DECEMBER 2018

CO N T E N TS VOL 28/M05

Founder Chief Editor EDITOR’S NOTE Late Dr. Monoj Chatterjee

Chairperson GLIMPSES OF “WHY STEEL?” SEMINAR AT VISAKHAPATNAM, 2018 Dr. Mrs. Jyotsna Chatterjee

Managing Director SECTION : SEMINAR PAPER Sakuntala Chatterjee Chanda Steel-concrete Composite Construction Advisor (Finance & Accounts) & Life Cycle Costing - Debashish Dutta 1 Prodosh Jana Roy

Editorial Consultant Visakhapatnam Metropolitan Region Partha Sarathi Bhattacharya Development Authority (VMRDA) - P. Basanth Kumar IAS 8

Content & Marketing Executive Gopal Ghosh Steel Structures – Satyajit Mohapatra 17 Joyanta Mani Sameer Kundu Steel Structures Accounts Advantages of steel structures in Civil infra structures – Abhai Sinha 24 Gobinda Roy

Regional Office (Mumbai) Usage of Steel in Mass Transit Systems - K K Rao 25 Sumit Roy

Design & Layout Narendra Nath Roy SECTION : ARTICLE

Spark Steel & Economy Processes Routes for HRC Production - Sanat Bhaumik 32 Research Centre Pvt. Ltd. (A Centre for Research, Information, Consultancy and Publication) Iron Ore Beneficiation - P. S. Bhattacharya 39 71/3B, Purnadas Road, Kolkata -700 029, India Tel : +91 8017623829, Pelletization - P. S. Bhattacharya 41

DATA BANK 43 ATTENTION SUBSCRIBERS Any complain of‘non-receipt’ of journal should reach ‘Steel Scenario’ office at Kolkata latest within a month of publication. - Publisher The views and data given by the authors are their own and Steel Scenario Journal Registration No. 53085 / 92 is not responsible for their authenticity Printed and Published by Ms. Sakuntala C.Chanda on behalf of Spark Steel & Economy Research Centre (P) Ltd. 71/3B, Purnadas Road, Kolkata - 700029 2019 will change the momentum for Steel Industry EDITOR’S NOTE With minimal new steel capacity expected to be commissioned until 2021 in India, robust steel demand -- especially from the construction, infrastructure and automotive sectors -- will keep end-product prices high, even as rising costs for key inputs, coking coal and iron ore profitability. It appears that the expectation of a prolonged turnaround in the global steel market fuelled by consumption growth, higher levels of production and capacity utilisation and rising steel prices has been cut short and the happenings in the next few months on which there is a great deal of uncertainty would determine the fate of the steel industry for 2019 and beyond that. Meanwhile, India's steel sector consolidation will drive improvement in the industry’s capacity utilisation levels and mute the pressure on profitability. India will be the brightest spot for the steel sector over the next 12-18 months, according to Moody's Investors Service. The first half of the calendar year 2019 will be a strong period for the steel industry globally, said TV Narendran, managing director of Tata Steel. He also added that apart from some concern on trade flows, the fundamentals are strong and growing in China, India, US and Europe is good. Asian steel demand will remain steady over the next 12 months to June 2019, because solid growth in 2018 will offset a likely softening in 2019. Demand in the ASEAN region is expected to resume its growth momentum backed by infrastructure programmes in 2019 and onwards. Risks are largely related to rising trade tensions between the US and China, currency volatility and political instability. India has already committed US$94 b to infrastructure up to 2020, which will see robust steel production and usage growth rates. Throughout 2019, Steel Scenario Journal will regularly cover various topics connected to steel awareness among end users, case studies of steel usage in numerous projects connected to infrastructure, housing, roads, mass transit systems, etc. We start our editorial calendar with a focus on various Public Enterprises which has played an important role in giving India its due momentum inspite of major economic crises and change in economic policies intermittently by various ruling governments. As we acknowledge the contribution of Public Sector Undertakings we cannot overlook the contribution by various Private Enterprises who have to lead the country to greate heights and gave India a recognition in the global development map. 2019 will remain a year of great expectations from all domains of the industrial sectors and steel will not be an exception. After a long dwelling crisis that was chocking the industry, by and large, this is the year to turn around and look forward. Let the whole fraternity come together to bring this major change in the mind set of users which is the only way of bringing the significant change in steel consumption in India.

DECEMBER 2018 “Steel is the Future Metal” - the outcome of WHY STEEL? Seminar in Visakhapatnam

Steel Scenario Journal in support of Ministry of Steel completed its 2nd Seminar on WHY STEEL in Visakhapatnam on 12th December. The Seminar was well attended from the user segment who are main users of the steel industry. Various departments from urban development, municipal corporation, Smart City, Panchayati Raj, architects, NHAI, builders from Indian Building Congress, CREDAI, Airport Authority and town planning were all present in the Seminar to discuss various pertinent issues concerning steel usage in their Sakuntala, Editor - Steel Scenario various projects.

Though the users understood the requirement to use steel in more quantity in various projects, they have major challenges in terms of cost of the project going up, difficulties in finding the adequate quantity and quality of steel for various projects. President of Indian Building Congress Shri Abhai Sinha spoke about the requirement to use more of steel in various building projects and WHY STEEL should be used and should be the future metal for building construction.

The Seminar started with a Keynote Address by Shri Debashish Dutta from INSDAG who spoke about “Steel Concrete Composite Building & LCA”. He emphasized on the solution for the building industry through Steel- Concrete Composite. This is applicable not only to rural houses but also in urban houses for a cost-effective way of building sustainable houses.

The Seminar was divided into another three Sessions, “Usage of Steel in Infrastructure, Usage of Steel in Urban & Rural Houses and Usage of Steel in Public Utilities & Mass Transit System”. The Session had very senior representatives from various segments as well as steel producers who deliberated on various projects happening under their departments and the requirement of steel for these projects. Shri P Basant Kumar, Commissioner VMRDA gave a detailed presentation of the various projects that are in pipeline and the steel museum they have constructed in record time with steel replacing concrete. During the Seminar Session discussion, Airport Authority Director Shri G Prakash Reddy, requested steel producers to submit a quotation and time frame for a three-tier car park project for the Visakhapatnam Airport.

The outcome of the Seminar was very impressive with many user segment organisations and state government departments requesting steel producers to come for further discussions to be part of the projects in the state. It is in-evident, that the mission of WHY STEEL was achieved to a great extent in this Seminar.

DECEMBER 2018 GLIMPSES OF “WHY STEEL?”

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Abhai Sinha, G. Pr akash R Indian eddy Building , Airport Authority of India Congr ess

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Ar . Y. Nar K. V asimha Rao . L. Sr eeram, Ama , IIA - Viz rav ag ati City De v. Corp. DECEMBER 2018 DECEMBER 2018

Section : SEMINAR PAPER

Steel-concrete Composite Construction & Life Cycle Costing by - Debashish Dutta, Assistant General Manager, INSDAG

• India transforming from developing to developed country • Upsurge in construction activities • Recent statistical studies show Indian subcontinent and Far East becoming more vulnerable to natural hazards • Proper selection of technology helps building our nation with more sustainable & durable construction & structures could withstand natural calamities • Popular method of selection followed abroad Life Cycle Cost Analysis (LCCA) • From value of LCC, function of construction w.r.t. strength, durability, longevity, disaster resistance etc. i.e. Life Expectancy could be well assessed • From LCCA, Scientific evaluation of different proposals would be easier • LCCA may indicate lesser LCC even when direct construction cost is more • If fast track technology, Steel-Concrete composite methodology adopted, due to the lesser construction period, the saving in interest burden on borrowed capital & early generation of revenue also reduces Net Construction Cost, also LCC • Life Cycle Management is required to ensure Sustainable Growth, Hollistic Development and upgradation towards more scientific living

DECEMBER 2018 1 Section : SEMINAR PAPER

ADVANTAGES OF STEEL-CONCRETE COMPOSITE • Steel-Concrete composite construction more resistant CONSTRUCTION against accidental loads • Composite sections have higher stiffness compared to only • Effective utilisation of materials viz. concrete in compression and steel in tension steel construction and hence experience lesser deflection than the non-composite steel sections • High ductility of steel leads to better seismic resistance of the composite section INSDAG’s study of LCC on a (B+G+20) storeyed residential • Large column free area. More usable space. Area of building with both RCC and Steel-Concrete Composite options composite column < area of RCC column Done in 2003 & updated in 2011 (Applicable Kolkata rates) • Faster construction by rolled / pre-fabricated components, The study extends further to compare 7 options – one with quicker return on the invested capital conventional RCC with brick walls and the six (6) others with • Quality of steel assured since produced under QAP in factory. steel-concrete Composite options having variations in storey Hence, more use of steel ensures better quality control height and type of cladding material including conventional • Cost effective, based on LCCA since steel structures can be bricks and lighter cladding materials maintained easily and less frequent repairs required for Though Steel construction is costlier than RCC structure, steel structure outcome of the study shows that Steel-Concrete Composite • Steel is more durable, highly recyclable and hence construction give encouraging results even in direct environment friendly construction cost & in LCC • For same span/loading, smaller sections reqd compared to Some examples on buildings have been worked out non-composite construction considering Direct Construction Costs of different proposals. • Reduction in overall weight of the composite structure, For item rates of repair and maintenance and weightage lesser foundation costs thereof IS 13174 – Part 1 & 2 (Annex C & D) and DSR 2007 with • Cost of formwork is lower compared to RCC construction Cost Index referred. For assessment of LCC Table 10 of IS 13174 • Cost of handling & transportation less because major part is (Part 2): 1994 followed. Reference made to various aspects as fabricated in workshop stipulated in the US Code ASTM E 917

Series 1 : For sales price of Rs. 2500/- per sq. ft. and rental charge of Rs. 10/-per sq. ft. OPTION NO. 1 2 3 4 5 6 7

FRAME TYPE RCC COMP COMP COMP COMP COMP COMP

FL TO FL HT (M) 3.15 3 2.85 2.85 2.85 2.85 3

B+G+ 20 20 21 20 20 21 20

CLADDING TYPE BRICK BRICK BRICK BRICK M2 M2 M2

DIRECT CONSTRUCTION COST 22.540 20.450 20.820 19.850 18.350 19.180 18.710 (Rs. in Crores) TOTAL SQ. FT. 161500 161500 169182.6 161500 161500 169182.6 161500

COST PER SQ. FT. 1396.00 1266.00 1230.00 1229.00 1136.00 1134.00 1159.00 BREAK-UPS OF COST VARIATIONS [MAJOR VARYING ITEMS- % CHEAPER FRAMING 0 17.23 12.79 17.83 17.87 13.69 18.33 CLADDING 0 -7.40 -3.05 1.15 23.29 20.19 17.54 FOUNDATION 0 18.02 15.32 18.02 24.92 20.34 21.80 :- OTHER ITEMS VARY NEGLIGIBLY] OVERALL COST COMPARISON % CHEAPER THAN OPTION NO. 1 0 9.27 7.63 11.93 18.59 14.91 16.99 OF DIRECT CONSTRUCTION COST IDC @ 11.75% (1.5 YRS.) 4.087 3.708 3.775 3.599 3.327 3.478 3.393 (Rs. in Crores) RENTAL EARNING (Rs. in Crores) 0.00 1.29 1.35 1.29 1.29 1.35 1.29 (Rs. 10 per sq. ft.) [CONSIDERING 8 MONTHS SAVING BY COMPOSITE CONSTRUCTION] NET COST(Rs. in Crores) 26.627 22.866 23.242 22.157 20.385 21.304 20.811 TOTAL RENTAL EARNING / YEAR 1.938 1.938 2.030 1.938 1.938 2.030 1.938 (Rs. in Crores)(Rs. 10 per sq. ft.) Y.P. [PAYBACK PERIOD] 13.74 11.80 11.45 11.43 10.52 10.49 10.74

2 DECEMBER 2018 Section : SEMINAR PAPER

From the above Table Comparison in Direct Super Built-up Area Construction Cost reveals:- An apartment area is categorized as under: • The cost of RCC building is 22.50 Crores having a covered area • Carpet Area - Apartment clear area only of 1,61,500 sq.ft. • Covered Area - Apartment area including wall • The storey height of RCC building is 3.15 m to accommodate • Super-built up Area - Apartment covered area the designed beam conforming to the Municipal by laws + undivided (apportioned) share of land • The Steel-Concrete Composite Option with brick wall storey + Amenities + Facilities height 3m is 9.27% cheaper than the RCC option with brick wall Series 1 : For sales price Rs. 2500/- per sq. ft. and rental charge Rs. 10/-per sq. ft. Series 2 : For sales price Rs. 2100/- per sq. ft. and rental charge Rs. 8/-per sq. ft. • The Composite Option with brick wall of storey height of 2.85 m Series 3 : For sales price Rs. 1800/- per sq. ft. and rental charge Rs. 6/-per sq. ft.

and an additional floor, costs 7.63% cheaper than RCC options Chart 1 : Showing profit % for various options without superbuilt -up area • Composite Options with brick wall and storey height of 2.85 120.0 100.0 98.5 m, costs 11.93% cheaper than RCC Option 98.1 94.0 82.0 82.2 80.0 76.6 • Composite option with lighter cladding material (M2 Panel, 64.7 60.0 64.3 61.0 51.6 51.1 51.3 Aerocon Block, Gyperete etc) and storey height of 2.85 m, 46.7 40.0 39.1 39.4

% of Profit 36.3 27.4 28.0 28.2 costs 18.59% cheaper than RCC 20.0 24.3 9.2 • Composite option with lighter cladding material and storey 0.0 1 2 3 4 5 6 7 Series 1 height of 2.85m and one additional floor, costs Various Options 14.91%cheaper than RCC Series 2

• Composite option with lighter cladding material and storey Chart 3 : Showing profit % for various options with 20% superbuilt - up area height of 3.0 m, costs 16.99%cheaper than RCC 160.0 140.0 137.7 138.2 132.8 Comparison of total Direct Cost for RCC & Composite Options 120.0 118.4 118.7 111.9 100.0 97.1 97.6 93.2 82.0 81.3 81.6 Series 1: RCC Options 80.0 76.0 66.9 67.3 60.0 63.6 Series 2: Composite Options 52.8 53.7 53.8 % of Profit 49.2 40.0 31.0 30 20.0 25 0.0 1 2 3 4 5 6 7 Series 1 Various Options 20 Series1 Series 2 15 Series2 Chart 2 : Showing profit % for various options with 15% 10 superbuilt-up area 5 140.0 127.8 128.3 120.0 123.1 0 109.3 109.6 100.0 103.1 12 21 65 125 88.9 89.4 80.0 85.1 TOTAL HEIGHT (M) OF BUILDING 74.4 68.7 73.8 74.0 60.0 59.9 60.3 56.7 46.5 47.3 47.4 40.0 43.0

Net Cost = Direct Construction Cost + IDC - Rental % of Profit 20.0 25.6 charges over the saved period of construction time 0.0 1 2 3 4 5 6 7 Series 1 Various Options • For IDC an interest rate of 11.75% has been considered Series 2 because the promoter / developer is supposed to borrow Chart 4 : Showing profit % for various options with 30% money at an interest rate as minimum equal to the Prime superbuilt-up area lending rate (PLR) of the commercial bank, which was at 180.0 160.0 158.1 time of study about 12% 157.5 152.2 140.0 136.6 136.9 129.5 120.0 • A possible reduction in PLR is considered (11.75%) 113.6 114.1 109.3 100.0 97.1 96.7 90.7 96.4 80.0 80.8 81.2 77.2 • IDC over period of construction is considered on average 66.5 66.7 60.0 65.6 61.6 % of Profit basis because lending organizations disburse loan in stages 40.0 41.9 • For worst case, it is considered that over period of saved 20.0 0.0 construction time the building is rented out instead of 1 2 3 4 5 6 7 Series 1 selling it out at an early date Various Options Series 2

DECEMBER 2018 3 Section : SEMINAR PAPER

Series 1: RCC Options In the Present Worth Method the initial investment and all the Series 2: Composite Options future expenses incurred to keep the asset functioning are converted to the present value whereas the Annualised Cost Method ammortises all costs over the life of the item or project. Arithmetically both the methods are identical In INSDAG study Present Worth (PW) Method or Net Present Value (NPV) Method has been adopted In this method all direct expenses incurred at beginning of project and at different times over life of project are discounted to present value at base year of life cycle cost study & added together to arrive at the Net Present Value of a project alternative If ‘S’ is the cost incurred in a project at ‘t’th year then with a discounting factor of ‘i’ the present value of that future cost will be given by Life Cycle Cost (LCC) includes:- S • Repairs (occasional ) cost & Maintenance (regular) cost P = ------where 1 / (1+i)t = Present Worth Factor (pwf) required to make the Structure operational till its Life (1+i)t ( As per IS 13174 (Part 2): 1994 Annex A or Table 4) Expectancy TABLE 4 • In this study assumed 80% of present Net Construction Cost is spent in future for maintenance & minor repairs over PRESENT WORTH FACTORS (pwf) WITH RESPECTIVE expected life of building DISCOUNT RATE AND SPECIFIED NUMBER OF YEARS • 20% of the present Net Construction Cost is spent at every 1 10th year as major repair cost over same period pwf = ------(1 + 0.01 x DR)N • Considered Straight-line method of Depreciation Year (N) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Discount Rate (%) (DR) • Cost for a new building replacement to make budget for a 8 0.68 0.63 0.58 0.54 0.5 0.46 0.43 0.4 0.37 0.34 0.32 0.29 0.27 0.25 0.23 0.22 9 0.65 0.6 0.55 0.5 0.46 0.42 0.39 0.36 0.33 0.3 0.28 0.25 0.23 0.21 0.19 0.18 Sinking Fund 10 0.62 0.56 0.51 0.47 0.42 0.39 0.35 0.32 0.29 0.26 0.24 0.22 0.2 0.18 0.16 0.15 11 0.59 0.54 0.48 0.43 0.39 0.35 0.32 0.29 0.26 0.23 0.21 0.19 0.17 0.15 0.14 0.12 • Residual value at the end of the study period 12 0.57 0.51 0.45 0.4 0.36 0.32 0.29 0.26 0.23 0.21 0.18 0.16 0.15 0.13 0.12 0.1 13 0.54 0.48 0.43 0.38 0.33 0.3 0.26 0.23 0.2 0.18 0.16 0.14 0.13 0.11 0.1 0.09 • 2 study periods considered - 80 yrs & 100 yrs the - life 14 0.52 0.46 0.4 0.35 0.31 0.27 0.24 0.21 0.18 0.16 0.14 0.12 0.11 0.1 0.08 0.07 15 0.5 0.43 0.38 0.33 0.28 0.25 0.22 0.19 0.16 0.14 0.12 0.11 0.09 0.08 0.07 0.06 expectancy of RCC structure is about 70 years and for 16 0.48 0.41 0.35 0.31 0.26 0.23 0.2 0.17 0.15 0.13 0.11 0.09 0.08 0.07 0.06 0.05 Steel-Concrete Composite Options it is about 100 years TABLE 5 • Rate of Inflation on book 5.5% whereas market inflation at UNIFORM PRESENT WORTH FACTORS (upwf) WITH actual is assessed to be 10% RESPECTIVE DISCOUNT RATE AND SPECIFIED NUMBER OF • 2 tables preferred with 5.5% and 10% discounting rates for YEARS each 80 years and 100 years of study periods K (1 – KN) 1 CPI (this year) – CPI (last year) upwf = ------where K = ------Rate of Inflation of consumer prices (%) =------x (1 – K) (1 + 0.01 x DR) 100 Year (N) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CPI (last year) Discount Rate (%) (DR) 8 3.99 4.62 5.21 5.75 6.25 6.71 7.14 7.54 7.9 8.24 8.56 8.85 9.12 9.37 9.6 9.82 IS 13174 (Part 2): 1994 suggested 2 methods for assessing Life 9 3.89 4.49 5.03 5.54 6 6.42 6.81 7.16 7.49 7.79 8.06 8.31 8.54 8.76 8.95 9.13 10 3.79 4.36 4.87 5.34 5.76 6.15 6.5 6.81 7.1 7.37 7.61 7.82 8.02 8.2 8.37 8.51 Cycle Cost (LCC):- 11 3.7 4.23 4.71 5.15 5.54 5.89 6.21 6.49 6.75 6.98 7.19 7.38 7.55 7.7 7.84 7.96 12 3.61 4.11 4.56 4.97 5.33 5.65 5.94 6.19 6.42 6.63 6.81 6.97 7.12 7.25 7.37 7.47 1. Present Worth Method (PW) 13 3.52 4 4.42 4.8 5.13 5.43 5.69 5.92 6.12 6.3 6.46 6.6 6.73 6.84 6.94 7.03 14 3.43 3.89 4.29 4.64 4.95 5.22 5.45 5.66 5.84 6 6.14 6.27 6.37 6.47 6.55 6.62 15 3.35 3.78 4.16 4.49 4.77 5.02 5.23 5.42 5.58 5.72 5.85 5.95 6.05 6.13 6.2 6.26 2. Annualised Cost Method (AC) 16 3.27 3.69 4.04 4.34 4.61 4.83 5.03 5.2 5.34 5.47 5.58 5.67 5.75 5.82 5.88 5.93

4 DECEMBER 2018 Section : SEMINAR PAPER

LCC Summary Tables for 100 years @ 12% SOME LIVE EXAMPLES OF STEEL-CONCRETE

FOR A YEAR OF 100 YEARS COMPOSITE BUILDINGS DESIGNED BY INSDAG DISCOUNT RATE 12 % COMMERCIAL CENTRE OF PRABHAT GROUP ) T @ @ S S R . ) R T E T ) S

O A At Borivali, Mumbai S . E S R S E R C E S P ) O O O Y Y R R N D M M T C R C 0 Y O % R E S U U O ( . C 1 I R Y R E N I N T O M T . E N P T B C N N A N N I C U E C F I O A I P . A A S O N R N L U E A I I N L E S S T E C O T R R R . C . I M R R S A P D Y T P E E ( L S N ( T A E O D C S P D P S R O A A V ( T R E I E C N E N P C A T H C % % T O E R N 2 2 E E E N I C N T C 1 1 P Y R U A L U N L X I P P A O O A E A E E T C C T D R M O S S I I O T D T D 1 RCC 22.54 70 0.322 0.258 2.147 0.644 0.306 24.99 0 2 COMP 1 20.45 100 0.205 0.164 1.363 0.409 0.194 22.01 11.94 3 COMP 2 20.82 100 0.208 0.167 1.388 0.416 0.198 22.41 10.35 4 COMP 3 19.85 100 0.199 0.159 1.323 0.397 0.189 21.36 14.53 5 COMP 4 18.35 100 0.184 0.147 1.223 0.367 0.174 19.75 20.99 6 COMP 5 19.18 100 0.192 0.153 1.279 0.384 0.182 20.64 17.41 7 COMP 6 18.71 100 0.187 0.15 1.247 0.374 0.178 20.14 19.44

Series 1 : LCCA Study Period 30 Yrs. Rate of Inflation 8% HANDLOOM HOUSE (2005) Series 2 : LCCA Study Period 100 Yrs. Rate of Inflation 8% • Client – CPWD (Nomination basis) Series 3 : LCCA Study Period 30 Yrs. Rate of Inflation 12% • Site Location – Janpath New Delhi Series 4 : LCCA Study Period 100 Yrs. Rate of Inflation 12%

30.000

25.000

20.000

15.000 Series1 Series 3 10.000

5.000

0.000 1 2 3 4 5 6 7

30.000 Total Structural Steel consumed about 1400 Tonnes Reinforcements consumed about 700 Tonnes 25.000

20.000 Series1 15.000 Series2 Series3 10.000 Series4

5.000

0.000 25.940 22.610 23.019 21.946 20.288 21.205 20.686

DECEMBER 2018 5 Section : SEMINAR PAPER

INDIRA PARIYABARAN BHAWAN, NEW DELHI (2010) • Client – CPWD (Nomination basis) • Site Location – Jorbagh, New Delhi

Total Structural Steel consumed about 645 Tonnes Profiled Deck Sheet consumed about 3192 sq m

Guest House-cum-Marriage Hall at Howly, Assam

Data Centre Office Building at Shillong, Meghalaya

6 DECEMBER 2018 Section : SEMINAR PAPER

• As thumb rule, 1 tonne of CO2 emitted to produce 1 the investment of public / private money tonne of Concrete; 1.8 tonnes of CO2 evolved to produce • LCCA will help policy makers to take decisions with due 1 tonne of Steel consideration of Cost Benefit Ratio of projects • Over last 50 years, Steel industry could reduce its energy • Environment aspects of sustainability is also ensured by this consumption per tonne produced by 60% methodology • Through “Climate Action Recognition Programme” of WSA, References:- expected to reduce more • B+G+20 Storeyed Residential Building with Steel-Concrete • Improvised carbon capture technology, in nascent stage, Composite Option – published by Institute for Steel reduce carbon footprints in climate in future Development & Growth (INSDAG), 2003, edited D. Datta and • For High strength-to-weight ratio, small Steel could replace G. Chakraborty large Concrete to withstand typical loading condition. • Multistoreyed Residential Building (B+G+20) with Steel- Hence, comparative sustainability is achieved by use of Concrete Composite Construction – published by Institute more Steel in Structures for Steel Development & Growth (INSDAG), 2010, edited D. • Use of Steel ensures Reduce, Reuse & Recycle of material, Datta supports sustainable development • Life Cycle Cost Analysis of Buildings – published by Institute Technologies are required to be developed not only to give the for Steel Development & Growth (INSDAG), 2010, edited D. immediate economic and strength impact but also to offer Datta rational and responsible choices with respect to life cycle costs • Sustainability of steel in transition to a low carbon economy, and the long-term environmental effects on the community to edited D Datta ensure sustainable development

CONCLUSIONS:- • Lawson R M “Composite Structure Cost of Modern Commercial Buildings”, SCI Publication, 1993. • Through LCCA proper comparison of invested sum would be easily assessed • Bandyopadhyay T K, “Basic Concepts in Composite Structures”, Refresher Course on Composite Construction Net Value = L1 Price + Life Cycle Cost using Structural Steel, 17-21 January 2000, organized by • It is desirable that the concerned authorities of Government Institute for Steel Development & Growth (INSDAG) and / Private sectors ask contractors to submit the LCCA of their Jadavpur University, Kolkata proposals because the least bidder with respect to Direct • Finance Management by I M Pandey Construction Cost may not necessarily be the least bidder with respect is the Life Cycle Cost • Today’s extra expenditure may save future expenditures, thereby an overall benefit could be achieved with respect to

DECEMBER 2018 7 Section : SEMINAR PAPER

Visakhapatnam Metropolitan Region Development Authority (VMRDA) by - P. Basanth Kumar IAS, Metropolitan Commissioner

VMRDA PROFILE Ø Plan - Preparation of Visakhapatnam Metropolitan Region Development Plan Ø VMRDA is Constituted under the Andhra Pradesh Ø Metropolitan Region and Urban Development Development Control - to monitor progress of Authorities Act, 2016 (Act No. 5 of 2016) on 05-09- development in Visakhapatnam as per its 2018. Metropolitan Region Development Plan Ø Ø Declared the ‘Development Area’ for Visakhapatnam Co-ordinate with line departments - give directions to Metropolitan Region to an extent of 6501.65 Sq. Kms. other departments, whereas VUDA is an independent agency and planning apex body. Ø The VMRDA will be governed under the monitoring Ø of the VMRDA Board and the Executive Committee. Monitor/Supervise Ø Ø Management and administration of the affairs of the Implement Authority shall vest in the Executive Committee. Ø Promote & secure planned development Ø The full board of the Metropolitan Region Ø Develop high quality infrastructure. Development Authority is yet to be constituted to Ø guide and steer the development of the Metro VMRDA undertakes investment plan in addition to Region. The orders appointing Chairperson officers infrastructure and land use plan where as VUDA dealing with Transportation, R&B, Energy, undertakes only land use plans Environment and experts in the areas of Urban PROJECTS Governance / Planning, Conservation, Environment and Transportation as members are yet to be issued. COST Ongoing Project -Rs.150 Cr Proposed Projects Rs.1190.00 Cr FUNCTIONS OF VMRDA Commercial Complexes/ Auditoriums / Kalyanamandapams Rs.33.09 Cr. Markets / Rythu Bazars Rs.7.32 Cr. Ø As per Section 5, the Apex Policy Body is vested with Sports Complexes Rs.6.00 Cr. the following functions encompassing all spheres of Other Development works Rs.5.74 Cr. development including economic development Total Rs.1568.42 Cr.

8 DECEMBER 2018 Section : SEMINAR PAPER

On Going Projects: Construction of Flyover at NAD Junction, Construction of Flyover at NAD Junction, Visakhapatnam Visakhapatnam Purpose: To overcome the Traffic problems with sustainable urban junction solution for a seamless Pedestrian and Vehicular movement, at the Intersection Ü Estimate Cost: Rs.150.00 Crores. Ü Tender Approval : G.O Rt No. 699 MA&UD (H2) Dept dated: 06-10-2017. Ü N a m e o f t h e Contractor : M/s V i j a y N i r m a n Company Pvt Ltd., Visakhapatnam Ü Agt No. & Date: 09/2017-18 dated: 18.11.2017 Ü Agt Amount: Rs. 113, 60,82,310/- Ü Date of Completion : 17.11.2019 Ü Proposed to construct Multi Level Rotary’s separately for LMV’s, HMV’s and Pedestrians. Construction of Flyover at NAD Junction, Status: Visakhapatnam Ü The Contracting Agency is constructing the arms of the upper level rotary after making necessary traffic diversions and barricading the site. Ü Agency has established Ready Mix concrete plant, laboratory and casting yard for girders at Vepagunta Ü The agency has completed 17 foundations and 11 pier caps out of total 64 piers. Ü The agency has completed 12% of the work. Ü Proposals for additional RoB submitted by Railways to head office at Bhubaneswar in Nov,2018. AIRPORT ARM

DECEMBER 2018 9 Section : SEMINAR PAPER

Construction of Flyover at NAD Junction, Proposed Projects Visakhapatnam 1. Development of IT City at Madhurawada NSTL ARM The project is proposed in the vacant VMRDA land at Madhurawada to promote IT & ITES development in Visakhapatnam. Ü Area of land available – 22.12 Acres Ü Proposed IT & ITES space – 5 Million Sqft Ü Other developmental activities – Commercial, Residential, Entertainment etc Ü MOU signed with IT Dept, Govt of A.P for rental guarantee on 26-02-2018. GOPALAPATNAM ARM Ü Mode of development – Trough Special P u r p o s e Ve h i c l e (SPV). Ü Consultant – Andhra Pradesh Urban Infrastructure Asset Management Ltd (APUIAML) Status: Ü Master plan finalized for the site. Ü Conceptual design of proposed IT towers are under finalization. Ü Cost of the project MARRIPALEM ARM about Rs. 1000 Cr. Ü O r d e r s o n formation of SPV VIEDCO issued on 29.10.2018. Ü RFP for the soil excavation under soil monetization mode to form the Roads is invited in Nov, 2018. The last date was extended from 06.12.2018 to 21.12.2018. Ü Tenders for construction of one tower of 18 floors along with trunk infrastructure will be invited shortly.

10 DECEMBER 2018 Section : SEMINAR PAPER

2. Proposed integrated museum & tourism complex in beach road with underground parking Proposed to develop an Integrated Naval Museum together with an underground parking for parking about 700 (4-wheelers) in the Beach Road for the facility of visitors.

Ü The conceptual designs integrating all facilities like TU-142, Proposed Sea Harrier with Museum, Submarine Museum etc., are prepared. Ü Public opinion is invited for finalization of the best design as per the directions of the Hon’ble Chief Minister. Ü Comments received from the public during meeting on 09.10.2018 are being considered in the finalization of the conceptual designs. Ü Considering various aspects and public opinion Revised plan prepared deleting under passage. Ü Public Representatives gave their consent on 24.11.2018 for the Revised plan. Way Forward:

Ü Proposed to take up the renovation of Rajiv Smruthi Bhavan and Sea Harrier museum in first phase. Ü Detailed plans prepared in consultation with Navy officials (INS Hansa, Goa) on 27.11.2018. Estimates under preperation. Ü Tentative project cost of Phase – I is about Rs. 10 cr in the over all project cost of about Rs.80 Crores

DECEMBER 2018 11 Section : SEMINAR PAPER

3. COMPREHENSIVE DEVELOPMENT OF ‘YARADA Slope Analysis HILLS’ WITH STAR HOTELS, RESORTS ETC. Ü The site Lies on the ridge of the hill and about 53% of VMRDA in possession of 1394 acres at Yarada Hill, the site is good for development. aspires for Comprehensive Development with Ü 21% of the site should not be developed and requires special focus on Tourism preservation of slopes. Ü Promotion of Eco-Tourism, Star Hotels, Resorts, Golf Courses, Botanical Gardens with focus on basic infrastructure development, attracting private investments Ü Innovative tourism facilities connecting Yarada Beach with other recreational facilities Ü RFP invited in July 2018 for providing consultancy services for Master plan & Comprehensive Developable Zone Area % Development of Yarada Hills. (Acre s) Ü The entire assignment is bifurcated in to four activities No Development 295 21 Moderate 353 25 Viz Master Plan preparation, DPR for the selected Development Good for 745 53 mode (PPP/BOQ), Tender evaluations and Development Agreements etc. Total Area 1394 100 Ü Seven eligible consultants have submit the Technical presentation before the committee on 29.10.2018. The consultants have submitted a broad Master Plan for development of Yarada Hills as per their expertise. Ü Technical evaluation of the 7 bidders is Completed. Ü Evaluation of bids completed - LOA to be issued. Ü Selected Consultant will prepare detailed master plan after detailed analysis of the site. Ü Some of the concepts suggested by the consultants are as follows for information.

1. Golf Course ZONING DIAGRAM 2. Botanical Garden BOTANICAL 3. Club House GARDEN 4. Wellness Resort 5. Villas / Time Share Apartments AMENITIE ADVENTURE/ CITY CENTRE/ HOSPITA S FOR BIKE TRAILS COMMERCI LITY 6. Town Center AL /HOTELS VILLAS 7. Walking and Biking Trails 8. Eco Cottages

BOTANICAL GARDEN

RESORTS/ STAR HOTEL

ECO TRAILS / NATURE/ FARMS

SPORTS/ VILLAS/WEEKE WEEKE GOLF PARKS/ ND ND RECREATION HOMES HOMES

12 DECEMBER 2018 Section : SEMINAR PAPER

4. Development of Mudasarlova Park: 5. Restoration & Re-development of 380 Ac As per the orders of the Govt, VMRDA proposes to Kailasagiri Hill Park develop the park as international tourist destination in Restoration and Re-Development of 380 Acres of the city. Kailasagiri Hill top park is being taken up by VMRDA Ü Area to be developed – 20 Acres. under Andhra Pradesh Disaster Recovery Project Ü Project Cost – Rs.50.00 Crores. (APDRP). Ü Ü AP Urban Greening & Administrative Sanction: G.O.RT No. 64 Revenue (DM) B e a u t i f i c a t i o n Dept Dated 04-05- 2016 Corporation Ltd was Ü Cost of project : Rs. 40.00 Crores. requested to finalize Ü Consultant for preparation of DPR and Supervision of the detailed designs works : M/s SAI Consulting Engineers Pvt., Ltd, and drawings for Ahmedabad development of Ü Agt No. & Date: 07/2017-18/CE/ VMRDA Dated: 31- park. 07-2017. Ü A r c h i t e c t u r a l Ü Agt value: Rs. 3,65,75,500/- consultant – M/s. Status: Design Accord, New Ü Delhi The consultant submitted final conceptual Master plan drawings on 30.10.2018. Ü The Hon’ble Chief Minister of A.P has approved the Ü VMRDA reviewed the proposals on 06.11.2018 and components proposed by the design consultant suggested certain revisions/improvements. Major components: Ü The World Bank officials reviewed the concept plan on a. Entrance Plaza, 28.11.2018. b. Adventure walk, Ü The consultant will submit the final master plan in this c. Heritage walk with shops, week. Ü Stakeholders meeting is expected to be conducted in d. Landscaping and fountains, the next week e. Restaurants, Ü Final DPR will be submitted in Dec’2018. f. Children’s play area, g. Amphi theatre, h. Parking facilities. Status: Ü The VMRDA Board meeting held on 10.08.2018 approved the components to be taken up to an amount of Rs.19.00Crores in this financial year. Ü Tenders for Gate complex, Signature pavilion etc., are invited with last date of submission as 14.12.2018.

DECEMBER 2018 13 Section : SEMINAR PAPER

Restoration & Re-development of 380 Ac Kailasagiri Hill Park

6. Development of Multi-Level Car Parking & Instit. complex

Proposed to construct Multi level car parking and institutional complex with a holistic approach duly taking the parking requirement of UDYOG BHAVAN, HSBC, GURAJADA, Children Arena etc.

Ü Area of land available – 1.35 Acres AREA STATEMENT Ü Consultant: M/s. Andhra Pradesh Urban # Description Details 1 Net Plot Area 6288.92 Sq m Infrastructure Asset Management Ltd. Parking Area No.of 4W No.of 2W Basement Floor 1 - Area 52337.20 Sq m 145 - Status: Basement Floor 2 - Area 52337.20 Sq m 145 - Basement Floor 3 - Area 52337.20 Sq m 145 - 2 Ü Master plan prepared with 5 floors parking and 6 Stilt Floor - Area 3401.57 Sq m - 792 Floor 1 above Stilt - Area 3197.95 Sq m 75 floors for commercial use. Total Parking Floors BUA 22611.12 Sq m 510 792 Total ECS achived 708 Ü Detailed designs and estimates are under progress. Commerical Development Floors Area Each Typical Floor Area 2158.60 Sq m 3 Ü Total Commercial Development EOI is being invited for taking up the project under 12951.60 Sq m Floors Area - ( 6 x 2158.60 ) PPP mode parallelly. 4 Total BUA (Parking + Commercial) 35562.72 Sq m

14 DECEMBER 2018 Section : SEMINAR PAPER

7. Commercial Complexes, Auditoriums & Kalyanamandapams 1. Shops near RTC complex opposite to City Central Park Ÿ Total Cost : Rs. 235.00 Lakhs Ÿ No. of shops : 42 No’s(G+1) Ÿ Each shop size : 9 x 12 Status: Finishing works in progress – 90% completed. 2. Commercial Complex at Pitapuram Colony Ÿ Total Extent : 947.50 Sqm IN PROGRESS Ÿ Total Cost : Rs.760.00 Lakhs Ÿ No. of floors/Total area: G+3 (1847.80sqm) Ÿ Parking Area : 649.70sqm Status: Work is in progress – 75% Completed. 3. Commercial Complex at Ramnagar Site-1 & 2 Ÿ Total Extent : Site-1: 2432.30 Sft & : Site-2: 602.39 Sft IN PROGRESS Ÿ Total Cost : Rs.1350.00lakhs Ÿ Total floor Area(G+3) : Site-1: 2811.24 Sqmt & : Site-2: 1312.40 Sqmt Status: Estimate revised as per 2018-19 rates – Tenders will be invited shortly 4. Kalyanamandapam at Chinmushidivada VMRDA Layout, Ground floor+ 1st floor, Visakhapatnam IN PROGRESS Ÿ Total Extent : 53915 Sft (Ac.1.23 cts) Ÿ Total Cost : Rs.513.75lakhs Ÿ No. of floors : (G+1) Status: Work is in progress – 15% completed. 5. Proposed construction of Community Hall / Kalyanamandapam / Meeting Hall at Thadichetlapalem, IN PROGRESS Dharma Nagar, Ward No.35 Visakhapatnam Ÿ Total Extent : 321.79 Sqm Ÿ Total Cost : Rs.156.00lakhs Status: Work is under progress – Plinth beams under progress. 6. Development of Open Auditorium at Gajuwaka Ÿ Total Extent : Ac.1.56 cts IN PROGRESS Ÿ Total Cost : Rs.225.00lakhs Status: Roof truss under progress. 7. Construction of Kalyanamadapam for Christian minorities at Chinagadili Village, Visakhapatnam Ÿ Total Extent : 575 Sqm Ÿ Total Cost : Rs.70.00lakhs Status: Foundations under progress. IN PROGRESS

DECEMBER 2018 15 Section : SEMINAR PAPER

Markets / Rythu Bazars 1. Construction of Modern fish market opposite VMRDA City central park,Visakhapatnam. Ÿ Total Extent : 732.50 Sqm Ÿ No. of floors : (Cellar+silt+2) Ÿ Total Cost : Rs.360.00lakhs Status: About Rs.1.74 crores is deposited by Fisheries department Existing market for the project. No Response to the 1st call Tenders - to be recalled. Sports Complexes Completed 1. Indoor sports complex infrastructure facilities at Z.P.High School Gopalapatnam Ÿ Total Extent : 1865 Sqm Ÿ Total Cost : Rs.350.00lakhs Status: Work completed. Other Development works 1. Construction of Ground floor and 1st floor building for Fire Station at Suryabaugh, Visakhapatnam. Ÿ Total Extent : 929 Sqm Ÿ Total Cost : Rs.110.00lakhs Status: 1st floor Brick Masonry work is in progress. IN PROGRESS 2. Construction of RDO Office at Anakapalli. Ÿ Total Extent : 984.34 Sqm Ÿ No. of floors : Rs.320.00lakhs Status: Roof slab completed. 3. Construction of framed structure for school building (G+2) for IN PROGRESS shifting of Adarsh Public School at Pedagantyada, Visakhapatnam. Ÿ Total Extent : 14758 Sqft Ÿ Total Cost : Rs.144.00lakhs Status: Columns up to plinth level completed and remaining work is in progress. IN PROGRESS

16 DECEMBER 2018 Section : SEMINAR PAPER

Steel Structures

by – Satyajit Mohapatra General Manager –Technical Marketing (Marketing & Sales), Essar Steel

India's Steel Sector: Strong Outlook

Overall Steel Consumption by Segment in India

Auto Sector poised to grow from US$ 74 Bn in 2015 to US$ 260-300 Bn in 2026 Anything which is low can only go UP!

Focus Sectors promising Steel Demand

DECEMBER 2018 17 Section : SEMINAR PAPER

Infrastructure Investment Drivers

Indian Infrastructure: Powering Ahead

18 DECEMBER 2018 Section : SEMINAR PAPER

Demand from India's ever-expanding Highways Why Steel?

Ÿ Over 100,000km of National Highways in India Ÿ New Road construction Target @41 Kms per day Ÿ Major demand for Coated steel for usage in Bridges, Crash Barriers, and for General Engineering

Port Developments

As part of Sagarmala Programme, more than 577 projects (Cost: Rs. 8.57 Lacs Cr.) have been identified for implementation, during 2015-2035, across the areas of port modernization & Newport development, port connectivity enhancement, port-linked industrialization and coastal community development.

As of 31-Mar-2018, a total of 492 projects (costing around Rs. 4.25 Lac Crore) wereunder various stages of implementation, development and completion.

DECEMBER 2018 19 Section : SEMINAR PAPER

Steel Grades –Product Criticality

Essar's Initiative Defence…Make In India

20 DECEMBER 2018 Section : SEMINAR PAPER

Make In India -Supplies to Critical Projects

Make In India-Exports to Prestigious Projects

DECEMBER 2018 21 Section : SEMINAR PAPER

Product Positioning –Essar's Branding Initiative

Essar Steel –SC network

22 DECEMBER 2018 Section : SEMINAR PAPER

Why Essar is a preferred supplier ? Ø Dedicated port infrastructure –ease of movement for raw material & finished goods Ø Raw material security with largest pellet capacity in India Ø Wide product mix. Ø Presence across all segments Ø Express Deliveries –Geographical Advantage. Ø Customer centric approach Roadmap to achieve 300 Million tons

NINL Registers Highest Single-day Sinter Production Odisha's Kalinga Nagar-based Neelachal Ispat Nigam Limited (NINL) set another benchmark in production with highest ever single- day Sinter output of 5680 ton on 28th December, 2018 surpassing the previous best of 5640 ton recorded in 2013. Mr. S.S. Mohanty, Vice-Chairman & MD, NINL, congratulated the team and all concerned in and around. Earlier, Brahmani, the Blast Furnace of the company, registered 110 percent of the rated capacity on 15th December, 2018 with highest single-day Hot Metal output of 3412 ton. NINL resumed billet production earlier this month by restarting its state-of-the-art Steel Melting Shop which is the second milestone, the company has planned for the turnaround of the plant. NINL had achieved the first milestone with the completion of the Blast Furnace and expects to achieve the third milestone with operation of its captive iron ore mines towards the end of the present Financial Year. The company has also plans to produce TMT Bars and Wire Rods soon.

DECEMBER 2018 23 Section : SEMINAR PAPER

Steel Structures Advantages of steel structures in Civil infra structures

by – Abhai Sinha, Former D.G, C.P.W.D, National President, IBC

Advantages of Steel Structures ? No porosity, hence no entry for mold and mildew. ? High tensile strength. ? Offsite fabrication and fast component assembly. ? High strength per unit mass, so light structure, cost ? Endlessly recyclable. saving in design of foundation. Uses ? For large span structure, steel sections will be small. ? For Skyscrapers, agriculture buildings and garages. ? Steel frames are with CAD accuracy and offer Arch ? Attractive building options from start to finish- design, planning and design flexibility. Sustainable, Affordable and durable. ? Steel in concrete to offer tensile strength. ? Suitable for hybrid construction works. ? Steel structures are with high strength, stiffness, ? It can be used at any stage of construction framing, toughness and ductile property with integrity. floor joists, roofing materials. ? Most suitable for Industrial and Commercial buildings. ? Steel is cheaper/lighter than wood. ? Most durable and least maintenance cost. ? Faster construction which is high quality controlled, no Constructability scope for human error as projects/sections are factory finished with less impact on surrounding. ? Can Be fabricated into endless variety of shapes ? Saves money, labor, decreased construction time, less ? Faster construction at site due to bolting and welding. maintenance cost and less repair/replacement cost. ? Distribution of compression and tensile forces in beams ? No Construction waste at site. offers Architectural freedom in design of spaces and last-minute changes. ? Steel structures are having unrivaled ability to with stand high speed winds, heavy snow loads, fire and Cost Effectiveness seismic activities, pests and decay, less insurance cost. ? Due to Standardization, steel structure sections are ? It can be moulded in any shape. easy to erect after fabrication. ? Any roofing pattern with wood-like siding. ? Shorter Construction period-less duration of ? It can afford any artistic imagination without disturbance in vicinity. compromising any inherent property. ? Steel prices are dipping continuously and uninterrupted ? Highly energy efficient structure. supply at site. ? Complete sealed buildings. Safety ? Roofing panels can be primed or made cool metal ? Non-Combustible with fire resistant coating. roofing to decrease solar heat gain, which increases ? Water resistant coating so no corrosion. energy efficiency.

24 DECEMBER 2018 Section : SEMINAR PAPER

Usage of Steel in Mass Transit Systems

by - K K Rao, Director, Steel Exchange India Ltd.

THE 4 MASS TRANSIT SYSTEMS Container ship STEEL IN SHIPS & PORTS

Passenger ship

Bulk Carrier Ship

SHIPS Oil tanker ship Measur es f or enhancing steel consumption Encourage river and coastal shipping. More ships and vessels to be built in India; for international & coastal shipping as well as Navy. Produce more steel plates of ship hull quality. Ship internals need normal grade steels too - plates, structurals, pipes and hollow sections. Encourage installation in ships, of stainless steel tanks, fittings, railings and furniture etc

DECEMBER 2018 25 Section : SEMINAR PAPER

Visakhapatnam Port

GANGAVARAN PORT

Coal berths

PETRONET LNG LTD Layout of berths

Dredging

PETRONET LNG LTD

26 DECEMBER 2018 Section : SEMINAR PAPER

PORTS Measures for enhancing steel consumption Berths, buildings, storage sheds and conveyor Construction of new major and minor ports. systems: These are all constructions at site. Construction of rail lines to the new ports. Cargo &mobile crane: Purchased/outsourced. Construction of steel buildings in future ports. Tugs, boats, vehicles, fire tender: Purchased Replacement of rails, if situation so warrants. Storage facilities: Open yards and large sheds. Construction of steel shelters in bus stops etc. Services: Stevedoring, dredging and transport. Use of steel lighting poles for streets & parks. Goods transport: Rail and road (truck/ trailer) Encourage usage of steel------Coated sheets for roofs and cup boards. Steel used for RCC, berths, buildings, sheds, conveyors, rail lines, roads and parking areas. Stainless Steel: Railings, benches, chairs etc. STEEL IN PLANES & AIR PORTS

AIR PLANES AND AIR LINES

DECEMBER 2018 27 Section : SEMINAR PAPER

Delhi T3 Terminal AIRPORT STRUCTURES

Visakhapatnam Airport AIRPORT STRUCTURES AIR PORTS (Construction - RCC & Steel, SS, Al, PVC, glass, Measures for enhancing steel consumption. granite and tiles) Start construction of approved new airports. Units: Main building, runway, traffic control tower, Prefer steel buildings over RCC constructions. hangers, aero bridges, loading & towing m/c s, fuel & fire tenders and water &fuel tanks. Lattice structure in front enhances appearance.

Main building houses offices, check in counters, Pre-engineered steel buildings be preferred for security checks, boarding gates, waiting lounges, aircraft hangers and cargo storage sheds. food courts & shops and passenger amenities. Encourage usage of steel – Lighting, air conditioning, fire detection, lifts, escalators, baggage scanners, belt conveyors, Sheets for roofing, cupboards /storage devices. display & public address systems are installed. SS: Hand railings, passenger benches, chairs etc. Roads, parking, public conveniences provided.

28 DECEMBER 2018 Section : SEMINAR PAPER

STEEL IN TRAINS & RAILWAY STATIONS

OUR TRAINS – ON LIGHTER SIDE

Indian Railways Logo Adv ertisemen ts Solar Panels on train New model train

Victoria Terminus (VT), then Chapatrapati Sivajji Terminus (CST) Chennai Central

Secunderabad VIJAYAWADA RAILWAY JUNCTION VISAKHAPATNAM RAILWAY STATION

DECEMBER 2018 29 Section : SEMINAR PAPER

RAILWAY STATIONS Construction material: RCC, steel, granite, tiles, wood and glass. Houses offices of station master, staff; ticket counters, vending m/cs, RPF, waiting halls & rooms, cloak room and food court & kiosks etc. Platforms, stairs, escalators, foot over bridges, fans, lights, benches, chairs, potable water, display boards and public address systems. Signal cabins, goods shed and misc. buildings. Approach roads, parking and water tanks etc.

Measures for enhancing steel consumption Steel buildings are better for seismic zones. They can be constructed faster than your imagination. Country needs more express and goods trains- i.e., more engines, The 30 storey Arc Hotel , Changsha (CHINA) built in just 15 days! bogeys and wagons. Expeditious construction of new railway lines, track doubling and electrification works. Require more RCC sleepers, steel poles, rails, foot over bridges and barriers between tracks. Preference be given for items made of steel – Coated sheets, cupboards and storage devices. SS: Hand railings, platform benches, chairs etc.

Use of Galvanized Reinforcement

Reinforcement used in the white concrete shells and also the binding wires was REINFORCEMENT STEEL entirely galvanized so as to High Strength Deformed Bars & Wires prevent the long-term for Concrete Reinforcement effect of rusting. S i n c e g a l v a n i z e d High strength deformed bars and wires reinforcement for concrete for concrete reinforcement is seldom used in India, several tests were carried [IS 1786 - 2008 not specific to any process] out to ensure that the TOR/CTD: Hot rolling followed by cold working. Lotus Temple, New Delhi mechanical properties of TMT: Thermo Mechanical Treatment reinforcement did not Completion - 1986 become adversely affected [Hot rolling of bar/ coil, rapid quenching after due to galvanizing. exit stand and tempering on cooling bed] Sandblasting done to Cold Twisted Deformed (CTD) steel Micro Alloying: Cr, Mo and V reduce pickling time and bars used for reinforcement. Strengthening elements: Nb, V,B and Ti also to avoid hydrogen Prior to galvanizing, bars preheated embrittlement. to 100 Deg C to drive out moisture. Low alloy steels: Cr, Cu, Ni, Mo and P

30 DECEMBER 2018 Section : SEMINAR PAPER

TEMPCORE COOLING

Beware!

All steels sold in market may not meet quality standards. Physical High strength Be aware of steel application Properties deformed needs and desired quality specifications. steel bars Make sure, you get steel of Dimension Steel Chemical right quality, right quantity Tolerances Product Properties and in right time. Insist on manufacturer’s test certificate, especially when Sectional quantity is reasonably high. weight Make cross check, if need be.

DECEMBER 2018 31

TATA STEEL ADVT Section : ARTICLE

Processes Routes for HRC Production

by- Sanat Bhaumik, Director (Sales & Marketing), Steel Plantech India

INTRODUCTION Production of hot rolled steel coils involves hot rolling process which requires rolling of steel slabs at a high temperature (typically at a temperature more than 9250C or 17000F), which is above the re-crystallization temperature of steel. When steel is heated above re-crystallization temperature, it can be shaped and formed easily. Hot rolling process uses this property of steel for production of hot rolled coils. There are mainly five process routes for production of hot rolled coils (HRC) and these are: 1. Steckel Mill route, 2. Conventional Hot Strip Mill (HSM) route Hot Rolled Coils at the Delivery Section of a HSM 3. Thin Slab Casting & Rolling Mill (CSP® or fTSR or QSP) route For the same strip width of 1650mm, a thin slab casting & rolling 4. Endless Strip Production (Arvedi ESP) route and mill (CSP® or fTSR/QSP) will be able to produce 1.4 - 1.5mtpy 5. Direct Strip Casting (DSC, HSBC, BCT, CASTRIP) route with a single casting strand and the production capacity can be Selection of right production process depends on the product doubled by adding a 2nd casting strand in future. The CSP® mix (strip thicknesses, widths & steel grades), product quality (Compact Strip Plant) or fTSR (Flexible Thin Slab Rolling / QSP and production capacity of the plant. (Quality Strip Production) route can produce minimum strip thickness of 1.2mm on regular basis and is being produced by For example, a 2-stand Steckel mill will be able to produce about many plants worldwide but some of them are also claiming 0.90 – 1.00 million tons of HRC per year if we consider 1650mm production of even 1.0mm thickness. maximum width strips. Again, such steckel mills cannot produce good quality HRC of less than 1.80mm strip thickness on An Arvedi ESP (Endless Strip Production) can produce ultra thin consistent basis. Even with implementation of latest HRC of 0.80mm thickness and undoubtedly the best technology automation hardware and software systems, the thickness and available for production of ultra thin HRC on consistent basis flatness tolerances on output HRC from Steckel mills will be with very good thickness and shape tolerances. However, an below market average considering the outputs from other units Arvedi ESP will be able to produce maximum 1.5 – 1.6mtpy HRC like conventional HSM, CSP®/fTSR/QSP or ESP. for 1650mm maximum width but there is no possibility of any major production capacity expansion of the same plant in Conventional Hot Strip Mill (HSM) can produce minimum strip future. thickness of 1.2mm but the optimum production capacity will be approximately 3.8 to 4.0mtpy of HRC if we consider 1650mm With a few pilot plants in operation, Direct Strip Casting (DSC) maximum width strip. Annual production capacity of less than technology has probably reached a stage from where it may be 2.5mtpy for commercial grade steel will make such plant feasible process route for HRC production. DSC process consists economically unviable. of a caster in which liquid steel is fed on an intensively cooled

32 DECEMBER 2018 Section : ARTICLE revolving belt (see Figure 1). After solidification in protective every complete pass. Output coils from Steckel mill will be atmosphere, the cast strip is about 10-15mm in thickness which normally of minimum strip thickness of 1.8mm. A shearing is directly hot rolled without reheating. The development of DSC mechanism is also provided in this mill to cut the irregular head process should be viewed in the context of other near net shape and tail of the incoming slab. casting developments like twin roll strip casting carried out by European steel companies to produce new steel grades with improved mechanical properties at reduced overall cost.

Figure 1: Schematic Drawing of a Direct Strip Caster

Before we reach a final conclusion for the best production route for HRC production, let us have a look through these five process Two-stand Steckel Mill in Operation routes and technology. In the Steckel mill, several passes have to be taken to get the STECKEL MILL desired thickness reduction. The Steckel mill has quality problems due to temperature losses during these passes. The A Steckel mill also known as a reversible finishing mill except rated production in a Steckel mill is also lower than a that two coiler furnaces are used to feed the material through conventional HSM. the mill. One coiler is on the entry side and the other on the exit side. The coilers pull the material through the rolling mill In India, Steckel mills are mainly used for production stainless or stand. The material is fed back and forth through the mill until alloy steel strips primarily for low production capacity. Jindal the desired thickness is reached, much like a reversing rolling Stainless (JSL), a leading producer of stainless steel in India, mill (see Figure 2). started with a Steckel mill in Hisar plant and then installed a conventional HSM in Odisha both for higher capacity and HR Steckel mils process slabs to produce hot rolled coil (HRC). The strip quality. Steckel mill allows the rolling of a large slab by providing heated reels (Steckel Furnaces) on both sides of the mill to store the CONVENTIONAL HOT STRIP MILL (HSM) increased length produced during rolling. The primary function of the Hot Strip Mill (HSM) is to reheat

Figure 2: Schematic Diagram of a 2-stand Steckel Mill

These Steckel furnaces are used for additional heat retention semi-finished steel slabs nearly to their melting point, then roll and thermal consistency in the rolled piece, which in turn them thinner and longer through successive rolling mill stands produces improved uniformity throughout the rolled product. A driven by motors, and finally coiling up the lengthened steel furnace is provided in both sides of the mill, which covers the strip for transport to the next process (see Figure 3). mandrels each in one side upon which the slab is rolled after

DECEMBER 2018 33 Section : ARTICLE

THIN SLAB CASTING & ROLLING MILL (fTSR, CSP® or QSP) For such plants there are three commercially proven solutions: (1) CSP® or the Compact Strip Plant developed, patented and implemented in about twenty eight plants worldwide by SMS Siemag AG, Germany, (2) fTSR or Flexible Thin Slab Rolling developed and implemented by Danieli Italy for about ten plants and (3) QSP or the Quality Strip implemented by JP Steel Plantech Co. (SPCO), Japan for only one plant in Thailand. CSP® is a compact plant concept comprising a two or single Reheating Furnace for a Hot Strip Mill strand casting machine, a roller-hearth furnace or tunnel furnace (160 to 220 meters long) and a 6-stand rolling mill The HSMs in India roll slabs weighing up to 35 tons between train. Thin slabs, 55 - 90mm thick, are cast and fed directly to 800mm and 2250mm width. Steel slab 200mm to 250mm thick the CSP® rolling mill after temperature equalization in the and up to 10 – 11 meters long is rolled into strip as thin as 1.6mm roller-hearth furnace and then rolled to the finished strip (may be 1.20mm) and up to 500 meters in length. Coils are gauge (see Figure 4). This roller-hearth furnace is also used as a produced with a 762mm inside diameter ('eye') on one of coilers, with outside diameter limitations of 2200mm, corresponding to buffer for storing the slabs during roll changes in the mill 1000 pounds-per-inch-width (PIW) or 22kg/mm width. stands.

Figure 3: Schematic Diagram for a conventional HSM

For a 1650mm wide HSM the optimum production capacity will be about 3.8 - 4.0mtpy and such conventional HSMs will be able to produce highest quality HRC with precise control of gauge, thickness and crown. However, installation of new HSM for production of 1650mm wide HRC is rare now and almost all present day HSM installations are mainly for 1850mm to 2250mm wide strip production with annual capacity varying between 4.5 to 5.5mtpy.

Tunnel Furnaces of a fTSR plant The compact CSP® process makes it possible to produce hot strip with a homogeneous microstructure and constant mechanical and physical properties over the entire length and width of the strip. Additional features are the close tolerances with regard to gauge, width, profile, contour and flatness. These can be achieved by the homogeneous temperature distribution in the Finishing Mill train of MHI Hot Strip Mill in Operation thin slab and to the low temperature losses between the roller

34 DECEMBER 2018 Section : ARTICLE hearth furnace and the rolling mill. These conditions result in an There is only one fTSR under implementation in India and it is at extremely stable rolling process at constant rolling speeds and NMDC Nagarnagar and on completion this plant will be quite temperatures. similar to MMK Atakas plant in Turkey.

Figure 4: Schematic Diagram for a Compact Strip Plant or CSP®

The first CSP® in India was installed in Ispat Dolvi (now JSW Ispat JP Steel Plantech Co., Japan has only one QSP (see Figure 6) Dolvi Works) in 1998 and presently there are 3 more plants are installation at G-Steel, Thailand. The concept of this QSP is very under operation – these are at Bhushan Steel & Power (Odisha), good and with a coil box separating the roughing mill train from Essar Steel (Hazira) and Tata Steel (Jamshedpur). Out of these finishing mill train. It can compete with almost all product grades plants, the CSP® at Essar Steel is for production of 3.5mtpy HRC from conventional HSM. This QSP is equipped with Sumitomo with three casting strands. Caster, MHI Mill stands and other equipment from SPCO (Tunnel Furnace, Descaler, Crop shear, Laminar Cooling and Delivery section equipment, etc). But considering the number of installations worldwide and overall performance records, CSP® of SMS AG is more reliable than the fTSR of Danieli, Italy. Since QSP of SPCO is implemented only in one plant (G-Steel Thailand), we cannot judge its performance considering only one installation and again, it is not properly utilized to its fullest potential to produce high end steel grades. Over the years G-Steel has been producing commercial grade hot rolled coils only.

Mill Section of a Compact Strip Plant or CSP® fTSR (see Figure 5) or Flexible Thin Slab Rolling is a concept implemented by Danieli in almost ten plants. It has two differences from the CSP® of SMS Siemag and these are (1) Vertical curved caster in place of full vertical caster and (2) Roughing and Finishing Mill trains are separated in place of all mill stands in a single cluster (see Figure 5). Figure 6 : Schematic Diagram for JP Steel Plantech QSP in G Steel, Thailand

Figure 5 : Schematic Diagram for a Flexible Thin Slab Rolling Plant or Danieli fTSR

DECEMBER 2018 35 Section : ARTICLE

For 1650mm wide strips, annual production capacity of a single produce up to 1.2 – 1.5million tons of HRC per year (depending casting strand CSP® or fTSR/QSP will be about 1.4 - 1.5mtpy and on product mix) and the minimum strip thickness can be as low adding a second strand in future, the capacity can be increased as 0.8mm. to 3.0mtpy. Overall line length in all three cases will be about 480 Presently two Arvedi ESP Lines are in operation in Italy and five in to 500 meters. Rizhao Steel, China. ENDLESS STRIP PRODUCTION (Arvedi ESP) The Arvedi ESP was developed and implemented by Siemens VAI Austria (now Primetals) with Acciaieria Arvedi SpA, Italy. This ESP produces hot rolled strip in a combined, continuous and uninterrupted casting and rolling process (see Figure 7). In this type of plant, the energy consumption and the associated costs are up to 40 percent lower than those of conventional hot strip mills or casting and direct rolling processes. This also means a significant reduction of CO2 emissions. With a length of just 180 – 200 meters, the plants also have considerably more compact dimensions than conventional casting and rolling mills like CSP®, fTSR or QSP. A wide range of high-quality and ultra-thin steel grades can be produced with the endless cast-rolling process. Arvedi ESP in operation at Acciaieria Arvedi SpA Italy Due to the highly compact ESP line arrangement with a total length of only 180 – 200 meters combined with the direct linkage DIRECT STRIP CASTING of the casting and rolling processes, lower investment (CAPEX) With increasing competition in global steel market, strip casting and operating costs (OPEX) will be incurred in comparison with technology (Figures 8, 9 &10) potentially offers an efficient, conventional HSM or thin-slab-casting and direct-rolling plants.

Figure 7: Schematic Diagram for an Arvedi ESP

The endless rolling operations allow strip production with economical, and environment friendly approach to produce hot uniform and repeatable mechanical properties along the entire rolled coils. There are various strip casting initiatives that have strip length and yield losses are reduced to a minimum because been carried out in the past as well as present. Twin Roll Casting head- and tail-end strip crops are virtually eliminated. Another (TRC), Horizontal Single-Belt Casting (HSBC) or Belt Casting decisive advantage is that with continuous rolling operations, Technology (BCT) and Near-Net-Shape-Casting are some of the roll gap and pressure adjustments are constant during the these emerging technologies. entire rolling process – resulting in a longer roll lifetime – as The CASTRIP® facility at Nucor Steel Crawfordsville, Indiana can compared to the discontinuous and wear-intensive rolling of produce ultra thin cast strip products of 0.8mm to 1.5mm discrete transfer bars. thickness which can be used as replacement of many cold rolled An Arvedi ESP line for 1650mm maximum wide strips can sheets. This process essentially consists of two counter rotating

36 DECEMBER 2018 Section : ARTICLE rolls as shown in Figure 9. The molten steel delivered from the The commercialization of Horizontal Single Belt Casting (HSBC) top solidifies on the surface of the casting rolls. This results in the or Belt Casting Technology (BCT) is still to be established. In formation of two separate shells which are joined together at general both these technologies have good potential to compete the roll nip to form a continuous solid strip. with thin slab casting & rolling solutions but still a long way to go The CASTRIP® process has many inherent advantages over reach the stage CSP® or fTSR reached today. The HSBC conventional casting and rolling technologies. These include a technology may be suitable for integrated steel plants while the smaller footprint, lower capital cost, simpler and more flexible TRC technology is suited only for mini mills. operating plants, etc.

Figure 8: Schematic Diagram for evolving Strip Casting Processes

However, till today these processes could not be fully OUTLOOK & CONCLUSION established for commercial applications and many steel At the beginning of this paper we observed that there are four producers in Europe, Japan and USA are making efforts to make established and one developing process routes for production of the strip casing technology commercially viable for hot rolled hot rolled coils and subsequently, we have briefly described coil production. these processes. We also found that selection of most suitable production process depends on the product mix (strip thickness, width & steel grades), product quality and production capacity of the plant. These observations are summarized below (with respect to a plant to produce 1650mm wide strips): Ÿ Maximum production in a Steckel mill will be 0.90 – 1.00mtpy and output quality of HRC may not be as good as other plants using alternative process. Ÿ Output HRC quality of conventional HSM is good but the Figure 9: Schematic of the CASTRIP Twin Roll Caster optimum production capacity should be 3.5 – 4.0mtpy to opt for this option. Conventional HSM can produce all steel grades The commercialization of Horizontal Single Belt Casting (HSBC) including HRC for automotive skin panels and CRGO. or Belt Casting Technology (BCT) is still to be established. In Ÿ Considering the number of installations worldwide and general both these technologies have good potential to compete overall performance till date, CSP® is more reliable than the fTSR with thin slab casting & rolling solutions but still a long way to go or QSP. However, till now this process is mainly established for reach the stage CSP® or fTSR reached today. The HSBC production commercial grade HRC. technology may be suitable for integrated steel plants while the TRC technology is suited only for mini mills. Ÿ Arvedi ESP may be the best option if the plant capacity is

DECEMBER 2018 37 Section : ARTICLE

Figure 10: Schematic Diagram of BCT Pilot Caster at Clausthal limited to 1.5mtpy and for phase II expansion another identical integrated steel plants. In fact, if we look into last 20 years' mill Arvedi ESP line will have to be installed. Obviously, the Capex will installations worldwide for hot rolled steel coil production, we be more but it will add more flexibility of operation. find at least two-thirds of the total production comes from the conventional HSM route. But the Thin Slab Casting & Rolling Ÿ Strip Casting technologies (HSBC or BCT) are yet to be proven technologies are putting up very tough competition depending commercially effective when compared with other processes on the selected product mix, production capacity and product like Steckel Mill, conventional HSM, CSP®, fTSR or QSP. applications. TSCR process is constantly challenging the convention HSM to optimize on its Capex and Opex. However, for After analyzing all these points for each of the described integrated steel plants HSM is a clear winner as far as the processes, we may infer that, for HRC production the production capacity, product diversity and product qualities are conventional HSM route still may be the best option for large concerned.

Laminar Cooling Section of a HS

38 DECEMBER 2018 Section : ARTICLE

Iron Ore Beneficiation by - P. S. Bhattacharya, Editorial Consultant

Iron and steel industry grew exponentially during the last decade. On the basis of growth witnessed the National Steel policy 2008 revised the estimated domestic steel production to 180 million tonnes by 2019-2020.Iron ore is the basic raw material for iron and steel making. Of total Domestic consumption of iron ore 98% is accounted for pig iron and sponge iron industries. Lumpy iron ore (-30 +10mm) and agglomerates like sinter and pellets form the production of pig iron in blast furnace, where as steel scrap, lumpy iron ore ( -18 + 6mm) or pellet are the feed for sponge iron production. Hematite and magnetite are the most prominent iron ores found in the country .Of these, hematite is considered to be most important iron ore because of its high grade quality and lumpy nature which is consumed by a large number of pig and sponge iron industries in India. Magnetic deposits are 1. Most of the iron ore mines in India have been operated not are not exploited so far for domestic use on account of by selective mining for maintaining high grade iron ore. poor lumps (-40% Fe) However it can be used after 2. To maintain high grade iron ore low grade lumps and beneficiation a finer size followed by pelletisation. laterites are rejected. Generally classifier fines (-10 As per United Nations Framework classification (UNFC) as to.15mm) are not processed any further and hence on 1.4.2010 the total resource in the country is estimated used in sinter making. to be 28.5 billion tonnes out of which hematite iron ore 3. The current industrial practice of iron ore washing is account for 62.7% and magnetite 37.3%.Almost all present oriented towards product with 2.5 to 3.0 Al2O3, in day production come from hematite reserves. The overall lumps and around 5% Al2O3 in Sinter plant. hematite reserves is of medium grade (+62% Fe) and account for 28% of total iron ore resources of the country, 4. The present iron ore processing circuits produce slimes particles below 0.15mm (-100 mesh) which are Domestic iron ore production mainly in the form of lumps discarded as waste. Generation of slimes is in the tune and fines is in the ratio of 2:3. Of these domestic of 20 to 25 %. consumption in iron and steel making is only around 40- 45%in the form of lumps and sinters, the remaining is 5. Present industrial practice causes huge loss of iron exported. The bulk (around 90%) of iron ore fines get values in process/mine rejects and then stacking has exported as they cannot be used in Iron making without adverse effects on environment causing economical agglomeration. A close look at the beneficiation imbalance. /processing practised in India reveals the following: 6. Low grade ores are exploited.

DECEMBER 2018 39 Section : ARTICLE

Processing is a must as any ore in general has impurities. In 4. In magnetite processing plant the process of flotation is many cases presence of deleterious impurities like silica, replaced by magnetic separation. The minerals are Alumina, sulphur and phosphorous beyond desired limits conveyed to the permanent magnetic dewatering tank make the ore unsuitable for use in BF or adversely affect for concentrate and then concentrate will enter productivity and quality. permanent magnet drum for a second magnetic Efficient and economic production of pig iron in blast separation. The concentrate after filtration and drying furnace depends on a large extent on appropriate raw are conveyed to ware material quality. There has been a change particularly for Advantages iron ore i.e. from totally lump oriented feed to use of 1. In crushing it adapts to additional 2 stages and closed higher sinter and pellets in blast furnace burden. Therefore circuit system for ideal fineness. Jaw crushers have fine requirement has gone up. Hence, emphasis on large crushing capacity. enriching the quality of fines through techno economically viable beneficiation is essential. 2. In grinding and classification with characteristics of a Higher grade lump ore reserves are limited and hence large processing capacity and small floor area superfine optimum utilisation of locked up valuables in sub grade lamination autogenously mill can save energy up to 85%. iron ore resources are essential for industries to survive 3. In classification hydro cyclone and vibrating screens can and grow and achieveing through appropriate enhance classifying effects. beneficiation technology. A short description of process is 4. It adapts the third generation tailings dry stacking depicted below. technology which can save energy by 60 to 80%. The lower grade sources of iron ore generally require Furthermore it can protect the environment and build a beneficiation, using techniques like crushing, milling, base for green mine. gravity or heavy media separation, screening and silica froth floatation to improve the concentration of the ore Major iron ore beneficiation equipment are jaw crusher, and remove impurities. This results in high quality fine ore cone crusher, vibrating screen , ball mill spiral classifier, powder known as fines. The process of beneficiation hydro cyclone, flotation machine, magnetic separator, depends on the nature of ore i.e. HG, MG or LG. Typical efficient thickener , press filter, slurry pump feeder, process is as given below: agitation tank, belt conveyor etc. Iron ore beneficiation plants in India 1. Raw iron ore for primary crushing are fed into a jaw crusher by plate feeder and reduced to secondary Such plants are highly adequate in India (i.e. 52 crushing. The cast iron ore is then sent to vibrating concentrators cater to the need of iron production of screen for classification. about 220 mtpa (mines 316) of these 50% are in Goa region ( 33 mtpa, mines 72) dedicated totally for exports After classification with below mesh size shall be and not for domestic consumption. transferred away as final products and the balance will return to the cone crusher thus forming a closed circuit. Present status and proposed action plan As per the requirement the size of products can be The Indian mining industry currently is being run in combined and graded. fragmented lease holds and operated by captive and non 2. The smaller crushed iron ore is fed to ball mill for captive consideration, producing iron ore in the ratio of grinding; the crushed iron ore will grind the ore to about 1:4. The non captive sectors are sources of high quality 2mm with 3inch steel balls. lumpy ores (within -18 + 6mm) to coal based DRI plants, leaving behind the huge stock of fines (-6mm) at the mines 3. The iron ore slurry is pumped to agitation tank and head and are being exported. finally pumped to flotation machine with the final sulphide ore (-0.074mm) going to froth flotation cells However, these fines are ideal feed for value addition for recovery of iron. through beneficiation for sintering / pelletisation.

40 DECEMBER 2018 Section : ARTICLE

Pelletization by - P. S. Bhattacharya, Editorial Consultant

Pelletization is a process of compressing or moulding Typical properties of pellets are:- material in the shape of a pellet. A wide range of different Chemical Analysis On dry basis Unit Value Tolerance materials are pelletized including chemicals, iron ore Fe 65 Minimum % 65 Minimum animal compound feed etc. FeO % 0.3 Maximum Si O2+Al2O3 % 5 Maximum For iron and steel industry pelletization is one of the CaO % 0.03 +/-0.01 agglomeration processes. It is the process of converting MgO % 0.06 +/-0.01 iron ore fines into uniform sized iron ore pellets, which has Basicity % 65 Maximum Phosphorus % 0.05 Maximum better tumbling index as compared to that of parent ore Physical properties which can be charged directly to a blast furnace (as Bulk density t/cum 2.2 +/-0.2 substitute for iron ore) or into a furnace used in the Tumbler Index % 93 Minimum production of DRI. The process involves mixing very finely Abrasion index % 3 Max+/- 0.5% Cold crushing strength AV Kg/p 250 minimum ground particles of iron ore fines of size less than 200 mesh Size Analysis with additives like bentonite and shaping them into 8-16mm 94 Minimum oval/spherical lumps of 8 to 16 mm in diameter by -5mm % 2 Maximum pelletizer and hardening the balls by firing with a fuel. +16mm % 4 Maximum Metallurgical properties Pelletization process, leads to substantial economic gains Porosity % 2 Minimum over time and given the shortage of quality iron ore lump Reducibility % 62 Minimum (which setting up a pellet plant can well alleviate), have led The two most accepted process of pelletization are to a paradigm change in the domestic market. compared below: Low grade iron ore, iron ore fines and iron ore Sl no. Straight travelling grate process Grate kiln process 1 Drying, preheating induration and Carried out in different units tailings/slimes accumulated over the years at mine heads cooling cycle carried out in a single and generated during the existing washing processes, unit 2 Green pellets remain undisturbed Entire process takes place in 3 equipments need to be beneficiated to provide concentrates of during the process travelling gate, rotary kiln and circular required quality to the Indian steel plants. However, these cooler. Hence pellet transfer takes place. 3 Grate car moves in the same speed Independent control at 3 zones. So better concentrates are too fine in size to be used directly in the in the drying, induration and operational flexibility existing iron making processes. For utilizing this fine cooling zones 4 Fines generation is negligible as Higher generation of fines due to material concentrate, pelletizing is the only alternative available. there is no material transfer transfer 5 There is no strength requirement Before transfer to kiln green pellets have There are 4 stages of pellet preparation: of intermediate product to be sufficiently hardened. 6 Process availability is higher. Lower process availability a) Raw material preparation 7 Higher specific energy Lower specific energy consumption 8 Lesser maintenance Higher maintenance b) Formation of green balls or pellets 9 Lower dust generation Higher dust generation c) Induration of the pellets 10 Higher investment cost Lower investment cost 11 Suited both for hematite and Process is more suitable for magnetite d) Cooling, storage and transportation of the pellets magnetite ores ores

DECEMBER 2018 41 Section : ARTICLE

Advantages of Pellets 6. The chemical analysis is uniform since it gets controlled Iron ore pellets is a kind of agglomerated fines which has during benification process. Fe content varies from 63 to better tumbling index when compared with iron ore and 68% depending on iron content in ore fines. Absence of LOI can be used as a substitute for the same both. is another advantage. 1. Pellets have good reducibility since they have high 7. Pellets have high and uniform mechanical strength and porosity(25 to 30%).Normally pellets are reduced can be transported to long distances without fine considerably faster than sinters as well as iron ore generation. Further it is resistant to disintegration. High lumps. High porosity also helps in better metallization in mechanical and uniform strength of pellets is even under DRI production. thermal stress in reducing atmosphere. 2. Their spherical shapes and containing open pores, gives Due to mining of iron ore, large chunk of fines have been them good bed permeability. generated at mines which becomes an environmental 3. Pellets have uniform size 8 to 16mmm. hazard. In order to utilise these fines, pelletisation is one of the technologies where the fines cannot be changed 4. Pellets have spherical shape and open pores which gives directly to iron making, hence, pelletisation is required. it better bed permeability. 5. Pellets have low angle of repose which is a draw back as With installation of larger BFS in India, utilisation of pellet it creates uneven binder distribution. in the change mix will be further enhanced.

CMI receives contract from Tata Steel India's leading steel producer and global steel giant, Tata Steel has awarded CMI Industry METALS a contract for three state of the art processing lines: 2 Continuous Galvanizing Lines (CGL) & 1 Continuous Annealing Line (CAL). All three high-end lines are to be supplied to the client's site at Kalinganagar in the Jajpur district of Odisha. The order placed with CMI for three processing lines, that are to provide the client with the very latest technology, will allow Tata Steel to produce skin panels for car outer bodies, helping it retain leadership among domestic suppliers to high-quality segments like the auto and white goods sectors. As such, all three lines are central parts of the phase two expansion of the client's steel plant, and are to increase the annual galvanized steel production by 1 million tons. Decisive factors for choosing CMI for this project were the company's extensive experience in steel processing lines, but also the high process security of the plant concept, which features the full spectrum of CMI's process technologies: Multi-stage cleaning section, Vertical annealing furnace (incl. CMI's L-Top math model and jet cooling system), Air-Knife system, APC Blowstab low vibration cooling system, Inline skin pass mill and Tension leveler, Chemical roll-coat post treatment, Side trimmer, Exit shear. The material grades will range from deep-drawing steels, hot-formed and high- strength steels, to dual-phase and complex-phase steels. Besides the traditional Gi coating, one of the new lines is designed to also process aluminized (AluSi) coatings, while the second line is to also apply galvannealed (Ga) coatings. The order covers the engineering, procurement and supply, as well as the supervision of the erection and commissioning. João Felix Da Silva, President of the CMI Industry Sector and Chairman – Board of Directors CMI FPE Limited stated, “We are honored to be part of the expansion plans of a long-lasting business partner like Tata Steel, and we are very proud to be able to assist our client in their reach for the highest steel quality and the related leadership in high-end segments like the automotive and white goods industries.” This is the 3rd contract that Tata Steel entrusts to CMI Industry METALS in the past 6 years. After the recent modernization of SEGAL, Tata's high-end automotive line in Belgium, this is the second order that Tata places with CMI in the framework of its automotive steel production. Another project that further strengthens CMI's leading position for the complete supply of high-quality automotive processing lines.

42 DECEMBER 2018 Section : DATA BANK

KOLKATA MARKET PRICES (In Rs.) Date-15.12.2018

Amount per MT Amount per MT Item Size ( Main Producer) Local 4. M.S.Tor Steel 10 mm 43350/- 39350/- 5. M. S. Tor Steel 12 mm 43350/- 39350/- 6. M. S. Tor Steel 25 mm 43350/- 39350/- 7. M.S.Angle 50x50x6 41350/- 36550/- 8. M.S.Angle 75x75x6 40350/- 37350/- 9. R. S. Joist 125x70 X 37350/- 10. R. S. Joist 200x100 38550/- 37550/- 11. M.S.Channel 75x40 43250/- 37550/- 12. M.S.Channel 150x75 43250/- 37550/- 13. M.S.Plate 6 mm 40500T'- 14. M.S.Plate 10 mm 40500/- 15. M.S.Plate 12 mm 40500/- 16. M.S.Plate 25 mm 40500/- 17. H. R. Coils 2.00 mm 42500/- 18. H.R. Coils 2.50 mm 41250/- 19. H. R. Coils 3.15 mm 41250/-

1. Some materials price has been decreased. 2. The Materials prices are increased due to sale down in market 3. The main producers are benefited due to increase/decrease the price of the materials.

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Total Crude Steel Production

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46 DECEMBER 2018