PRE FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/05...Vide Memo No....

Salagram Power and Steel Pvt. Ltd.

Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Mirzapur, PS + District: Bardhaman, West Bengal

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Pre-feasibility Report 0

PRE FEASIBILITY REPORT

FOR

PROPOSED INSTALLATION OF SPONGE IRON PLANT (1x350 TPD), WHRB

(1x35 TPH), INDUCTION FURNACE (1X7 T), HOT ROLLING MILL (1,00,000

TPA), SINTER PLANT (35 TPD), SUBMERGED ARC FURNACE (2x4.5 MVA)

AND TG SET (1X8 MW) UNDER FORWARD INTEGRATION, EXPANSION AND

PRODUCT DIVERSIFICATION PROGRAMME OF EXISTING MINI STEEL PLANT

AT

Palitpur Road, Village & P.O. Mirzapur,

PS + District: Bardhaman, PIN -713102, West Bengal

PROJECT PROPONENT:

SALAGRAM POWER AND STEEL PVT. LTD. 29 Ganesh Chandra Avenue, 1st Floor,

Kolkata-700 013

DECEMBER, 2017



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CONTENTS

1.0 INTRODUCTION

2.0 THE PROJECT

3.0 INDUSTRY SCENARIO

4.0 LAND AND SITE LOCATION

5.0 MAJOR PLANT UNITS AND AUXILIARY UNITS

5.1 Sponge Iron Plant

5.2 Induction Furnace

5.3 Continuous Casting Plant

5.4 Rolling Mill

5.5 Sinter Plant

5.6 Submerged Arc Furnace

5.7 Power Plant

6.0 RAW MATERIALS, CHEMICALS & UTILITIES

6.1 Raw Materials

6.2 Fuel

6.3 Water

6.4 Other Utilities

6.5 Power



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7.0 ENVIRONMENTAL ASPECTS

7.1. Air Pollution Control

7.2 Water Pollution Control

7.3 Solid Waste Management

7.4 Noise Pollution Control

8.0 FIRE PROTECTION SYSTEM

9.0 GREEN BELT DEVELOPMENT OBJECTIVE

10.0 RAIN WATER HARVESTING

11.0 MANPOWER REQUIREMENT

12.0 PROJECT SCHEDULE

13.0 FINANCIAL DETAILS

14.0 CONCLUSION



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PRE-FEASIBILITY REPORT

1.0 INTRODUCTION

M/s Salagram Power and Steel Pvt. Ltd. (SPSL), a Private Limited Company, was

incorporated on September 29, 2011, having its registered office at 29, Ganesh Chandra

Avenue, First Floor, Kolkata - 700013.

The Company was previously known as M/s SHYAM SEL & POWER LIMITED under

Shyam Group of Industries. Shyam Group was subsequently demerged.

Vide Memo No. 1983-7/WPBD-Cont(752)/99 (Pt.-II) dated 03.10.2016, West Bengal Pollution

Control Board has recorded change of Name of the Company as SALAGRAM POWER

AND STEEL PRIVATE LIMITED (SPSL) for the existing Mini Steel Plant at village Mirzapur,

Bardhaman. Mirzapur Village is about 5 Km away from Burdwan Town.

Vide Consent Letter Number CO 100575, Memo Number 1212-7/WPBD-Cont.(752)/99 dated

29.06.2016 (and also Memo on Renewal of Consent to Operate dated 27.06.2014 and Memo

on Change of name and correction of capacity dated 03.10.2016), WBPCB has granted the

Company (SPSL) “Consent to Operate” for 3 years (from 01.07.2016 till 30.06.2019) this

Existing Mini Steel Plant having DRI Kilns (3 x 50 TPD producing 45,000 TPA Sponge Iron),

Induction Furnaces (1x4 T, 2x3.5T and 1x6 T producing 56.000 TPA liquid steel), one Twin

Strand Billet Caster (54,000 TPA MS Billets), WHR Boilers (3x4.5 TPH), one AFBC Boiler

(1X24 TPH) and Power Plant (1x8 MW TG Set).

Salagram Power and Steel Pvt. Ltd. is promoted by Mr. Pawan Kumar Agarwal, Mrs.

Santosh Devi Agarwal and Mr. Suyash Agarwal.



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2.0 THE PROJECT

To take full advantage of improved market scenario in near future as projected by the

Industry, SPSL intends to undertake forward integration, expansion and also product

diversification of the Mini Steel Plant.

Existing Process Route of DR-IF-CC (Direct Reduction – Induction Furnace –

Continuous Casting) will be adopted for rationalization and ease of operation by existing

manpower, which has already gained adequate skill and experience to operate these units.

Additional manpower of required skill will be employed for operation and maintenance of all

units under expansion.

The Company is contemplating forward integration to produce TMT Bars and Rods, Flats and

Structurals. It is proposed to install a Hot Rolling Mill of 1,00,000 TPA capacity.

About 1,05,000 TPA of MS Billets will be required for production of above quantity of

1,00,000 TPA TMT bars and rods. Existing 6/11 m Twin Strand Billet Caster is having

adequate in-built capacity to produce 1,05,000 TPA MS Billets. No additional Billet Caster is

therefore envisaged under expansion.

About 1,10,000 TPA liquid steel (which is almost double of existing capacity) will be required

for production of 1,05,000 TPA MS Billets. To meet above liquid steel demand, it is proposed

to expand Steel Making Capacity by installing one No. 7 T Induction Furnace in addition to

modernization / up gradation of existing 4 Induction Furnaces to higher capacity (3x 7 T +

1x6T) as indicated by Equipment Suppliers.

Sponge iron is a major feed material for Induction Furnace Steel Making and constitutes

about 80% of Charge Mix. Sponge Iron requirement will be about 1,00,000 TPA for

production of 1,10,000 TPA liquid steel. The Company presently operates 3 Nos. 50 TPD

DRI kilns to produce 45,000 TPA Sponge Iron. To meet requirement of Sponge Iron for

enhanced Steel Making Capacity under expansion and also additional quantity for Sale, 1

No. of standard sized 350 TPD DRI Kilns will be installed. This will ensure adequate steam

from WHRB for 8 MW Power Generation. Total Capacity of Sponge Iron after expansion will

be 1,50,000 TPA. After meeting the requirement of 1,00,000 TPA Sponge Iron for steel

making, 50,000 TPA Sponge Iron will be available for Sale in Domestic Market improving

Plant Economics.

Existing 8 MW TG Set of Power Plant is designed based on steam generated in 3 WHRB

utilizing waste hot flue gases of DRI Kilns and AFBC Boiler burning Char / Coal / Husk. Char



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generation in existing DRI Kilns being insufficient to meet steam balance, the Company has

to purchase costly fuel (Coal / Husk) for existing AFBC Boiler.

Proposed 1x350 TPD DRI Kilns will be designed with one WHR Boiler (1x35 TPH).

All Char generated in 4 DRI Kilns (3 existing and 1 proposed) will be utilized in the existing

AFBC Boiler.

Total Steam generation from existing and proposed WHR Boilers and existing AFBC Boiler

will be about 72.5 TPH. Above steam will be sufficient to generate 16 MW of Power. It is

therefore proposed to install an additional 1x8 MW TG set in the expansion stage increasing

Captive Power Plant Capacity to 16 MW.

It is further proposed to diversify into production of Silico Manganese (Si-Mn) by installing

2x4.5 MVA Submerged Arc Furnace (SAF). In these SAF it will be possible to produce Ferro

Chrome (Fe-CR) depending on Market Demand.

To utilise fines generated during handling of coal and iron ore lumps / iron ore pellets (raw

material feed to DRI Kilns), a 35 TPD Sinter Plant will be installed. Dust recovered from Bag

Filters & ESP of DRI Plant and scales from CCP & Rolling Mill will also be utilised in Sinter

Plant. Sinter produced will form a part of the Charge Mix to SAF.

SPSL has rightly decided to expand the capacity of the Plant by installing additional Sponge

Iron Kiln (1x350 TPD), WHR Boiler (1x35 TPH Steam), modernization / up gradation of

existing Induction Furnaces, one additional Induction Furnace (1x7 T), one Rolling Mill

(1,00,000 TPD) for forward integration, one Sinter Plant (35 TPD), two Submerged Arc

Furnaces (2x4.5 MVA) producing Ferro Alloys for product diversification and a TG Set (8

MW).

Existing CCM is having adequate in-built Capacity to produce 1,05,000 TPA Billets required

in Rolling Mill to produce 1,00,000 TPA TMT Bars, rods etc.

All existing Service Facilities will be suitably augmented as well as additional Service

Facilities are proposed to be installed to meet the requirement of the Mini St.eel Plant after

Expansion.

Configuration of Major Existing Units and Units under Expansion is indicated in Table 2.1



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CONFIGURATION OF MAJOR UNITS OF THE PLANT: TABLE 2.1

*Present Production Capacity is as per WBPCB’s Memos.

Sl. No.

Existing Units Present Production

Capacity

Proposed Units under Expansion

Total Production

Capacity after Expansion

Product (For Sale)

1. 3x50 TPD Sponge Iron

Kilns

48,000 TPA * Sponge Iron

1x350 TPD Sponge Iron Kiln

500 TPD or 1,50,000 TPA

Sponge Iron (50,000 T/Y)

2.

1x4 T, 2x3.5 T and 1X6 T Induction Furnaces

56,000 TPA Liquid Steel

1x7 T Induction Furnace

and modernization / up gradation of

existing Furnaces to augment capacity (to

3x7 T + 1x6 T)

1,10,000 TPA

Liquid Steel (Nil)

3.

6/11 m, 2 Strand Continuous

Casting Machine

54,000 TPA * MS Billets for sale -100x100 mm, 125x125 mm & 160x160

mm

Nil

1,05,000 TPA (existing CCM is having In-

built Capacity)

MS Billets

(Nil) Nil)

4.

Nil

Nil

1 No. Hot Rolling Mill

1,00,000 TPA

TMT Bars, Rods, Flats

and Structurals

(1,00,000 T/Y)

5.

Nil

Nil

1x 35 TPD Sinter Plant

10,500 TPA (to be used as part of Charge

Mix of SAF)

Sinter (Nil)

6. Nil

Nil

2x4.5 MVA Submerged Arc Furnaces (SAF)

12,960 TPA

Silico - Manganese /

Ferro - Chrome

(12,960 T/Y) 7. 3XWHR Boilers 3x4.5 TPH 1XWHR Boiler

(1x35 TPH) 48.5 TPH

Steam (Nil)

8. 1x AFBC Boiler 1x24 TPH Nil 24 TPH

Steam (Nil)

9. 1x 8 MW TG Set for Captive Power Plant

8 MW

1x8 MW TG Set

16 MW

Power (Nil)



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Adequate Pollution Control Facilities will be installed to conform to Pollution Norms.

SPSL is having 25.8 Acres of land in their Possession. The proposed expansion will be

accommodated within the existing Plant Boundary and also some adjoining land

(approximately 3.0 Acres) which will be acquired. The land is generally flat and does not

come under flood zone. There is no human settlement in the project site. Adjoining land (to

be acquired) will be reformed / developed from its existing land use.



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3.0 INDUSTRY SCENARIO

Indian steel industry is the major backbone in the country’s economic growth.

According to Joint Plant Committee (JPC), Ministry of Steel, Govt. of India, India produced

about 95.6 Million Tonne of Crude Steel in 2016 and remained, for two consecutive years,

Third Largest Crude Steel Producer in the World after China (808.4 MT) and Japan (104.8

MT). In 2016, the world crude steel production reached 1628 million tonnes and showed a

growth of 0.8% over 2015.

Demand-Supply Gap

On a conservative estimate, the steel demand in India is expected to touch around 150

MTPA by 2020. Steel supply is, however, expected to reach only around 145 MTPA by same

time.

World Steel Association has projected Indian steel demand to grow by 5.7% in 2017 while

globally steel demand has been projected to grow by 0.5% in 2017

The National Steel Policy 2017 has been formulated keeping in mind the rapid developments

in the domestic steel industry (both on the supply and demand sides) as well as the stable

growth of the Indian economy. The National Steel Policy 2017 aims to achieve 300 million

tonne of steel-making capacity which will require an additional investment of Rs 10 lakh crore

by 2030-31 setting a target of 160 kilograms per capita steel consumption by 2030. In

comparison, per capita finished steel consumption in 2015 is placed at 208 kg for world, 489

kg for China and only 61 kg for India.

As a facilitator, the Government monitors the steel market conditions and adopts fiscal and

other policy measures based on its assessment. In view of rising imports, the Government

had earlier raised import duty on most steel items twice, each time by 2.5% and imposed a

gamut of measures including anti-dumping and safeguard duties on a host of applicable iron

and steel items.

The liberalization of industrial policy and other initiatives taken by the Government

have given a definite impetus for entry, participation and growth of the private sector

in the steel industry. This had led to expansion, forward integration, diversification and

modernization of existing units.



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The Cabinet also cleared another policy which will mandate giving preference to iron and

steel products that are manufactured in India for all government tenders. At least 15 percent

value has to be added to the notified steel product in India to qualify as domestic steel.

There is a distinct relation between steel consumption and the GDP growth rate world over.

In India, GDP is expected to remain a figure of above 7% in Current and Next Financial

Years while it is expected to touch thereafter Double Digit Figures of 11-12%. This will be

possible with National Focus on Large Infrastructure Development with huge Investment and

India is bound to witness sustained growth in the steel requirement in the years to come.

India will emerge as the Second Largest Producer of Crude Steel in near future.

It is foreseen that there will be sufficient demand in local/Indian Market of Sponge Iron

for Steel Making, TMT Bars and Rods for constructional needs and Silico Manganese

for Steel Making.

M/s SPSL has drawn up a growth plan with the objective of increasing its market share in

Indian steel industry. Keeping all these in mind, the Company has planned expansion,

forward integration and diversification of the existing Mini Steel Plant in a effective

environment friendly way.



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4.0 LAND AND SITE LOCATION

The Plant is located at Palitpur Road in Village & P.O. Mirzapur, Saraitikar Gram Panchayat,

P.S.& Dist. Burdhaman, West Bengal, Pin – 713102. Its graphical coordinates are Latitude

23°17'09.25" N and Longitude 87°52'09.76" E with mean sea level as 107 ft.

The Plant is located adjacent to and at the west side of M/s Shyam Ferro Alloys on Palitpur

Road. Plant location is indicated in subsequent Maps and satellite Pictures.

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Pic. 1 - Burdwan District Map

Pic.2 – Satellite Picture showing Burdwan Railway Station and Palitpur



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Pic. 3 – Satellite picture showing Dewandighi and Palitpur Road

Pic. 4 – Satellite Picture showing Dewandighi, Palitpur Road and Shyam Ferro Alloys

Bardhaman Town (District H.Q.) is about 4.5 km from project site. Burdwan Railway Station

is about 4.3 km from the Plant Site. National Highway-2 (NH-2) is passing through the south

direction, at a distance of around 4.0 km away. River Damodar is passing approx. 7.5 km



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distance in south direction. There is no National Park & Reserve Forest within 10 km radius

of the project site.

The Plant Site Area is well developed and has all necessary infrastructure facilities such as

motorable road up to the plant site, nearness to rail head, Power lines and Sub Stations,

telephone facilities etc.

The nearest industrially developed town Durgapur is situated at around 60 km away in the

north-west direction. Kolkata city is located at a distance of about 95 km from the Plant.

Distance from Howrah Railway station to the plant site is about 92 km. The nearest airport is

Kolkata which is about 93 km from the plant site. Kolkata Port is around 95 km away and

Haldia Port is 135 km away from the plant site.



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5.0 MAJOR PLANT UNITS AND AUXILIARY UNITS

5.1 SPONGE IRON PLANT

As already indicated earlier, one (1) Sponge Iron Rotary Kiln, having a capacity of 350 TPD,

will be installed for production of 1,05,000 TPA sponge iron. With this expansion measures,

Production Capacity of Sponge Iron will be increased to 1,50,000 TPA. The Charge Mix of

Induction Furnace for steel making consists of Sponge Iron (80%) and Scrap / Pig Iron

(20%). After meeting internal demand for steel making, about 50,000 TPA of Sponge Iron

will be available for Sale.

Manufacturing Process

In the Existing Plant, Sponge Iron is produced through well established Non Coking Coal

based Technology in Rotary Kilns. Same Technology will be adopted for Expansion. Iron ore

lump/ pellet will be reduced with non coking coal in rotary kilns to produce sponge iron.

The rotary kiln used in Sponge Iron Making Process functions as:

a conveyor of solids

a vessel for carrying out complex chemical reactions

a heat exchanger

From Day Bins, metered quantity of Iron Ore lumps ( 5-18mm) and Iron Ore Pellets (12 mm

MPS) along with Coal (3-20 mm) and Dolomite (- 6 mm) are conveyed at the feed end of the

Rotary Kiln and fed into the preheated kiln through a feed pipe mounted through the feed end

housing. Because the rotary kiln is inclined from the feed end to the discharge end, its rotation

causes the feed material mix to traverse downward towards the exit. The rotational speed of the

rotary kiln can be adjusted to maintain the desired loading of the kiln and ensuring the required

time to complete the reduction of the iron ore.

Inside the bed of Charge Mix in rotary kiln, CO gas is generated from coal at around 950°C.

The CO reacts with Fe2O3 in iron ore lump / pellet and reduces it to metallic Fe. Shell air fans

are mounted on the kiln Shell, which inject air in controlled manner into the kiln for creating

reducing atmosphere and also to generate heat. The kiln is lined with refractory for sustaining

high temperature at desired level (up to 1050°C) in different points of preheating and

reducing zones of the rotary kiln. Coal fines are pneumatically injected into the kiln from

discharge end to keep desired temperature profile and carbon balance at different zones.



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Main reduction reactions in Rotary Kiln are:

Fe2O3+CO=FeO+CO2

FeO+CO=Fe+CO2

C+CO2=2CO

2CO+O2=2CO2

C+O2=CO2

Iron Ore reducing reactions are endothermic in nature. This heat requirement is met by

combustion of over bed gas which heats up the refractory lining as well as the bed surface.

Tumbling of material transfers the heat from the surface particles to the bed. The hot kiln wall

which enters the bed also releases its heat to the bed. By the end of its travel through the

Rotary Kiln (about 8 hours), iron ore is metalized to about 90% and falls through a transition

chute into the Rotary Drum Cooler at about 1000°C.

The Cooler is an inclined steel cylinder. The cooler shell is sprayed with water. The water

serves as the indirect coolant of the sponge iron. Heat from the product is conducted through

the cooler shell to water. The water is collected in a trough beneath the cooler and is re

circulated through cooling tower and pump house. The product gets cooled to 150°C at the

outlet of cooler. The cooled product will be conveyed to the product processing building by a

system of belt conveyors.

Product Separation

The sponge iron along with unburnt coal in the form of Dolo Char comes out of the cooler. The

cooled product is subjected to screening and magnetic separation to separate magnetic product

and non-magnetic Dolo Char. Sponge Iron Lumps and fines are stored in their designated

product bins. Bypass arrangement will be provided at discharge end of the cooler for

emergency discharge of materials.

The gases generated in the rotary kiln flow counter current to the flow of solids and exit the

reactor at the feed end. The gases leave the reactor at about 800-850o C through reactor

feed end housing. The flue gas that contains coal volatile matter, fine carbon particles, iron

ore fines and sponge iron dust is treated separately in the waste gas handling system before

releasing through the Chimney to the atmosphere ensuring environmental norms.



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In-plant de-dusting system

Reverse air jet bag filters shall be installed for catching the dust from various conveyors,

material handling equipment and-product handling equipment.

Raw Materials

The main raw materials for sponge iron production are iron ore lump / pellet, non-coking coal,

and dolomite. The specific consumption and annual requirement of these raw materials for

1,50,000 TPA Sponge Iron from existing 3x50 TPD Kilns and proposed 1x350 TPD Kilns are

shown in Table 5.1

ANNUAL REQUIREMENT OF RAW MATERIAL FOR SPONGE IRON PLANT: TABLE 5.1

The iron ore lump/pellet should have Fe - 65%, SiO2+Al2O3 -5%, Sulphur – 0.01%,

Phosphorus -0.05%; Tumbler Index of Iron Ore – 90%.

Non Coking Coal should have high reactivity, FC – 45%, low ash content (20% max.),

medium volatile matter (25-30%), high ash fusion temperature (1400°C), low Sulphur (less

than 1%) and low caking index (3% max.).

Dolomite is used as desulphuriser to fix Sulphur present in coal and should have MgO – 22%

minimum and CaO – 28% maximum.

Product characteristics of coal based Sponge Iron is as follows:

Sl. No.

Raw material

Specific

Consumption

T/T

Quantity in TPA

1. Iron Ore Lump/Pellet 1.5 2,25,000

2. Coal 1.0 1,50,000

3. Dolomite 0.03 4,500

Item Value

Fe (total) 92% min

Fe (met) 83 % max

Metallization 90 %



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Major plant facilities

The major plant facilities for the sponge iron plant envisaged are as follows:

1. Day Bins

2. Rotary Kiln and Cooler

3. Off-gas System including WHRB

4. The Water Circuit

5. Product Processing and Storage.

Day bins

There shall be a day bin building to cater to raw material requirement of the kiln. These bins

will generally have storage of about one day’s requirement of iron ore lump/pellet, feed coal

and injection coal & dolomite. Weigh feeders will be provided to draw the required quantity of

various materials in proportion from the bins and the same will be conveyed to the kiln feed

and discharge end Buildings.

Rotary kiln and cooler

The 350 TPD Rotary Kiln with 4.2 m diameter and 72/76 m long will be installed. The kiln will

be lined with abrasion resistant refractory castables throughout its length with dams at feed

end and discharge end.

The rotary kiln will be supported on 3 piers. A slope of about 2.5% shall be maintained. The

main drive of the kiln will be by D.C dual drive. The speed of the kiln will be in the range of

0.25-0.75 rpm. There are two auxiliary drives which are powered by DG Set.

Rotary Kiln is mounted on tyres and supported by support rollers. The transverse motion of

the Kiln is controlled with the help of hydro thruster and thrust rollers. The kiln is rotated with

the help of a girth gear mounted on the kiln and connected with pinion drives, which in turn

are coupled with gear boxes and motors.

Carbon 0.25 % max

S 0.025% max

P 0.05% max



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

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

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

c. On board equipment like fans, slip ring, instrumentation etc. d. Cooling fans at feed end and discharge end. e. Feed end double pendulum valve & dust valves.

Rotary Drum Cooler of 3.4 m diameter and 46 m long will be installed. Coolers will be

supported on 2 piers and will have a slope of 2.5% and is rotated at variable speed of 0.7 to 1

rpm with the help of a girth gear mounted on the cooler and connected with single pinion

drive, which is coupled with a gearbox and an AC motor with VVVF drive. An auxiliary drive is

provided to rotate the cooler in case of emergency.

To facilitate conduction of heat from hot product through Cooler to Cooling Water (sprayed on

to Cooler Shell), lifters are provided inside the cooler.

The cooler shell is perforated up to a certain distance from the discharge end to form a

trommel inside the discharge end housing. The trommel serves to screen the normally sized

product from over-sized lumps or fused materials which may have been formed in the rotary

kiln during processing. Some quantity of accretion material/aggregate comes out of the Kiln

into the Cooler. These are separated from the product at the trommel and stored at the lump

gate. This lump gate is opened time to time for discharging.

Off-gas System

The Off-gas System consists of:

(a) Feed End Housing and Dust Settling Chamber (DSC) – Coarse dust particles

from waste flue gases, coming out of the Rotary Kiln, is settled in DSC.

(b) After Burning chamber (ABC) - Air is blown by Fans into the ABC for converting

any un-burnt CO (in waste flue gases) to CO2. Water is injected in ABC to control

temperature rise.

(c) Auxiliary Stack and Stack Cap – These are provided in the off gas circuit to

evacuate the Kiln off gases in case of any failure of equipment in the downstream

side after ABC. Normally the cap will remain closed. The stack cap is opened

through a hydraulic power pack either from operator’s desk in control room or from

local control panel as per requirement.



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(d) Waste heat recovery boiler (WHRB) – Latent heat of waste flue gases is utilised

to produce steam for power generation. Gases are then passes to ESP at 200°C

(e) Electrostatic precipitator (ESP) – Fine dust particles gets electrically charged and

is deposited in electrodes. Clean waste gases are then let out to the atmosphere

at around 80°C.

(f) ID fan –Creates required draft in the Kiln and forcing clean waste gases to

atmosphere through a chimney. The motor of ID Fan is provided with necessary

control system to vary the Draft as required.

(g) Chimney – The height of Chimney will conform to Environmental Norms.

The Water Circuit

Make up water will be available at the battery limit of the plant to provide water for the following

circuits. :

a) Rotary cooler water circuit

b) Kiln bearing cooling water circuit

c) Dust Handling System

d) Off Gas Circuit.

e) Misc. Equipment like compressor, DG etc.

Product Processing and Storage

There shall be one product processing unit for handling the cooler discharge. The product

containing sponge iron and dolochar from the cooler discharge will be conveyed to the

product processing building. The product will first be screened in a double deck screen

having 3 mm and 10 mm screens. +10 mm materials shall be passed through magnetic Drive

Pulley of the Belt conveyor to separate non-magnetic particles. The screened product i.e. +3

– 10 mm and -3 mm fraction shall be separately subjected to magnetic separation for

removal of dolo char. Magnetic Product will be sent to the product storage bins and fines

bunker. The sponge iron lump and fines will be further conveyed from the respective bunkers

by truck to the steel making unit as per the requirement.

The dolo char shall be stored in separate bins from where it will be sent to the existing AFBC

Boiler for generation of steam for Power Plant.

Typical Process Flow Diagram of Sponge Iron Plant is presented below.



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I.Coal – Injection Coal; DSC – Dust Settling Chamber; ABC – After Burning

Chamber; WHRB – Waste Heat Recovery Boiler; ESP – Electro Static Precipitator;

ID Fan – Induced Draft Fan; TG Set – Turbo Generator Set; MS -Magnetic

Separator; PB 1 – Product Bunker for Sponge Iron Lumps; PB 2 – Product Bunker

for Sponge Iron Fines; PB 3 &

PB 4 – Bunkers for Dolo Char

5.2 INDUCTION FURNACE

In addition to the existing 4 Nos. 7 T Induction Furnaces, it is proposed to install one (1) more

7 T Induction Furnace under expansion. With installation of above, Steel Making Capacity of

the Plant will increase from present 54,000 TPA to 1,10,000 TPA Liquid Steel. Liquid Steel

will be cast into MS Billets (100x100mm, 125x125 mm & 160x160 mm) in the existing 2

Strand Billet Caster which has sufficient in-built capacity to produce 105,000 TPA MS Billets.



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The process flow sheet for steel making and continuous casting is shown below.

Steel Making by Induction Furnace

Induction Furnace (IF) is used for melting of metals and holding it in liquid condition.

Due to improved reliability and technological advancement of power electronics, Inverters

are now available at economical rate and application of Induction Furnace has spread widely

for Steel Making.

Melting the Charge

Sponge Iron (80%), Pig Iron and Scrap constitute major raw material for steel making in the

induction furnace. This is because elimination of some element from the molten steel is

difficult in an induction furnace melting. In the case where these are present in high

quantities, a secondary metallurgical unit (Ladle Refining Furnace etc.) is required to refine

the metal up to a desired extent. The only exception is phosphorus, when present in the



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molten metal cannot be eliminated even with the help of a secondary refining unit and thus

procurement of the appropriate kind of raw material is of utmost importance in Induction

Furnace melting practice.

The charge should be compact. It should consist of good quality sponge iron mixed with

clean turnings, pig iron and a moderate amount of heavy melting of commercial grade scrap.

This is to provide the initial conditions of a high flux path through the charge for facilitating

generation of heat and commencement of melting.

The process for manufacturing steel in IF may be broadly divided into the following stages:

i) Melting the charge mix and

ii) Ladle teeming practice for Casting

Induction Furnaces are Steel Framed and rugged in construction. It consists of a Coil, which

works like Primary Coil of a Transformer. The Coil is lined with Refractory Material. Charge to

be melted is put inside the lined Coil. The Charge acts like Secondary Coil of the

Transformer.

The furnace is switched on, current starts flowing at a high rate and a comparatively low

voltage through the induction coils of the furnace, producing an induced magnetic field inside

the central space of the coils where the crucible is located.

As the magnetic fluxes pass through the scrap and complete the circuit, they generate induce

eddy current in the scrap. This induced eddy current, as it flows through the highly resistive

bath of scrap, generates tremendous heat and melting starts. Melting rate depends primarily

on the density of magnetic fluxes and compactness of the charge. The magnetic fluxes can

be controlled by varying input of power to the furnace, especially the current and frequency.

In a medium frequency furnace, the frequency range normally varies between 150-10K

cycles per second. Heat is developed mainly in the outer rim of the metal in the charge but is

carried quickly to the center by conduction. A metal pool is quickly formed at the bottom

causing the charge to sink. At this point remaining charge mix is added gradually. The eddy

current, which is generated in the charge, imparts a motor effect on the liquid steel, which is

thereby stirred and mixed and heated more homogeneously. This stirring effect is inversely

proportional to the frequency of the furnace. Furnace frequency is selected in accordance

with the purpose for which the furnace will be utilized.

The melting continues till all the charge is melted and the bath develops a convex surface.

However, as the convex surface is not favorable to slag treatment, the power input is then

decreased to flatten the convexity and to reduce the circulation rate when refining under a



.


reducing slag. The reduced flow of the liquid metal accelerates the purification reactions by

constantly bringing new metal into close contact with the slag. Before the actual reduction of

steel is done, the liquid steel which might contain some trapped oxygen is first treated with

some suitable deoxidizer. When no purification is attempted, the chief metallurgical

advantages of the process attributable to the stirring action are uniformity of the product,

control over the super heat temperature and the opportunity afforded by the conditions of the

melt to control de-oxidation through proper addition of deoxidizer.

At the end slag is skimmed off and necessary alloying elements are added. When these

additives have melted and diffused through the bath, the power input may be increased to

bring the temperature of metal to the point required for pouring. The current is then turned off

and the furnace is tilted for pouring into a ladle. After pouring of metal, slag adhering to the

wall of the crucible is scrapped out and the furnace is prepared for next charging cycle.

As the furnace is equipped with a tight cover over the crucible, very little oxidation occurs

during melting. Such a cover also serves to prevent cooling by radiation from the surface of

the molten metal. Hence, the use of slag covering for preventing heat loss and protecting the

metal is unnecessary. Another advantage of the induction furnace is that there is hardly any

melting loss compared with Arc Furnace.

Ladle Preparation

Adequate number of bottom pouring and refractory lined ladles will be provided for tapping of

liquid steel from Induction Furnaces. After teeming of liquid steel from ladles into CCM, ladles

are cleaned by removing skull and refractory lining is patched up as required. The ladle is

then preheated, as and when necessary, in oil fired ladle pre-heaters to a maximum

temperature of about 1000°C. Preheating of ladle is done to reduce the thermal shock to the

brick lining while pouring hot liquid steel and to reduce the chilling effect. Further, preheating

will also remove any moisture from the refractory lining thus preventing explosion due to

generation of steam when liquid steel is poured.

Slide gate mechanism is adopted for bottom pouring of liquid steel from the ladle. A refractory

plate with a hole is made to slide on the nozzle surface for closing and opening of the flow of

liquid steel. Hydraulic mechanism is provided for sliding operation of the refractory plate. The

ladle is prepared after each heat by patching of its refractory lining and changing the slide

gate. These ladles are lined with basic or neutral refractory. Since the slide gate can be

changed from outside, this can be undertaken in a very hot condition of the ladle, if needed.



.


View of a Typical Induction Furnace

5.3 CONTINUOUS CASTING MACHINE

SPSL is presently operating one 6/11 m Twin Strand Continuous Casting machine. The CCM

is having in-built capacity to produce 1,05,000 TPA MS grade Billets of 100x100mm,

125x125 mm and 160x160 mm size. As such no additional CCM is envisaged in the

expansion phase. The molten steel from the ladle is bottom poured into the Tundish of the

Continuous Casting Machine to produce billets.

The process of casting is continuous. Liquid steel is continuously poured into a ‘bottomless’

mould of CCM at the same rate as a continuous steel casting is extracted. Before casting

begins, a dummy bar is inserted to close the bottom of the mould. A ladle with hot molten

steel is lifted above the casting machine and the slide gate is opened for pouring / teeming.

As the steel’s outer surface solidifies in the mould, the dummy bar is slowly withdrawn

through the machine, pulling the steel with it. Water is sprayed along the machine to cool /

solidify the steel into billets.

At the end of the machine, the steel Billet is cut to the required length by gas torches and

transported hot to the hot rolling mill for further processing. A Reheating Furnace will also be

installed for heating cold billets prior to rolling.



.


Schematic Flow Diagram of CCM is shown below.

1: Ladle. 2: Stopper. 3: Tundish. 4: Shroud. 5: Mold. 6: Roll support. 7: Turning zone. 8:

Shroud. 9: Bath level. 10: Meniscus. 11: Withdrawal unit. 12: Billets

A: Liquid metal. B: Solidified metal. C: Slag. D: Water-cooled copper plates. E: Refractory

material.

5.4 ROLLING MILL

SPSL has planned to set up a Rolling Mill of 1,00,000 TPA capacity for production of TMT

Bars, Rods, Strips and Structural as finished product.

Rolling of TMT product is a process of converting feed stock (billets) to desired finished

section in hot condition by way of passing the material between sets of grooved rolls (put in

pairs) and providing suitable draft at various stages. The whole rolling operation has to be

conducted at a particular temperature range and within a limited time span.

The stages of rolling operation are comprised of heating of feed stock to roll-able

temperature (in case of cold billets), rolling the feed stock in different mill stands, cropping

the hot bar during process of rolling between mill stands as necessary and subsequently



.


finishing same in the form of hot rolled deformed bar in straight length. The hot bar coming

out of last pass will be then conveyed through TMT Line and collected in a cooling bed after

shearing. The bars at almost ambient temperature are sheared to commercial length, stored

and kept ready for dispatch.

Rod Mill with TMT Facilities

To produce 8 to 16 mm dia. hot rolled deformed bar in straight length and converting the

same to TMT bar, it is proposed to use 1.2 M long 100 mm sq. & 125 mm sq. Billets as feed

stock. The semi continuous mills are equipped with cross-country primary & intermediate

mills followed by continuous finishing mills.

Stock Preparation

Billets shall be checked for any surface defect. Any defective cold billet should not be

charged to reheating furnace. The billets will be then stacked on charging grid of the furnace.

Billet Reheating

It is envisaged to normally feed hot Billets to Rolling Mill as it will be located near CCM. In

case cold billets are to be rolled, same will be heated prior to rolling. An Oil-fired Re-Heating

Furnace has been envisaged for this purpose.

Heat from Waste Gases coming out of Reheating Furnace will be used for preheating air

required for Oil Burners. Heat Exchangers will be installed for this purpose. Subsequently

waste gases will be let out to atmosphere through a Chimney.

Cold billets are charged from one end to oil fired reheating furnace by suitably rated pusher.

After heated and soaked to desired rolling temperature level at about 1200°C, hot billets are

side discharged at the other end. Temperature is maintained at 650°C in Heating Zone and at

1250°C in Soaking Zone. Thermo Couples are provided to measure temperature in various

zones of the Re-Heating Furnace. In order to avoid de-carburisation on heating, the ingots

are heated slowly and uniformly up to 800°C and then rapidly to 1200°C. At this temperature,

ingots are soaked properly for maintaining almost uniform temperature across the cross-

section for better deformation during rolling. After soaking, billets are discharged to a delivery

table and from where with the help of roller table the billets are conveyed to the roughing mill

stand.



.


Rolling

A Y-table is connected at entry side and a drop wall arrangement at exit side of the first 400

mm Roughing Mill stand. Hot billets directly from CCM or cold billets after heating in the

reheating furnace is first conveyed over Y-table and enters to top pass of Roughing Mill

Stand-I. The bar coming out shall turn 90° over drop wall and fall on delivery roller table and

enter the bottom pass. The bar will be conveyed out of bottom of Y-table through flap and

allowed to travel over Y-table for top pass. Such to and fro rolling in top and bottom passes in

the first stand shall be carried out till a definite square section shall be obtained in 6th pass.

The bar will be then fed to 7th pass at top to get an oval pass and then will be allowed to feed

to bottom pass of Roughing Mill Stand-II over a repeater for formation of a square. In

Roughing Mill Stand-III an inter-stand repeater has been provided and as such the square

thus formed shall be fed to top pass of same stand for formation of an oval. The oval bar will

then be allowed to pass through one pass in each 280 mm Intermediate Mill comprising

four stands. Repeaters are provided on either side of mill stands for material transfer. The

oval bar coming out of second stand of Intermediate Mill shall be conveyed to pass through

two 260 mm stands of First Continuous Finishing Mill and with a repeater the bar will pass

through to 260 mm stands of Second Continuous Finishing Mill form where 8 mm dia. Hot

rolled ribbed bars shall be produced. The higher sizes of the deformed bar shall be finished

from last stand of First Continuous Finishing Mill.

The roughing mill speed shall be 125 rpm. The roughing mill stands shall be driven by a 1000

HP A.C. motor through pinion stand & gear box. The four (4) stands of intermediate mill shall

be driven by a 800 HP motor through pinion stand & gear box. A speed increaser drives the

first continuous finishing mill while a 600 HP A.C. motor drives each stand of second

continuous mill. Depending upon the requirement, the speed in these stands can be adjusted

during process.

Thermo Mechanical Treatment (TMT)

It is a metallurgical process that combines mechanical process with thermal process where

low carbon bars are quenched in a controlled manner to produce high strength bar. The

quenching converts bar’s surface layer to martensite and causes it to shrink. The shrinkage

pressurizes the core, helping to form the correct crystal structures. The core remains hot and

its micro structure is austenitic. A microprocessor controls the water flow to the quench box,

to manage the desired temperature difference through the cross-section of the bars. As the

bar cools, heat flows from the bar's centre to its surface so that the bar's heat and pressure

correctly tempers an intermediate ring of martensite and bainite. Finally, the slow cooling in

the cooling bed automatically tempers the austenitic core to ferrite and pearlite. These bars

therefore exhibit a variation in microstructure in their cross section, having strong, tough,

tempered martensite in the surface layer of the bar, an intermediate layer of martensite and



.


bainite, and a refined, tough and ductile ferrite and pearlite core. This is the desired micro

structure for high quality construction rebar. TMT bars resist corrosion better than cold,

twisted and deformed (CTD) bars. Prodtion of TMT Bar will cover Fe: 415/500/550/600

grades.

A Crank type Flying Shear cuts the bars to suit cooling length. For production of 8 & 10 mm

deformed bar, the finishing speed is about 14.7 m/s & 10.0 m/s respectively. However, it is

always necessary to reduce its speed to the acceptable limit of cooling bed. The cut piece

from flying shear shall be allowed to pass through a pinch roll and a tail end speed breaker.

The breaker engages and rebases for a brief period depending upon bar speed and bar

length. The breaker can take two bars at a time and engage/disengage of breaking of these

bars can be taken up independently. After releasing, the breaking bar will smoothly enter into

the cooling bed. In cooling bed the cut pieces are stored for a pre-determined period of time

for further surface cooling to ambient temperature. However, here the heat from the core of

the bar will flow to the surface causing tempering. With the ambient cooling in cooling bed the

hardened zone is tempered by temperature homogenization in the cross-section and the

austenitic core is transformed to fine grained ferrite-pearlite. The bar is then conveyed to a

roller table to shear to cut to commercial length. The cut pieces are then stored and kept

ready for dispatch.

Changes in micro structure of TMT Bars at different stages of processing are shown below.



.


Rolling Mill Process Flow Sheet for Production of TMT Bars & Rods is shown below.

5.5 SINTER PLANT

Sinter Plant is an excellent scavenger in a Steel Plant. It uses all raw material fines and dusts

generated in the plant (during handling and operation) and convert same into agglomerate

that can be reused in steel making / Ferro Alloys production. It is proposed to install one 35

TPD Pot Type Sinter Machine under Expansion Phase of the Mini Steel Plant.

Fines, generated during handling of Iron Ore Lumps and Pellets and other Raw Materials and

Dust and sludge from Process and waste gases captured in cyclones, bag filters and Electro

Static Precipitators will be utilised as feed-mix in Sinter Plant in effective manner. Scales

generated in CCM and Rolling Mill will also be utilised thereby solving disposal and

environmental problems of Solid Wastes. The Agglomerate Sinter produced will be used in

the Charge Mix of SAF.



.


Iron ore lump / pellet fines, mill scale as well as dust and sludge ESP will be thoroughly

mixed with water and fuel (coke breeze and coal fines) in a rotary mixer and placed in a pot

having perforations at the bottom. Upward and downward suctions are employed for drying,

preheating and sintering and also preheating of air. Sinter Cakes formed are then removed

from Pots, broken and sent to SAF as feed.

Adequate Dedusting facilities (cyclones, bag filters) will be installed before the waste flue

gases are let out to atmosphere through a Stack.

5.6 SUBMERGED ARC FURNACE (SAF)

Ferro alloys are intermediate products used in steel making as deoxidizers and as a specified

addition to give particular properties to the steel. Ferro Alloy Industry is an essential and vital

industry producing basic alloys, which are required for the growth of the steel industry. With

Increase in domestic steel production, requirement of Ferro Alloys also increases. Ferro Alloy

industry in India is making inroads into exports market as well.

Demand for medium carbon Si Mn and low carbon Si Mn has gone up due to usage of these

Ferro-alloys in stainless steel making. Silico Manganese is an alloy containing high amount of

manganese and silicon. It finds extensive applications as deoxidizer and an alloying element.

Under Product Diversification, SPSL proposes to manufacture 12,960 TPA Silico Manganese

(Si Mn) by installing 2 Nos. 4.5 MVA Submerged Arc Furnace (SAF) in the Mini Steel Plant at

Mirzapur Village. Depending on Market Demand it will be possible to produce Ferro Chrome.

Production of Ferro Alloys is highly energy intensive process. Si Mn will be produced by

carbo-thermic reduction of oxidic raw materials in SAF. Same type of furnace is also used for

production of other Ferro Alloys.

Raw materials required for production of Si Mn in SAF are Mn Ore, Mn slag from Fe Mn

operation, Iron Scrap, Quartzite, dolomite and Pearl Coke. Low volatile coal is also used as a

source of carbon for reduction. Sinter produced utilizing Iron ore fines, scales and dust in Mini

Steel Plant will also be used as Raw material.

Raw materials from Storage Yards are brought to a Ground Hopper. It is then conveyed to

Raw Material Storage Bins. Mix Material after weighing, batching and blending is taken to

Charging Hoppers above SAF furnace. The mix is then gravity-fed through a feed chute.



.


The principle of a conventional SAF is electric resistance heating. Electric energy is

converted into heat & reduction energy by using the resistance (R) of the molten slag and

reinforced by the electrical resistance of an arc between the slag and carbon electrodes.

During the initial period of melting, the applied power is kept low to prevent damage to

furnace walls and the roof from radiation, while allowing the electrodes to bore into the

mixture of raw materials. As soon as the arcs have become shielded by the surrounding raw

material mixture, the power is increased to complete melting. As the charge enters the

smelting zone, the alloy formed by chemical reactions of the oxides and the reductants, being

heavy, gradually settles at the bottom. At regular intervals the furnace is tapped. The tap-hole

is opened by oxygen lancing pipe and after tapping is completed, it is closed by clay plugs.

The liquid Ferroalloy is collected and cast in dressed beds. After solidification the cakes are

broken manually to required lump size.

Unlike in EAF, the electrodes of SAF penetrate the raw material. The lower ends of the

electrodes are maintained at about 0.9 to 1.5 meters (3 to 5 feet) below the charge surface.

Normally the slag penetrates into this coke bed, but not as far as to be in contact with the tip

of the electrode. Reaction gases from the smelting zone, mainly CO gas, pass upwards

through the descending raw materials partly preheating them giving off its sensible heat and

partly causing solid state reduction of the higher iron oxides.

However, the thickness of the zone where materials are heated to reaction temperature is so

small that the gases do not have sufficient retention time to give an extensive reduction. 10 -

20 % pre-reduction is normal in cold charge operation.

Without considering the power factor on the electric grid, the ohmic resistance on the hearth

and the allowable amperage in the electrodes are the determining parameters for the load in

a furnace. However, the effect of a low power factor can easily be compensated by

installation of capacitor banks to correct the power factor on the grid.

The quality of the raw material has the biggest impact on the process. The physical

properties determine whether the SAF can run in the (i) conventional resistance mode using

the electrical resistance of slag, or (ii) shielded arc mode using the electrical resistance of the

slag and arc or using the electrical resistance of the feed mix.

High-carbon Silico-Manganese is made in 4.5 MVA SAF operating at a voltage of 90-100

Volt.

The charge for making high-carbon Silico-Manganese is composed of manganese ore,

Quartz and coke.



.


Silico Manganese will contain 60 -70% Mn and 14-18%Si, 0.04% S and o.25-0.30% P.

In the Ferro Silicon process, the important reactions are:

SiO2 + C = SiO + CO

SiO + 2C = SiC + CO

2SiO2 + SiC = 3SiO + CO

SiO + SiC = 2Si + CO

The following processes take place when making high-carbon Silico Manganese:

(a) Removal of volatiles and moisture from the charge and heating of the charge

(b) Reduction of iron and manganese ores with simultaneous formation of metal carbides

(c) Melting of the elements reduced with the formation of molten metal

(d) Formation and melting of slag and

(e) Reduction of Manganese and silicon from the slag.

Features of SAF

SAF comprises a circular shaped furnace shell with separate tap holes for slag and metal.

The furnace is lined with fire bricks, silicon carbide bricks and carbon tamping paste.

Furnace Shell is water cooled by a special sidewall cooling system. The shell bottom is

cooled by forced air ventilation. The electrodes are consumed by the furnace bath. The self

baking electrodes with casings are periodically extended by new pieces. The electrode is

semi automatically slipped into the bath with the furnace at full electric load and with no

interruptions of the furnace operation.

The electrode column assemblies contain all facilities to hold, slip, and regulate the

penetration into the bath. All electrode operations are performed hydraulically. The electric

power is supplied from the furnace transformer via high current water cooled flexible bus

tubes at the electrodes and the contact clamps to the electrodes. The major normal features

of AC based furnaces are as follows

Low maintenance electrode columns for various electrode types

Fail safe, robust designed electrode holding and slipping device

Robust furnace design does not allow bulging/movement

Hollow electrode charging system

Gas tight water cooled roof design provides high quality CO rich gas

Application of energy recovery system possible

Presently more than 99 % of Ferro Alloys production is carried out in AC Submerged Arc

Furnaces.



.


View of a Typical Submerged Arc Furnace

Adequate Pollution Control Facilities like Smoke Hood, Spark Arrestor, Forced Draft

Cooler/Heat Exchangers, Cooling Towers, Cyclone, Bag Filter, ID Fan and Chimney will be

installed.

Slag Processing Unit

To recover metallic Iron (scrap) from slag generated in Induction Furnaces and SAF, a Slag

Processing Unit is be installed, capacity of same will be augmented as required under

expansion.

5.7 POWER PLANT

SPSL is already operating one 8 MW Power Plant. It is designed based on Steam generated

from existing WHR Boilers (3 Nos.) and AFBC Boiler (1 No.).

About 72.5 TPH Steam will be generated from existing WHR Boilers (3x4.5 TPH), existing

AFBC Boiler (1x24 TPH) and Proposed WHR Boiler (1x35 TPH). This will be sufficient to

generate 16 MW Power. It is therefore proposed to increase Power Generation Capacity from

present 8 MW to 16 MW by installing 1x8 MW TG Set.



.


Configuration of WHR Boilers is shown Table 5.2

CONFIGURATION OF WHR BOILERS: TABLE 5.2

SL.

NO.

UNITS FACILITIES WASTE GAS

GENERATION

EXISTING FACILITIES

1

WHR

BOILERS

3 NOS.

(ONE FOR

EACH 50

TPD DRI

KILNS)

3X12,000

NM3/HR AT

900-1000 °C

PROPOSED FACILITIES UNDER EXPANSION

2

WHR

BOILER

1 NO.

(ONE FOR

350 TPD DRI

KILN)

1X90,000

NM3/HR AT

900-1000 °C



.


6.0 RAW MATERIALS, CHEMICALS & UTILITIES

All Existing Service Facilities and Utility Systems in the Plant will be suitably augmented.

In addition, New Facilities will be created to cater to requirement under Expansion.

6.1 RAW MATERIALS

The major raw materials to be handled will consist of Iron Ore Lump / Pellet, Non Coking

Coal, Dolomite, Pig Iron, Ferro Alloys etc. The annual requirement of raw materials and their

sources are shown in Table 6.1

SOURCES AND ANNUAL REQUIREMENT OF RAW MATERIALS: TABLE 6.1

SUBMERGED ARC FURNACE (2X4.5 MVA)

(RAW MATERIAL REQUIREMENT SHOWN HERE IS FOR SI-MN PRODUCTION)

1 QUARTZITE 4,000 MARKET

2 MANGANESE ORE 6,400 MARKET

3 COKE 6,500 MARKET

SL.

NO.

RAW MATERIALS ANNUAL

REQUIREMENT

IN TPA

SOURCE

DRI PLANT (3X50 TPD + 1X350 TPD)

1. IRON ORE LUMP /

PELLET

2,25,000 MARKET

2. COAL 1,50,000 MARKET / SOUTH AFRICA

3. DOLOMITE 4,500 MARKET

INDUCTION FURNACE (4X7 T + 1X6 T)

1. SPONGE IRON 1,00,000 IN HOUSE GENERATION

2. STEEL SCRAP 6,000 IN HOUSE GENERATION

3. PIG IRON 20,000 MARKET

4. FERRO ALLOYS 1,500 MARKET



.


4 PIG IRON 1,300 MARKET

5 MN. SLAG 18,000 MARKET

6 DOLOMITE 3,500 MARKET

7 SINTER 3,500 IN HOUSE PRODUCTION

FROM RAW MATERIAL FINES

AFBC BOILER (1X24 TPH)

1 DOLOCHAR 45,000 IN PLANT GENERATION

2 COAL/HUSK 20,000 IN PLANT GENERATION,

MARKET

Raw materials will be received at plant site by road. All the trucks for raw material and

finished product transportation shall comply with the applicable environmental norms.

Liquid Steel from Induction Furnaces will be converted into MS Billets in the Continuous

Casting Machine. MS Billets from CCM will be fed to Rolling Mill for producing Long Products

(TMT Bars, Rods, Flats and Structurals)

6.2 FUEL

For meeting the requirement of Furnace oil and Light Diesel Oil of the plant, adequate

infrastructure in terms of tanks, pumps, pipe lines and dispensing units have been set up

which shall be further augmented to meet the requirements at Expansion Stage. The required

fuel is being sourced locally from Indian Oil Corporation.

6.3 WATER

Water systems of the Plant shall comprise of the following:

Make-up water

Re-circulating water

Once through water

Emergency water

Drinking water

Fire water

Dust suppression water



.


Water will be mainly required for cooling of equipment, dust suppression etc.

Space provision has been kept in the Plant General Layout for installation of an intake well

pump, raw water treatment plant, ground reservoir etc.

Emergency water system:

Emergency water will be required to cool the vital parts of cooler during the transition period

between normal power failure and emergency power supply. Emergency water will also be

required for cooling of vital equipment of other Production Units.

Emergency water shall be supplied from a structural overhead tank.

Drinking and sanitary water system:

Drinking and sanitary water requirement for the plant is met from drinking water overhead

tank. A portion of the make-up water is chlorinated by gaseous or liquid type chlorinator and

is stored in the above overhead tank for further distribution to consuming points and for fire

fighting.

Fire water system:

The emergency water pipelines will be led throughout the steel division complex for fire

fighting. These fire fighting pipelines will be connected to the emergency water storage tank.

In addition to the fire fighting pipelines, additional fire hydrants would also be provided at

suitable locations.

Distribution pipe work:

In general, mild steel pipes are considered for re-circulating and make-up water piping.

Mainly buried pipes are considered except for shop internal pipes. Pipe work shall comprise

all necessary valves, fittings, hydrants etc.

Source of water

Ground water will be used for meeting the daily make up water requirement of the plant. As

per initial estimate, additional make up water to the tune of 160 cu.m /day will be needed for

the proposed expansion including 10 cu.m /day for in-plant domestic use. Total make-up

water requirement for the Plant after Expansion will be 365 cu.m /day



.


The estimated unit wise and phase wise (existing and expansion) make up water requirement

for the Mini Steel Plant are given in Table 6.2

RAW WATER DEMAND: TABLE 6.2

Sl.

No.

Description Water

Demand for

existing

plant

(in cu.m/day)

Water

Demand for

expansion

(in

cu.m/day)

Daily Total

Water Demand

(in cu.m/day)

1. Sponge Iron Plant

(3x50 TPD + 1x350 TPD)

21.0 49.0 70.0

2. Steel Melting Shop

(Induction Furnaces [5x7

T] + Twin Strand

Continuous Billet Caster)

10.0

10.0

20.0

3. Rolling Mill (1,00,000

TPA)

NIL 13.0 13.0

4. Captive Power Plant

(8 MW+8 MW)

160.0 60.0 220.0

5 Submerged Arc Furnaces

(2X4.5 MVA SAF) + Sinter

Plant

NIL 18.0 18.0

6. Domestic 14.0 10.0 24.0

TOTAL 205.0 160.0 365.0

The Company has the sanction to operate 2 Bore Wells for groundwater withdrawal.

Permission will be taken for sinking additional Bore Wells to meet increased make up water

demand of the Plant under expansion.

6.4 OTHER UTILITIES

COMPRESSED AIR SYSTEM

Major utilization of compressed air will be in pneumatic cylinder of various plant units and

especially for rotary shears in Rolling Mill. Air receiver with adequate capacity will also be

provided to cope up the temporary peak requirement of various units. The compressors,



.


dryers and associated pipe work will be located in one place, within a building. Compressed

air to various consumers will be distributed through compressed air piping system.

AIR CONDITIONING AND VENTILATION SYSTEMS

Ventilation system with fan-filter units will be provided for protection of equipment from

excessive thermal loading. These systems will generally be installed in the electric rooms

and other closed premises requiring protection of equipment.

Air conditioning will be provided in the plant control rooms, PLC room, laboratory and Plant

offices and Administrative Building. The air conditioning will be achieved by providing window

model/package type air conditioners.

COMMUNICATION SYSTEM

Suitable communication network has been envisaged for quick transmittal of information

within the plant. The network shall contain automatic internal telephone system (PAX) and

two-way audio communication system.

AUXILIARY FACILITIES

Various services facilities like repair and maintenance shop, central stores, administrative

building, canteen, guesthouse, time office, laboratory etc. will be provided during

construction of expansion phase.

6.5 POWER

The estimated power demand of the Mini Steel Plant after expansion will be 24.5 MW. The

power requirement will be met from Captive Power Plant which will generate 16 MW after

proposed expansion. Balance Power will be drawn from nearby grid of WBSEB / DVC.

Total Power Demand and unit wise and phase wise (existing and expansion) breakup for the

Mini Steel Plant is shown Table 6.3



.


POWER DEMAND WITH UNIT WISE BREAKUP: 6.3

SL

NO

UNITS

POWER

DEMAND

FOR

EXISTING

PLANT

ADDITIONAL

POWER

DEMAND FOR

EXPANSION

TOTAL

POWER

DEMAND IN

MW

1. Sponge Iron Plant

0.65 1.50 2.15

2. Steel Melting Shop and

Continuous Billet Caster

5.0

5.0

10.0

3. Rolling Mill NIL 3.0 3.0

4 SAF and Sinter Plant NIL 6.0 6.0

5. Captive Power Plant

(in-house consumption)

1.0 1.0 2.0

6. Auxiliary & other loads 0.7 0.65 1.35

TOTAL 7.35 17.15 24.5



.


7.0 ENVIRONMENTAL ASPECTS

This chapter covers all aspects of pollution – sources and nature of pollution & proposed

measures required for meeting the prevailing statutory requirements of gaseous emissions,

solid wastes and waste water discharge characteristics, noise level etc. for environmental

management purpose in connection with the installation and operation of Mini Steel Plant

under Expansion Phase.

Salagram Power and Steel Pvt. Ltd. operate the Mini Steel Plant at Palitpur Road,

Dewandighi Village. The Company is well aware about the importance of Pollution Control.

The Company has installed adequate Pollution Control Measures in this Plant. Strict

Monitoring is done regularly through Approved Agencies/Laboratories of WBPCB. WBPCB

also checks whether pollution levels are within Stipulated Norms and issues Analyses and

Test Reports to the Company. Based on various Reports, WBPCB on 29.06.2016 has

granted the Company “Consent to Operate” this Plant for 3 years from 01.07.2016 till

30.06.2019.

In general Pollution Prevention and Control Measures are enumerated as below:

Genesis of Pollution:

The genesis of industrial pollution can be assessed from the project concept described in

earlier chapters. The specific aspects, which need to be looked into for assessing the

pollution potential, are:

(i) Physical and chemical characteristics of raw materials,

(ii) Manufacturing technology involving a set of physical and chemical conversions of

raw materials and

(iii) The generation of all types of wastes, namely, gaseous, liquid and solid having

specific characteristics.

The pollutants in the form of solids, liquids and gases are expected to be generated from

various Units of the proposed Steel Plant. Release of such pollutants without proper care

may affect the environment adversely. Pollution of the environment not only adversely affects

the human beings, flora and fauna but also shortens the life of plant and equipment. This vital

aspect, therefore, has been taken into account while planning the plant and equipment and

adequate measures have been proposed to limit the emission of pollutants within the

stipulations of statutory norms.



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7.1 AIR POLLUTION CONTROL

Air pollution is of two categories:

i) Pollution from Process Emissions and

ii) Pollution from Non-process Emission

Process emissions arise during production/operation of the plant while non-process

emissions are generated during handling of various raw materials. The main air pollutants

from process emissions would be SO2, NOx and to some extent Particulate Matter while for

non-process emission the main pollutant would be Particulate Matter.

A number of systems have been proposed for air pollution control which will provide safe

environmental conditions in the working area and will ensure acceptable air quality in the

surrounding area of the steel plant. Different air pollution control facilities / equipments that

would be considered include dry fog dust suppression systems, dust extraction systems,

cyclones, bag filters, ESP etc. Cleaned waste gases would be discharged through

Stacks/Chimneys, of adequate height commensurate with Norms, to ensure adequate

dispersion and dilution of pollutants.

The Company presently operates a Captive Power Plant of 8 MW Capacity based on steam

generated in 3 WHR Boilers and an AFBC Boiler. Adequate Pollution Control Measures have

been installed for all above facilities.

In the Expansion Phase, no additional TG Set is planned and Capacity of Power Plant will

remain at 8 MW. However, WHR Boilers will be installed to utilise Waste Gases from 2x100

TPD DRI Kilns. Steam generated in these two (2) WHR Boilers will help in Steam Balance

and the Company will avoid purchase of costly fuel (coal/husk). Adequate Pollution Control

Equipment have been planned for new WHR Boilers.

Contribution to air pollution would be from Particulate emission from the stack and this would

be governed according to the Central Pollution Control Board Emission Regulation.

Cyclones, Bag Filters and Electrostatic Precipitators (having efficiency of 99.89% or better)

will achieve the limit of particulate emission within Environmental Norms.



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7.2 WATER POLLUTION CONTROL

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, as far as practicable.

This will ensure adequate reuse of water in the respective re-circulating systems and

economizing on the make-up water requirement.

Sewage generated from toilet blocks etc. shall be treated in the existing Sewage Treatment

Plant (which will be augmented as required) and the treated effluent shall be collected in the

existing sump, located in a low lying area. The water thus collected shall be used for dust

suppression at raw material handling system, landscaping etc.

Thus, Water system will be designed for “Zero Discharge” wherein all discharges will be

treated and reused in the plant.

Surface run-off will be settled in a settling basin prior to reuse/ disposal.

7.3 SOLID WASTE MANAGEMENT

Adequate Dust Extraction Systems (cyclones, bag filters and ESP) will be planned. All dust

captured in these Pollution Control Equipment will be used in Sinter Plant.

Dolo-char generated in DRI units will be used in AFBC boiler. The fly ash generated will be

stored in ash silo and sold as a raw material for cement plants and also used for brick

manufacturing and land filling.

The hot slag generated from IF and SAF will be transferred to slag yard after cooling and

scrap recovery. It will be used as construction material/sold to cement manufacturers.

Mill scales generated from CCM and RM will be used in sinter plant.

Scraps (Billet crops, end cuts in Rolling Mills etc.) will be used in Charge Mix of Induction

Furnace.

Thus all solid wastes generated in the Plant will either be reused / recycled in various

Production Units or will be sold / utilised for land filling and other gainful purposes.



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7.4 NOISE POLLUTION CONTROL

Noise generation will be considered while selecting equipment. Equipment would not

generate noise more than 85 dB (A) at 1 m distance. Wherever required noisy equipment will

be placed on vibration isolators or housed in a separate enclosure or surrounded by baffles

covered with noise absorbing material. As the operator would be stationed in the control

room, there will be minimum chance of exposure to high noise levels. However personnel

working in high noise zones will be provided with personal noise protection equipment (e.g.

ear muffs, ear plugs) and their duty hours will be regulated to control noise exposure levels.



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8.0 FIRE PROTECTION SYSTEM

In addition to the yard fire hydrant system, the fire protection systems envisaged for the plant

are as follows:

Internal fire hydrant for multi storied buildings to be tapped-off from the outdoor fire

water header

Fire detection and alarm system for electrical rooms, cable basements/cellars, cable

tunnels, selected oil/hydraulic cellars

Portable fire extinguishers such as CO2, foam and dry chemical powder in all areas of

the plant with fire hazard.



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9.0 GREEN BELT DEVELOPMENT OBJECTIVE

To capture the fugitive emission, if any from the plant and to attenuate the noise generated

from the plant machinery, and to improve the aesthetics of the plant site, a green belt will be

developed within the plant area.

The green belt is a set of rows of trees planted in such a way that they form an effective

barrier between the plant and the surrounding. Prevalent wind directions shall be taken into

considerations to ensure adequate capture of the air pollutants around the Plant.

Open spaces, where tree plantation is not possible shall be covered with shrubs and grass.

The plantations shall match with the general landscape of the area and be aesthetically

pleasant. Adequate attention will be paid to planting of trees and their maintenance and

protections.

SPSL is presently having 25.8 Acres of Land. Additional 3 Acres will be acquired. Out of 28.8

Acres, Green Belt Cover will be about 10.0 Acres (more than 33% of total area).

The plant layout showing the proposed facilities with Green Belt area has been shown in

Drawing No. KKS/SPSL/2017/L-0 Rev.2



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10.0 RAIN WATER HARVESTING

It is proposed to achieve proper utilization of rain water by harvesting through rainwater

harvesting mechanism in the plant area. Rain water harvesting will be done following the

guidelines of the concerned Authority.



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11.0 MANPOWER REQUIREMENT

Operation and maintenance of proposed plant require human resources in different

categories like managers, engineers of different discipline like metallurgical, mechanical,

electrical, electronics, computer, civil, structural, chemical, etc., highly skilled, skilled and

semi-skilled work force in different disciplines, commercial, accountants and financial

managers, unskilled labour force, clerical, security personal, etc.

Factory human resources

In order to operate and maintain the plant facilities, including its technical and general

administration needs, the estimated additional manpower requirement for the proposed

project has been estimated to be 334 persons (including 195 through Labour Contractors).

This is over and above existing manpower of 596 persons (including 405 through Labour

Contractors) employed at present.

The above estimate covers the top management, middle and junior level executives and

other supporting staff.



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12.0 PROJECT SCHEDULE

The installation of several production units along with utilities and services will involve award of

all contracts, procurement of plant and equipment, construction & erection and supervision of

all activities at plant site.

The factors which are responsible for timely implementation of the project are :

i) Arrangement of proper finance for the project.

ii) Finalization of layout of the proposed plant.

iii) Design of utilities and services.

iv) Placement of orders for plant and machinery.

v) Arrangements for Govt. sanctions and supply of power.

vi) Recruitment of personnel.

As per an initial estimate around 24 months will be needed for implementation of the

Expansion Phase of the project.



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13.0 FINANCIAL DETAILS

The focus of proposed project is cost reduction by producing quality material as per the

required specification. There will be complete integration right from the beginning to finished

products (viz Sponge Iron, TMT Bars & Rods and Silico Manganese/Ferro Chrome). The

estimated cost of the project is expected to be around Rs. 108 Crores.

There will be substantial savings due to the said project as company will also be eligible for

various incentives. The company has good track record of implementing and commissioning

projects within schedule time. The Company will be able to implement the proposed project

as per schedule. The total project is expected to be commissioned over a period of 24

months in phased manner. The benefit from the project planned will start accruing from very

first year of Operation Phase.



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14.0 CONCLUSION

The feasibility of the project has been examined from 3 angles, which are backbone of any

project to succeed:

Environmental feasibility

Commercial and financial viability and

Pre and post project scenario in which company will operate.

The outcome shows that results are positive which indicate a positive feasibility.

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