PRE FEASIBILITY REPORT
FOR PROPOSED INSTALLATION OF SPONGE IRON PLANT (2X100 TPD), WHRB (2x10 TPH), INDUCTION FURNACE (1X7 T), HOT ROLLING MILL (1,00,000 TPA), SINTER PLANT (35 TPD), SUBMERGED ARC FURNACE (4.5 MVA) AND TG SET (1X4 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 - 700013
NOVEMBER, 2017
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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
Pre-feasibility Report 1
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
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
Pre-feasibility Report 2
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 M/S SALAGRAM POWER AND STEEL PRIVATE LIMITED (SPSL) for the existing Mini Steel Plant at Dewandighi, Bardhaman. The Mini Steel Plant is located at Mirzapur Village, 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.
Pre-feasibility Report 3
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
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 new 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 Twin Strand Billet Caster is having 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 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 98,000 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 additional requirement of Sponge Iron 2 Nos. of standard sized 100 TPD DRI Kilns will be installed. This will ensure continuous availability of sponge iron for steel making even if one of the kilns is under shut down for maintenance. Total Capacity of Sponge Iron after expansion will be 1,05,000 TPA. After meeting the requirement of 98,000 TPA Sponge Iron for steel making, about 7,000 TPA Sponge Iron will be available for Sale in Domestic Market.
Existing 8 MW TG Set of Power Plant is designed based on steam generated in 3 Waste Heat Recovery (WHR) Boilers utilizing waste hot flue gases of DRI Kilns and AFBC Boiler burning Char / Coal / Husk. Char generation in existing DRI Kilns being insufficient to meet steam balance, the Company has to purchase costly fuel (Coal / Husk) for existing AFBC Boiler.
Pre-feasibility Report 4
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
Proposed 2x100 TPD DRI Kilns will have WHR Boilers (2x10 TPH)
All Char generated in 5 DRI Kilns (existing and 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 57.5 TPH. Above steam will be sufficient to generate about 12 MW of Power. It is therefore proposed to install 1x4 MW TG set in the expansion stage increasing Power Plant Capacity to 12 MW.
It is further proposed to diversify into production of Silico Manganese (Si Mn) by installing a 4.5 MVA Submerged Arc Furnace (SAF).
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 be utilised in Charge Mix to SAF.
SPSL has rightly decided to expand the capacity of the Plant by installing additional Sponge Iron Kilns (2x100 TPD), WHR Boilers (2x10 TPH Steam), modernization / up gradation of existing Induction Furnaces, one additional Induction Furnace (1x7 T), one Rolling Mill (1,00,000 TPA) for forward integration, one Sinter Plant (35 TPD), one Submerged Arc Furnace (4.5 MVA) for product diversification and a TG Set (4 MW).
Existing CCM is having adequate in-built Capacity.
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 Steel Plant after Expansion.
Configuration of Major Units of Existing Plant and Plant after Expansion is indicated in Table 2.1.
Pre-feasibility Report 5
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. CONFIGURATION OF MAJOR UNITS OF THE PLANT: TABLE 2.1 Total Present Sl. Proposed Units Production Product Existing Units Production No. under Expansion Capacity after (For Sale) Capacity * Expansion 3x50 TPD 48,000 TPA 2x100 TPD 350 TPD or Sponge Iron 1. Sponge Iron Sponge Iron Sponge Iron Kilns 1,05,000 TPA (7,000 TPA) Kilns 1x7 T Induction Furnace
and modernization 1x4 T, 2x3.5 T7 T / up gradation of Liquid Steel 2. and 1X6 T 56,000 TPA 1,10,000 TPA existing Induction (Nil) Induction Liquid Steel Furnaces to Furnaces augment capacity (to 3x7 T + 1x6 T) 54,000 TPA 6/11 m, 2 Strand MS Billets for sale 1,05,000 TPA MS Billets 3. Continuous -100x100 mm, Nil (In-built (Nil) Nil) Casting Machine 125x125 mm & Capacity) 160x160 mm TMT Bars, Rods, Flats 1 No. and 4. Nil Nil 1,00,000 TPA Hot Rolling Mill Structurals (1,00,000 TPA) 1x35 TPD Sinter 5. Nil Nil 10,500 TPA Sinter Plant (Nil) 1x4.5 MVA Silico - 6. Nil Nil Submerged Arc 6,480 TPA Manganese Furnace (SAF) (6,480 TPA) 2XWHR Boilers Steam 7. 3XWHR Boilers 3x4.5 TPH 33.5 TPH (2x10 TPH) (Nil) Steam 8. 1x AFBC Boiler 1x24 TPH Nil 24 TPH (Nil) 1x 8 MW TG Set Power 9. for Captive 8 MW 1x4 MW TG Set 12 MW (Nil) Power Plant
*Present Production Capacity is as per WBPCB’s Memos.
Adequate Pollution Control Facilities will be installed to conform to Pollution Norms.
Pre-feasibility Report 6
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 2.0 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.
Pre-feasibility Report 7
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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.
Pre-feasibility Report 8
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
Pre-feasibility Report 9
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
Pic. 1 - Burdwan District Map
Pic.2 – Satellite Picture showing Burdwan Railway Station and Palitpur
Pre-feasibility Report 10
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
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 4.0 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. 8.1 km distance in south direction. There is no National Park & Reserve Forest within 10 km radius of the project site.
Pre-feasibility Report 11
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
Pre-feasibility Report 12
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 5.0 MAJOR PLANT UNITS AND AUXILIARY UNITS
5.1 SPONGE IRON PLANT
As already indicated earlier, two (2) Sponge Iron Rotary Kilns, having a capacity of 100 TPD each, will be installed for production of 60,000 TPA sponge iron. With this expansion measures, Production Capacity of Sponge Iron will be increased to 1,05,000 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 7,000 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.
Pre-feasibility Report 13
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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.
Pre-feasibility Report 14
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 1,05,000 TPA Sponge Iron from existing 3x50 TPD Kilns and proposed 2x100 TPD Kilns are shown in Table 5.1
ANNUAL REQUIREMENT OF RAW MATERIAL FOR SPONGE IRON PLANT: TABLE 5.1
Specific Sl. No. Raw material Consumption Quantity in TPA T/T 1. Iron Ore Lump/Pellet 1.5 1,57,500 2. Coal 1.0 1,05,000 3. Dolomite 0.03 3,150
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:
Item Value Fe (total) 92% min Fe (met) 83 % max Metallization 90 % Carbon 0.25 % max S 0.025% max P 0.05% max
Pre-feasibility Report 15
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 100 TPD Rotary Kilns with 3.2 m diameter and 40 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 A.C motors with VVVF drive control. The speed of the kiln will be in the range of 0.3-0.9 & 1.05-3.15 rpm. The auxiliary drive of the kiln will be by A.C motors.
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.
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.
Pre-feasibility Report 16
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. e. Feed end double pendulum valve & dust valves.
Rotary Drum Cooler of 2.4 m diameter and 22 m long will be installed. Cooleris having a slope of 2.5% and is rotated at variable speed of 0.3 – 1.2 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 motor.
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. (d) Waste heat recovery boiler (WHRB) – Latent heat of waste flue gases is utilized 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.
Pre-feasibility Report 17
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 dolo-char 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.
Pre-feasibility Report 18
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
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
Pre-feasibility Report 19
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 5.2 INDUCTION FURNACE
In addition to the existing 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) in the existing 2 Strand Billet Caster which has sufficient in-built capacity to produce 105,000 TPA MS Billets.
The process flow sheet for steel making and continuous casting is shown below.
Pre-feasibility Report 20
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 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.
Pre-feasibility Report 21
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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
Pre-feasibility Report 22
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 and 125x125 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
Pre-feasibility Report 23
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 7: Turning zone A: Liquid metal 2: Stopper 8: Shroud. B: Solidified metal 3: Tundish 9: Bath level C: Slag. 4: Shroud 10: Meniscus D: Water-cooled copper plates 5: Mold 11: Withdrawal unit E: Refractory material 6: Roll support 12: Billets
Pre-feasibility Report 24
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
Pre-feasibility Report 25
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
Pre-feasibility Report 26
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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. Production 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.
Pre-feasibility Report 27
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
Rolling Mill Process Flow Sheet for Production of TMT Bars & Rods is shown below.
Pre-feasibility Report 28
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 6,480 TPA Silico Manganese (Si Mn) by installing a 4.5 MVA Submerged Arc Furnace (SAF) in the Mini Steel Plant at Dewandighi.
Production of Ferro Alloys is highly energy intensive process. Si-Mn will be produced by carbo- thermic reduction of oxidic raw materials in SAF. The same type of furnaces is used for Fe-Mn
Pre-feasibility Report 29
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. and Fe Si alloys. Operation of the Si-Mn process is often more difficult than the Fe-Mn process because higher process temperature is needed.
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.
Pre-feasibility Report 30
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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
Pre-feasibility Report 31
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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.
Pre-feasibility Report 32
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 57.5 TPH Steam will be generated from existing WHR Boilers (3x4.5 TPH), existing AFBC Boiler (1x24 TPH) and Proposed WHR Boilers (2x10 TPH). This will be sufficient to generate 12 MW Power. It is therefore proposed to increase Power Generation Capacity from present 8 MW to 12 MW by installing 1x4 MW TG Set.
Configuration of WHR Boilers is shown Table 5.2.
CONFIGURATION OF WHR BOILERS: TABLE 5.2
SL. WASTE GAS UNITS FACILITIES NO. GENERATION
EXISTING FACILITIES
3 NOS. 3X12,000 WHR (ONE FOR EACH NM3/HR AT 1 BOILERS 50 TPD DRI KILNS) 900-1000 °C PROPOSED FACILITIES UNDER EXPANSION 2 NOS. 2X25,000 WHR (ONE FOR EACH NM3/HR AT 2 BOILERS 100 TPD DRI KILNS 900-1000 °C
Pre-feasibility Report 33
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 ANNUAL SL. NO. RAW MATERIALS SOURCE REQUIREMENT
DRI PLANT (3X50 TPD + 2X100 TPD) 1 IRON ORE LUMP / PELLET 1,55,000 MARKET 2 COAL 1,05,000 MARKET / SOUTH AFRICA 3 DOLOMITE 3,150 MARKET
INDUCTION FURNACE (4X7 T + 1X6 T) 1 SPONGE IRON 98,000 IN HOUSE GENERATION 2 STEEL SCRAP 6,000 IN HOUSE GENERATION 3 PIG IRON 20,250 MARKET 4 FERRO ALLOYS 1,550 MARKET SUBMERGED ARC FURNACE (4.5 MVA) 1 QUARTZITE 1,950 MARKET 2 MANGANESE ORE 3,175 MARKET 3 COKE 3,250 MARKET 4 PIG IRON 650 MARKET 5 MN. SLAG 9,100 MARKET 6 DOLOMITE 1,780 MARKET IN HOUSE PRODUCTION 7 SINTER 3,500 FROM RAW MATERIAL FINES AFBC BOILER (1X24 TPH) 1 DOLOCHAR 33,600 IN PLANT GENERATION IN PLANT GENERATION, 2 COAL/HUSK 30,000 MARKET
Pre-feasibility Report 34
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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.
Pre-feasibility Report 35
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 firefighting.
Fire water system:
The emergency water pipelines will be led throughout the steel division complex for firefighting. These firefighting pipelines will be connected to the emergency water storage tank. In addition to the firefighting 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.
In the existing units daily make up water demand is 204 m3/day including domestic water demand. As per initial estimate, water to the tune of 151 m3/day will be needed for the proposed project. This includes about 7 m3/day of water for in-plant domestic use. Thus overall daily make up water demand will be 355 m3/day including domestic water demand. The estimated unit wise make up water requirement for the proposed project are given in Table 6.2.
Pre-feasibility Report 36
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. RAW WATER DEMAND: TABLE 6.2 Water Water Demand Daily Total Demand for Sl. No. Description for expansion Water Demand existing plant (in cu.m/day) (in cu.m/day) (in cu.m/day) Sponge Iron Plant 1. 21.0 31.0 52.0 (3x50 TPD + 2x100 TPD) Steel Melting Shop (Induction Furnaces [5x7 T] 2. 10.0 10.0 20.0 + Twin Strand Continuous Billet Caster) 3. Rolling Mill (1,00,000 TPA) NIL 13.0 13.0 Captive Power Plant (8 4. 160.0 80.0 240.0 MW+4 MW) Submerged Arc Furnace 5 NIL 10.0 10.0 (SAF) + Sinter Plant 6. Domestic 13.0 7.0 20.0 TOTAL 204 151 355.0
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.
Pre-feasibility Report 37
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 proposed units is around 13.15 MW. The power requirement will be met from captive power plant and from nearby grid of WBSEB.
Total Power Demand and unit wise breakup for the proposed project is shown Table 6.3.
Pre-feasibility Report 38
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. POWER DEMAND WITH UNIT WISE BREAKUP: Table - 6.3
POWER ADDITIONAL TOTAL DEMAND FOR POWER POWER SL NO UNITS EXISTING DEMAND FOR DEMAND IN PLANT EXPANSION MW 1. Sponge Iron Plant 0.65 0.85 1.5 Steel Melting Shop 2. + Continuous Billet Caster) 5.0 5.0 10.0 3. Rolling Mill (1,00,000 TPA) NIL 3.0 3.0 4 SAF (4.5 MVA) + Sinter Plant NIL 3.2 3.2 5. Captive Power Plant 1.0 0.5 1.5 6. Auxiliary & other loads 0.7 0.6 1.3 TOTAL 7.35 13.15 20.5
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. operates 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.
Pre-feasibility Report 39
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
.
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.
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.
Pre-feasibility Report 40
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 / equipment 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, 4 MW Capacity of Captive Power Plant will be installed. 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.
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.
Pre-feasibility Report 41
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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.
Pre-feasibility Report 42
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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.
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 2.0 Acres will be acquired. Out of 27.8 Acres, Green Belt Cover will be about 9.6 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.1
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.
Pre-feasibility Report 43
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 300 persons (including 200 through Labour Contractors). This is over and above existing manpower of 600 persons (including 400 through Labour Contractors) employed at present.
The above estimate covers the top management, middle and junior level executives and other supporting staff.
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.
Pre-feasibility Report 44
Salagram Power and Proposed expansion of existing Steel Plant at Palitpur Road, Village & P.O. Steel Pvt. Ltd. Mirzapur, PS + District: Bardhaman, West Bengal
. 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 TMT Bars, Rods and Silico Manganese). The estimated cost of the project is expected to be around Rs. 89 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 capital for the proposed project as per schedules. 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.
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.
Pre-feasibility Report 45
E
N S
KATWA W BARDHAMAN
Sponge Iron Storage
Scrap Storage Transfer Track Boundary Wall New Boundary Wall
Ladle Preparation Area
Sponge Iron Boundary Wall Boundary storage DM Water
Slag Handling
Area Boundary Wall Boundary STORAGECOAL YARD
New Boundary Wall
SAF J.H SAF Casting
Area Boundary Wall Boundary
Boundary Wall
MIRZAPUR
BARDHAMAN BARDHAMAN WEST BENGAL BARDHAMAN
27.80 Acres
Client SALAGRAM POWER AND STEEL PVT.LTD.
Consultant KALYAN KUMAR SENGUPTA
REVISIONS RELEASED FOR DATE Drawn PARTHA Mark Descriptions Date Chkd. Scheme 02-06-17 Project Designed Partha Bag Tender EXPANSION OF SPSL Construction Checked K.K. Sengupta Boundary Wall Fabrication Checking Approved Boundary Wall Approval K.K. Sengupta REFERENCE DRAWINGS Title GENERAL LAYOUT Job No. Drawing Nos. Date Boundary Wall Scale N.T.S Date Drawing No. Rev. Sheet Size-A1, Plotting Scale-1:180