VSL STEELS LTD. Plant Layout VSL Steels Ltd. VSL Steels Ltd is Flagship Company of VSL Group ( V S Lad & Sons), the pioneer in Iron ore mining and one of the oldest mining companies in the State of Karnataka. VSL Group, in its endeavour to expand its business, is delighted to be part of the Core Iron & Steel Industry. We have established a Pig Iron Plant in the name of V.S.L. Steels Ltd. in Paramenahally Village, Hiriyur Taluk, Chitradurga District, Karnataka State capable of producing about 1.5 Lakh (0.15 Million) M.T. of Pig Iron per annum. V.S.L. Steels has a Mini Blast Furnace of 262 M3 capacity, designed / technology by MECON Ltd. The commercial production was started in January, 2007. Major Facilities 262 M3 Blast Furnace ( Useful Volume) with 2 Nos. of PCM & SGP Power Plant 4 MW ( B F Gas Based) Coke Oven Plant 100 MT / Day Sinter Plant 33 M2 (Under Construction) BLAST FURNACE OF 262 CUBIC METERS TAP HOLE DRILLING TO TAKE OUT HOT METAL LANCING OF TAP HOLE SHIFTING OF HOT METAL BY LRS CRANE HOT METAL POURED IN TO THE PIG CASTING MACHINE TO PRODUCE PIG IRON CLOSING OF TAP HOLE BY MUD GUN MACHINE BLAST FURNACE DETAILS : Description Unit Value Blast Furnace No 1 Volume M3 262 Productivity T/M3 ~ 2.0 HM Production Tons / Day 500 Coke Rate Kg/thm 650 Slag Rate Kg/thm 250 Slag Basicity CaO/SiO2 0.95 Hot Blast Temp. Centigrade 1000 Highlights of Blast Furnace Performance Highest Hot Metal 519 MT (12th Feb 2010) Production Lowest Coke Rate 593 Kg/THM ( 2nd Jul 2009 ) ( Net & Dry ) Highest Monthly Hot Metal 14,684 MT ( Jan – 2010 ) Production Highest Productivity 2.26 T/M3 Effective Total Storage Sl. No of Material Volume Capacity in No. Bins (cum) Hours 1 Coke 2 140 12 2 Iron Ore 2 140 20 3 Nut Coke 1 110 80 4 Limestone 1 35 25 5 Dolomite 1 35 40 6 Quartzite 1 35 60 7 Manganese Ore 1 35 150 HOT BLAST STOVE DETAILS No. of Stoves 3 Nos. Shell Height 28 M Shell Diameter 5.3 M Dome 1250 Deg. Cent. Temperature Checker hole 40 mm diameter Burner type Ceramic Cold Blast 1.5 Kg/cm2 pressure Waste gas 350 Deg. Cent. Temperature Hot Blast 1000 Deg. Cent. Temperature GAS CLEANING PLANT-THERMAX LTD Gas volume at inlet 64000 nm3/hr Gas pressure 4000 mmwc at inlet Gas Inlet 300Deg Temperature Gas out let 50 Deg mm Temperature Dust content at 10 gm/m3 inlet Dust content at 5 mg/m3 outlet Water requirement 150 m3/hr (Circulation) Pressure Volume Stage ( mmwc ) ( m3/sec ) 1st 2300 8.25 2nd 4945 9.29 3rd 7985 10.5 4th 11425 11.99 5th 15275 13.57 SLAG GRANULATION PLANT Slag Tapped per 125 MT Approx. day Slag Flow Rate 1.5 – 3.0 T / min Water Flow 450 m3/hr ( Circulation ) Water Pressure 3.0 kg /Cm2 Special Features of Blast Furnace 1.RTDs: Resistance temperature detectors (RTDs) fixed in all tuyers inlet and outlet for quick judgment of performance of tuyers. 2. Thermocouples( Below the Tuyers): Total 10 thermocouples fixed below each of the tuyers (to know the condition of the tuyers) PACKAGE BOILER DETAILS Make Thermax Capacity 3 TPH Working 15 kg/Cm2 Pressure Fire Tube Type Boiler CRANE & PCM Details LRS Cranes Details: PCM Details: 1. M/s. Mukand Ltd., 1. M/s. METCO Engineering Capacity: 500 T/Day Capacity: 50/20 T No. of Moulds: 250 Chain Length: 35 Mtr Speed: 6 – 12 Mtr/Min 2. M/s. Globe Engineering 2. M/s. METCO Engineering Capacity: 50/20 T Capacity: 500 T/Day No. of Moulds: 250 Chain Length: 35 Mtr Speed: 6 – 12 Mtr / Min With Ladle Hydraulic Tilting Device CAPTIVE POWER PLANT - 4 MW BOILER Thermax Make Babcock Wilcox BF Gas & Oil Type Fired Capacity 22 T/hr Hydraulic test 79.5 kg/cm2 pressure Steam outlet 44 kg/cm2 pressure Steam outlet 440 Deg. Cent. temperature TURBINE DETAILS Make Triveni Year of Mfg 2006 Power 4500 kw Triveni Turbine gear box Gears Gear ratio 5.519 ALTERNATOR Make BHEL Synchronous Type Generator Voltage 3.3 KV RPM 1500 Capacity 4 .0 MW Air Cooled Condenser Make Paharpur Ltd Type Air Cooled Fan 9.14 Mtr Diameter Fan Speed 114 RPM DG SET DETAILS 1. MAN B & W DG Set AVK Make, 11 Alternator KV, 750 RPM, 3.8 MW 2. Pilistick DG Set TDPS Make, Alternator 3.3 KV, 500 RPM, 2.5 MW 100 MT PER DAY COKE OVEN PLANT SINTER PLANT Capacity - 33 M2 Supplier – SSIT (China) Type - Circular Production/hr. - 59.40 T/hr. Productivity - 1.80 T/M2/hr. SINTER PLANT UNDER CONSTRUCTION SINTER PLANT UNDER CONSTRUCTION We have created artificial lake in an area of about 25 Acres for Rain Water Harvesting and recharging of Bore wells. WATER RESERVOIR WATER RESERVOIR Quality Assurance Lab VSL Steels has setup a Quality Assurance Lab with modern equipment along with well qualified staff. Raw materials are checked to ensure their quality by the applicable Indian Standards (IS) Methods. The Pig Iron produced is checked for its quality by an Optical Emission Spectrometer. As the analysis reports are given instantaneously by Spectrometer, it helps the Operation department to take immediate corrective actions so as to control the quality of Pig Iron being produced. The quality of Process Water and CPP Water is checked by HATCH instrument. VSL Steels Limited has been awarded ISO 9001:2008 & ISO 14001:2004 certificates by Perry Johnson Registers, INC. Spectrometer Quality Lab Marketing VSL Steels produces various grades of Pig Iron which are utilized by the foundry industry to produce superior grade and high quality precision castings. We are catering to the needs of foundry industry throughout India from Tamil Nadu to Punjab. Our quality is well accepted because of the consistency of specification of the Pig Iron supplied. Product Despatch: Pig iron is analyzed by Spectrometer. Pig iron is heaped in batches according to the Heat Numbers produced. Test certificates will be issued to every Heat produced indicating the grades of pig iron. Care is taken to ensure that there is no mix-up of heaps. We are moving our product by road and by rail. For Rail transhipment, the Pig Iron is first moved to Chitradurga Railway Station, which is 55 Km, from our plant and there on to Customer destinations through container rakes. Pig Iron Specification: The chart below depicts the various types of Pig Iron produced and their chemical composition. In addition to standard specifications, VSL Steels can produce pig iron with chemical composition according to customer needs. PIG IRON LOADING INTO THE CONTAINER AT RAILWAY STATION OTHER DETAILS RELATED TO PLANT VSL Steels Ltd plant location: Nearest Town : Hiriyur - 10 Kms Nearest Railway Station : Chitradurga - 55 Kms Nearest Sea Port : New Mangalore Port – 325 Kms Nearest Airport : Bangalore International AirPort – 170 Kms Nearest State Highway : SH 19 – 1Kms Nearest National Highway : NH 4 – 10Kms Karnataka Industrial Areas Development Board (KIADB) Land : 99 Acres and 5 Guntas (Paramenehalli & Doddaghata Village,Hiriyur Taluk,Chitradurga) Power Sanction : 5000 KVA from 66 KV State Grid (Hindusghatta Sub -Station,Hiriyur Taluk) Water : Permission to use ground water of 1260 Cubic Meters per day and to draw 1 Lakh Cubic Meters per of water from Vedavathi River bed per annum. Present Water consumption including domestic is 600 M3 / Day. WATER SOURCES 1. Ground Water : a. Borewells within the Plant Area – 12 Nos, ( We can draw approx 500 M3/Day) b. Borewells in Farm House – 11 Nos, ( We can draw approx 800 M3/Day) 2. River Bed: We have permission to draw 1,00,000 M3 / Annum. 3. Rain Water Harvesting (Artificial Lake) 25 Acres Area: Presently we can collect and store 2,00,000 M3 of Runoff water during rainy season from catchment area of 900 acres. Holding / storage of water can be increased upto 4,00,000 M3 with further excavation MAP SHOWING LOCATION OF BOREWELLS Water Pipeline Route RAW MATERIAL SOURCE Iron ore: a) Chitradurga District Mines (Sesa Goa,Mineral Enterprises ,R.Praveenchandra ) .These mines are about 60 Kms from the plant. b) Tumkur District Mines (Balaji Produce, Tumkur Minerals etc) .These mines are about 50 to 70 Kms form the plant. c) Bellary District Mines (NMDC ,SMIORE,Mysore Minerals Ltd,B.Kumar Gowda,MSPL,VESCO,SKME,Tiffins Baryets , etc . These mines are about 150 to 170 Kms from the plant. LAM Coke: Import: Nearest Sea port: New Mangalore -325 Kms from the plant. Domestic: Sl.No. Plant Name & Place Prod. Capacity ( MT/Monthly)Approx. Dist. From Plant 1 Sathavana Ispat Pvt. Ltd., Bellary 30000 175 KM 2 Gujarat NRE Coke, Dharwad 20000 300 KM 3 Basudha Udyog Pvt. Ltd., Chennai 10000 550 KM 4 Bhatia Coke Pvt. Ltd., Chennai 12000 550 KM 5 SESA ( Sterlite ) Goa, Goa 50000 450 KM 6 S F L, Mundra / Porbander, Gujarat 100000 1700 KM All other flux (Lime Stone,Dolomite,Quartz & Manganese) All the flux are available in Chitradurga & Tumkur district and the distance from the plant to the source is about 50 to 80 Kms. Land Details ❖ KIADB land : 99-05 Acres (Paramanahalli & Doddaghatta Village, Hiriyur Taluk, Chitradurga) ❖ Agriculture land adjacent to plant : 45-24 Acres (Doddaghatta Village, Hiriyur Taluk, Chitradurga) ❖ Agriculture land adjacent to SH-19 : 15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga) UDUVALLI - GUEST HOUSE 15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga) VSL Steels Ltd (Details of Water, Land ,Railway Line and Iron ore for expansion) Water : Details of Upper Bhadra Project,Karnataka.