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Durgapur Iron & Steel Co. Pvt. Ltd

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Durgapur Iron & Steel Co. Pvt. Ltd SUMMARY FOR PROPOSED EXPANSION PROJECT OF DURGAPUR IRON & STEEL CO. PVT. LTD. At Vill & P.O. & Mouza: Bamunara, P.S.: Kanksha, Dist :- Paschim Burdwan, Durgapur – 713212, West Bengal PREPARED BY: PACIFIC SCIENTIFIC CONSULTANCY PVT. LTD., KOLKATA 1 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. SUMMARY FOR PROPOSED EXPANSION PROJECT Installation of 2 No. 7 MT Induction Furnaces with Ladle Refining Furnace AND 1 No. 8000 MT/ Month Rolling mill At J.L. No. 58, 65, Vill & P.O. & Mouza: Bamunara, P.S: Kanksa, Dist: Paschim Burdwan, Durgapur – 713212, West Bengal 1. COMPANY: Durgapur Iron & Steel Co. Pvt. Ltd. is one of the distinguished manufacturers who are engaged in making of one of the most useful material, MS Ingots, TMT Bars. The company’s corporate office is situated at 2, CLM Lane, Raniganj-713347, Dist- Paschim Burdwan, West Bengal. The manufacturing unit is located at J.L. No. 58, 65, Vill & P.O. & Mouza: Bamunara, P.S: Kanksha, Dist: Paschim Burdwan, Durgapur – 713212, West Bengal. Therefore, realizing the demand of steel and allied products, the management has taken decision for expansion. Particulars Existing Subsequent Modification/Addition Induction Furnace 2 no. 7 MT 2 no 7 MT M.S. Ingot/ Billets 4200 MT/Month 4200 MT/ Month Continuous Caster 1 Nos. 2 strand - Rolling mill - 8000 MT/ Month Ladle Refining Furnace - 1 x 15 MT Slag Crusher 2x125MT/Day - 2. PROJECT SITE The factory is located at J.L. No. 58, 65, Vill & P.O. & Mouza: Bamunara, P.S: Kanksha, Dist: Paschim Burdwan, Durgapur – 713212, West Bengal at a distance of 0.5 Km (Appox.) from NH-2. The distance of site from Durgapur railway station is about 6.0 Km (Appox.). 2 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. Original land surface is little undulating and irregular in shape which has been already developed. Total land area is around 5.99 acres (24240.67sqm) at J.L. No. 58, 65, Vill & P.O. & Mouza: Bamunara, P.S: Kanksha, Dist: Paschim Burdwan, Durgapur – 713212, West Bengal. The site is falling under Gopalpur Gram Panchayet. The latitude and longitude of the project site is 23°29'50"N, 87°22'33"E respectively. The area is well connected by road to Durgapur town as well as to other industrial town like Asansol, Raniganj, Dhanbad and other neighbouring areas by recently developed Durgapur Expressway (NH-2) and G.T. Road. The place is well connected to railway station (Easter Railway) and towns by bus, jeeps, taxi and rickshaw. All the civic amenities like market, bus stand, hospital, school, college, hotel, restaurant etc. all are available in the town which is about 5-7 km from the site. 3. PROJECT DETAILS The proposed expansion has been planned based on the following operating condition: Induction Furnace Capacity No of Induction Furnace 2 Capacity (MT) MT 7.00 Total Production (MT) /heat MT/heat 14 No of Heats Per day 10 Number of days available Per annum 350 Total Liquid Metal Production MT 49,000 Actual Yield of Billets @ 99.5% MT 48,755 Total Project Cost: The Project cost of the expansion project has been estimated at Rs. 1599.33Lacs. Raw materials: The Durgapur and Ranigunj areas consists of many sponge iron, pig iron and ferro alloy plants which will ensure ample and uninterrupted supply of raw materials for the Induction furnace. Though in developed countries sponge iron or hot briquetted iron in varying proportion being used but scrap still maintains its leading role for making steel through 3 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. electric furnace route. Besides steel scrap of different grades and physical characteristics, various ferro-alloys like ferro-manganese, ferro-silicon, silico-manganese alloy, aluminium in required proportions are also needed while furnace and ladle refractories form the major consumable materials. Raw Material Requirement at 100 % Capacity Induction Sponge Iron MT 0.783 Pig Iron MT 0.029 Scrap MT 0.048 Ferro Silicon MT 0.005 Silicon Manganese MT 0.005 4. OTHER REQUIREMENT: Water: Water requirement for the proposed project will be for cooling (make-up) and domestic & other purposes. The required water will be sourced from deep water tube well. The total water requirement is given below: Particulars Requirement for Requirement for Existing Plant (m3/Day) Proposed Plant (m3/Day) Water for cooling (Make up) 21.0 30.0 Domestic purposes & other uses 6.0 9.0 Total 27.0 39.0 The water will also be available from Rain Water Harvesting (RWH) system. Manpower: The total requirement of manpower for the proposed Steel Melting shop is estimated at 99 numbers. The required manpower will be available locally. The implementation of industrial laws and regulations and locational factors of labour employment will also have to be considered. 4 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. Power: 6.0 MVA power is already available in the factory with the help of DPL. Power (approx. 6.0 MVA for new project) can be enhanced with the help of them (DPL). Apart from this there are two D.G. sets of 500KVA and 125 KVA as backup unit. Fuel Requirement: The only fuel required is Diesel. It will be used for D.G. sets @ 4KL/Month. 5. MANUFACTURING PROCESS: FLOW SHEET OF MANUFACTURING PROCESS AS A WHOLE 5 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. MS INGOT: Sponge Iron C C Pig Iron/ Scrap LRF M Furnace Molten Steel Fluxes/ M.S.Billets deoxidizers Electric Power 900 V at 500 Hz Rolling Mill Despatch At the beginning, in tilted condition of the crucible, M. S. Scrap / pig iron is charged with the help of magnet crane and the furnace crucible is heated up till it is in molten condition. Again the crucible will be tilted for next charging of Cast Iron Scrap and again heating up is continued till the C I Scrap is totally melted. Next, Sponge is charged when some boiling is observed due reaction of oxygen available from FeO of Sponge Iron & Carbon from Cast Iron & Pig Iron. Slag, so formed out of above reaction, which being the lighter material floats up & the same is continuously skimmed of by the furnace crews with the help of long spoon. Around 30 minutes before the tapping of the molten steel, flash sample are taken for finding out the carbon level. Depending on the bath sample carbon is adjusted by adding of Met Coke or CPC. Finally, around 10 minutes before the tapping of the molten steel, required Ferro Alloy addition (silica Manganese/ Ferro Manganese/ Ferro Silicon) are done depending on the chemical composition required for bottom pouring of the pencil ingots. The molten metal is then trapped in a ladle refining furnace for teeming purpose and finally converted to billets of sizes ranging from 80 mm sq. to 125 mm sq by using a 4/7 M radius 2 stand continuous casting machine. 6. ENVIRONMENTAL CONSIDERATIONS: The factory is planned as far as practicable as an inherently non polluting unit. o Air Pollution from Induction Furnace has been taken care of by installing Flue air duct to 30 mt. height steel chimney via Bag filter and ID fan. 6 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. o There will be no generation of effluent water from process and the domestic sewerage about 5KLD will be discharged in the local Govt. Body’s Sewerage system after treated as per PHE rules. o The solid waste generated will be in the form of slag. Slag would be collected from the point of arising and proper slag handling and disposal system will be maintained. Slag will be crushed and after recovery of iron, the inert material will be used in road construction and remaining amount will be planned to dump in an environmental friendly manner in a separate area. o To attain the guide line standards all the dust generating areas will have dust suppression systems to contain the fugitive dust with in the limits of the plant. Auto sprinkler system Following control rooms are proposed to be fitted with Auto Sprinkler system with smoke Detection Equipment. i) Induction Furnace ii) Raw Material Handling section AIR POLLUTANTS The sources of air pollution from the plant activities are as follows: a) The emission from Induction furnace during transfer of raw materials b) Fumes from the Induction furnace c) Fugitive emission during breaking of ferro-alloys and packing. In steel melting shop, there would be anti-pollution system namely bag filters. The cleaned gas would be discharged through stack. The dust emission from Induction Furnace would be controlled through dust extraction (DE) system by bag filters. The dust concentration level in the chimney will be periodically monitored. Corrective steps will be taken, if the concentration is not as per the acceptable limits. The particulate concentration from the bag filters will remain within 50 mg/Nm3. Raw material handling can cause dust generation at the point of storage and transportation. The fugitive dust can have adverse impact on air quality inside the plant and its immediate surrounding. This would be prevented by spraying water at storage yard area. 7 Executive Summary Durgapur Iron & Steel Co. Pvt. Ltd. Ambient air quality monitoring stations in and around the premises will be done as per direction by West Bengal Pollution Control Board (WBPCB). For 2x7T Induction furnace there will be bag filter with chimney. The clean gas is then disposed through a 30 m high chimney. Source APC System Concentration of dust Inlet Outlet Induction furnace Bag filter 1 - 2 gm/Nm3 <50 mg/Nm3 D.G Proper stack with exhaust - <150 mg/Nm3 Solid Waste Management In the proposed unit there will be one no.
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