annexure - 1environmentclearance.nic.in/writereaddata/online/... · coke (hard+nut) to bf...
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ANNEXURE - 1
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ANNEXURE - 2 Production and manufacturing process 1. Production
1.1 Intermediate Products (‘000 TPY)
Hot Metal .. 10,700
DRI .. 3,100
Liquid Steel .. 13,130
Crude steel .. 12,800
1.2 End Products(‘000 TPY)
Saleable Products .. 12,200 Bar & Wire Rods .. 400 Medium & Heavy Section 800 TMT Rebars 1,200 Wire Rods 600 Plates 1,200 Hot Rolled Coils 3,500 Cold Rolled Products 4,000 Stainless Steel Products 500 2. Manufacturing Process
2.1 Process Route
The proposed production of liquid steel and subsequent rolling will be accomplished via Blast Furnace (BF)-DR Plant -Basic Oxygen Furnace (BOF)- Electric Arc Furnace (EAF)Induction Furnace (IF)-Caster route, followed by Hot & Cold rolling. The process of liquid steel making is of pyro-metallurgical, having operational temperature 16000C to 17000C.
2.2 Process Description
2.2.1 The process steps for carbon steel products in sequence are as follows:
- Coal Carbonization in coke ovens with recovery of coke oven gas (COG)
- Agglomeration of Iron Ore fines by sintering & pelletization
- Hot Metal making in BF by reduction of sintered and lump iron ore with coke in presence of additive materials
- Production of DRI in coal based DR plant as well as Coke oven gas based MIDREX plant
- Oxidation of carbon present in the hot metal by oxygen blowing in presence of lime in BOF for producing liquid steel.
- Melting of DR and a portion of hot metal in Electric Arc Furnace
- Refining of liquid carbon steel by addition of micro- alloys to get the desired chemistry of liquid carbon steel for casting
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- Continuous casting of refined liquid carbon steel to billets / slab.
- Further rolling of billets/slab to produce different types of long and flat products (hot & cold rolling)
2.2.3 The supporting process units as planned would be –
(i) Lime and dolo calcining,
(ii) Oxygen Plant,
(iii) Captive Power Plant and
(iv) Waste Water Treatment Plant
3. Main Production Facilities
The following are the main production facilities for achieving desired end products of 12.8 MTPA capacities:
Facilities Existing
facilities Existing Capacity
Proposed facilities
Proposed capacity
Total Tentative capacity
MTPA MTPA MTPA
Coke Oven Batteries with by-products recovery
2x64 ovens, 1x 74 ovens
2.16 1x74 ovens, 2x64 ovens
2.84
5.00
Sinter Plant 1 X 177sqm, 2 X 204 sqm,
6.4
1 X 224 sqm 2 X 480 sqm
10.22 16.62
Pellet Plant 7.0 MTPA 7.0 - - 7.0
Blast Furnace 1681 cum, 3814 cum,
3.8 3400 cum (Augmentation of 1681 cum), 4500
cum(Augmentation of 3814 cum),5800
cum (New),
6.9 10.7
DR Plant 10X500 TPD rotary kilns (Coal based)
1.5 COG based MIDREX Plant (1 X
1.6 MTPA)
1.6 3.1
Calcining Plant 4X300 tpd, 1X600 tpd
0.6 6X600 tpd 0.98 1.78
BOF 2X200 ton, 3.07 2X250 ton, 2X200 ton
6.0 9.07
EAF 1X60ton,1X180 ton 2.22 2X100 ton 1.55 3.77
IF 6X15 ton 0.3 - 0.3
Bar & Rod Mill - - 1 unit 0.4 0.4
Medium &Heavy section Mill
- - 1 unit 0.8 0.8
Rebar Mill - - 1 unit 1.2 1.2
Wire Rod Mill - - 1 unit 0.6 0.6
Plate Mill - - 1 unit 1.2 1.2
CSP 1 unit 3.5 3.5
Hot strip Mill 1 unit 4.1 Augmentation of the existing Hot Strip Mill
5.1 5.1
Cold Rolling mill
- - 3 units 4.0 4.0
Stainless Steel mill
1 unit 0.5 0.5
Captive Power Plant (CPP)
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW 1 x 165 MW
1 x 12 MW (TRT) 1 x 20 MW (TRT)
Defined on the
generation capability
2 x 165 MW 1 x 40 MW (TRT)
Defined on the
generation capability
638 MW
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ANNEXURE - 3 Facilities for storage of goods or materials Solid raw materials like iron ore, coking coal, non-coking coal, limestone etc will be stored in open stock pile within the plant boundary. COG, BF gas and BOF gas will be stored in dry type gas holders. Raw water supply from Brahmani River coming through pipeline will be stored in reservoir within the acquired area adjacent to the plant boundary. The BF slag after granulation would be sold off for cement production. Other solid wastes after reuse in the plant will be temporarily stored in the earmarked area within the plant boundary for future use.
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ANNEXURE - 4 Facilities for treatment or disposal of solid wastes or liquid effluents Solid wastes disposal
Non-hazardous solid wastes (NHSW)
It is estimated that 6.62 MTPA (about 18900 TPD) NHSW would be generated. The percentagewise distribution of such NHSW would be as follows:
BF Slag .. 63.00 % Steemaking Slag .. 31.80 % Millscales & sludges, .. 3.40 % Flue Dusts .. 1.80 %
Disposal of NHSW
It is planned to market nearly 95 per cent of granulated BF slag will be sold off for Cement making. Similarly, as much as possible of BOF slag will be internally used through waste recycling plant (WRP). Balance part of BOF and EAF/LD slag would be used as construction material.
It is planned that around 100 per cent of dusts, mill scales will be used
in the sinter plant.
There would be dump site within the plant boundary for temporary storage of NHSW. Hazardous wastes (HW)
The HW would comprise acid sludge, tar, oil sludge, chrome sludge and other combustible wastes. Tar sludge would be generated in the range of around 4,000 tons per year. The acid sludge would be neutralized before disposal. Chrome sludge, with estimated generation of about 30 tons per year, would be disposed of in a secured landfill pit. Liquid effluents
The liquid effluents will be of three types, namely, (i) Coke Oven effluent containing dissolved ammonia, phenolic compounds, cyanide compounds, etc, (ii) Mill effluent containing suspended solids, oil and grease, and (iii) Gas Cleaning Plant effluent containing suspended solids. Each production shop generating this type of effluent will be equipped with treatment plant of adequate capacity. Treated coke oven effluent along with other treated effluent will be utilised in slag cooling, dust suppression and other non-production use. The treatmemt schemes will be suggested in EIA Report. Expected discharge of treated effluent from the plant will be around 2% in emergency situation.
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ANNEXURE - 5
Water withdrawal consent
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ANNEXURE - 6
Minerals For the proposed 12.8 MTPA crude steel production, it is estimated that nearly 34.2 MTPA minerals would be required as presented in Process Flow Scheme in Fig. 1. The relative requirements of minerals and mineral based products would be as follows:
A. Main Minerals (‘000 TPY)
Iron Ore (Fines) .. 20444.8
Coking Coal .. 6667.7
Non coking Coal .. 1560
PCI Coal .. 1605
Sub-total (A) .. 30,277.5
B. Additives (‘000 TPY)
Limestone .. 2662.3
Dolomite .. 1214.8
Sub-total (B) .. 3877.1
Note : Quantity state above is Net & dry
Hard Coking Coal
Hard Coking Coal Hard Coking Coal 441,000
229,200 1,988,800 Semi soft Weakly caking coal
Semi soft Weakly caking coal Semi soft 1,653,700 112,200
859,600 57,300 1,325,900
Coke Plant 12x 64 ovens Stamp Charge with CDQ
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
CALCINING PLANT4 x 300 tpd1 x 600 tpd
Limestone 972,740 Limestone 1,324,270
Gross Coke Gross Coke Gross Coke
859,600 2,486,000 1,645,500
CDQ Dust CDQ Dust Coke for sale CDQ Dust
4300 12400 90600 8300
Coke (Hard+Nut)
to BF Stockhouse
Coke Breeze Coke
(Hard+Nut) to
Coke Breeze Coke Breeze from BF
stock house
Purchased
Coke Breeze
Coke breeze
(crushing of excess
Coke (Hard+Nut)
to BF Stockhouse
Coke Breeze
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
to BF Stockhouse (Hard+Nut) to
BF Stockhouse
stock house Coke Breeze (crushing of excess
nut coke)
to BF Stockhouse
790,900 64,500 2,287,100 186,500 121,800 454,900 - 124,000
Calcined LimeLime fines to SPCalcined Lime Lime fines to SP 1,430,900
252,400 161,800 389,200 181,100
Coke Breeze Coke Breeze Coke Breeze Coke Breeze Coke Breeze
109,900 109,900 120,700 257,900 257,90095,400
Coke Breeze
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
109,900 109,900 120,700 257,900 257,900
Iron Ore Fines Iron Ore Fines Lime Stone Fines Iron Ore Fines Lime Stone Fines Iron Ore Fines Iron Ore Fines Iron Ore Fines Lime Stone Fines
1,338,400 1,542,500 186,700 1,542,500 186,700 1,693,800 205,000 3,618,300 438,000 3,618,300 438,000
Lime Fines Lime Fines Dolomite Fine Lime Fines Dolomite Fine Lime Fines Lime Fines Lime Fines Dolomite Fine
22,700 26,200 106,400 26,200 106,400 28,700 116,900 61,400 249,676 61,400 249,700 Bentonite Iron Ore Fines
70,000 7,091,000
Mill Scale Flue Dust Mill Scale Flue Dust Mill Scale Flue Dust Mill Scale Flue Dust Mill Scale Flue Dust Mill Scale Flue Dust Coal Dolomite
22,700 12,100 26,200 14,000 26,200 14,000 28,700 15,300 61,400 32,800 61,400 32,800 217,000 105,000
95,400
162,000
Dolomite Fine Dolomite Fine
92,400
Dolomite Fine
Lime Stone Fines Lime Stone FinesLime Stone Fines
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Total Pellet 7,000,000
Total Sinter Return Fines Total Sinter Return Fines Total Sinter Return Fines Return Fines Return Fines
1,829,500 315,500 2,181,200 436,300 2,181,200 436,300 2,395,000 479,000 5,116,300 1,023,200 1,023,200
To MIDREX Plant
2,461,000 2,400,000
Charge Sinter Charge Sinter Charge Sinter
2,139,000
To DR PlantPellet to BF's
Charge Sinter Charge Sinter
Return Fines
5,116,300
Total SinterTotal Sinter
Charge Sinter
Total Sinter
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
Charge Sinter Charge Sinter Charge Sinter
1,514,000 1,744,900 1,744,900 1,916,000 4,093,100
Steam Charge Sinter Oxygen Charge Sinter Charge Sinter
Purchased Pellets 186,000 78400 3956400 220 x 10^6 Ncum 5,086,800 6,075,900 Oxygen 265 x 10^6 Ncum
From Pellet Plant 2,139,000 Oxygen Air Steam Air Composite Pellet Steam 120400
Dolomite 175 x 10^6 Ncum 3100 x 10^6 Ncum 100800 4000 x 10^6 Ncum 989,000
60,000 Air
Iron Ore Pellet 2,325,000 Reducing Gas (COG+BOF gas) Lime Pellet PCI 420,000 Quartzite 126,000 4800 x 10^6 Ncum Quartzite 150,500
Iron Ore Pellet
2400000
828,000
Charge Pellet
Charge Sinter Charge Sinter
4,093,100
Charge Sinter
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
Iron Ore Pellet 2,325,000 Reducing Gas (COG+BOF gas) Lime Pellet PCI 420,000 Quartzite 126,000 4800 x 10^6 Ncum Quartzite 150,500
Non-Coking Coal 1,560,000 4.24 x 10^6 Gcal 3600 644,000 PCI Dolomite 43,200 PCI
Dolomite 33,600 540,000 Limestone 28,800 645,000 Dolomite 51,600
Charge Coke Limestone 22,400 Charge Coke Limestone 34,400
1,148,000 Quartzite 89,600 Scrap 18,000 1,763,000 Scrap 21,500
Scrap 14000 Dry Slag 70,200 Hot Metal Slag Dry Slag 83,900
CHAR Flue Dust Slag Granulated Slag 1,333,800 Flue Dust 1677000 Granulated Slag 1,593,200
300,000 Flue Dust Slag 1092000 Dry Slag 54600 72000 1404000 86000
56000 Granulated Slag1037400 280,800
2400000
3,600,000
1,600,000
1,500,000 To EAF 2,800,000
DRI Total Hot Metal Hot Metal
Charge Coke from CO Plant
1,476,000
4,300,000
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
56000 Granulated Slag1037400 280,800
Sized DRI DRI Fines
1,050,000 450,000 Hot Metal Hot Metal PCI/ GPI
Lime 85,400 Scrap 3,200,400 3,167,500 266,800
2,900 381,000 13600 Pig Iron Ferro Alloy
Briquetted DRI Fines Pet Coke Ferro Alloy 3,028,600 27,000
364,600 1,300 4,200 Hot DRI from MIDREX Carbon Dolomite
Ferro Alloy Carbon Lime Dolomite 1,600,000 Scrap 14,400 36,000
SMS-1C
266,800
DRI from Coal
SMS-1A
Sized DRI
Briquetted DRI Hot Metal Based DR Plant
1,022,700 669,000
SMS-1B SMS-2A
1,600,000
SMS-2B
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
HMDS2 x 200 ton
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
HMDS2 x 200 tonHMDS
2 x 250 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
Ferro Alloy Carbon Lime Dolomite 1,600,000 Scrap 14,400 36,000
3,500 3,500 33,800 12,700 161,400 Lime Ferro Alloy Hot Metal Iron Ore Ferro Alloy Hot Metal Iron Ore
Iron ore 144,000 36,000 3,184,400 60,000 35,600 3,151,600 59,400
69174 Ferro Alloy 36,300 60,600 Lime Scrap Lime Scrap
308,610 15,500 Lime Scrap 255,000 167,600 252,400 165,900
Briquetted DRI Briquetted DRI 2,100 Lime Dolomite 257,400 151,400
Fines to EAF Fines to IF 131,800 23,300
85,400 364,600 Slag Slag
Liquid Steel Liquid Steel Slag 415700 415700
288,000 422,400 434000
Slag Liquid Steel Liquid Steel
Ferro Alloy
3,013,408
Additives
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVABOF Shop2 x 200 ton
HMDS2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
BOF Shop2 x 200 ton
HMDS2 x 200 ton
BOF Shop2 x 250 ton
HMDS2 x 250 ton
Electric Arc Furnace2 x 100 ton/ 100 MVA
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
Slag Liquid Steel Liquid Steel
310000 3,000,000 5,969,200 2,969,200
Liquid Steel Liquid Steel Liquid Steel Liq Steel 1,550,000 3,100,000
144,000 126,700 295,700
500,000
1,050,000
500,000 Slag
15500
Liq Steel
Liquid Steel
144,000
Liquid Steel
1,800,000
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRFLRF
1 x 180 ton
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
VD/VOD1 x 60 ton
LRF1 x 60 ton
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
15500
Slag
Liquid Steel Liquid Steel Slag 25422
288,000 422,400 31000
3,100,000
Liquid steel to SMS 1C 1,762,200 3,400,000
157,500
1,005,200 1,919,700 1,337,800 5,153,800
1,550,000
Liq steel
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
VD/VOD1 x 60 ton
LRF1 x 60 ton
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
1,005,200 1,919,700 1,337,800 5,153,800
Scrap 2,542,200
Billet Slab to HSM Transfer to CSP Scrap Scale Scale Scrap 77,307
279,400 414,000 387,300 38400 19200 6700 26800
Billets ,Blooms and other sections 975,100 1,304,300 Slabs to plate mill
Billets to bar and rod mill 1,862,100 Billets
133,000
Billet to Bar & Rod Mill Slabs From
Slab
5,050,724
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
Slab Caster - 23 x 1 strand
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
VD/VOD1 x 60 ton
LRF1 x 60 ton
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
CSP2 x 1 Strand
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Billet Caster1 x 8 strand
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
Combi Caster1x6 strand
Slab Caster1 x 1 strand
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
ASP1 x 135 TPD + 1 x 340 TPD +1 x 405 TPD1 x 1200 TPD1 x 1118 TPD
2 x 1200 TPD1 x 2500 TPD
Billet to Bar & Rod Mill Slabs From
412,400 Slab Caster-1 Slab for Sale
414,000 250,000
1,237,100 625,000
842,100
HRC
Scrap Scale
8300 4300 2,929,500
5,214,724
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
Slab Caster - 23 x 1 strand
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
Bar & Rod Mill
VD/VOD1 x 60 ton
LRF1 x 60 ton
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
CSP2 x 1 Strand
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Billet Caster1 x 8 strand
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
Combi Caster1x6 strand
Slab Caster1 x 1 strand
4 Hi Reversing Plate MillWire Rod MillMedium & Heavy Section Mill TMT Rebar Mill
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
ASP1 x 135 TPD + 1 x 340 TPD +1 x 405 TPD1 x 1200 TPD1 x 1118 TPD
2 x 1200 TPD1 x 2500 TPD
8300 4300 2,929,500
800,000 Medium & Heavy Section TMT Rebar 1,200,000 Wire Rods 600,000 Plates 1,200,000 387,300
27800 scrap scrap 24,500 scrap 16,500 scrap 84,800
400,000 0.97 14,300 Scale Scale 12600 Scale 8,500 Scale 19600
scrap
387,300 Scale 76,483
38,200
5,100,000
Rebars & Wire Rods
Transfer of steel from EAF shop
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
Slab Caster - 23 x 1 strand
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
Bar & Rod Mill
VD/VOD1 x 60 ton
LRF1 x 60 ton
Hot Strip Mill
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
CSP2 x 1 Strand
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Billet Caster1 x 8 strand
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
Combi Caster1x6 strand
Slab Caster1 x 1 strand
4 Hi Reversing Plate MillWire Rod MillMedium & Heavy Section Mill TMT Rebar Mill
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
ASP1 x 135 TPD + 1 x 340 TPD +1 x 405 TPD1 x 1200 TPD1 x 1118 TPD
2 x 1200 TPD1 x 2500 TPD
8,029,500
LEGEND :
Existing Facilities
HRC for Sale
New Facilities coming under Stage-I expansion (8.2 mtpa) 3,500,000 Crude Steel 12,815,186
New Facilities coming under Stage-II expansion (12.8 mtpa) Scale 10,900 Scrap 610,448
5,100,000
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
Slab Caster - 23 x 1 strand
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
Bar & Rod Mill
VD/VOD1 x 60 ton
LRF1 x 60 ton
Hot Strip Mill
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
CSP2 x 1 Strand
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Billet Caster1 x 8 strand
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
Combi Caster1x6 strand
Slab Caster1 x 1 strand
4 Hi Reversing Plate MillWire Rod MillMedium & Heavy Section Mill TMT Rebar Mill
CRM Complex-22.0 MTPA
CRM Complex-30.8 MTPA
0.5 MTPAStainless Steel Complex
CRM Complex-10.6 MTPA + 0.6 MTPA
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
ASP1 x 135 TPD + 1 x 340 TPD +1 x 405 TPD1 x 1200 TPD1 x 1118 TPD
2 x 1200 TPD1 x 2500 TPD
New Facilities coming under Stage-II expansion (12.8 mtpa) Scale 10,900 Scrap 610,448
Scrap 96,200 Scale 4000
Slip Coils 550,000 Scrap 31,900
1,200,000 Coils 787,800 Sheets 194,000 500,000
Sheets 550,000 Coils 535,600
Total scrap from CRM 228571
Coke Plant 12x 64 ovens Stamp Charge with CDQ
(4.3 m height)
Coke Plant - 21 x 74 oven Top Charge with CDQ
(7.6 m height)1 x 74 Top Charge with CDQ (7.6 m height)
Coke Plant - 32 x 64 oven Stamp Charge with CDQ
(6.5 m height)
Sinter Plant 11 x 177 Sq. m machine
Sinter Plant 21 x 204 Sq. m machine
Sinter Plant 31 x 204 Sq. m machine
Sinter Plant 51 x 480 Sq. m machine
Sinter Plant 61 x 480 Sq. m machine
Pellet Plant7.0 mtpy
Blast Furnace 1Useful volume - 1,681 Cum
After CE augmented to 3,400 Cum
Blast Furnace 2Volume - 3,814 Cum
After Augmentation vol 4,500 Cum
Blast Furnace 3Volume - 5,800 Cum
Induction Furnace6 x 15 ton Twin Crucible
Electric Arc Furnace
1 x 60 ton/ 55 MVA
LRF1 x 15 ton
VD/VOD1 x 60 ton
Billet Caster1 x 2 strand &
1 x 3 strand
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin Shell CONARC1 x 180 ton / 145 MVA
LRF2 x 200 ton
LRF1 x 180 ton
Slab Caster - 23 x 1 strand
DR Module10 x 500 TPD Rotary Kilns
COG based MIDREX Plant1 x 1.6 MTPY
Briquetting Plant
Slab Caster - 11 x 1 strand , 1300
mm
Bar & Rod Mill
VD/VOD1 x 60 ton
LRF1 x 60 ton
Hot Strip Mill
BOF Shop2 x 200 ton
HMDS2 x 200 ton
ARS - Online2 x 200 ton
Twin LRF2 x 200 ton
CSP2 x 1 Strand
BOF Shop2 x 250 ton
HMDS2 x 250 ton
ARS - Online2 x 250 ton
LRF2 x 250 ton
Billet Caster1 x 8 strand
Electric Arc Furnace2 x 100 ton/ 100 MVA
LRF2 x 120 ton
Combi Caster1x6 strand
Slab Caster1 x 1 strand
4 Hi Reversing Plate MillWire Rod MillMedium & Heavy Section Mill TMT Rebar Mill
CRM Complex-22.0 MTPA
CRM Complex-30.8 MTPA
0.5 MTPAStainless Steel Complex
CRM Complex-10.6 MTPA + 0.6 MTPA
AOD1 x 120 ton
CALCINING PLANT
3 x 600 tpd
CALCINING PLANT4 x 300 tpd1 x 600 tpd
CALCINING PLANT
3 x 600 tpd
1 x 33 MW + 1 x 77 MW +
12 MW + 20 MW1 x 165 MW
1 x 12 MW (TRT)1 x 20 MW (TRT)
2 x 165 MW1 x 40 MW (TRT)
Pellet Plant7.0 mtpy
Sinter Plant 41 x 224 Sq. m machine
ASP1 x 135 TPD + 1 x 340 TPD +1 x 405 TPD1 x 1200 TPD1 x 1118 TPD
2 x 1200 TPD1 x 2500 TPD
Fig 1- Process flowsheet for 12.8 MTPA crude steel production for BSL, Meramandali