2019 PRE-FEASIBILITY REPORT FOR INTEGRATED STEEL PLANT OF ELECTROSTEEL STEELS LIMITED FOR PRODUCTION OF 3.0 MTPA HOT METAL WITH BLAST FURNACE (1×1050 m3, 1×350 m3, 1×1700 m3) ALONG WITH CPP OF CAPACITY 160 MW M/s ELECTROSTEEL STEELS LIMITED (an enterprise of Vedanta Limited) at Siyaljori, Bhagabandh, Budhibinor, Alkusha, Dhandabar, Bandhdih, Hutupathar , Dist Bokaro, Jharkhand -827013 Pre-feasibility Report for Integrated Steel Plant of Electrosteel Steels Limited for production of 3.0MTPA Hot Metal with Blast Furnace (1×1050 m3, 1×350 m3, 1×1700 m3) along with CPP of Capacity 160 MW located at village Siyaljori, Bhagabandh, Budhibinor, Alkusha, Dhandabar, Bandhdih, Hutupathar, Dist Bokaro, Jharkhand-827013 Table of Contents CHAPTER-1............................................................................................................ 7 EXECUTIVE SUMMARY........................................................................................... 7 CHAPTER-2.......................................................................................................... 11 INTRODUCTION OF THE PROJECT......................................................................... 11 2.0 INTRODUCTION ..........................................................................................................11 2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT.......................................12 2.2 BRIEF DESCRIPTION AND NATURE OF THE PROJECT...................................................13 2.2.1 Chronology of the Project Implementation..........................................................13 2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION ...15 2.4 DEMAND–SUPPLY GAP ...............................................................................................18 2.5 IMPORTS VS. INDIGENOUS PRODUCTION & EXPORT POSSIBILITY..............................19 2.6 NATIONAL STEEL POLICY.............................................................................................23 Table 2.1 Direct Manpower Requirement..............................................................................................................25 CHAPTER-3.......................................................................................................... 26 PROJECT DESCRIPTION ........................................................................................ 26 3.1 PROJECT HEIGHLIGHTS ...............................................................................................26 3.2 LOCATION ...................................................................................................................26 Figure 3.1:Location Map.........................................................................................................................................28 Figure 3. 2:Google Image........................................................................................................................................29 Figure 3.3: Buffer Area Topo Map..........................................................................................................................30 Figure 3.4: Plant Layout..........................................................................................................................................31 3.3 DETAILS OF ALTERNATE SITES.....................................................................................32 3.4 SIZE OR MAGNITUDE OF OPERATION ..........................................................................32 3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ........................................................32 Table 3.1 Project Configuration..............................................................................................................................32 3.5.1 Raw Materials Handling System..........................................................................34 3.5.1.1 Facilities Associated with the Raw Material Handling System.................................................................40 Table 3.2: Details of Stockpiles...............................................................................................................................41 3.5.2 Coke Ovens...........................................................................................................41 2 Pre-feasibility Report for Integrated Steel Plant of Electrosteel Steels Limited for production of 3.0MTPA Hot Metal with Blast Furnace (1×1050 m3, 1×350 m3, 1×1700 m3) along with CPP of Capacity 160 MW located at village Siyaljori, Bhagabandh, Budhibinor, Alkusha, Dhandabar, Bandhdih, Hutupathar, Dist Bokaro, Jharkhand-827013 3.5.2.1 Production Program ..................................................................................................................................42 Table 3.3 Tentative Oven Dimension .....................................................................................................................42 3.5.2.2 Coke Plant Ancillary Units .......................................................................................................................42 3.5.2.3 Coal Preparation, Blending and Crushing Station...........................................................................................43 3.5.2.4 Flue Gas for Power Generation.................................................................................................................43 3.5.3 Iron Ore Grinding Plant ........................................................................................43 3.5.3.1 Design Basis..............................................................................................................................................43 3.5.3.2 Plant Feed .................................................................................................................................................44 3.5.3.3 Product......................................................................................................................................................44 3.5.3.4 Description of Plant ..................................................................................................................................44 3.5.3.5 Major Equipment and Facilities ................................................................................................................45 3.5.4 Pellet Plant ...........................................................................................................47 3.5.4.1 Plant Facilities...........................................................................................................................................48 3.5.5 Blast Furnace........................................................................................................51 3.5.5.1 Design Basis..............................................................................................................................................51 3.5.5.2 Major Facilities .........................................................................................................................................51 3.5.6 Steel Making ........................................................................................................54 3.4.6.1 Production Facilities .................................................................................................................................54 3.5.6.2 Heat Size ...................................................................................................................................................55 Table 3.4 Average BOF TAP-To-TAP Time...............................................................................................................55 3.5.6.3 Plant and Equipment .................................................................................................................................55 3.5.6.4 Hot Metal Handling ..................................................................................................................................56 3.5.6.5 Scrap Handling..........................................................................................................................................56 3.5.6.6 Flux and Additive Handling......................................................................................................................56 3.5.6.7 Ferro-alloy Handling Facilities .................................................................................................................56 3.5.6.8 Gas Cooling, Cleaning and Recovery .......................................................................................................56 3.5.6.9 Secondary Emission Control...........................................................................................................................56 3.5.6.10 Liquid Steel and Slag Handling ............................................................................................................57 3.5.6.11 Secondary Refining Facilities...............................................................................................................57 3.5.6.12 Continuous Casting...............................................................................................................................57 3.5.7 Rolling Mill ...........................................................................................................58 3.4.7.1 Bar Mill ..........................................................................................................................................................58