Fortune Steel and Wire Ltd

PRE- F E A S I B I L I T Y PROJECT REPORT

for

800 TPD MS Billet/Ingots and 800 TPD Rolled Products by installing 3 x 20 TPH Induction Furnaces for the production of MS Billets/Ingots

SUBMITTED BY

Fortune Steel and Wire Ltd.

Village Paharuwal, Paharuwal Road, Ldh. - Chd. Road, Kohara Tehsil Ludhiana East, District Ludhiana, (Punjab)

Fortune Steel and Wire Ltd.

SUMMARY

1.0 Fortune Steel and Wire Limited is a limited company registered in the year 2018 for the manufacturing/production of MS ingots/MS billets from iron scrap and rolling of M S products. The industry intends to setup three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year)at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab).

2.0 The capital investment on the project would be around 137.65 Crores. The project would operate for 330 days in a year.

3.0 Ludhiana District is in the northwestern region of India and is a part of the Indo-Gangetic alluvial plains. The district lies between north latitude 30°-34' and 31°-01' and east longitude 75°-18' and 76°-20'. It has an average elevation of 268 meters. Ludhiana’s climate corresponds to semi-arid with high variation between summer and winter temperatures. Average annual rainfall is in a range of 750 mm. The weather is generally dry but is very humid from mid-May to the end of August. Rainfall is primarily from the south-west due to monsoon weather and is concentrated in the period July to mid-September. The surrounding districts are Rupnagar district in the east, Moga district in the west, and Barnala, Sangrur and Patiala districts in the south and souteast, respectively. Total Geographical area of the district is 3767 sq. km. Out of this, the net cultivated area is 302100 hectares. Forest occupies 68sq. km. of the total geographical area of the district. There are 896 villages in the district.

4.0 The promoters of the project are already having 2.48 hectares of land at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The benefits of the location are as below; . Required raw material is abundantly available in the area. . Well connected by road/rail network . Manpower available for industrial purposes . Huge market for the product . Easy availability of power . Saving in the energy for the production of MS rolled products by using hot billet directly for rolling

Pre-Feasibility Project Report – MS Ingots/Billets @ 800 MT/day and Rerolling of MS products @ 800 MT/day 1

Fortune Steel and Wire Ltd.

6.0 The induction furnace process will have process steps namely - Furnace loading, Heating, Slag removal, Alloying, Moulding, Cooling.

7.0 The industry would install 66 KVA substation for the power required for the project. Power requirements would be around 25 MW. Power would be made available from PSPCL.

8. The industry would install air cooled and water cooled cooling towers @ 200 m3/day, two D G sets of 500 KVA capacity as a part of the utilities.

9. The industry will use scrap iron @ 850 MT/day as basic raw material. Besides this, alloyingmetals @ 10 MT/day would be used for the production of MS Billets @ 800 MT/day.

10. Fresh water requirements for the industry would be around 25 m3/day This includes water requirements for cooling towers and domestic requirements. Domestic effluent @ 4.5 m3/day would be generated which after treatment would be used on land for irrigation purposes.

11. The industry would install pulse jet type bag filters as APCD for the control of emissions from the induction furnaces.

Pre-Feasibility Project Report – MS Ingots/Billets @ 800 MT/day and Rerolling of MS products @ 800 MT/day 2

Fortune Steel and Wire Ltd.

CHAPTER – 1 INTRODUCTION

Fortune Steel and Wire Limited is a limited company registered in the year 2018 for the manufacturing/production of MS ingots/MS billets/rolled products etc. from iron scrap. The industry is proposed to be set up at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The promoters of the project intend to setup three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year).

As per the latest technological developments in induction furnaces, power consumption reduces in higher capacity furnaces. Accordingly, the promoters of the project intend to set up 3 sets of induction furnaces (3 sets of 20 TPH capacity furnaces) with an installed capacity of 800 MT/day, or 264000 MT/year and a rerolling mill of 800 MT/day or 264000 MT/year.

The project ensues a capital investment of about Rs. 137.65 crores. The industry would operate for 330 days in a year. After installation of the complete project, the industry would require a power input of around 25 MW which would be made available from PSPCL. The total manpower requirements for the industry would be around 250 persons.

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Fortune Steel and Wire Ltd.

Table 1 : Salient Features of the Project

S. Particulars Details No. 1. Nature & Size of the Project Secondary metallurgical ferrous industry involved in production of MS ingots/MS billets from iron scrap @ 800 MT/day (264000 MT/year) and a MS rolling mills @ 800 MT/day (264000 MT/year) 2. Category of the Project Sr. No. 3(a); Category ‘B’ converted into Category ‘A’ due to industry located within 10 kms. radius of Ludhiana City, a critically polluted area. 3. Location Details Village Paharuwal Tehsil Ludhiana East District Ludhiana State Punjab Latitude 30°54'08.73’’N Longitude 76°00’10.53’'E 4. Total Plant Area 2.48 Hectares 5. Greenbelt / Plantation Area 0.82hectares, i.e. ~33% of the project area will be covered under greenbelt/ plantation 6. Environmental Setting Details Nearest Village Paharuwal Nearest Town & City Ludhiana City (5 km in West direction) Nearest National Highway /  NH 44 (8 km) State Highway  Ludhiana Chandigarh State Highway (4 km) Nearest Railway station Ludhiana Railway Station (15 km) Nearest Airport Chandigarh (80 km ) National Parks, Wildlife No National Parks, Wildlife Sanctuaries, Sanctuaries, Conservation Reserves, Conservation Reserves, Tiger / Elephant Reserves Tiger / Elephant Reserves fall within 10 km radius from the plant site River / Water Body (within 10 km No river or natural water body within a radius of 10 radius) km. from site 7. Products to be manufactured MS Ingots/Billets – 800 TPD MS rolled products – 800 TPD 8. Raw Material Consumption M S Scrap –850MT/day 9. Working Days 330 days / annum

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Fortune Steel and Wire Ltd.

CHAPTER – 2 PROJECT LOCATION

2.1 About the State : Punjab is a state in the northwest of the Republic of India, forming part of the larger Punjab region. The state is bordered by the Indian states of Himachal Pradesh to the east, Haryana to the south and southeast, Rajasthan to the southwest, and the Pakistani province of Punjab to the west. To the north it is bounded by the Indian state of Jammu and Kashmir. The state capital is located in Chandigarh, a Union Territory and also the capital of the neighboring state of Haryana.

Agriculture is the largest industry in Punjab. It is the largest single producer of wheat in India. Other major industries include the manufacturing of scientific instruments, agricultural goods, electrical goods, financial services, textiles, machine tools, sewing machines, sports goods, starch, tourism, fertilisers, bicycles, garments, and the processing of pine oil and sugar. Punjab also has the largest number of steel rolling mill plants in India, which are located in Steel Town Mandi Gobindgarh, District Fatehgarh Sahib.

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2.1.1 ABOUT THE DISTRICT Ludhiana District is one of the 22 districts in the state of Punjab in northwest India. It lies between north latitude 30°-34' and 31°-01' and east longitude 75°-18' and 76°-20'. Ludhiana is a centrally located city of Punjab, which is on the NH 44 from Delhi to Amritsar. Ludhiana city, the district headquarters, is the hub of industry in Punjab. The main industries are bicycle parts and hosiery. Ludhiana is the biggest city of the state. It has eight tehsils, seven sub-tehsils and twelve development blocks. As of 2011 census, the district population constituted 12.59% of the total Punjab population.

It is bounded on the north by the Satluj River, which separates it from Jalandhar district. The river forms its northern boundary with Hoshiarpur district. On other sides it shares common boundaries with Rupnagar district in the east, Moga district in the west, and Barnala, Sangrur and Patiala districts in the south and souteast, respectively.

2.1.2 Topography : The topography of Ludhiana is typical representative of an alluvial plain. It owes its origin to the aggravation work of the Satluj River. The alluvium deposited by the river has been worked over by the wind, which gave rise to a number of small dunes and sand mounds. Most of these dunes have been leveled by farmers. The district can be divided into the flood plain of the Satluj and the upland plain.

2.1.3 Physiographics: The district has 7 sub-divisions, 8 tehsils, 6 sub-tehsils, 13blocks, 908gram panchayats and 896 inhabited villages.

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Fortune Steel and Wire Ltd.

2.1.4 Rainfall and Climate : The climate of the area is characterized by dryness except a brief spell of monsoon season, a very hot summer and a bracing winter. The cold season is from mid- November to the early part of March. The succeeding period until the end of June is the hot season. July, August and half of September constitute the southwest monsoon. The period of mid-September to about the middle of November may be termed as post-monsoon or transitional period. June is generally the hottest month. Hot and scorching dust-laden winds blow during summer season. December and January are the coldest months. The average annual rainfall of the district is around 750 mm. The variation in the rainfall from year to year is not large. The monsoon starts late in June and generally lasts up to September. 90% of the rainfall is received from July to September. August is the month with more number of rainy days.

2.1.5 Soil and Land Classification: Ludhiana District forms part of the Indo-Gangetic Alluvial plain consisting of Quaternary sediments. These sediments can be broadly classified into three sub divisions viz. Older Alluvium, formed by the depositional processes of older streams, Newer Alluvium, formed by the present-day streams and Aeolian Deposits in the form of sand dunes and sand sheets representing the depositional feature of the wind action. The Older Alluvium is extensive whereas the Newer Alluvium and the Aeolian Deposits have limited distribution. The Older Alluvium comprises, polycyclic, interbanded clay, sandy clay, silt and sand with admixture of kankar. On the surface, it is chiefly represented by massive, pale reddish brown clayey silt to fine sandy silt with disseminated kankar. The Sutlej and its tributary, the Buddha Nala, constitute the chief hydrographic features of the district.

2.1.6 Industries: Ludhiana district has been a great contributor to the industrial scenario of the country. As of now 1494.88 acre of land has been acquired in Ludhiana districts for Industrial Focal Points in which a total no. of 2313 plots have been developed out of which 2138 has already been allotted. The district has 153 large and medium scale units as on 31.03.2015. The more investment in large sector shall provide more opportunities for vendorisation in Medium Scale Enterprise sector. As per District Industries Centre (DIC), the district has 38552 micro & small scale units registered with DIC as on 31.03.2015.

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LUDHIANA DISTRICT AT A GLANCE

S. NO. Parameter 1. Total Geographical Area of the district 3767 sq. km. 2. Area under Forests 68 sq. km. (1.9 %) 3. Area under agriculture 302100 hectare 4. Total population of the district 3498739 5. Sex ratio (female : male) 873 : 1000 6. Literacy Ratio 82.2 % 7. Population Density 978/sq. km. 8. Workers in total population 32.5 %

2.2 SELECTION OF SITE

The basic criteria for the selection of site for the induction furnace project are as below;

. Raw material availability . Raw material cost . Transportation cost . Accessibility to markets within and nearby states . Availability of land . Connectivity of road/rail network. . Market for final Product

Advantages of the location at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab)for the proposed project.

The promoters of the project are already having around 2.48 hectares of land at the site. Besides this, the other benefits of the location are as below;

a. Ludhiana is India’s one of the biggest industrial town of North India having major steel goods market. b. Required raw material is available. c. Well connected by road/rail network d. Govt. of Punjab support for subsidized power charges e. Manpower available for industrial purposes

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Fortune Steel and Wire Ltd.

2.3 Site Details The plant site is located around 5 Km away from Ludhiana City. The connectivity of the site to airport, railway and road is as follows: a. Airport connectivity- The nearest airport is Chandigarh which is about 80 Kilometers away. b. Rail connectivity- The nearest railway station is Ludhiana, which is about 15 kilometers from the site. c. Road connectivity- Nearest highway areNH-44 and Ludhiana Chandigarh State Highway which are around 8 km. and 4 km. respectively from site. d. Hospital- Government PHC & CHC within 5.0 km in Ludhiana. f. Schools, Colleges, Bank, ATM, Dispensaries, Hospitals, Markets, Police Station & Places of Worship in nearby area of the project site.

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CHAPTER – 3

PROCESS DESCRIPTION

3.0 Fortune Steel and Wire Limited are proposing to secondary metallurgical ferrous industry with three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year) at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The company is already having adequate land at the existing location for the proposed expansion project. The industry would be operational for 330 days in a year. The complete power requirements for the industry have been estimated to be about 25000 kW (25 MW).

3.1 INDUCTION FURNACE PLANT OPERATION

A coreless induction furnace operates on a similar principle to a transformer, i.e., the induction coil acts as primary coil, having many turns, and the charge acts as a secondary coil, with only as single turn. When an alternating current is applied to the induction (primary) coil of a furnace, a significantly larger current is induced in the metallic charge materials. The resistance to the passage of induced current within the furnace charge causes the charge to heat up until it eventually melts. Once the metal is molten, the magnetic field generated creates a stirring action in the bath, producing both homogenization of the chemical composition and assimilation of any bath additions. Electrical energy at 11 kV (3-phase) is converted to 1250 V, through a transformer. It is further subjected to a 3-phase rectifier and inverter system which converts the power to single phase, high voltage – high frequency. The frequency converter amplifies the frequency from 50 Hz to 500 Hz. This power is applied to furnace coil to generate heat.

The electrical circuit and equipment of the induction furnace needs to be cooled with water. The cooling water is continuously recirculated from the storage tank. Any water lost due to evaporation, etc., is made up by adding fresh water.

The inputs, for the overall manufacturing process, will be; a) MS scrap, sponge iron b) Water (for cooling) c) Ferro-alloys – manganese, carbon, silica (as additives for alloying) d) Electrical power (only source of energy).

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The specific equipment requirement comprises of; a) Induction furnaces of 15 MT loading capacity – two sets (4 in number – including furnace crucible, power pack, capacitors, hydraulic power pack, and other accessories) b) Electrical equipment/accessories – transformer, vacuum circuit braker, etc. c) EOT cranes d) Cooling tower e) Cast iron moulds

Figure 1 (below) shows the schematic flow diagram of the process involving induction furnace.

Raw Material (MS Scrap)

Furnace Loading

Heating/Melting

Slag Removal

Alloying

Pouring in CCM

Ejection from CCM and cutting

MS Billet for Rolling

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Furnace loading – The raw material (steel scrap crushed into suitable sizes which can be accommodated in the furnace) is loaded into the furnace crucible, to the brim, with the furnace set on.

Heating – The loaded pieces are heated to melting (temperature of about 1600C) and steel scrap is loaded incrementally till the furnace crucible is completely filled (up to its rated capacity) with molten volume. The initial melting (melting of first stage loading) may take about 30 – 35 minutes, whereas, the time taken to complete the melting process may range from 50- 70 minutes.

Slag removal – The impurities present in the molten content, being light, gets collected as slag at the top and requires regular removal from the top of the molten volume.

Alloying – Calculated quantities of carbon, manganese, silica, etc., are added to the molten metal, for alloying, to obtain the steel of desired grade/characteristics.

Moulding – The contents of the furnace are emptied by tilting it (by raising bottom of the furnace crucible against the outer edge of the furnace platform) and molten metal is poured into interconnected continuous casting moulds.

Cooling – The filled mould are allowed to cool at a particular temperature and after desired cooling the billet from the mould is cut to the size and sent for rolling.

3.2 REROLLING PLANT OPERATION

The manufacturing process will comprise of following steps;

Rolling – The red-hot pieces received from the induction furnace section are fed into box mouths of rolls and are passed through a series of roller mills (in the order of roughing mill, intermediate mill, first finishing mill, and second finishing mill) to roll them into desired shapes and sizes.

Cooling – The rolled product as well as mills, which are hot, are cooled by using water. The cooling water is stored in a recirculation tank from where it is continuously recycled.

Trimming – Both of the ends of the rolled product suffers from deviation from the desired sizes which is removed by cutting to obtain final product of consistent dimensions.

Storage – The final product, so obtained, is stored and dispatched to market as per requirements.

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3.3 SUNDRY UTILITIES

The various utility and auxiliary requirements for the processes (induction furnace and rolling mills) will include; a) Cooling water b) Lubricants and oils c) Electrical sub-station

3.3.1 Cooling water

The industry would install air cooled cooling towers and water cooled cooling towers for both the sections. The average cooling water recirculation rate is expected to be about 200 m3/hour for both the sections. The cooling water, in the process, is consumed/reduced from the system due to evaporation and drift losses. In order to maintain desired characteristics of the cooling water being recirculated, periodic blow-down of cooling water is employed. Whole of the deficit (blow-down, evaporation, and drift losses) is made-up by injecting fresh water into the cooling water system. Treated soft water will be used for cooling water make-up. Total fresh water requirement will be a maximum of about 20 m3/day.

3.3.2 Lubricants and oils

The requirements will include hydraulic oil (for hydraulic operations), lubricant oils (for machinery, in-house vehicles and DG sets), transformer oils (for transformers in electrical substation), and coolant oil. The hydraulic oil will be used in closed loop and needs to be rejected (to account for loss of its desirable properties) periodically. The rejection, and hence, make-up, requirement will be about 1000 litre/year.

3.3.3 Electrical sub-station

The complete power requirements have been estimated to be about 25000 kW (25 MW). The industrial unit would set up 66 kVA main electricity receiving station for the receiving and distribution of electricity.

3.3.4 DG sets

The industry has plans to install a DG sets of 500 x 2 kVA, as a back-up to state electricity supply for auxillary use in case of non-availability of of electric power. The DG sets will be operated on HSD as fuel with fuel consumption of about 100 litre/hour/D G set when operated.

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CHAPTER – 4 RAW MATERIALS 4.0 Fortune Steel and Wire Limited are proposing to secondary metallurgical ferrous industry with three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year) at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The company is already having adequate land at the existing location for the proposed expansion project. The industry would be operational for 330 days in a year. The complete power requirements for the industry have been estimated to be about 25000 kW (25 MW).

4.1 Raw Materials Requirements

The induction furnace will use scrap iron as basic raw material. Besides this, alloys such as Silicon, Silicon Manganese and Aluminum would be used for the production of Billets.Consumption of raw materials for the induction furnace plant is given below;

S. Item Unit Total No. 1. MS Scrap MT 850 2. Alloys such as Silicon, Silicon Manganese and MT 10 Aluminum

4.2 Raw Material Availability The industry would procure MS scrap from indigenous sources as well as from importing it from other countries. The sponge iron would be used in a smaller proportion and would be made available from indigenous sources only. The MS Billets produced in the induction furnace section would be used as raw material for the rolling mills section.

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CHAPTER – 5 PRODUCTION 5.0 Fortune Steel and Wire Limited are proposing to secondary metallurgical ferrous industry with three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year) at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The company is already having adequate land at the existing location for the proposed expansion project. The industry would be operational for 330 days in a year. The complete power requirements for the industry have been estimated to be about 25000 kW (25 MW).

5.1 Production

Daily production of Billets from the induction furnace plant is given below;

S. Item Unit Total No. 1. MS Billets MT 800 2. By-products Iron Slag MT 3 3. MS rolled products MT 800

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CHAPTER – 6 ENVIRONMENTAL MANAGEMENT AND POLLUTION CONTROL

6.0 Fortune Steel and Wire Limited are proposing to secondary metallurgical ferrous industry with three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year) at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab). The company is already having adequate land at the existing location for the proposed expansion project. The industry would be operational for 330 days in a year.

During the operation of the industrial unit, environmental pollution would be generated from different sources. The industry would adopt the latest technologies for the abetment of pollution generated by the production process.

6.1 WATER POLLUTION 6.1.1 Fresh water consumption The industrial unit will use fresh water for the following purposes;  Cooling of induction furnace electrical equipment  Domestic consumption

The industry would install water recirculation-based cooling towers @ 200 m3/day. Water would be required for the makeup of the evaporation losses in the cooling towers. On an average evaporation loss would be around 0.5 % of total water recirculation. The industry would require around 20 m3/day of water for cooling tower makeup. There will not be any cooling tower blowdown.

To support drinking water and sanitary requirements of the workers, industry will need a maximum of 5 m3/day of fresh water, which will contribute to less than 4.5 m3/day of domestic sewage. The industry will construct septic tank for the treatment of domestic sewage before its use for plantation purposes. Ground water from existing borewell installed at the location would be used for industrial purposes.

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Effluent generation

Total average fresh water consumption and wastewater generation from the project can be summarized as under;

S. Purpose Water requirement Wastewater No. generation (m3/day) (m3/day) 1. Cooling water 20 0 2. Domestic requirement 05 4.5 Total 25 4.5

6.2 Air pollution

6.2.1 Induction furnace section There is no combustion related polluted gaseous emissions as no fuel is being used in the process. The air pollution will be the result of the heating and melting process in the induction furnace. The gaseous emissions coming out of the mouth of the furnace crucible will be polluted and need cleaning before discharging it into the atmosphere.

The gaseous emissions will comprise of vapors/fumes, suspended particles, and some gases. The vapors are, primarily, of metals (chiefly iron) and metal oxides, oil/grease (in very low quantities). Dust and metal particles also contribute to the suspended particulates. Gaseous pollutants are, mainly, carbon di-oxide, carbon mono-oxide, and nitrogen oxides, though in very low amounts. The vapors, on condensation, add to the strength of suspended particulates.

The characteristics of the gaseous emissions do not remain constant because of regularly changing conditions of the contents of the furnace crucible throughout the process and batch nature of operations. Typically, on the initiation of melting of a loaded bunch of scrap (bunches are fed regularly into the furnace), there is a surge of polluted emissions which slowly dies down. Thus, the emissions are produced in surges at regular interval.

The critical suspended particulate matter (SPM) concentration, in the condition that the gaseous emissions are completely removed and there is no further dilution effect (from the surrounding air), can be estimated to be about 800-2000 mg/Nm3. Most of the particulates (about 75%) are expected to have size in the range of 1-5 microns. The emissions (after dilution) will have temperature of about 150-200C.In case of an induction furnace, the Pre-Feasibility Project Report – MS Ingots/Billets @ 800 MT/day and Rerolling of MS products @ 800 MT/day 17

Fortune Steel and Wire Ltd.

criticality of the pollution problem is borne out of the very nature of the operational practices which make the capture of the emissions (coming out of the furnace) difficult. It requires an unconventional emission collection system that goes well with the operations.

As per the applicable statutory norms, the SPM level in the gas emission, at discharge point, shall not exceed 150 mg/Nm3. Additionally, the stack height requirements for discharge of process emissions is also to be complied with.

6.2.2 Air Pollution Control System The contaminated emissions, from the mouth of the furnace crucible, will be collected through a hood and will be made to flow into the air pollution control device (APCD), which will clean it, of the pollution load, to desired levels. The cleaned gas will flow into the stack through a blower. The blower is meant to provide the gas flow with necessary pressure and velocity requirements. The stack will discharge the cleaned gas at desirable elevation.

The collection hood is meant to convey the emissions into the hood opening, from where it is carried to the APCD. Low canopy type swivel hood would be installed. The emissions capture mechanism, for an induction furnace will lay special emphasis on the following;

a) Emissions, from the furnace crucible, are released in puffs b) Once out of the furnace, the emissions cool down very quickly c) The vertical natural lift, quick cooling, horizontal blowing, etc., results in emission acquiring shape of an inverted bell (flaring as it goes up), obliquely inclined towards the pit (where the moulds are kept) area d) The emissions are likely to contain some incompletely oxidized volatile matter which need excess air for complete oxidation (before temperature of the emissions drop significantly) to reduce pollution levels e) The emission capture system should not interfere with the normal production operations

Air Pollution Control System The proposed APCD will be pulsejet type baghouse filter with spark arrester. Compartmentalised pulsejet bag filter has four compartments, out of which three will remain in operation and the fourth will be offline for effective cleaning and settling of dust. Pneumatic dampers would be provided at the inlet and outlet of the bag house filter for its effective

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operation. Dust would be collected outside the bags and clean air will flow from outside to inside of the bag filters. Reconditioning of bags would be done by the pulse of high pressure air jet which rapidly pressurises and inflates the bag causing it to snap away from the spotting cage, breaking the dust cake and dislodge the accumulated dust from the fabric. The dust will be taken out of the bottom hopper by operating a rotary air lock valve proposed at the bottom.

The ID fan The blower (ID fan) –centrifugal flow (axial inlet and tangential outlet) type – generates necessary static gas pressure to compensate for suction pressure requirements; kinetic losses suffered by the gas flow; and inlet and outlet losses.

The stack The stack will be provided with adequate provisions, such as, a sampling port, ladder, elevated platform, etc., for sampling and monitoring of stack emissions.

6.2.3 DG set

As per the applicable norms, the DG sets will be housed in an acoustic chamber.The combustion emission outlets will be provided with a muffler along with a minimum stack height of 3 m above the height of nearest building.

6.2.4 Solid waste Solid waste will include; a) Induction furnace slag – 15 MT/day The above waste has commercial worth and will be sold.

6.2.5 Hazardous waste Hazardous waste will include; a) Used/spent lubricant and transformer oil (Category 5.1 of Schedule – I) – 1000 litre/year. The used oils will be sold to the authorized recyclers. b) Dust from APCD @ 2000 kgs./day

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CHAPTER – 7

PROJECT ESTIMATES

ESTIMATED OVERALL PROJECT INVESTMENT

The estimated cost of project for the secondary metallurgical ferrous industry with three sets of induction furnaces (each of 20 MT/heat capacity, with a production capacity of about 800 MT/day, or 264000 MT/year) and a rerolling mill with installed capacity of 800 MT/day (or 264000 MT/year) located at Village Paharuwal, Paharuwal Road, Near Kohara, Chandigarh Road, Tehsil and District Ludhiana (Punjab) would be as below;

S. No. Particulars Cost (Rs. In Lakhs) 1. Civil Works (Sheds & Building) 2000.00 2. DRI, Scrap & Billet Handling Equipment 700.00 3. Melting & Casting Equipment 3500.00 4. Re-Rolling Mill 2000.00 5. Cranes 700.00 6. Scrap Processing Unit 1000.00 7. Water System 60.00 8. Fire Fighting 25.00 9. Electrical Work 250.00 10. Cost of 66 KVA Substation 350.00 11. Security Deposit 500.00 12. Line Expenses 300.00 13. Misc. Fixed Assets 200.00 14. Freight, Cost of Foundation, erection and Commissioning @ 10% 425.00 Total 12010.00

TOTAL PROJECT COST :

S. No. Description Amount 1. Total Fixed Assets 12010.00 2. Pre-Operative Expenses 450.00 3. Interest During Construction 650.00 4. Contingencies @ 5% on Total Fixed assets 655.00 TOTAL PROJECT COST 13765.00

Pre-Feasibility Project Report – MS Ingots/Billets @ 800 MT/day and Rerolling of MS products @ 800 MT/day 20