−35

Argon

Argon (99.995% purity) will be required in Vacuum Degasser

(VD) in SMS-2.

Facilities proposed

An ASP of capacity 600 TPD will be required to meet the

above demand of oxygen, nitrogen and argon. The ASP will be

installed in Build-Own-Operate (BOO) basis. Besides, the oxygen

plant will have adequate liquid generation and storage capacity so

as to supply 72 hours of oxygen, nitrogen and argon in the event of

stoppage of operation of the ASP.

Oxygen will be available at pressure levels of 40 kscg and

8 kscg from the ASP. Nitrogen will be available at pressure of 20

kscg. Argon will be available at the pressure of 10–12 kscg.

Buffer vessels and pressure reducing stations for oxygen,

nitrogen and argon will be provided to cater to the various peak

requirements of the process.

PLANT MATERIALS FLOWSHEET

The plant materials flowsheet for the proposed steel plant is

given in Drawing No. 11330-04-0001.



5−1

5 – UTILITY AND SERVICE FACILITIES

This Chapter presents electric power distribution system,

water system, various utility systems and auxiliary facilities of the

proposed project.

POWER DISTRIBUTION SYSTEM AND ELECTRICS

This section presents the estimated power requirements,

characteristics of plant loads, source of power and power

distribution philosophy for the proposed steel plant at Bilaspur,

Chhattisgarh.

Plant power requirements

The estimated power requirements for the proposed plant are

indicated below:

Annual Energy Consumption, million kWh

.. 1,288

15–min. maximum demand: in MW in MVA (0.9p.f.)

.. ..

196 217

1–min. peak demand, MVA .. 248 Note: The power balance reveals that around 62 MVA power

will be exported from the plant to the grid considering all proposed captive power generations.

Characteristics of plant loads

The major consumers of power for the proposed plant will

impose a more or less steady load on the power system.

The electric arc furnaces (EAF), ladle furnaces (LF) and main

drives of Mills will be fluctuating power consumers and will impose

flicker and harmonics in the power system.



5 – Utility and service facilities (cont’d)

5−2

In order to mitigate the effect of flicker adequately rated

static var compensation (SVC) equipment will be provided.

In order to mitigate the effect of harmonics, reactive power

compensation equipment with power factor improvement capacitor

banks arranged in harmonic filter circuits will be provided. The

plant overall power factor will be maintained in the range of 0.9.

Source of power

The power requirement of the proposed plant will generally

be met from the following captive power plant sources:

(i) Two (2) captive power plants, each having capacity of

130 MW, with coal fired boilers.

(ii) Two (2) captive power plants, each having capacity of 7.5 MW, from by-product gas. This plant will also generate 20 MW mechanical power which will be sent to blast furnace blower.

(iii) One (1) captive power plant of capacity 4.5 MW with top pressure recovery turbine (TRT) of blast furnaces.

Further, it is given to understand that there will be

connectivity over 220 kV over head lines with the nearby 220 kV

grid substation located approximately 20 km away from the

plant.

Power distribution philosophy

A new 220 kV Main Receiving & Step down Substation

(MRSS) will be established in the proposed area for the expansion

project.

The transmission line from grid substation will be terminated

at the incoming line gantries of MRSS. The switchyard at MRSS

will be laid out with double busbar arrangement with one incomer,

one outgoing and one bus-coupler bays. The space for future

expansion will be kept in the MRSS.




5−3

The power distribution system will be so developed that the

electrical power generated from 2 X 130 MW CPP, 2 X 7.5 MW CPP

and 1 X 4.5 MW TRT will be utilized for feeding plant loads. The

excess generation will be evacuated to grid. The start-up power for

CPPs will be arranged from 220 kV MRSS over suitable power

distribution arrangement.

The power will be stepped-down to 33 kV for feeding bulk

power. The EAFs, LFs and Induction Furnaces will be fed from from

33 kV dirty bus and other steady loads like existing DR plant,

sinter plant, BFs, continuous casting machines and rolling mill

loads will be fed from 33 kV clean bus.

The power will be further stepped-down to 6.6 kV at

respective plant units for feeding HT motors and 6.6 kV/415-240 V

load centre substation transformers.

The LT consumers will be fed from respective 415 V

switchboards of load centre substations.

INSTRUMENTATION AND AUTOMATION SYSTEMS

This section describes the automation systems proposed in

general for various individual process plant units as well as on

overall organization basis for the project. The automation systems

are envisaged to enable NISL to achieve higher productivity with

better quality in a planned and well-co-ordinated manner using

state-of-the-art equipment and facilities.

Structure of proposed automation system

The automation systems proposed have been structured

application-wise into four hierarchical levels as follows:

Level 1 - Instrumentation and Basic Automation

Level 2 - Supervisory Computer and Process Automation

Level 3 - Manufacturing Execution (Level 3) System (MES)




5−4

The salient features of Level 1, Level 2, Level 3 automation

systems as well as the SCADA systems, Communication and FDA

systems are presented in the following:

Instrumentation and level-1 automation

The various plant units will each be provided with dedicated

DCS/PLC based Level 1 automation systems and necessary

instrumentation, which will perform all the functions for

controlling, regulating, data acquisition, alarms and interlocks

including material tracking, drive control and other process

specific technological control system (TCS) functions, wherever

required. The system will have necessary hardware and software

features to ensure plant safety as well as ease in operation and

maintenance. As far as possible, it is proposed to adopt common

type of hardware and software. The system will be suitably

interfaced with higher level (level 2) process computer system,

wherever required.

The instrumentation and Level 1 automation system will be

configured around an Open System Architecture for implementing

smooth interoperability among different systems as well as

maximum unit availability, using an integrated, functionally

distributed Programmable Logic Controller (PLC)/Distributed

Control System (DCS) based system.

The digital control system will mainly comprise required No.

of intelligent HMI’s and Process Stations / PLCs interconnected

over the data communication bus system. The HMI’s will consist of

Personal Computers along with TFT-LED monitors, keyboard,

alarm, event and report printers.

HMI’s will also include engineering and programming

terminals. Laptop type programming terminal will be provided for

programming of PLCs and drives.




5−5

The Process Stations / PLCs will be of the latest state-of-art

technology suitably connected to the bus system. The data

communication bus as well as CPU, communication processors and

power supply unit in PLCs will be in redundant configuration.

Package PLCs will be conceived where ever essential and will be

suitably interfaced with the corresponding main PLC, etc.

Remote input/output units connecting inputs/outputs

in different plant areas with the PLC system will be envisaged. I/O

bus will be fiber optic if required based on distance between PLC

and Remote I/O units.

Parallel redundant type UPS will be envisaged for power

supply to Automation, Instrumentation, Communication and FDA

system equipment with battery back-up for a duration of minimum

30 mins.

The design of control system and related equipment will

adhere to the principle of “Fail Safe Operation” at all system levels.

The software for the Level-1 automation and

instrumentation system will be simple, user friendly and have the

provision of on-line editing and programme development without

interrupting the process lines and the same will support on-line

diagnostic features.

All field sensors and instruments will be of latest state-of-

the-art design. All transmitters will be “Smart” type conforming to

HART/FF protocol. Field bus (Profibus/FF) technique will be

adopted wherever found suitable.




5−6

Process automation (level-2) system

The proposed steel plant will be equipped with state-of-the

art supervisory computer and process automation system (Level 2)

for improved quality, process optimisation management, product

tracking and reporting functions. The systems will be configured

based on client-server architecture and will have provision for

future expansion and upgradation, when needed.

The production units such as blast furnace, hot metal

desulphurization station, electric arc furnace, ladle furnace,

vacuum degasser, continuous billet casting machines, wire rod

mill, medium merchant mill, light merchant mill as well as the

reheating furnaces will have dedicated Level 2 systems to achieve

higher productivity with better quality in a planned and

coordinated manner. All necessary control functions including

process models as well as supervisory functions like PDI handling,

product tracking, data archival, reporting, etc. will be considered

for optimized operation of the units.

Also, following automation systems may be considered for

better tracking & utilization of process units for optimized

operation:

- Laboratory Management System

- Yard Management System

- SMS area Ladle tracking System

Supervisory control and data acquisition system (SCADA)

A supervisory control and data acquisition system will be

implemented at specific places for monitoring & control (if

required) of production, distribution and consumption of the

different utilities and water systems as well as for the electric

power system.




5−7

The SCADA system will be installed in a central location in

the plant and will be based on Client/Server architecture with

server and HMI clients and necessary Remote Terminal Units (RTU)

located at various strategic points.

Manufacturing execution (level-3) system

A production planning and control system, more commonly

known as ‘Manufacturing Execution System’, at the next higher

level of the automation hierarchy is proposed on overall plant

basis. The system will be used for execution of various production

automation related functions like Provision for order entry,

Technical dressing of commercial order, Production planning,

Detailed production scheduling, Resource allocation, Production

progress control & monitoring, Quality data collection and

assessment, Data acquisition and archival, KPI monitoring, etc.

The system will be designed considering servers housed in a

central location in the plant and clients distributed in various

areas and departments.

IT infrastructure

Data communication network will be proposed for providing

intranet/internet facility for all kind of business related data with

required servers and application software. The network will include

switches and related cabling within the plant area. The proposed

network will have 3-tier star topology based architecture. Access

switches will be at the lowest level and connected to the

corresponding zonal switches. Zonal switches will be connected to

the centralized core switches at the top level. The proposed

network will also have the facility to further integrate/ interface

with the future expansion.




5−8

PLANT COMMUNICATION SYSTEM

Following communication facilities are envisaged for reliable

and quick communication amongst various units of the plant:

Plant telephone system

Plant telephone system as envisaged will comprise of

required nos. of exchanges/gateways located at strategic nodes of

the plant along with associated cable network, for providing

telephone facilities all over the plant. These exchanges/gateways

will be interconnected over Plant OFC backbone to work together

as an integrated virtual single telephone exchange.

Loudspeaker intercommunication (LSIC) system

Independent loudspeaker intercommunication (LSIC) system

is envisaged in respective plant unit to ensure quick

communication facility amongst various sections inside the

respective plant unit. Each LSIC system will provide announcement

and point to point calling facility.

Closed circuit television (CCTV) system

Independent closed circuit television (CCTV) system is

envisaged in respective plant unit for viewing and monitoring

critical operating areas from control rooms. Each CCTV system will

be IP based and will comprise of cameras, PC based monitors and

other equipment.

Wireless communication system

VHF Wireless Communication system is envisaged for

communication between cranes or moving machine operators and

control room/supervisory personnel on shop floor as well as

amongst operation & maintenance personnel.




5−9

Plant optical fiber cable (OFC) backbone

An optical fiber cable (OFC) backbone is envisaged inside the plant

covering a number of strategic nodes at different plant units. This

OFC backbone will be used for integration of various systems (e.g.

plant telephone system, SCADA, fire detection and alarm system,

etc.)

FIRE DETECTION AND ALARM SYSTEM

Intelligent addressable microprocessor based fire detection

and alarm (FDA) system is envisaged in each plant unit in order to

have an early detection and location details in case of possible fire

outbreak in the plant premises. All the FDA systems will be

monitored from central fire station of the Plant.

WATER SYSTEM

Water is primarily required in the steel plant for equipment

cooling. In addition, it is also used for process use, for collecting

and conveying of scales, control of dust and debris; for drinking

and sanitation; for fire-fighting and for other miscellaneous

purposes.

Water requirement

It is estimated that the total make-up water requirement for

the proposed plant will be 2,040 m³/hr out of which 20 m³/hr will

be soft water, 60 m³/hr will be DM water and 20 m³/hr will be

used for drinking and sanitation purpose.

Total make–up water requirement of 2,040 m³/hr is

considered based on water cooled condenser of the power plants

and wet handling type gas cleaning plant (GCP) for blast furnace.

Out of the estimated make-up water requirement of 2,040 m³/hr,

about 905 m³/hr make-up water is required for proposed

expansion to 1.5 mtpy integrated steel plant and balance 1,135

m³/hr make-up water is required for the power plants.




5−10

Estimated shop-wise break-up of the make-up water

requirement is given in Table 5-1.

TABLE 5-1 – MAKE-UP WATER REQUIREMENT

Sl. No. Consumers Make-up water requirement

Cu m per hour

1. Raw Material Handling System

30

2. Coal washery 15

3. Lime calcining plant 7

4. Oxygen plant 57

5. Sinter Plant 11

6. Blast Furnace including pig casting machine & slag granulation plant

219

7. DR plant 105

8. Steel Melt Shop (SMS-1) consisting of induction furnace, ladle furnace, billet caster

49

9. Steel Melt Shop (SMS-2) consisting of electric arc furnace, ladle furnace, vacuum degassing unit, billet cum bloom caster

329

10. Wire rod mill 74

11. Medium section mill 91

12. Light section mill 36

13. BF TRT power plant 22

14. Surplus BF gas based power plant

168

15. Coal based power plant 1248

16. DM Plant 60

17. Softening Plant 20

18. Drinking & Sanitation 20

19. Fire water 5

20. Miscellaneous Requirement 30

Total

2596

Recovery from treated effluent from the system and reused

556

Grand Total

2040

Note: Blow down/waste effluent from the various water systems will be collected in blow down sump and common effluent plant and the same will be treated and reused for various consumers.




5−11

Source of water

The water source for the proposed steel plant is from river

Sheonath.

The proposed plant is located about 100 m away from the

river. An existing intake pump house had already been constructed

and rising main of 250 mm was laid from the intake pump house to

the plant for supplying water to the existing plant comprising one

(1) no. 500 TPD DR plant.

It is understood from NISL that the existing intake pump

house is not capable to handle additional water requirement. So, a

separate intake pump house will be installed to meet the water

requirement for proposed expansion project. It is also understood

from NISL that at present, withdrawal of about 560 m³/hr water on

a continuous basis is allowed from river Sheonath. Out of the 560

m³/hr water available, 250 m³/hr water has to be delivered by the

existing intake pump house to one (1) no. existing 500 TPD DR

plant. So, remaining 310 m³/hr make-up water can be drawn by

the new intake pump house and delivered to the proposed plant

facilities. NISL will arrange to provide additional 1,730 m³/hr by

obtaining permission from the State Water Resource Department to

meet the requirement of proposed plant.

Plant water system

A raw water reservoir, of 14 days storage capacity, will be

provided within the plant boundary. The requisite quantity of water

will be continuously withdrawn from the reservoir to be treated in

the Raw Water Treatment Plant to makeup water quality.

This grade of water will be supplied as make-up to the

various re-circulating water systems. In addition to this, a portion

of this water will be further treated to produce soft water, to be

supplied as make-up to various close-loop systems, and drinking

water for the plant personnel.




5−12

In order to conserve water to the maximum possible extent,

independent recirculating system with cooling towers, pump

houses and treatment units, wherever required, have been

proposed for the units envisaged for this project. Make-up water of

desired quality will be supplied to each individual recirculating

system. In certain contaminated circuits make-up water will be fed

from blowdown of non-contaminated circuit to conserve water

consumption.

The plant water system comprises make-up water system,

recirculating water systems, drinking water system and water

based fire-fighting system, emergency water supply system for the

vital units of the plant, waste water, effluent and sewage generated

in the plant will also be reused after treatment. Adequate

arrangement will be made for rain water harvesting by collecting

the rain water in the plant.

The schematic water flow diagram for the proposed plant is

given in Drawing No. 11330-05-0001.

The different plant water systems considered in this section,

their respective consumers and broad facilities provided for each

system indicated in Table 5-2 in the next page which reflects a

conceptual water supply scheme for plant water systems.




5−13

TABLE 5-2 – MAJOR WATER SYSTEMS Sl. No.

System

Main consumer/source

Main facilities

1. Make-up water

system Cold wells of various recirculating systems, consumptive and once-through water systems, Softening Plant, DM Plant, etc.

Make-up water storage tank, pumphouse with pumpsets and accessories, raw water treatment plant, distribution pipework.

2. Drinking water

system Plant Personnel and laboratory.

Pumpsets, filters, chlorination unit, overhead tank, pipework.

3. Water based

fire fighting system

Yard/shop hydrant. Motor driven and diesel engine driven pumpsets, storage reservoir of required capacity, ring main, yard and shop hydrant system.

4. Soft water

system Various close-loop cooling systems, By-product plant.

Softening plant with regeneration system, supply pumps and pipework.

5. Coal washery

recirculating system

Contaminated open cooling circuit.

Pumphouses, pumps and associated equipment, settling tank, etc.

6. Lime calcining

plant recirculating system.

Open-loop indirect cooling systems.

Pumphouses, pumps and associated equipment, cooling towers.

7. Oxygen Plant

recirculating system.

Open-loop indirect cooling system

Pumphouse, pumps and associated equipment and cooling tower.

8. Sinter Plant



Pumphouses, pumps and associated equipment, cooling towers.

9. Blast Furnace


Various close-loop and open-loop indirect cooling systems, contaminated Gas Cleaning Plant water system

Pumphouses, pumps and associated equipment, cooling towers, heat exchangers, waste water treatment plant.

10. Slag

Granulation Plant water system


Pumphouses, pumps and associated equipment, settling tank, etc.

11. Pig Casting

Machine recirculating system


Settling tank, sump and pumpsets.




5−14

TABLE 5-2 – MAJOR WATER SYSTEMS (cont’d) Sl. No.

System

Main consumer/source

Main facilities

12. DR plant recirculating system


Pumphouses, pumps and associated equipment, cooling towers, settling tank.

13. SMS-1 consisting of induction furnace, ladle furnace, caster recirculating system

Various close-loop and open-loop indirect cooling systems.

Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant.

14. SMS-2 consisting of electric arc furnace, ladle furnace, vacuum degassing unit, caster recirculating system

Various close-loop and open-loop indirect cooling systems.

Pumphouses, launders, pumps and associated equipment, cooling towers, heat exchangers, flumes, scale pit, pressure filters and waste water treatment plant.

15. Wire Rod Mill recirculating system.

Various close-loop and open-loop indirect cooling system and contaminated direct cooling system

Pumphouses, pumps and associated equipment, cooling towers, flumes, scale pit, settling tank and pressure filters.

16. Medium Section Mill recirculating system.



17. Light Section Mill recirculating system.



18. BF TRT power plant

Condenser cooling and other open-loop indirect cooling systems, DM water Plant.

Pumphouse, pumps and associated equipment, cooling tower, cold well, pipework, DM plant, etc.

19. Surplus BF gas based power plant



20. Coal based captive power plant



21. Effluent Water Treatment system

Waste effluent generated from various shops

Effluent water treatment plant.




5−15

Waste water and effluent treatment management

Waste water generated from the different areas of the plant

will be treated to the desired extent in suitable treatment facilities

and recycled back to the process, to attain “zero” discharge,

facilitating adequate reuse of water in the respective recirculating

systems and economizing on the make-up water requirement.

Sewage generated from toilet blocks, etc., will be collected by

means of suitable sewer system for treatment in package type

Sewage Treatment Plant (STP) and the treated sewage will be

transported to Effluent Treatment Plant (ETP). The blow down from

the indirect cooling water will be collected in a blow down sump.

The water accumulated in the blow down sump will be reused as

make up to low end users such as pig casting machine, slag

granulation plant contaminated open cooling circuit, raw material

handling system and make-up to fire water reservoir. Balance

waste effluent generated from the various units will be treated in

ETP and the treated effluent will be used as make–up in make-up

water system.

Distribution pipework Mild steel or pipes of suitable material of construction are

considered for various units of plant water system. All the

pipelines except fire water line, drinking water line & treated waste

water line will be routed over ground in the yard. Fire water line,

drinking water line & treated waste water line will be routed in

buried condition with necessary corrosion protection. However, for

railway crossing, pipe tunnel has to be considered. Shop internal

pipes with protection-painting will be routed through the building

structure. The pipe-work will comprise all necessary pipes, valves,

fittings and hydrant complete with all other accessories as required

as per relevant standards.




5−16

UTILITY SYSTEM

Fuel system

The by-product BF gas generated i.e. blast furnace gas will

be mixed with LPG/propane and utilised as fuel for various heating

applications of the steel plant. Balance available gas will be

utilised in power plant for steam and power generation.

The major consumers of fuel gas in the steel plant are for

blast furnace stove heating, sinter plant, heating equipment in the

steel melt shop, furnaces in the mills, lime calcining plant and the

boilers. Small quantities of fuel would also be required for the

repair shops, etc.

By-product gas generation: The generation of by-product gas

is given in Table 5-3.

TABLE 5-3 - GENERATION OF BY-PRODUCT GAS

By-product gas Volume Energy N cu m/hr 109 kcal/yr

BF gas .. 268,000 1,823

Availability of by-product gases for power generation

Surplus by-product gases, which will be available after

meeting the plant demands, will be as given in Table 5-4.

TABLE 5-4 – SURPLUS BY-PRODUCT GAS AVAILABILITY (N cu m/hr)

By-product gas Quantity

N cu m/hr BF gas .. 120,000




5−17

LPG/propane manifold

In addition to being used as a fuel, LPG/propane will be

required for cutting operation of the caster. To meet the

requirement of LPG/propane, one (1) no. LPG/propane manifold

system with distribution piping of suitable capacity is envisaged.

Process steam

Process steam required for the plant will be made available

through controlled extraction of the condensing turbine of the

by-product gas fired power plant. Steam network of around 13 kscg

and temperature of 2200C has been envisaged within the plant for

process steam.

Plant and instrument air system

Plant grade compressed air for general service purpose usage

like pneumatic conveying, bag filter pulsing and dry instrument

grade compressed air for the operation of pneumatic devices for

instruments and controls, pneumatic tools, etc., will be required in

each of the production shops and other ancillaries.

Requirement of plant grade compressed air and balance

requirement for dry instrument grade compressed air will be met

from one centralised compressed air station of suitable capacity of

centrifugal compressor, along with required nos. air receivers of

requisite capacities. The pressure of the available compressed air

will be around 7-8 kscg.

Suitable nos. of refrigerated air dryers along with required

nos. air receivers of requisite capacities have been envisaged to

meet the balance oil-free dry instrument grade compressed air

requirement. The pressure of the available dry instrument grade

compressed air will be around 5-7 kscg.




5−18

Air pollution, ventilation and air conditioning

Air pollution control systems: The scheme proposed for

prevention of air pollution is as follows:

- Collection of fumes from deslagging station and argon

rinsing station and discharging them to the atmosphere through stacks after cleaning.

- Removal of dust generated during various operations by

local exhaust systems.

Ventilation systems: The ventilation systems proposed to

achieve desired conditions in different areas are as follows:

- Switchgear rooms, cable tunnel, cable basement, oil and

hydraulic cellars: Mechanical ventilation system using fan-filter units for supply and exhaust fans.

- Compressor Building, transformer rooms: mechanical

ventilation system using exhaust fans. - Production building: natural ventilation by roof monitors

as necessary. Natural ventilation arrangement will be adopted in most of

the production buildings.

Air conditioning systems: The air-conditioning systems are

proposed to be designed to maintain the following condition in the

spaces serviced:

- 25 ± 2 0C dry bulb temperature and 55 ± 5 percent relative humidity for control rooms, control pulpits, computer rooms, PLC rooms, laboratory, etc.

- To meet the above requirement, chilled water based air

conditioning are envisaged throughout the plant. Chilled water plants

Vapour compression type chilled water plant of adequate

capacity are envisaged to satisfy the air conditioning and

ventilation needs of various units. Chilled water inlet and outlet




5−19

temperature will be maintained at 160C and 70C respectively. Ring

mains for both supply and return pipelines will be suitably

provided around the shops.

Overhead yard pipework

The Steel plant will have a piping network for distribution of

the air separation plant products, various utility services, steam,

water, etc. The yard portion of the pipework for all services (except

water) will be laid on towers and trestles with a clear height of 7 m

above finished ground level (FGL). Shop internal pipework will

generally be routed in multiple rows through building columns

taking support from buildings and girders.

Central utility monitoring and control

A centralised control room for utilities and water services will

be located at the Energy Management Centre (EMC) in Fuel

Management building for overall monitoring of critical parameters

of utility systems provided for the new facilities.

AUXILIARY FACILITIES

Laboratories

To meet the analytical and testing needs of the proposed

plant, suitable laboratory facilities will be considered at different

locations in the plant.

Repair shops and stores

Repair and maintenance shops are important units of any

integrated steel plants not only for the manufacturing spares and

replaceable items but also for catering to the capital and running

maintenance requirement of the various units of plant.

It has been envisaged that total repair and maintenance

work of the steel plant including manufacturing operational spares




5−20

will be outsourced to the competent agencies. NISL will provide

the following infrastructural facilities:

- Shop with EOT cranes/hoists

- Open yard, wherever necessary.

- Shop lighting arrangement without light fittings

- Electric power at one point near the equipment/machine

tools for operation

- Portable and industrial water at one point

- Industrial grade compressed air at one point

- Metering facilities for the utility services

Facilities for repair shops and stores: It is envisaged that

the following repair shops and stores will cater to the need of

maintenance services and repair activities:

- Central repair shop,

- Electrical repair shop,

- Mobile equipment repair shop

- General store

- Refractory store

- Alloy store

- Oil and lubrication store

ANCILLARY FACILITIES

Necessary ancillary facilities, such as administrative

building, canteen, car park, cycle and scooter stands, first-aid

station, etc., will be provided based on the manpower requirement

for the plant.

Drainage and sewerage system

Open type drain has been envisaged for the plant storm

water drainage. The drains will be laid generally by the side of the

roads. Storm water run-off, collected through arterial and trunk

drain, will be discharged to the existing river Sheonath.




5−21

Sanitary faecal sewage will be collected from the ablution

blocks through pipeline and the same will be connected to a

sewage treatment plant. The effluent from sewage treatment plant

will be utilized for the development and maintenance of greenery.

Roads

Adequate plant road system will be provided considering the

types of vehicles and the traffic volume. The road system will be

designed to minimize cross movement of vehicles. Adequate vehicle

parking facilities and road weighbridges will be provided.



6-1

6 - ENVIRONMENTAL POLLUTION MITIGATION MEASURES

The proposed project involving the expansion of Integrated

steel plant of NISL to 1.5 MTPA crude steel production, comprises of

coal washery, sintering, iron making, steelmaking, casting and

rolling etc. have been discussed in the previous chapters. This

production would generate wastes in different forms, the recipient

of which would be air, water and land environment causing

pollution of these environmental elements.

This Chapter accordingly outlines the various mitigation

measures in compliance with the prevailing Environment Protection

Acts & Rules and amendments thereof taking into consideration of

the proposed production facilities envisaged for the project.

Review of Pollution Potential

The production from new production units; namely, Sinter

Plant, Coal Washery, Blast furnace, DR Kiln, Lime Calcining Plant,

SMS and the mills. The off gases would be utilized for in-plant use

and power generation. Also power would be generated from BF top

gas heat recovery turbine.

Hence, the project would generate particulate dusts, Volatile

organic compounds (VOCs), Dioxins, Furans, oxides of sulphur and

nitrogen and carbon dioxide to the air environment.

Likewise, there would be generation of waste water due to

enhanced capacities, contaminated with total suspended solids

(TSS), B.O.D, C.O.D, oil and grease etc. which are of major concern

from environment perspective.



6 - Environmental Pollution Control Measures (cont’d)

6-2

The land environment may get disturbed due to generation of

the solid wastes like BF slag, SMS slag, mill scales etc which may

call for other secondary environmental problems.

Proposed Mitigation Measures

In view of the aforementioned plant facilities, there would be

pollution load, for which adequate mitigation measures as described

below have been considered:

Air Pollution Control (APC) Measures

Material Handling Area: There would be fugitive dust

emission from the handling and stockpiling of the added raw

material, which would be controlled by Dry Fog (DF) system. The

raw material handling section is provided with dust suppression

(DS) by water sprinkling at open stockyard. All conveyors would be

of covered types and leak proof to prevent any emission of dusts

during transport of raw materials and products. All closed zone

working areas such as raw materials handling zone, conveyor

transfer points, dust generation points at screen is provided with

multiple dust extraction (DE) systems/dry fogging (DF) at several

emission points to control the fugitive dust emissions. DE system

shall consist of suction load followed by bay filter, ducts, extraction

fans and stack of adequate height.

Coal Washery: In coal washery, the primary air pollution

control measure would dust suppression system (DS). During

conveying the coal, dust emissions from junction house and

discharge points would be mitigated by Dust Extraction (DE)

systems. Other areas would be facilitated with water sprinklers to

minimize suspended dust levels.

Sinter Plant: In Sinter Plant, the principal air pollution

control system is dust extraction (DE) or fume extraction (FE)




6-3

systems and ESPs with stacks of appropriate heights. Stretching of

the capacity of sinter plant would add to the present pollution level,

requiring augmentation of present APC equipments.

Blast Furnace: In addition to cleaning of BF gas in gas

cleaning plant (GCP), which is a process requirement, dust and

fumes emission in stock house and cast house areas would be

controlled by dust and fume extraction (DE & FE) systems

respectively in all the operating BFs.

DR Plant: The exhaust gas from the kiln would be

contaminated with dust particulates, SO2, NOx and carbon. At the

kiln inlet, a dust settling chamber (DSC) would be provided for

allowing the dust to settle before entering the After Burning

Chamber (ABC). The ABC would be provide with additional

combustion air fans for proper burning of the combustibles

contained in the kiln off-gas. The dust collected at the DSC would

be emitted from time to time through a wet scraper, located at the

bottom of the DSC and dispatched to the dumping yard. The DR

Kiln off gas would pass through the Post Combustion Chamber to

burn out CO in the flue gas before it is taken to the Waste Heat

Recovery Boiler (WHRB) for generation of power.

Calcining Plant: The emissions arising due the fuel burning

in lime calcining plant is taken through a bag filter to separate out

the lime fines. The kilns would be provided with separate DE

systems, complete with bag filters and stack of adequate height.

EAF and IF: The primary emissions would be extracted by

fume extraction (FE) system. Fumes would be indirectly cooled and

cleaned through a bag filter for separation of particulates and the

clean gas would be vented into the atmosphere through a tall stack

of adequate height. The secondary emissions would be controlled

through canopy hood extraction, integrated with the main system to




6-4

clean the fugitive emissions during charging and tapping

operations. The gas cleaning system would be complete with water

cooled duct, fume & gas cooler, bag house, ID fan and stack of

adequate height.

LF: The primary emissions extracted from the LF area

collected by fume extraction (FE) devices. Dust laden fumes are

indirectly cooled and cleaned through a bag filter for separation of

particulates and the clean gas is vented into the atmosphere

through a tall stack of adequate height.

Mills: The reheating furnaces are incorporated with low NOx

burner and controlled combustion would take place. The flue gas,

which is fairly clean, is vented through a stack of adequate height.

These pollution control measures would be carried on and

additional APC measures would be adopted as per requirement.

Water Pollution Control (WPC) Measures: The source water

for the plant would be the Sheonath river which is situated adjacent

to the plant. The wastewater from various units would be treated in

the Common Effluent Treatment Plant (CETP) to make it suitable for

recycling to the plants direct make up water circuit.

Three different types of process effluent streams would be

generated from the steel plant complex.

For Type-I effluent streams, mostly physico-chemical

treatment schemes like oil separation, settling, clarification, pH

adjustment etc, would be employed.

Type-II effluent, CT blow downs would be taken to the treated

waste water storage reservoir for recycling purpose after treatment

in the CETP.




6-5

Type-III effluent, which is plant sanitary wastewater, would

be separately treated in a sewage treatment plant before the same is

also routed to the treated effluent storage reservoir.

Zero Discharge Concept

In order to have a ‘near zero discharge’ of the proposed plant,

the CT blow down along with all other primary treated wastewater

streams with high TDS levels may be further subjected to Reverse

Osmosis (RO) treatment to reduce the TDS levels and the residual

oil & grease, BOD and COD levels, so that this treated waste water

as RO permeate can be added to the plants make up water circuit.

Work Zone Pollution Control Measures

The work zone pollution would be mostly fugitive dust, heat

and noise. The fugitive dust emission would be controlled by DS

and DE system as described earlier.

All the process vessels would be lined with adequately thick

refractory bricks to contain the surface heat emission and in some

cases they would be indirectly cooled by water. In addition to this,

there would be provision for adequate ventilation of the closed zone

work environment.

Noise arising from the mechanical machineries like crushers,

screens, compressors, blowers, pumps etc can not be ruled out.

Such noise-prone equipment would be installed in a separate

housing so as to enhance the noise attenuation. Isolation of the

operational staff from the high noise prone zone would be adopted

by providing noise proof control room so that they are not exposed

to the noise level exceeding the allowable limit.




6-6

Solid Waste Generation and Utilization

There would be generation of solid by-products like BF slag,

EAF slag, LF slag, IF Slag, mill scales, caster scrap, refractory

debris, flue dusts, coal washery rejects etc from the proposed

project. It is estimated that the proposed expansion would

generated nearly 2.1 MTPA solid wastes comprising mainly of BF &

EAF, IF & LF slags, dusts, etc.

TABLE 6-1 - SOLID WASTE GENERATION 1.5 MTPA STAGE

Sl. No. Solid By-product

Expected generation at 1.5 MTPA crude steel

stage, TPA

1. BF slag 453,900 2. EAF slag 265,300 3. IF slag 13,400 4. LF slag 19,600 5. Dust, mill scales and

sludges 58,100

6. Coal Tailings 451,500 7. CPP Ash 993,693

BF slag would be required to be granulated before it is sold

off. The flue dusts, mill scales and scraps would be recycled to the

Sinter plant and SMS. EAF and IF slag would be processed for

metal recovery and also partly recycled in Sinter Plant, EAF and IF.

The non metallic part would be used for various construction

purposes. Coal middlings/reject from the washery would be reused

in the power plant. CPP ash would be disposed in an earmarked

area.

Plant Safety

Plant safety measures would be an integral part of the

environment protection plan of the proposed plant. Workers’ safety

would be of highest degree of concern as required by the Factories

act-1948 and OSHAS 18001-2007 so as to avoid any personal

injury or untoward incident. In-built safety measures of the plant




6-7

and machinery would be made adequate in order to avoid

hazardous events causing damage to the life and property.

Plant Greenbelt and Landscaping

As per the recent regulatory requirement, 33% of the plant

area has to be reserved for peripheral greenbelt, gardening and tree

plantations. This would not only prevent the fugitive dust emissions

but also improve the plant peripheral appearance from aesthetics

view point. This would be considered while planning for the

expansion facilities.

Design Targets for Environmental Protection

The proposed mitigation measures would be adopted the

following design targets:

I. Stack emissions

Particulate matter : 50 mg/N cu m SO2 emission : 500 mg/N cu m NOx emission : 500 mg/N cu m II. Wastewater discharge

Temperature : Ambient pH : 5.5 to 9 Total Suspended Solids : < 100 mg/l BOD3 (270C) : < 30 mg/l COD : < 250 mg/l Oil and grease : < 10 mg/l Iron (as Fe) : < 3 mg/l

III. Workzone Environment

Exposure to Dusts : 3 mg/cu m (max) in a closed environment 500 mcg/cu m (max) in an open environment within

20 to 30 m aerial coverage Exposure to Noise : Leq 85 dB(A) for a continuous period of 8 hours exposure




6-8

Environmental Monitoring

While design and engineering of the plant, the principal

pollution sources like BF, EAF, IF, DR Kilns and captive power

plant stacks would be provided with on-line monitoring device for

routine monitoring of pollutants like TSP, SO2 and NOx. In addition,

conformance to the ambient air and waste water discharge

standards would also be monitored.



7-1

7 – IMPLEMENTATION SCHEDULE

This chapter deals with the construction aspects of

project-overall construction schedule and construction facilities for

implementation of the project are also presented in this chapter.

IMPLEMENTATION SCHEDULE

The preliminary overall implementation schedule for the

project, indicating the time required to complete the major

activities like engineering, construction, procurement of

equipment, erection, testing/trial run and commissioning and hook

up of the various plant facilities is shown in the form of a bar chart

in Fig. 7-1 on the following pages.

It is envisaged that the project will be completed within a

period of 36 months from “Go-Ahead date”.

The schedule has been developed on the basis of the

estimated quantum of work, expected delivery and installation

periods of plant and equipment and the need to commission the

plant facilities in the shortest possible time. Scheduled

commissioning of the plant can only be achieved if construction,

delivery and erection periods, as shown in the bar chart, can be

met by respective suppliers and contractors.

Completion time of major Plant units:

Coal washery .. 24 months DR plant .. 30 months

Sinter plant .. 30 months Calcining plant .. 25 months Blast furnace .. 30 months SMS-1 .. 30 months SMS-2 .. 36 months Rolling mills .. 36 months Captive power plant .. 25 months



7 – Implementation schedule (cont’d)

7-2




7-3




7-4



8-1

8 – CAPITAL COST ESTIMATE

The order of magnitude estimates of capital cost for this

capacity augmentation is presented in this chapter. The estimates

are based on the information available with CONSULTING

ENGINEERS for similar projects. The estimates are based on price

levels, taxes & duties and exchange rates prevailing during

2nd quarter 2014-15.

CAPITAL COST ESTIMATE

The estimate of capital cost includes plant cost, preoperative

expense, working capital margin and interest during construction

(IDC). The plant cost comprises the costs of plant & equipment (as

erected) together with the cost of pollution control, design,

engineering, consultancy and administration during construction

and contingency.

Plant cost

The plant cost consists of the following components:

Plant and equipment (as erected): It includes cost of plant

and equipment and civil and structural. Additionally, taxes, duties,

transportation and erection (on normative basis) have been

considered to arrive at the cost of plant and equipment (as

erected).

Pollution control equipment: It includes the cost towards

air pollution control, water conservation, energy conservation etc.

A provision has been made at 10 per cent of the project cost.



8 – Capital cost estimate (cont’d)

8-2

Design, engineering, consultancy, administration during

construction (DE and ADC): A provision has been made at 5 per

cent on the supply cost of plant and equipment including civil,

structural and erection.

Contingency: A contingency provision has been made at 5

per cent on the plant cost towards unforeseen items. Forward

escalation and exchange rate variation are not included in the

above provision.

INTEREST DURING CONSTRUCTION

Interest during construction (IDC) has been calculated based

on the following:

- Implementation period of 36 months for the project - Interest rate at 12 per cent per year

Based on the above, capital cost estimated for the project

works out to about Rs.10,834 crore. About 7-9 per cent of the

total plant cost has been kept for environment management

measures.

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