jai balaji industries limited · 2006 approved the merger of shri ramrupai balaji steels limited,...

JAI BALAJI INDUSTRIES LIMITED ( Unit – I )

PRE-FEASIBILITY REPORT

for Proposed expansion of existing Steel Plant by installation

of Sponge Iron Plant with 5x100 TPD DRI Kilns, 4x15 T

Induction Furnaces, 50 TPH Coal Washery, Iron Ore

Beneficiation & Palletization Plant & 22 MW capacity

Captive Power Plant along with the product mix change of

existing 2x7 MVA Submerged Arc furnaces

at G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar,

District – Burdwan, West Bengal

September – 2018

ABC INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.

TEFR for expansion program of steel complex. 1 - 1

CHAPTER - 1

INTRODUCTION

1.1 BRIEF WRITE UP ABOUT THE GROUP :

Kolkata based Jai Balaji Group is among the top ten steel producers of the

country, having turnover around Rs. 2,500 Crores. The group is engaged in the

production of Sponge Iron, Pig Iron, Steel Billets, Alloy Steel, Rounds, TMT

Bars, along with facilities like Coal Washery, Coke Ovens and Captive Power

Plants Pellet Plant and Sinter Plant.

Jai Balaji Group is a well known steel manufacturing group in the secondary

sector in eastern India. The group has a chain of value-added products which

include Sponge Iron, Pig Iron, Reinforcement Steel TMT Bars, Alloy and Mild

Steel Billets, Wire Rods and Carbon, Alloy and Mild Steel Heavy Rounds. The

group draws its strength from an old tradition of reliable customer service and

quality products.

The group comprises of Jai Balaji Industries Limited ( JBIL ), Jai Balaji Jyoti

Steels Limited, Nilachal Iron & Power Limited, Jai Salasar Balaji Steels Limited

and Chandi Steel Industries Limited.

1.2 BRIEF WRITE UP ABOUT THE COMPANY :

M/s jai Balaji Industries Ltd. (JBIL) previously M/s Jai Balaji Sponge Ltd.

(JBSL), was initially incorporated in West Bengal as a private limited company

on 1st July 1999.

The Board of Directors of the company at their meeting held on 28th August,

2006 approved the merger of Shri Ramrupai Balaji Steels Limited, another

flagship company of the Jai Balaji group with M/s Jai Balaji Sponge Limited

with effect from 1st April, 2006. Subsequently after the merger, the name of the

company was changed to M/s Jai Balaji Industries Limited from M/s Jai Balaji

Sponge Limited.

1.3 FUTURE PLANS FOR SPONGE IRON, ITS FORWARD AND BACKWARD

INTEGRATION

Jai Balaji Industries Limited (JBIL) has an operating steel iron plant at

Mangalpur Industrial Complex, P.O.-Baktarnagar, Raniganj, District – Paschim

Bardhaman of West Bengal. Encouraged by the good results of the already

operating plants and anticipating future market, the company has decided further

expansion of its existing plant at Mangalpur Industrial Complex, details of which

is given in the next page.



Sl.

No

Facilities Existing Capacity

(Having NOC)

Proposal Ultimate Capacity

1. DRI Plant 7 X 50 TPD

or 1,05,000 TPA

5 X 100 TPD

or 1,50,000 TPA

850 TPD or

2,55,000 TPA

2. Coal Washery 2,16,000 TPA (50 TPH) 2,16,000 TPA (50 TPH) 4,32,,000 TPA

3. Iron ore

Beneficiation

Plant

- 6,00,000 TPA

6,00,000 TPA

4. Iron ore Pellet

Plant

6,00,000 TPA 6,00,000 TPA

5 Steel Melting Shop

(Induction Furnace)

2,37,600 TPA (4 X 15 MT)

2,37,600 TPA (4 X 15 MT)

6. Ferro – Alloys Plant

2 X 7 MVA Ferro-Manganese –

15,576 TPA Silico Manganese –

14,580 TPA Total 30,156 TPA

]

Change of Product-Mix (Ferro-Chrome

inclusion)

Keeping the plant configuration unchanged

Either Ferro Manganese - 30,156 TPA (capacity optimized)

or Silico Manganese- 29,.160 TPA (capacity optimized)

or Ferro Chrome – 24,000 TPA (capacity optimized)

Total Ferro-Alloys production will never cross 30,156 TPA

7. Captive Power Plant

18.3 MW

22 MW (10 MW WHRB + 12

MW AFBC )

40.3 MW



1.4 PLANT LOCATION

The existing plant of the company is located at Mangalpur Industrial Complex of

Raniganj (Lat 25° 52' N, Long- 87° 52 ' E) district – Burdwan of West Bengal

(shown in Fig 1.1). The location is in close proximity to various collieries

belongs to Raniganj Coalfield. The plant is situated on the NH-2 with a distance

of 200 Km. from Kokata.

Fig 1.1(Location of the Plant )

1.5 PLANT LAYOUT The layout showing location of each of the existing and proposed facilities is shown in

Plate 1.2.

Location of the Plant



1.6 PLANT MATERIAL FLOW SHEET

Integrated flow sheet of proposed expansion facilities is shown in Fig 1.3

1.7 AREA REQUIREMENT

The total area required for proposed expansion 85.5 acres land, which is already acquired

by the company.


TEFR for expansion of Steel Complex. 2-1

CHAPTER - 2

MARKET FOR DIRECT REDUCTION (DR) PRODUCTS

Direct Reduced Iron (DRI) has found its use in almost all smelting/ melting systems,

including blast furnaces, submerged arc furnaces, open hearths, basic oxygen furnaces,

induction furnaces (IF), electric arc furnaces (EAF) and cupolas (Fig 2.1). Of these, the major

usage of DRI is undoubtedly in the production of steel through EAF or IF route. Accordingly

the demand of DR products is closely related to the growth of the secondary steel sector. Any

projections about the demand of DRI/HBI should, therefore, be attempted in the overall

scenario of electric steel production projected for the country and the interplay of different

techno-economic considerations that determine the relative percentages of different metallics

in the production of electric steel. A brief review of these aspects is presented in following

paragraphs.

2.1 DEMAND OF STEEL IN INDIA

2.1.1 Past consumption trend

Recorded past consumption trend of steel in India for the period 1987-88 to

2002-03 is presented in Table 2.1 below:

TABLE 2.1

PAST TREND OF FINISHED STEEL CONSUMPTION (ACTUAL

DEMAND) IN INDIA -FOR THE PERIOD 1987-88 TO 2002-03

Year Consumption (‘000 T)

1987-88 12,806

1988-89 14,130

1989-90 14,118

1990-91 14,370

1991-92 14,830

1992-93 15,000

1993-94 15,320

1994-95 18,660

1995-96 21,650

1996-97 22,130

1997-98 22,630

1998-99 23,400*

1999-2000 26.710*

2000-01 29.270*

2001-02 31.630*

2002-03 33.000*

Source: 1. Steel Scenario - Statistical Yearbook 2001.

2. JPC statistics on Iron & Steel, March 2002.

3. SAIL statistics for Iron & Steel Industry in India, 2000.

* Website of Ministry of Steel updated on 04.02.2005



FIG 2.1 : CONSUMERS OF SPONGE IRON (DRI) or HOT BRIQUTTED IRON (HBI)

DRI/HBI

Blast Furnaces

Submerged Arc Furnaces

Open Hearths Basic Oxygen furnaces

Induction Furnaces

(IF)

Electric Arc Furnaces

(EAF)

Cupolas

Major Users

Smelting/melting systems

Other Users



It will be seen from Table 2.1 above that there is almost a steady growth (6.5%) in steel

consumption in last 15 years.

2.1.2 Future steel demand

Projections of the steel demand in India for varying time horizons up to 2011-12 have

been made by several agencies from time to time. In order to have a long term

perspective to facilitate planning, a Sub-Group on Steel and Ferro Alloys was constituted

for the steel sector under the aegis of the Planning Commission. The sub-Group

deliberated upon all aspects including supply-demand projections for finished steel

during the period 2001-02 to 2011-12. Considering a GDP growth rate of 6.5% as

realistic during 10th plan, the Sub-Group has projected the demand of finished carbon

steel in the country to rise as given in Table 2.2.

TABLE 2.2

PROJECTIONS OF FINISHED STEEL DEMAND IN INDIA (MT)

Year Forecast of demand for Finished

Steel

2001-02 28.24

2002-03 30.01

2003-04 31.91

2004-05 33.92

2005-06 36.05

2006-07 38.22

2007-08 40.74

2008-09 43.30

2009-10 46.03

2010-11 48.93

2011-12 52.01

Source : Web site of Ministry of Steel

2.2 STEEL PRODUCTION

The production of crude steel in India for the period 1987-88 to 2001-02 and the

corresponding ratios of crude steel production to finished steel consumption are presented

in Table 2.3.

TABLE 2.3

TOTAL CRUDE STEEL PRODUCTION TRENDS AND DEMAND

SATISFACTION RATIO IN INDIA FOR THE PERIOD 1987-88 TO 2002-03

(MT)

Year Total crude

steel

production

Finished steel

Consumption

(Ref. Table 2.1)

Demand satisfaction ratio (crude

steel production/ finished steel

consumption)

1987-88 12.510 12.81 0.98

1988-89 13.500 14.13 0.96



Year Total crude

steel

production

Finished steel

Consumption

(Ref. Table 2.1)

Demand satisfaction ratio (crude

steel production/ finished steel

consumption)

1989-90 13.370 14.12 0.95

1990-91 15.840 14.37 1.10

1991-92 16.760 14.83 1.13

1992-93 17.460 15.00 1.16

1993-94 17.300 15.32 1.13

1994-95 19.450 18.66 1.04

1995-96 22.430 21.65 1.04

1996-97 23.357 22.13 1.06

1997-98 24.759 22.63 1.09

1998-99 23.120 23.40 0.99

1999-2000 26.90 26.71 1.01

2000-01 27.29 29.27 0.93

2001-02 28.814 31.63 0.91

2002-03 30.50 33.00 0.92

A perusal of above table shows that crude steel production levels recorded an average

annual growth rate of around 7 per cent up to 1997-98 and then declined slightly in the

subsequent years. It may further be noted that the demand satisfaction ratio in India has

normally varied between 0.92 to 1.16, reflecting the high dependence of the Indian steel

industry on indigenous production.

In this context it may be noted that the demand satisfaction ratio basically depends on

two factors: namely, yield from crude steel to finished steel and net exports. With

increase in yield, the demand satisfaction ratio should decrease and with increase in net

exports, the ratio should increase. While yield from crude to finished steel is likely to

increase marginally in future; given the past trends, net exports should however exhibit a

marked increase. Accordingly, the demand satisfaction ratio should increase. However,

on a conservative basis, the crude steel production levels in the terminal years have been

estimated assuming a demand satisfaction ratio of 1.10 and are indicated in Table 2.4.

TABLE 2.4

ESTIMATED FUTURE CRUDE STEEL PRODUCTION AND

FINISHED STEEL DEMAND IN INDIA

Year Finished steel demand

(MT)

Crude steel production

demand (MT)

2006-07 38.22* 42.04**

2011-12 52.01* 57.21**

Note : * Figures adopted from Table 2.2

** Figures obtained by multiplying the finished steel demand by

assumed demand satisfaction ratio of 1.10



2.3 PRODUCTION OF ELECTRIC STEEL

The past production of steel produced in India through the EAF and IF route is indicated

in Table 2.5 below along with the share of this route in total crude steel production.

TABLE 2.5

ELECTRIC CRUDE STEEL PRODUCTION AND SHARE IN INDIA

FOR THE PERIOD 1987-88 TO 2000-01

Year Production of crude

steel by EAF/ IF

route ‘000 T

Total crude steel

production ‘000 T

(Refer Table 2.3)

Share of EAF/ IF

route in crude steel

production %

(1) (2) (3) (4) = (2) (3)

1987-1988 2,745 12,505 22

1988-1989 2,706 13,496 20

1989-1990 2,777 13,370 21

1990-1991 4,668 15,838 29

1991-1992 4,196 16,758 25

1992-1993 4,176 17,456 24

1993-1994 3,700 17,296 21

1994-1995 4,573 19,466 23

1995-1996 6,720 22,431 30

1996-1997 7,330 23,357 31

1997-1998 8,470 24,759 34

1998-1999 7,534 23,119 33

1999-2000 9,368 26,900 35

2000-2001 9,703 27,290 36

2001-2002 11,000 28,814 38

2002-2003 30,500

A perusal of the above table shows that crude -steel production by the secondary steel

sector increased from levels of around 2.8 MT in 1987-88 to 11.0 MT in 2001-02,

representing an average annual growth rate of around 10.5 per cent. This trend can be

seen in Fig 2.2. The share of the EAF/IF route also exhibited a corresponding increase

from levels of around 20% in the last decade to around 38% (Refer Table 2.5).

Keeping in view past trends in the growth of electric steel production and the increasing

importance of the secondary steel sector in the domestic steel industry, the share of the

EAF/ IF route is expected to exhibit a steady growth in future. The future expected shares

of the EAF/ IF route in crude steel production and corresponding production of electric

steel are indicated in Table 2.6.



TABLE 2.6

ESTIMATED FUTURE SHARE AND PRODUCTION OF CRUDE

STEEL (MT) THROUGH EAF/ IF ROUTE IN INDIA

Year Crude steel

production

Production of crude steel through EAF/ IF

route (assumed 40%)

2006-07 42.04 16.82

2011-12 57.21 22.88

2.4 METALLICS SCENARIO

2.4.1 Metallics requirement

The corresponding metallics requirement to support current and future levels of electric

steel production are given in Table 2.7, assuming a metallics requirement of 1.1

tonne/tonne of crude steel.

TABLE 2.7

CRUDE STEEL PRODUCTION (EAF/IF ROUTE) V/S SOLID

METALLICS REQUIREMENT

Year Crude steel production

through EAF/IF route (MT)

Solid metallics requirement

(MT) (@ 1.1 % of crude steel)

2006-07 16.82 18.50

2011-12 22.88 25.17

This metallics requirement has to be met either through scrap or DRI/HBI.

FIG 2.2 : CRUDE STEEL PRODUCTION THROUGH EAF/IF ROUTE

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

1987-8

8

1988-8

9

1989-9

0

1990-9

1

1991-9

2

1992-9

3

1993-9

4

1994-9

5

1995-9

6

1996-9

7

1997-9

8

1998-9

5

1999-2

000

2000-0

1

2001-0

2

2002-0

3

year

Pro

du

cti

on

Production of crude steel by EAF/IF route Crude steel production



2.4.2 Scrap scenario

Steel scrap is available indigenously from two sources

(i) process scraps produced by steel plants and

(ii) obsolete capital scrap obtained from scrapped iron and steel products like ships,

automobiles, etc.

The other major source of melting scrap is through imports.

The availability of melting scrap in India since 1987-1988 is given in Table 2.8 and

the same is shown in line graph (Fig 2.3).

TABLE 2.8

AVAILABILITY OF STEEL MELTING SCRAP IN INDIA

(EXCLUDING INTEGRATED STEEL PLANTS), ‘000 TONNES

Year Indigenous scrap availability Imports Total

1987-1988 2,200 1,860 4,060

1988-1989 2,880 2,120 5,000

1989-1990 2,231 2,269 4,500

1990-1991 1,978 2,822 4,800

1991-1992 3,992 1,268 5,260

1992-1993 2,827 2,573 5,400

1993-1994 4,446 754 5,200

1994-1995 4,004 1,416 5,422

1995-1996 4,886 974 5,860

1996-1997 4,500 1,165 5,665

1997-1998 4,500 831 5,331

1998-1999 5,600 880 6,480

1999-2000 5,300 823 6,123

2000-2001 5,100 1,512 6,612

Source : 1. Steel scenario statistical yearbook 2001

2. JPC Bulletin on Iron & Steel , March 2002

3. SAIL statistics for Iron & Steel Industry in India, 2000



It will be observed from the above that availability of melting scrap in India has been

around 5.4 MT in the past.

The internal generation of scrap by integrated steel plants is gradually decreasing due to

adoption of concast technology and modern rolling techniques and the same is not

expected to be available to other plants which use scrap as raw material. Recovery rates

of obsolete scrap in India have also not exhibited significant growth over the past few

years and the domestic scrap collection/ processing sector is not well organised. Further

availability of good quality capital scrap is also decreasing worldwide.

Keeping in view the above factors, researchers and planners do not expect indigenous

availability of scrap to exceed 5.0 to 5.5 MT per year over the next few years. Further,

with increase in the production of EF steel and gradual decrease in the quality of traded

scrap, it is difficult to envisage more than 2.0 to 2.5 MT being imported to India on

regular basis in the near future.

Based on the above, future estimated availability of scrap is indicated in Table 2.9.

FIG 2.3 AVAILABILITY OF STEEL MELTING SCRAP IN INDIA

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

1987-8

8

1988-8

9

1989-9

0

1990-9

1

1991-9

2

1992-9

3

1993-9

4

1994-9

5

1995-9

6

1996-9

7

1997-9

8

1998-9

9

1999-2

000

2000-2

001

YEARS

Pro

duction (

Mill

ion T

onnes)

Indigenous scrap availability Imports Total availability



TABLE 2.9

FUTURE AVAILABILITY OF SCRAP FOR MELTING PURPOSES

BASED ON PAST RECORD (REFER TABLE 2.8) (MT) (REFER TABLE

2.13)

Year Indigenous

availability

Imports Total availability

2006-07 5.0 2.0 7.0

2011-12 5.0 2.5 7.5

2.5 SPONGE IRON (DRI/HBI) AVAILABILITY

Sponge iron is produced through two alternative routes. Through a coal based

route, sponge iron is produced in the form of lumps or granules. It is called Direct

Reduced Iron (DRI). DRI can be produced by smaller capacity plants with lower

investments. However it has the disadvantage of slightly lower yields as compared to a

gas based DRI. Through a gas based route, sponge iron is produced in the form of

briquettes (small cubes of 9cm x 6cm x 3cm) and is called Hot Briquetted Iron (HBI).

HBI has the advantages of higher yields, however, it can be produced only through large

scale plants with large investments and substantial feedstock requirements.

India is the largest sponge iron producer in the world. The installed capacity of

sponge iron increased from about 1.52 MT in 1991 to about 6.60 MT in 2001.The

installed capacities in India are as given in Table 2.10.

TABLE 2.10

ANNUAL INSTALLED CAPACITY OF SPONGE IRON IN INDIA (‘000

T)

Sl. No. Name of Plant Process Installed capacity

1. Gas Based

i) Essar steel Midrex 2,200

ii) Ispat industries Midrex 1,200

iii) Vikram ispat HYL III 900

Total gas based 4,300

2. Coal Based

i) JSPL Jindal 720

ii) PIL SL/RN 300

iii) Tata sponge TDR 240

iv) Goldstar Codir 220

v) Monet ispat Jindal 200

vi) BSIL SL/RN 150



Sl. No. Name of Plant Process Installed capacity

vii) NISL SL/RN 150

viii) Llyods Metals Accar/OSIL 150

ix) Sunflag Codir 150

x) Sree Metaliks Popuri 150

xi) OSIL OSIL 100

xii) Ispat Godawri 100

xiii) Shyam Sel Ltd. Indigenous 100

xiv) Adhunk Corporation Ltd. Popuri 72

xv) Rexon strips Jindal 60

xvi) SIIL SL/RN 60

xvii) Bellary Steel SOO: 60

xviii) HEG SIIL 60

xix) KMCL SIIL 60

xx) Raipur Alloys SIIL 60

xxi) Deepak Steel & Power Ltd. Popuri 84*

xxii) Vandana Global SL/RN 50

xxiii) MSP Sponge SL/RN 45

xxiv) Tamil Nadu Sponge SIIL 30

xxv) Kusum Pwermet SIIL 30

xxvi) Suryaa Sponge Popuri 24

xxvii) Scan Sponge Popuri 24

xxviii) Ashirwad Steel SL/RN 24

xxix) Rungta Mines Ltd. Popuri 150*

Total coal based 3,593

Grand total 7,893

* Updated January, 2005

The production of coal-based DRI plants in the recent past (as available from

Sponge Iron Manufacturer’s Association – SIMA) has been as follows:

Year MT

1999-2000 : 1.88

2000-01 : 2.02

2001-02 : 2.48

The production of Sponge Iron from 1992-93 to 2002-03 is indicated in the

Table 2.11 below and the same is shown in Fig 2.4 by line graph.



TABLE 2.11

SPONGE IRON PRODUCTION TREND

PERIOD GAS BASED COAL BASED TOTAL (MT)

1992-1993 0.9 0.46 1.36

1993-1994 1.5 0.8 2.3

1994-1995 2.1 1.2 3.3

1995-1996 2.9 1.2 4.1

1996-1997 3.3 1.7 5.0

1997-1998 3.6 1.7 5.3

1998-1999 3.5 1.8 5.3

1999-2000 3.4 1.9 5.3

2000-2001 3.4 2.0 5.4

2001-2002 3.1 2.5 5.6

2002-2003 - - 6.91

2003-04 - - 8.08

From the above table it is seen that the sponge iron production increased from

1.36 MTPA in 1992-93 to 8.08 MTPA in 2003-04 which represents a consistent growth

in production of sponge Iron.

2.5.1 Metallics shortfall

The metallics shortfall which may be expected in the next decade has been

computed by subtracting the expected scrap and DRI availability from the total metallics

requirement for crude steel production through EAF/IF route and is given in Table 2.12.

TABLE 2.12

FUTURE METALLICS SHORTFALL FOR CRUDE STEEL

PRODUCTION THROUGH EAF/IF ROUTE (MTPA)

2006-07 2011-12

Total metallics requirement (Refer Table 2.8) 18.50 25.17

Scrap availability 7.00 7.50

DRI/HBI availability 6.00 6.00

Solid metallics shortfall 5.50 11.67

It will be seen from the above that as per projections by the sub-group, metallics

shortfall to the tune of 5.50 MTPA may be expected by 2006-2007 and it is expected to

further increase to 11.67 MTPA by the year 2011-12. This metallics shortfall is to be met

either through scrap imports or creation of additional DRI/HBI capacity.



With regard to probabilities of increased scrap imports, the same would depend on its

availability and relative price structure. As already indicated earlier, availability of good

quality scrap is steadily decreasing. Moreover, even under current market conditions,

landed price of scrap at end-user sites in India continues to be more expensive than

landed price of DRI. Possible reasons for this could include high freight rates, inland

transportation rates, heavy dependence on changes in custom tariff by GOI and high third

party commissions charged by scrap traders.

With regard to the creation of additional DRI/HBI capacity in India, it should be

mentioned that prospects of installation of new gas-based DR plants are very remote

keeping in view the natural gas allocation policy followed by the Government.

Accordingly, any new DRI capacities to be created would necessarily have to be based on

coal-based route. The prices of indegenous coal and iron ore are more or less stable and

therefore DRI manufacturing prices will remain competitive against the imported scrap

hence the viability of DRI industry in India.

2.6 CONCLUSION

i. Total crude steel production in India increased from 12.51 MT in 1987-88

to 30.50 MT in 2002-03 with annual growth of about 7% upto 1997-98

after which it reduced to about 4%

ii. The total finished steel consumption in India increased from 12.81 MT in

1987-88 to 33.00 MT in 2002-03 at an average growth rate of 6.5%.

FIG. 2.4 SPONGE IRON PRODUCTION TREND

0

1

2

3

4

5

6

7

8

9

1992-

1993

1993-

1994

1994-

1995

1995-

1996

1996-

1997

1997-

1998

1998-

1999

1999-

2000

2000-

2001

2001-

2002

2002-

2003

2003-

2004

Years

Pro

du

cti

on

(M

illi

on

Tto

nn

es)

Gas based Coal based Total



iii. The demand satisfaction ratio (crude steel production ÷ finished steel

consumption) varied from 0.91 to 1.16 for 1987-88 and 2002-03

respectively.

iv. A sub-Group on steel and Ferro Alloys was constituted under the aegis of

Planning Commision (2001-02) which projected the demand for finished

steel as 38.22 MT and 52.01 MT in 2006-07 and 2011-2012 respectively.

v. The future crude steel production in India is substantiated from finished

steel projection and has been projected assuming a conservative figure of

1.10 for demand satisfaction ratio hence these come to 42.04 and 57.21

MT for the years 2006-07 and 2011-12 respectively

vi. The share of crude electric steel (EAF & IF) in total crude steel in India

varied between 22% (2.75 MT) and 38% (11.0 MT) from 1987-88 and

2001-02 respectively. The projected electric crude steel at 40% and 46%

share corresponding to the years 2006-07 and 2011-12 respectively will be

16.82 and 22.88 MT respectively.

vii. Metallics requirement are projected @ 1.1 metallic/te of crude steel

produced hence they become 18.50 and 25.17 MT for the years 2006-07

and 2011-12 respectively.

viii. The total scrap (indigenous and imported ex-integrated steel plants)

availability has been 4.06 MT to 6.61 MT in 1987-88 and 2000-01

respectively in which imported share on an average has been about 27%.

The projected availability of total scrap is 7.0 and 7.5 MT for 2006-07 and

2011-12 with 57% and 31.25% share of imported scrap.

ix. Sponge iron production increased from 1.36 MT in 1992-93 to 8.08 MT in

2003-04. The future projected DRI/HBI availability is assumed as 6.0 MT

for calculating the solid metallic shortfall.

x. Solid metallics shortfall as calculated by subtracting available scrap and

DRI/HBI from total metallics requirement comes to 5.50 and 11.67 MT

for the year 2006-07 and 2011-12 respectively.

The summarised data in Table 2.13 shows the past and future status of all the

related parameters.

TABLE 2.13

SUMMARISED DATA OF PAST AND FUTURE LEADING TO

IDENTIFICATION OF DEMAND OF METALLICS

Sl.No Particulars 1987-88 1992-93 2000-01 2002-03 2006-07 2011-12

1 (a) Total crude steel production in

India by all routes, MT

12.51 30.50

(b) Growth rate 7%

2 (a) Total finished steel consumption

in India, MT

12.81 33.00



Sl.No Particulars 1987-88 1992-93 2000-01 2002-03 2006-07 2011-12

(b) Growth rate 6.5%

3. Demand satisfaction ratio (DSR) =

crude steel production ÷ finished

steel consumption

0.98 0.92

4. Future projection of finished steel

based on Sub-Group on Steel and

Ferro Alloys 2001-02

38.22 52.01

5. Future projection of crude steel

production calculated from future

projection of finished steel by

multiplying by DSR as 1.10

42.04 57.21

6. Past and future projected crude

steel share through Electric (EAF

and IF) route, MT

2.75 9.70 16.82 22.88

Percentage of total (Ref Sl.1a) 22% 37% 40% 40%

7. Future total metallics requirement

by EAF/IF, MT@ 1.1 times that

of crude (Ref Sl. 6)

- - 18.50 25.17

8. Present scrap available in India

(ex integrated steel plants), MT

a) Indigenous Average 73%

b) Imported Average 27%

Total 4.06 6.61

9. Future scrap availability, MT

a) Indigenous 5 5

b) Imported 2.0 2.5

Total 7.0 7.5

10. Past sponge Iron (DRI/HBI)

production MT

- 1.36 - 6.91

11. Future projected DRI/HBI

availability, MT

6.0 6.0

12. Solid metallics shortfall (Total

solid metallics requirement-scrap-

DRI/HBI), mil te

- - - - 5.50 11.67


TEFR for Steel Complex Expansion. 3-1

CHAPTER - 3

RAW MATERIALS

Proposed expansion programme of the company is planned on the basis of

optimum waste recycling policy, which is reflected in this chapter.

3.1 RAW MATERIAL REQUIREMENTS

Based on prevailing operating data for different steel complex the annual

rawmaterials requirement is estimated as in Table 3.1:

TABLE 3.1

ESTIMATED ANNUAL QUANTITY OF RAW MATERIALS FOR THE

PROPOSED UNITS AS WELL AS EXISTING UNITS

SL. NO. PRIME RAW

MATERIALS

ANNUAL REQUIREMENT ( IN TPA ) SOURCE

EXISTING PROPOSED ULTIMATE COAL WASHERY

1. ROM COAL 1,92,000 1,92,000 3,84,000 RANIGANJ

COALFIELDS

IRON ORE BENEFICIATION PLANT 1. IRON ORE FINES ( -20

MM. )

- 8,20,000 8,20,000 BARBIL

IRON ORE PELLET PLANT 1. IRON ORE FINES - 6,00,000 6,00,000 IN-HOUSE

DRI PLANT 1. IRON ORE LUMP 2,20,000 - 5,32,500 BARBIL 2. IRON ORE PELLET - 4,00,000 4,00,000 IN HOUSE

PELLET

PLANT 3. WASHED COAL 1,08,000 1,08,000 3,16,000 IN HOUSE

COAL

WASEHRY 4. NON-COKING COAL 24,000 1,04,000 1,28,000 RANIGANJ

COALFIELDS 5.. DOLOMITE 1,620 2,325 3,945 MINES IN

BHUTAN

CAPTIVE POWER PLANT 1. MIDDLINGS/REJECTS 84,000 84,000 1,68,000 IN HOUSE

COAL

WASEHRY

2. DOLOCHAR 40,000 60,000 1,00,000 IN HOUSE

DRI PLANT



OTHER RAW MATERIALS WILL BE PROCURED FROM THE MARKET.

3.2 RAW MATERIAL STORAGE

The number of days stock of raw materials in terms of consumption in various units of

plant as have been envisaged are given in Table 3.2

TABLE 3.2

STORAGE DETAILS OF RAW MATERIALS

Materials No. of days stock

Power plant

Char 10

Middlings 10

SL. NO. PRIME RAW

MATERIALS

ANNUAL REQUIREMENT ( IN TPA ) SOURCE

EXISTING PROPOSED ULTIMATE INDICTION FURNACE

1. DIRECT REDUCED

IRON

- 1,55,000 1,55,000 IN HOUSE DRI

PLANT

2. IRON SCRAP - 65,000 65,000 MARKET

FERRO-ALLOYS FERRO-MANGANESE

1. MANGANESE ORE 35,825 69,360 69,360 IN HOUSE

PELLET

PLANT 2. COKE 8,175 15,828 15,828 IN HOUSE 3. DOLOMITE 3892 7,536 7,536 MINES IN

BHUTAN SILICO-MANGANESE

1. MANGANESE ORE 25,512 51,024 51,024

2. QUARTZ 2,190 4,380 4,380 MINES IN

BHUTAN 3. COKE 9,480 18,960 18,960 IN HOUSE

COKE

OVEN

4. DOLOMITE 2,190 4,380 4,380 MINES IN

BHUTAN

5. FE-MN SLAG 7,296 14,592 14,592 MINES IN

BHUTAN FERRO-CHROME

BRIQUETTE - 48,000 48,000 IN-HOUSE

CHROME ORE - 9,600 9,600 MINES IN

ORISSA

COKE - 12,960 12,960 IN-HOUSE

QUARTZ - 4,800 4,800 BHUTAN



Materials No. of days stock

DR plant

Coal 15

Iron ore pellet 15

Dolomite 20

Iron Ore Beneficiation Plant

Iron ore Fines 20

3.3 BRIEF OF THE RAW MATERIALS

Non-Coking Coal -

Non-coking washed coal will be used as reductant and heat producing material in the DR

Plant. Non- coking coal with low ash and moisture contents and moderately high volatile

matter is generally used for sponge iron production.

JBIL envisages their required non-coking coal mostly from its own Coal washery and

and the balance from the mines in Raniganj Coalfield area.

Iron Ore fines -

The entire requirement of iron ore fines for pellet making would be procured from mine

owners namely Essel Mining & Rungta Mines for uninterrupted basis for which tie up

arrangement has already been concluded.

Dolomite -

It is suggested to procure the entire requirement from Bhutan. There are several private

owned dolomite mines in that area, trading dolomite mostly to Indian iron and steel

industry. The chemical analysis of the dolomite from this region used in iron and steel

industry is presented below:

CaO MgO Al203 Fe2O3 LOI

% % % % %

30 20.0 1.9 0.64 43.9



CHAPTER - 4

MATERIAL HANDLING SYSTEM

As already discussed, the existing and proposed activities are as follows :

I. Existing setup:

(i) 7 x 50 TPD Kiln for DRI - 1,05,000 TPA.

(ii) 2 x 7 T Submerged Arc Furnace – 30,156 TPA (Ferro-Alloys).

(iii) Captive Power Plant – 18.3 MW.

(iv) Coal Washery – 2,16,000 TPA

II. Proposed facilities and their capacities

Facility Proposed Capacity 100%

Coal Washery

DRI Plant

2,16,000 TPA

1,50,000 TPA

Iron Ore Beneficiation Plant

Pellet Plant

Steel Melt Shop

( 4 X 15 T Induction Furnace )

6,00,000TPA

6,00,000 TPA

2,37,000 TPA.

Captive Power Plant 22 MW

(10 MW WHRB + 12 MW AFBC)

Raw material quantities

The bulk raw material which will be handled through the material handling

system consists of Iron ore fines, non-coking coal, Dolo char, washery middlings

and dolomite etc. The quantities have been given in Table 3.1.

Process of raw materials

A coal washery is being installed at plant, from where sized & washed coal will

be available for directly feeding the kilns. Crushers and screens will be provided

for coal and dolomite to provide required size to the existing kilns and the

ancillary units.

Receipt of raw materials

Run of mines Coal, Iron ore fines are envisaged to be received by rail/road and

Dolomite/limestone of the required size shall come by road.

0.03T



Truck unloading, handling and feeding

Rear dump-trucks/Rail carrying coal, Iron ore fines, dolomite etc. will enter the

plant via weighbridges. Front end loaders will load the materials into 10 T

dumper which will feed the hopper of a crusher which, in turn, feed the same into

a belt conveyor which delivers the materials in to the respective areas. The trucks

carrying washed coals will unload into a hopper which in turn feed the same into

a belt conveyor which will deliver the coal in a day bin. The dolomite/limestone

will be stored either in an open or a covered shed. Dolomite shall be fed to the

day bin through belt conveyors.

Sampling and weighing

A sampler will be provided at the drive end of the dispatch conveyor I in the

junction house for manual collection of samples of prepared material.

Belt scales will be provided on the conveyors transporting the incoming materials

to the storage yard as well as on the reclaimed materials from the storage yard

upto process plant. Belt scales will also be provided on the product line to

ascertain the quantities of product.

Miscellaneous facilities

Provision will be made for installing dust extraction facilities in various

hoppers/buildings. Electrical and mechanical hoisting equipment facilities will be

provided for maintenance of the equipment installed in these houses and

buildings. Belt replacements facilities will also be provided for convenience in

replacement of conveyor belts.

Electrical equipment

The equipment of the raw materials handling system will be centrally controlled

from a master control desk located in the control room. The electrical control

system will be categorised as per intended operation requirements. The system

will be sequentially controlled with provision for local manual operation, and for

monitoring of equipment faults.



5 - MAJOR PLANT FACILITIES

5.1 RECEIPT, UNLOADING STORAGE AND HANDLING OF RAW

MATERIALS

This section describes receipt, unloading, storage & handling and despatch of raw

materials for different consuming units of the proposed plant.

The estimated gross quantity of raw materials to be handled and their mode of

receipt are tabulated in Table 3.1.

Materials received by rail/road will be stored in the respective open storage yard

(by Contractor). Materials received by rail/road will be unloaded manually by

contractor labour equipped with modern machines and will be stacked to the

respective pile in the yard.

5.2 DIRECT REDUCTION (DR) PLANT

JBIL has its operating plant of DRI of capacity 1,05,000 TPA and which has been

planned to increase by 1,50,000 TPA.

PHASE CAPCITY

Present 1,05,000 TPA

Proposed 1,50,000 TPA

Ultimate 2,55,000 TPA

5.2.1 Design basis

The Sponge Iron plant will be designed on the basis of production of about

1,50,000 TPA of Direct Reduced Iron (DRI) from five kilns of 100 TPD

each.The annual production of DRI will be based on 300 days of operation.

Accordingly, commercially established coal-based rotary kiln process will be

adopted for the DR plant.

5.2.2 Product quality

It is expected that the DRI produced will contain about 92 per cent of Fe (Total),

around 0.2-0.3 per cent carbon and the degree of metallisation will be 90 per cent

average.

5.2.3 Raw materials

The rotary kiln charge will consist of iron ore pellet, washed non-coking coal and



dolomite. The quality of raw materials have already been discussed in Chapter 4.

The specific consumption of various raw materials are indicated in Table 5.2.

TABLE 5.3

SPECIFIC CONSUMPTION OF RAW MATERIALS

FOR THE DRI PLANT

Raw materials Specific consumption

Kg/ton DRI

Iron ore pellet 1,500

Clean coal &

Injection coal 1,200

Dolomite 15

5.2.4 Major facilities

The facilities within the DR plant will comprise the following major units:

- Rotary kiln.

- Rotary cooler.

- Waste gas system.

5.2.5 Rotary kiln:

The dimensions of the rotary kilns would depend on the process parameters

selected, the technology adopted and quality of raw materials. The kilns will be

lined with refractory/castables. The rotary kiln will have a main drive for normal

operation. The main drive system of the kiln will be powered by means of a

thyristor controlled DC drive so that the speed of the kiln can be varied as desired

by operating conditions.

An auxiliary drive will also be provided for slow speed rotation during

emergency/process requirement.

Air required for proper burning of combustibles inside the kiln and maintaining

the desired temperature profile, will be introduced through air tubes provided at

certain intervals along the length of the kiln. These air tubes will be connected to

individual shell mounted air fans for supply of air. Apart from the air tubes, air is

also supplied through a central burner fan provided at the kiln discharge end.

Combustion air supplied by the shell air fans and central burner fan will be

regulated through a set of butterfly valves in accordance with the process

requirement



Besides the heat supplied by coal, additional heat may also be required to be

supplied by auxiliary fuel, especially during start-up of the kiln and in an

emergency. A central oil burner will be provided at the discharge end of the

rotary kiln for this purpose.

5.2.6 Rotary cooler:

The product discharged from the rotary kiln will be indirectly cooled in rotary

cooler by spraying water on the shell of the cooler. The cooler will only be

partially lined with refractory/castables. Both main and auxiliary drives will be

provided for the cooler.

5.2.7 Waste gas system:

At the kiln inlet, a dust settling chamber (DSC) will be provided for allowing the

dust to settle before passing through the After Burning Chamber (ABC). The

ABC will be supplied with additional air by fans for burning the combustibles

contained in the kiln off-gas. It is envisaged that the waste gas from the ABC will

be used to generate steam in a waste heat recovery boiler (WHRB), to be

installed in the captive power plant

5.2.8 Electrical System:

One 11 KV switchboard will be established at DRI plant electrical room to feed

the electrical loads including variable frequency drives for kiln rotation over

11/0.433-0.25 kV load centre substation. Power to 11 kV switchboard will be fed

from CPP through underground cable . feeders. HT motor for ID fan drive will be

fed from high voltage load centre (HVLC) with the 11/6.6 kV transformer to be

established within the plant.

All sequencing, interlocking and control functions of electrical drives including

instrumentation and process automation shall generally be in compliance with the

requirements described under plant electrical system in this chapter.

5.2.9 Production Process

The process for the production of sponge iron consists of the reduction of iron ore

pellets with solid carbonaceous material (coal/coke/lignite) in a rotary kiln at

high temperature, cooling to room temperature in the rotary cooler with indirect

water cooling system, screening and magnetic separation of the product. Sponge

iron being magnetic gets attracted and separated from the non-magnetic char.



In the process for the production of sponge iron, the raw materials (iron ore, feed

coal and lime stone /dolomite) are fed to the rotary kiln through feed tube in a

pre-determined ratio by electronic weighing equipment. Due to inclination and

rotary motion of the kiln the material moves from the feed 'end of the kiln to the

discharge end in approximately 5.5 hrs. (Tendency time). The fine coal is blown

counter currently from the discharge end of the kiln to maintain the required

temperature and the carbon concentration in the bed. The kiln has seven shells air

fans mounted on the top which blow air in the respective zones to maintain the

required temperature profile. The material and the hot gasses move in the counter

current direction and as a result iron ore gets pre-heated and gradually reduced by

the time it reaches the discharge end.

The kiln is divided into two zones namely pre-heating zone and reduction zone.

The pre-heating zone is normally 30% of the total length of the kiln and the rest

is taken as the reduction zone. The material gets heated to the reduction

temperature in the pre-heating zone up to 200°C, the iron ore, coal and limestone

gets dried and all the moisture is vapourised. Upto 800° C, the iron ore gets

roasted and any carbonates in it get calcinated. In the coal, the volatile matter

starts getting released. The limestone also gets calcinated and becomes active.

The iron ore, which is in the form of hematite, gets reduced to magnetite. After

this the materials enter to the reduction zone where the magnetite is reduced to

wustite and then to metallic iron.

Coal contains sulphur. During decomposition of the coal, sulphur is released in

the form of Iron sulphide.

The iron sulphide (FeS) has deleterious effect in the steel making and is to be

removed. So limestone is used to prevent the sulphur pick up by the sponge iron.

All the above reactions are possible only in the presence of CO. The generation

of the CO is most important reaction, which is called the Boudard reaction.

This reaction is highly endothermic which is also reversible. The conditions

favourable for the forward reaction i.e. the generation of CO is:

The higher temperature favours the production of CO.

The concentration of the reactants has. to high so that the forward reaction

occurs.

Low pressure favours the CO generation.

The oxygen required for the burning of these combustibles is supplied from the



air tubes placed along the length of the kiln. By controlled combustion, the

temperature in the various zones is maintained so that the reduction is proper and

to sufficient degree.

The reduction of iron ore is topo-chemical i.e. the reduction proceeds from the

surface to the core. The iron ore on partial reduction has all the different stages of

the reduction.

The hot material after the reduction is complete is then transferred to the rotary

cooler via the transfer chute. The rotary cooler is 1.5 Mts. in diameter and 15

Mts. Long made up of Mild Steel shell. It is also inclined at 2.5° approximately

and rotates at variable speed from 0.2- 1.2 rpm .It is driven by an AC variable

speed motor. The water is sprayed on the top of the shell, which cools the

material inside the cooler indirectly. The heat from the material is extracted by

the shell. In order to increase the surface area for the heat extraction fins are

welded inside. Complete shell is covered by thin layer of water. The heat is

transferred from the shell to the water by convection. By this the material gets

cooled to 80oC and is discharged on the belt conveyor by the double pendulum

valve. The double pendulum valve acts as the seal for the prevention of the

atmospheric air into the kiln cooler system. The total kiln cooler system is kept

under positive pressure about 0.3-0.5 mbar. This prevents the atmospheric air

from getting into the system. The kiln has to be always operated on positive

pressure, as any leakage into the system will cause the re-oxidation of the sponge

iron there by causing the drop in the quality of the product.

The material after the discharge from the cooler is dropped on to the cooler

discharge conveyor. A diversion chute is provided at the head end of this

conveyor for diversion of the material in case of break down in the production

separation. The material is then sent to the product separation system. In product

separation system consisting of double deck screen, the material is screened to 0-

3mm and 3-20mm size fractions. The oversize i.e. +20 mm obtained is small

quantity so it is taken on the floor or diverted to the sponge iron bin. The 0-3mm

size fraction is called the fines are fed to a drum type magnetic separator where

the magnetic sponge iron fines and the non-magnetic dolochar separated and fed

to the respective bins through the chutes and conveyor. The coarser fraction is

similarly separated by another magnetic separator and fed so respective bins. This

magnetic fraction is called the sponge iron lumps and the nonmagnetic as char

which is the unburned coal. This char can be recycled depending on the quality

obtained after processing.

The gasses, which flow in the counter current direction of the material, go to the

dust-settling chamber where the heavier particles settle down. These particles are

continuously removed by the wet scrapper system. The gasses then pass to the

after burner chamber where the residual carbon or CO is burned by the excess air

available. The gasses are at high temperature and have lot of heat energy, which



can be utilised for the power generation through the waste heat recovery boiler.

The hot gasses after the heat recovery boiler gets cooled to 200°C. The gasses are

then scrubbed and let of to the atmosphere at BO°C through the chimney.

Alternatively the hot gasses are quenched and scrubbed to clean all the dust in it.

And then they are let off to the atmosphere through the stack.

The chemical reactions taking place in the reduction zone is represented by the

following equation:

FexOy + CO FexOy-1 + CO2

The carbon dioxide formed is converted to carbon monoxide by means of the

carbon in the reductant in accordance with the boudourd reaction:

C + CO2 2CO

Burning of small amount of carbon and excess carbon monoxide by means of

outside air supplied through tubes to provide heat for the process reactions can be

shown by the following equations:

CO + 1/2 O2 CO20

It is to be noted that a reducing and oxidising atmosphere prevail side by side in

the rotary kiln. Within the material charge it is reducing atmosphere accompanied

with endothermic reaction while in the free board above are the oxidising

conditions with the exothermic reactions.

The separation of the two atmospheres is ensured by the pressure generated by

CO emerging from the charge into the kiln free board. This avoids re-oxidation of

the reduced particles at the charge surface.

5.3 IRON ORE BENEFICIATION PLANT

In order to produce about 6,00,000 TPA pellet grade iron ore concentrate at full

development stage, it is proposed to set up a 0.6 MTPA iron ore beneficiation

plant to beneficiate low-grade iron ore fines (-10 mm) from different mines.

PHASE CAPCITY

Present -



These low grade iron ore fines, after beneficiation, shall become suitable for



production of pellets. Iron ore will be ground to a size of (-) 150 micron in

grinding mill which shall then be beneficiated to upgrade it to (+) 65% Fe.

The iron ore fines (-10 mm) from different mines will be brought to the raw

material and material handling plant for open stockpiling. The stockpiled material

will be reclaimed and conveyed to the beneficiation plant. The material will be

processed in beneficiation plant utilizing grinding mill, hydro cyclone and wet

high intensity magnetic separator (WHIMS)/ High intensity magnetic separator

and, if required, by flotation to obtain the concentrate having 65% Fe. The

concentrate product will be transported to the pellet plant in the form of slurry.

The tail fraction, generated from the beneficiation plant, will be pumped to the

tailing pond.

5.3.1 The Process

The major process units involved to upgrade the ROM iron ore to 65% Fe content

as final product are grinding mill; wet high intensity magnetic separation

(WHIMS)/ High gradient magnetic separation HGMS unit; hydro cyclone;

thickener for tails; thickener for concentrate; process water storage tank and fresh

water storage tank.

The sub-grade, low and medium grade iron ore generated in different mines will

be transported to stock pile. The stockpile will be reclaimed and conveyed to

grinding mill. A hanging magnet and metal detector have been planned on belt

conveyor to remove foreign magnetic materials. A belt weighing scale has been

planned on conveyor to monitor and control the quantity of material.

The beneficiation plant covers grinding circuit with closed circuit operation,

hydro cyclones for de sliming and classification operation, wet high intensity

magnetic separator (WHIMS) / high intensity magnetic separation (HIMS) for

separation of magnetic and nonmagnetic material and thickener to re pulp the

tails slurry before sending to tailing pond. The material from stockpile will be fed

to the ball mill to grind the crushed product to (-) 150 micron or a size decided

after test results. The grinding mill operation will be made under close circuit by

using cluster of hydro cyclone. The underflow of hydro cyclone will be re

circulated to the mill by pump and the overflow material will be pumped to

WHIMS/HGMS. The magnetic fraction will be concentrate and nonmagnetic

fraction will be either tails or may be further upgraded by second stage magnetic

separation or flotation depending on ore characterization tests. The magnetic

fraction of WHIMS will be finally re grinded to (-) 325 mesh and collected as a

product in concentrate thickener and underflow of concentrate thickener will be

pumped to pellet plant whereas non magnetic fraction will be rejected and

pumped to a tailing thickener. The overflow water of thickeners will be pumped

to process water tank for re use of water in the plant. The underflow material of

tailing thickener will be pumped to the tailing pond. Water recovery will be done

from tailing dam and from pellet plant.



The Process would not be generating any Hazardous Waste, as there is no

Hazardous Chemical involved in the process. Disposable solid waste consisting

of impurities of naturally available iron ore would be used for filling of the

abandoned mines in the vicinity. Solid disposable waste is also ideally suitable

for brick making and would be delivered to local brick makers. Thus solid waste

generated will not be having any negative impact on the environment.

5.4 PELLET PLANT

It is proposed to put up a Pelletising Plant of capacity 6,00,000 TPA so as to

beneficiate the ore and produce pellets to use it as raw material for iron making.

In the pellet making process, use iron ore fines which will be further ground and

mixed with additives like Bentonite and coke breeze / non-coking coal.

PHASE CAPCITY

Present -



The pellet plant will operate with haematite iron ore concentrate (- 325 mesh).

Iron ore concentrate will be received in the plant in the form of slurry, which will

be filtered to form a cake. The cake will have less than 9.0% moisture level.

The raw materials required for the proposed pellet plant are haematite ore

concentrate cake (- 325 mesh, 80% minimum) and ground additives like

bentonite, limestone and coke breeze / non-coking coal. Iron ore concentrate and

additives are mixed in an EIRICH mixer. The green ball formation is done using

disc pelletiser. Heat hardening of green pellets is done in indurating machine

(pre-heating, drying, heating, firing and finally cooling) using LDO as fuel.

Beneficiated iron ore concentrate (-325 mesh, 80% minimum) in the form of

slurry will be received at the proposed pellet plant site. The bentonite

requirement of the proposed plant will be met through purchase.

The expected chemical composition of pellets is as follows:

Fe(t) : 65%

SiO2 + Al2O3 : 2%

CaO + MgO : 0.5%

FeO : <0.5%

5.4.1 The Process

Iron ore slurry is received in the thickener. Slurry is thickened in the thickener

and transported to the filtration unit. Filtered cake from the filtration unit is stored

in the storage bins.



Proportioned quantities of filter cake from concentrate storage bins and ground

additives like limestone, bentonite and coke breeze / non-coking coal are fed to

mixer for thorough mixing with moisture.

The mixed material is conveyed to the bins above individual balling disc for

subsequent balling to green balls in the balling discs. These green balls/ pellets

are screened for narrow size range (9 - 16 mm) in a double deck roller screen

with oversize and undersize material being returned to mixed material bins. The

right size (9-16 mm) green balls are fed on to the traveling grate indurating

machine over a bed of hearth layer and side layer of fired pellets and pass

through drying, preheating, induration and cooling zone. The cooled product

pellets are then taken away to stockpile through a series of belt conveyors after

separation of hearth and side layers in the hearth layer separation bin.

Major technological units of the pellet plant will include slurry storage and

filtration unit; additives (limestone, coke breeze / non-coking coal and bentonite)

grinding; concentrate and ground additives storage bins; mixing of filter cake and

additives; balling; induration; pellets segregation and hearth layer separation and

finished pellet stockpiles.

Major services facilities like material handling, water supply system, compressed

air, ventilation and air-conditioning, process gas & plant dedusting, building

structures, civil works and industrial safety, electrics, instrumentation and

automation, central control room etc. have been envisaged for the proposed pellet

plant.

Emergency stockpiles of finished pellets have been envisaged within pellet plant

for uninterrupted supply of pellets to the Blast Furnace. The pellets can be

reclaimed from the stockpiles and discharged to product conveyor leading to the

blast furnace.

All junction houses and transfer points are dust generating sources. To control the

dust two numbers of ambient dust catching system will be installed in the pellet

plant. The dust content after dust catcher shall not be more than 50 mg/Nm3.

Finally dust will be controlled by the ESP before discharge through stack.

The process flow diagram of the proposed pellet plant is presented in Figure

5.4.1.



`

Fig. 5.4.1: Process Flow of Pellet Plant

5.5 CAPTIVE POWER PLANT

PHASE CAPCITY

Present 18.3 MW

Proposed 22 MW

Ultimate 40.3 MW

Product Pellet Storing Bin

Water

Blower

Iron Ore Concentrate Bentonite

Proportioning

Mixing

Disc Pelletier

Double Layer Roller Screen

Distributor

Traveling gate

Rotary Kiln

Circular Cooler

Combustion

Fan

Chimney

Exhaust Fan

Dedusting

Producer Gas



The proposed power plant will generate power to meet the demand of the various

facilities envisaged in this report and further to the projects which are under

construction.

Present operation units are being power supplied by existing Captive Power Plant

of 18.3 MW. Proposed projects like Steel Melt Shop, Pellet Plant and Coal

Washery will require around 42.5 MW power for operation. A suitable power

generation facility has been planned based on heat recovery steam generators by

recuperating sensible as well latent heat of waste gases emanating from DR kilns

along with a Thermal Power Plant (TPP) based on middlings to be generated in

the coal washery and Dolo-char generated in the DRI Kilns located in the plant.

Circulating Fluidized-Bed Combustion (CFBC) boiler for this purpose shall also

utilise the char to be generated to the maximum extent. The basic configuration

of thermal cycle and other relevant technical details are furnished in the

subsequent paragraphs. Capacity of the proposed Captive Power Plant is so

designed to cater power for the proposed projects as well as to projects which are

under construction.

5.5.1 Steam cycle for captive power Plant

The steam cycle define the transformation of the heat energy to the mechanical

energy at the turbine shaft, through the various thermodynamic processes that is

capable of producing the net heat flow or work when placed between the energy

cource and energy sink. The heat energy is derived from burning of fuels or

using heat energy already available in the hot waste gases. The cycle needs a

working fluid and steam is viewed as the most favored working fluid mainly

because of its unique combination of high thermal capacity, high critical

temperature, wide availability at cheaper cost and non toxic nature. Higher

thermal capacity of the working fluid generally results in the smaller equipment

for the given power output or heat transfer.

All the steam based power plants operate under the Rankine cycle. Simplistically

the cycle is described as the combination of the various processes like the

isentropic compression of water in the boiler feed water pumps, reversible heat

addition to the working fluid through the liquid, two phase and super heat states,

isentropic expansion of the working medium in the turbine and the constant

pressure heat middlingion to the atmosphere through the condenser and the

cooling water system. The cycle to be adopted for this project will be a modified

Rankine cycle with the addition of a Regenerative feed water heating. To

improve the efficiency of the cycle the feed water from the condenser is heated

with the steam extracted from the turbine.

5.5.2 Description of the captive power plant scheme and Plant operating Parameters

The proposed enhancement scheme for the JBIL,Unit-I , Raniganj plant, consist

of 1No. Waste Heat Recovery Boilers (WHRB) of 50 TPH capacity with steam



outlet parameters of 91 Ksc(a), 515 Deg C and 1 No. Atmospheric Fluidized Bed

Combustion of 91 Ksc( a) , 515 Deg C and one 22 MW double extraction cum

condensing turbo generators.. The proposed waste heat recovery boiler is capable

of operating round the year with waste gases generated from the DRI Kilns in the

plant.

The fluidized combustion boiler will be capable of operating round the year with

Coal, Dolo Char & Washery Middlings, which is available as waste in the DRI

Plants and the coal.

The feed water management programme shall ensure the supply of good quality

make up water to the system. In the proposed extension of power cycle most of

the steam will be supplied to the turbine , about 98%, will come back as the

condensate from surface condenser and through the feed water heating system.

Middlings. The make up required will be approximately 3% of the steam

generated in the boiler, which includes all the losses in the system and blow

down in the boiler. The complete make up required for the plant operation will be

treated water. Reverse Osmosis (RO) water treatment plant of adequate

augmented capacity will be provided. The make up cycle will be added in the

condensate storage tank and the quantity of makeup will be controlled by

dearator level control system.

The boiler being proposed will be with the steam parameters of 91 Ksc(a) and

515 +5 0C at the boiler outlet. The AFBC boiler will be designed with coal Char

and coal as fuels. The inlet feed water temperature for the waste heat boiler will

be 115 Deg. C with feed water heated in the dearator. The inlet feed water

temperature for the CFBC boilers will be 150 Deg C, with the feed water heated

in a dearator and HP heater.

5.5.3 Fuel Balance

The CPP is based on one waste heat recovery boilers and one AFBC Boiler.

For the waste heat boilers, no fuel is required as the heat available in the waste

gases generated from the sponge iron plant are used.

The 50 TPH AFBC boiler will be operated with coal char, washery middlings,

“D” grade coal. With the available coal char it is possible to generate a steam

capacity of 12 TPH . For the balance steam requirement of 38 TPH , 50 TPD of

washrey middling will be used along with coal.

5.5.4 Power Balance

The total power generation in the plant will be 22,000KW.



The following gives the detailed break up of the auxiliary power consumption in

the captive power plant.

Boiler Auxiliaries : 950 KW

Turbogenerator auxiliaries : 100 KW

Cooling Tower : 525 KW

Fuel and Ash Handling System : 175 KW

Other pumps (DM, Raw, make-up water): 50 KW

Air compresors : 50 KW

Water Treatment Plant : 35 KW

Ac & Ventilation : 50 KW

Lighting

Transformer and other losses : 100 KW

Total For Power plant : 2,035 KW

The power requirement of the in house enduse plants will be met by CPP by

operating parallel with grid. Also the power requirement ( inclusive of losses) of

auxiliaries of the CPP at 2,035 KW will be met from the generated power

through Three No’s of 3.0 MVA capacity step down distribution transformer.

There will not be any export to the grid.

5.4.5 Plant and Equipment Design Criteria.

General

The proposed captive power generation facilities at JBIL, Unit-1, Ranigunj will

be operated on a continuous basis, throughout the year (300 days). These

facilities will be located at JBIL, Unit-1, Ranigunj in the state of West Bengal.

These power generation facilities will be designed for year round operation. All

the plant and equipment of the power plant will be designed for a minimum of

7200 hrs of operation in a year.

Design Criteria for Captive Power Plant (CPP)

The CPP proposed will generate a gross output of 22,000 kW at the generator

terminals. After meeting with the internal power requirement of CPP auxiliaries,

the power will be fed to the enduse plants and their auxiliaries, by operating the 1

x 22 MW turbogenerators in parallel with the grid. In order to maintain full production on the kilns, during periods when the turbine

is out of service, the turbine is provided with an associated desuperheating and



dump condensing facility to handle the steam produced. This will also take care

of the high load fluctuation in induction furnaces. The surface condensers shall

be designed considering this additional dumping steam.

The 22 MW CPP will be with one turbogenerator, receiving steam from two (2)

different boilers. One of the boilers will be waste heat recovery boiler generating

the steam from heat recovered from the waste gases leaving the rotary kiln of the

sponge iron plant. The AFBC boiler will be using the coal char from the sponge

iron plant, and washery middlings. The system is designed such that all the

boilers operate in parallel supplying the total steam required to the 1 no. of 22

MW turbogenerators.

The electrical loads of the induction furnaces introduces a lot of harmonics into

the system. The one no. of 22 MW Generators and system design shall be made

to take care of system harmonics. The generator has been oversized to take care

of the heating effects due to the harmonic loads. A detailed study is to be

undertaken during the contract execution stage to finalize the actual sizing required

for the generator.

All the plant and systems shall be designed to achieve the best possible efficiency

under the specified operating conditions. The Captive power cycle shall be

designed with one two LP heaters (Deaerator) and two HP heaters. The steam

requirements of the deaerators and the HP heaters shall be met from the

extraction from the turbines.

The complete plant instrumentation and control system for CPP shall be based on

DCS, covering the total functioning requirements of measuring, monitoring,

alarming and controlling, logging, sequence interlocks and equipment protection

etc.

The Plant layout shall make optimum use of the land and facilities to Minimize

the cost of installation. The optimum arrangement of the Equipment shall be

determined by the considerations of functional requirement, economy of piping

and electrical cables, economy of equipment supports, installation and

maintenance access requirements, ventilation requirements and equipment

generated noise and vibrations.

Plant & Machinery design criteria

This section of the report gives the basic criteria for the design of the plant .The

design parameters like the size, layout, ratings, quantities, materials of

construction, type of equipment etc., described in this report approximate.

Necessary changes could occur as the detailed engineering of the plant

progresses and such changes are permitted as long as the detailed engineering of

the plant achieves the intent of this report.



Ambient Conditions

Plant Elevation above Mean Sea Level (MSL) : 126.0 meters

Temperatures :

• Maximum Temperature : 40.0 Deg.C

• Minimum Temperature : 16.3 Deg.C

• Plant Design Temperature (Dry Bulb) :30.0 Deg.C

• Plant Design Wet Bulb Temperature :23.0 Deg.C

• Plant ,Design Temperature for Electrical :50.0 Deg.C

Equipment

Relative Humidity :

• Maximum : 86%

• Minimum : 27%

• Plant Design Relative Humidity : 60%

5.5.6 Composition of waste gases from the rotary kilns.

The waste heat recovery boilers at the back end of the rotary kilns will recover the waste

heat from the hot gases generated from the DRI Kilns. The following is the analysis of

waste gas, leaving the after burning chamber (ABC) at the back end of the kiln. These

composition shall be taken for the design and guarantee performance of the waste heat

recovery boilers.

Gas composition (% by Volume)

➢ Carbon di oxide :20%

➢ Moisture : 16%

➢ Nitrogen : 63 %

➢ Oxygen : 1 %

➢ Sulphur di oxide : Nil

➢ Dust content (gm / N.Cu.m) : 30

Gas Temperature leaving the ABC : 950 Deg.C.

5.5.7 Properties for the Coal char, Washery middlings, "D" grade coal

The design and guarantee fuel for the FBC boiler will be Coal char, Washery middlings.

The following will be the analysis:



Coal Char composition (% by weight) :

Ultimate Analysis:

Carbon(%) : 25.8

Hydrogen(%) : 1.5

Nitrogen(%) : 0.7

Sulphur ( %) : 0.3

Oxygen(%) : 4.2

ASH (%) : 64.4

Moisture (%) : 3.1

Gross Calorific Value (Kcal / Kg) : 1300

Washery middlings composition (% by weight)

Ultimate Analysis:

Carbon(%) : 24.53

Hydrogen(%) : 01.59

Oxygen(%) : 03.16

Moisture (%) : 10.00

Nitrogen(%) : 00.72

Sulphur ( %) : 0.00

ASH (%) : 60

Gross Calorific Value (Kcal / Kg) : 2700

5.5.8 Raw Water

The raw water supply will be from LocalAuthority. This raw water will be used as a

make up for the losses in theboiler blow down, servics water for the CPP etc.

5.5.10 Boiler Feed Water

The boilers shall be capable of operating with the following feed water

quality requirements.

pH : 8.8 - 9.2

Oxygen : 0.007 ppm (max.)

Hardness : Nil

Total Iron : 0.01 ppm (max.)

Total Copper : 0.01 ppin (max.)

Total Silica : 0.02 ppm (max.)

Hydrazine residual : 0.01 -0.02 ppn1

Specific Electrical Conductivity at : 0.5 pslcm

25°C measured after Cation



exchanger in the H + form and

after COz removal (max)

Total C02 : Nil

Oil : Not allowed

5.5.11 Steam Purity

All boilers shall be capable of supplying uninterrupted steam at the

MCR rating with the following steam purity levels.

Total Dissolved Solids : 0.1 ppm (max)

Silica : 0.02 ppm (max)

Performance Guarantee Tests for waste heat recovery boilers

▪ Maximum Continuous Rating (MCR) of the waste heat boiler, with

the feed water temperature of 115°C and superheater outlet

parameters of 91 Ksc(a) and 515°C.

▪ Auxiliary Power Consumption under MCR operating conditions.

▪ Steam purity for all operating loads.

▪ Dust Concentration in the flue gases leaving the ESP

Performance Guarantee Tests for the FBC boiler

▪ Maximum Continuous Rating (MCR) of the AFBC boiler, with the

feed water temperature of 150°C and superheater outlet parameters

of 91 Ksc(a) and 515°C.

▪ Boiler Efficiency at MCR on GCV basis while firing 70 % coal char

+ 30 % washery middlings

▪ Auxiliary Power Consumption under MCR operating conditions.

▪ Steam purity for all operating loads.

▪ Dust Concentration in the flue gas leaving the ESP.



5.5.12 Turbogenerator & Auxiliaries

The turbo generators shall be a double extraction cum condensing machine. The first

extraction shall be uncontrolled at 8 Ksc(a) and the second extraction shall be

uncontrolled at 2.5 Ksc(a). The following shall be the salient design parameters. The

speed of the turbine shall be less than 8000 RPM.

Number of Turbogenerators : One (1 x 22 MW)

Steam flow at the turbine stop valve : 50,000 (max.) (at each turbine)

at boiler MCR (KgIHr)

Steam pressure at the turbine stop : 84

valve (Ksc(a))

Steam temperature at the turbine : 515

stop Valve (Deg.C)

Extraction Steam Requirements

First Extraction (HP) Parameters:

Type : Uncontrolled

Steam Pressure (Ksc(a)) : 8.0

Quantity Requirements

Normal (Kg / Hr) : 4365 (from each turbine)

Temperature of Extraction steam

required at the terminal point (Deg.C): 190

Second Extraction (LP) Parameters:

Type : Uncontrolled

Steam Pressure (Ksc(a)) : 2.5

Performance Guarantee Tests

The performance test shall be conducted for the following parameters as per ASME PTC

6 and DIN 1943:



Power Output at Generator Terminals with the inlet steam Parameters of 84 Ksc(a) and

515°C, specified power factor and cooling water temperature of 32°C. The extraction

shall be at the indicated Normal flow conditions.

• Auxiliary Power Consumption under Guarantee conditions.

• specific Steam Consumption and heat rate.

• maximum temperature rise in the generator windings.

5.5.13 Auxiliary Plant and Equipment

Fuel handling

For the waste heat boilers no fuel is required, but only the gases from the rotary kiln is to

be routed to the boilers through refractory lined ducts. The fuel for the FBC boiler is Coal

char, washery middlings. Coal char & washery middlings will be mixed and loaded in

the ground hopper manually or by front end loaders. Mixed fuel will thenconveyed to the

crusher / screen house through a belt conveyor (CC-1).

After passing through the crusher, the crushed fuel will be screened. The fuel of less than

6 mm size will be conveyed to boiler front bunker through belt conveyor (CC-2). Higher

size fuels will be recycled to the conveyor (CC-1) through conveyor (CC-3). Allowable

inclination for the belt conveyor is 18" (max.). The belt speed shall be approximately 1.0

metres / second. The fuel handling system shall be designed for a capacity of 60 TPH.

The fuel handling system is selected for 12 hours operation in a day.

5.5.14 Ash handling

Waste Heat Recovery Boilers

The ash handling system envisaged is of dense phase pneumatic ash handling type. It is to

be noted that there is no ash generation in the waste heat boilers. The dust already

available in the waste gases is passing through the waste heat boilers.

The ash will be dry and powdery in nature and occasionally with hot solids.

The ash from Superheater / Evaporator zone / Economiser zone will be dry and powdery

in nature and occasionally with hot solids. The temperature will be around 200°C.

The ash from ESP will be dry and powdery in nature and occasionally with hot solids.

The temperature of ash will be around 170°C.



AFBC Boiler

Since furnace & boiler bank ash will be at high temperature (600°C to 950°C), the same

shall be cooled with the help of ash coolers using air before taking into dense phase ash

handling system. The ash from furnace and bank ash will be dry and powdery in nature

and occasionally with hot solids.

The ash from Economiser will be dry and powdery in nature and occasionally with hot

solids. The temperature will be around 350°C maximum. The fly ash from the Air Heater

Hopper will be dry and powdery in nature and occasionally with hot solids. The

temperature of the ash will be around 250°C maximum.

The fly ash from ESP will be dry and powdery in nature and occasionally with hot solids.

The temperature of ash will be around 150°C maximum.

The ash from the discharge points of waste heat boilers will be collected by means of

pipes with the help of compressed air into the ash storage silo provided for WHRBs. The

ash from the discharge points of AFBC boilers will be collected by means of pipes with

the help of compressed air into the another ash storage silo provided for AFBC boilers.

There will be one (1) ash silos WHRB and one (1) ash silo of capacity for the AFBC

boiiers.

The storage silos are selected considering 12 hour storage capacity. From the ash silo the

ash will be disposed off by trucks/trailers.

5.5.15 Pumps

The head / flow characteristics of pumps will be such that the head continuously rises

with decreasing capacity until a maximum head is reached at zero flow. Maximum run-

out flow should at least 130% of duty point flow.

The shut off head should be at least 1.1 times the duty point head and should not be more

than 1.2 times the duty point head. The power curve should be of non-overloading type

with the maximum power occurring at or near duty point or towards maximum run out

flow.

NPSHR curve should be a continuously rising one in the range of Operation from the

minimum in the range to the maximum flow in the range Required NPSH values shall

not exceed available values over The entire range minimum to rated flow

5.5.16 Condensate system

The condensate from the surface condenser will be used to meet the feed Water

requirement of the CPP boilers. The make up water for the cycle Will be from the water

treatment plant.



Water treatment Plant based on Reverse Osmosis (RO) principle. The RO plant shall be

designed to have single stream with a capacity of 25 TPH The RO plant shall be designed

based on the raw water analysis furnished elsewhere in this section of this report.

The RO water quality at the outlet of the RO plant shall be as follows:

PH : 8.8 - 9.2

Hardness : Nil

Total Iron : 0.01 ppm (max.)

Total Copper : 0.0 1 ppm (max.)

Total Silica : 0.02 ppm (max.)

Hydrazine residual : 0.0 1-0.02 ppm

Specific Electrical Conductivity at : 0.5 s/cm

25°C measured after Cation

exchanger in the H + form and

after CO2 removal (max)

Total C02 : Nil

Oil : Not allowed

The raw water at the inlet of the RO plant will be delivered at a pressure of 3.0 Kg/

Sq.Cm. The Treated water at the outlet of the RO Plant will be delivered at a pressure of

3.0 Kg/ Sq.Cm . The RO plant will be provided with a mixed bed polishing unit to deliver

the required quality of the treated water.

All vessels shall be designed with adequate free board. Only seamless pipe shall be used

wherever rubber lining is done. All fabricated equipment shall be designed according to

IS: 2062. The regenerants like Hydrochloric Acid and Caustic Soda shall be stored

in bulk in the RO plant premises, and pumped to the RO plant for regeneration. Manual

handling of the regenerants shall be avoided to the maximal extent. Adequately sized

neutralizing pit shall be provided near the RO plant for collecting the discharges from the

RO plant and effectively neutralizing the same before pumping the waste to the power

plant's effluent treatment system.

5.5.17 Vessels & Heat Exchangers

The design shall be as per ASME Sec. VIII, HE1 and TEMA. All heat exchangers and

vessels for steam application shall be designed for full vacuum conditions. The heat

exchangers shall be provided with stai-tup vent cotu~ections. The design shall have

provision for complete drainage on both shell and tube sides. The heat exchangers shall

be provided with emergency drains, shell side safety valves, and individual bypass with

manual valves. A minimum corrosion allowance of 1.6 mm shall be provided. The tube

bundle shall be of removable type. The tube material shall be stainless steel, unless

otherwise specified in the specifications.



5.5.18 Fire Protection System

For protection of the plant against fire, all yards and plants will be protected by any one

or a combination of the following systems:

• Hydrant system

• High pressure water sprinkler-system

• Foam system

• Emulsifier system (mist formation)

• Portable fire extinguishers

The system will be designed in conformity with the recommendations of the Tariff

Advisory Committee of Insurance Association of India. While designing the fire

protection systems for this power station its extreme ambient conditions need special

attention. Codes and Standards of National Fire Protection Association (NFPA), USA

will be followed, as applicable.

The crusher house and transfer houses will also be provided with hydrant headers

connected to plant header hydrant network.

Unit auxiliary transformers down to 3000KVA rating and also all coal conveyor galleries

and tunnels will have automatic HPW sprinkler protection. The coal bunker conveyor

floors, coal crusher house and transfer points and the turbine oil tanks will have

automatic HPW sprinkler protection. Suitable fire detectors, and manual call points etc.

as suited will be provided at all such locations with necessary annunciations in the fire

control station, fire water pump house and unit control room Effective measures will be

taken to tackle fire in the cable galleries. Fire barriers with self-closing fire resistant

doors will be provided wherever necessary to prevent spreading of fire. Ventilation

system of the cable galleries will be so interlocked with the fire alarm system that in the

event of a fire alarm the ventilation system in the respective area will be automatically

switched off. All cable entries/openings in cable galleries, tunnels, channels, floors,

barriers etc. will be sealed with non-inflammable/fire resistant sealing material.

Adequate number of portable and mobile chemical fire extinguishers will be provided at

suitable locations throughout the plant.

5.6 STEEL MELTING SHOP WITH BILLETS CASTER(BILLET

DIVISION)

This chapter deals with the steel melt shop (SMS). It discusses the major facilities

proposed to be provided to achieve the desired production. The annual requirement of

major raw materials for steel making is indicated in this chapter.



It is proposed to install 4 (four) numbers of 15 t (each) Induction furnace having

production capacity of 2,37,600 TPA liquid steel.

PHASE CAPCITY

Present -



5.6.1 Steel making process

The primary steel making unit will be 4 Nos. Induction furnaces of 15 ton capacity (tap

weight). The furnaces will be designed with a charge mix of suitable proportion of hot

metal from blast furnaces, sponge iron from rotary kilns and in plant generated scrap. In

keeping with the modern trend, the Induction furnaces will be used mainly as a fast

melting-cum-decarburisation unit. Along with melting & decarburisation, phosphorous in

the molten steel will be brought down to the desired range. The semi-finished liquid steel

will then be tapped slag free into a preheated ladle. Depending on the steel grade aimed,

the liquid steel will then be subject to secondary refining & finishing treatment in the

Ladle Furnace.

5.6.2 Process details:

The process involves the charge mix of Raw material mainly sponge iron/scrap 70%, Hot

metal from Blast furnace 30%, poured into molten bath with constant power tract through

Solid State generator converting A.C. Power into D.C. Power and again to convert the

same into A.C. Power after changing the frequency of cycle in between 250 to 500 Hz

through thryster (an electronic device). This converted A.C. power with a frequency of

250 to 500 Hz is passed through capacitor Rack to achieve the desired voltage and the

same is passed through copper Bus Bar into Molten bath having copper coal, cooled

through water circulation, transparent the heat energy into molten bath at constant voltage

and KW to melt the Iron and Steel at a temperature of 1550oC.

This method is established all over India. Sponge iron manufacturers and Medium

Frequency Melting Induction furnace equipment manufacturer/arc furnace manufacturers

have developed the process parameters by which considerable quantity of sponge iron are

used in steel making.

5.6.3 Charge Mix :

Sponge Iron is being mixed with hot liquid metal of blast furnace, which are less rusty.

Hot liquid contains higher carbon higher carbon percentage is used for sandwiching

sponge iron. Sponge iron contains less percentage of carbon and cast iron with high

percentage of carbon make the mix charge perfectly to melt. The agitation of Furnace is

so high that the sponge iron take little time to attain molten metal. The reactive slag



formed in one bath attain the same temperature that of molten metal so quickly that by

addition of sponge iron into bath, nothing is hold by slag. Sponge charging is

discontinued once the metal bath level attains the two third height of crucible.

Extra carbon either in the form of free carbon or excess carbon present in the liquid hot

metal of blast metal is charged per ton of sponge iron. This is required to ensure F.C.

recovery from FCO with the use of sponge iron, the bath will have a rising tendency

because of the presence of FCD in sponge iron. Therefore, one bath should be suitably

killed by slagging off the impurities from molten bath. The induced current circulates the

charge in a direction opposite to but parallel with the current of primary coil.This current

is induced in one outer layers of the charge but the head produced is conducted quite

rapidly to the interior. As soon as a pool of molten metal starts to form, the charge sinks

and extra metal, as required, is being added. The current induced in the molten metal

causes a rapid stirring action and helps in melting the rest of charge by washing molten

metal. Thus the uniformity of among the charge is assured and necessity of any manual

stirring is avoided.

When as the mix charge is completely melted, necessary Ferro Alloys and de-oxiders are

added. The temperature of liquid metal is allowed to rise in the Furnace till the correct

pouring temperature is achieved which is checked with the help of Immersion Pyrometer.

After that the furnace is fitted with the help of the hydraulic system. The hydraulic

control ensures a smooth but rapid stop action in any attitude. Tilt speed is infinitely

variable and maximum speed varies with the size of furnace. Maximum tilt can be done

upto 95 degree.

The hot metal is poured with the hydraulic system in the pre-heated ladle after adding

certain fluxes so that the temperature is maintained at about 16000C. Ladle is then

carried by EOT crane to the concast machine and kept above the tundish of the concast

machine. The bottom of the ladle is opened by hydraulic system and hot metal starts

pouring out into the concast machine. Through tundish, it passes through copper moulds.

Copper moulds give the particular desired shape. To initiate casting, a dummy bar is

inserted into the bottom end of the mould, while the other end of the dummy bar is held

by withdrawal/straightening rolls when the moulten steel at the correct temperature

reaches the stipulated level inside the mould, the withdrawal rolls and mould

reciprocating unit are operated. The cooling water circulation through the mould

(primary cooling) and in the secondary circuit started a few minutes before the actual

casting operation. The dummy bar is withdrawn followed by the hot solidify billet. The

cooling water circulating around the mould carries away enough heat from the liquid

steel to produce a solid outer skin of sufficient strength to safely envelope the liquid

portion at the interior that to will be solidify by the secondary cooling, which consist of

spraying of water jets on the body of the billet. Before beginning to withdrawn the

dummy bar it must be insured that the outer casing of the billet is strong enough

otherwise a rupture in the skin may occur resulting in a break out which releases the

molten metal and forces a shut down of the operations. Thus the important parameters

are temperature of liquid steel, rate of primary and secondary cooling, mould



reciprocating characteristics, which all influences the casting rate and the quality of the

casting. The solidified billet further passes through straightening machine, cut to

required length and sent to the cooling through the roll conveyer system. The total

system requires soft water for cooling of copper moulds. Sized billets are lifted by

rectangular magnets to finishing yard for inspection and storage/dispatch.

5.6.4 Steel Making facilities.

The major facilities in steel melt shop include Induction Furnace and Billet Caster. All

the liquid steel produced are continuously cast into Billet. Automation and

computerization for the process are envisaged for making the operation efficient, in time

with the modern trend, for achieving high productivity and quality to compete in the

international market.

5.6.5 Technologies in Steelmelt Shop

The state-of-the-art technologies to be adopted in steel melt shop are: Induction Furnace

for melting DRI (Sponge Iron) along with Hot Metal available from MBF instead of

charging Solid Pigs for energy saving and higher productivity.

5.6.6 Selection of Equipment

The size and number of various facilities in the steel melt shop have been selected with

the following basic considerations:~

• Utilizing maximum hot metal available from Blast Furnace.

• Attaining the required production level with minimum number of steel making

and casting facilities.

• Maximizing availability of facilities provided by state-of-the-art technologies and

practices.

5.6.7 Equipment availability:

The continuous billet caster availability is envisaged as 330 days (approx) in a year

considering scheduled / unscheduled maintenance and operational breakdowns.

Availability of the Induction Furnace and secondary metallurgical facilities has also been

considered as 330 days (approx.) in a year to match the availability of the caster.

Considering the equipment availability a nominal heat size of 2 x 15 i.e. 30 MT is

selected to meet the annual liquid steel and market requirements. The selected heat size

also matches the caster cycle time as discussed below:



HEAT CYCLE TIME

Time

Mins.

------------

Pig / Scrap Charging 10

Pig Iron/Hot metal charging 15

Blowing

Deslagging, Sampling etc. 15-20

Average Reblow 7-8

Tapping 15

Slag splashing, slag-off 15

Vessel Inspection, delays etc. 10 – 12

-----------

Total 87 - 95

-----------

However, considering converter operational downtime like tap hole repair, mouth jam

cleaning, track cleaning gunning etc. as well as the caster cycle time, the average number

of heats is considered as 12 heats per day.

5.6.8 Selection of Continuous Casting Machine:

The number of strands required to cast 100 mm sq. and 160 mm sq. billets is worked out

of two. One 2 – strand billet casting machine suitable for casting 100 mm sq. and 160

mm sq. billets has been selected.

The size of billets that are cast in the shop is 100 mm sq. and 160 mm sq. to suit the

various grades of steel to be produced in the shop. It is planned to cast both the above

sizes of billets from 30 tons heat size in about 95 minutes for Construction and Alloy

Steel.

5.6.9 Major equipment and facilities

Furnace transformer capacity

AC furnace is envisaged in this report. In case of each 15 ton (tap weight) capacity

furnace, the transformer rating will be 7.1 MVA (Continuous rated). This will ensure a

high level of effective power input which is desirable because furnace charge will

comprise of high proportion of DRI/sponge iron which will be fed into the furnace

continuously at regulated rate.

Water cooled panels (WCPS)

Although the application of high power transformer concept results in greatly improved

furnace productivity, it also gave rise to stringent demand on furnace refractories

resulting in increased refractory consumption and considerably higher refractory costs.



With high power input, hot spots develop on the furnace wall directly behind the

electrodes, while cold spots occur on the furnace wall between the consumption, WCPs

in the side wall as well as in roof (WCR-Water cooled roof) have been envisaged.

Electric bottom taphole (EBT)

The EBT which is a modified design of the conventional taphole, permits rapid and

practically slag-free tapping, which is an essential requirement for efficient refining and

finishing of the steel by ladle metallurgical processes.

The salient features of IF AC) are indicated below:

Number of furnace 4

Nominal capacity 15 tons each

Type of Unit Double station type with common change.

Transformer rating 7.10 MVA

Power rating 6000 kW

Operating frequency range 300-700 Hz

Tilting System By hydraulic cylinder

IF gas cleaning system

Separate fume extraction system and gas cleaning facilities will be provided for the IF to

extract the furnace fume through fourth hole in the roof and discharge it to the

atmosphere after cleaning. The gas cleaning system will be complete with water cooled

duct, gas cooler, bag house, ID fan and sufficiently tall stack. The cleaned gas discharged

into the atmosphere will have a dust content well within the statutory limits of WBPCB

& CPCB. The dust collected in the bag house will be stored in a dust silo. Periodically

the dust will be loaded into trucks for disposal.

Secondary refining facility (ladle gurnace)

The desired secondary refining functions, which need to be performed include the

following or a suitable combination thereof :

- De-oxidation and control of chemistry

- De-sulphurisation

- Arc heating & temperature control

- Inert gas stirring for thermal & chemical homogenization as well as for

scavenging the inclusions

- Inclusion shape control

The proposed LF will be used for arc heating, de-sulphurisation, de-oxidation, inert gas

stirring, alloy & flux addition etc. This unit can also be utilized to hold the heats for an

extended period of time, should it be necessary for any reason, such as, sequencing of

casting in the cc machine, hold up in the cc machine etc. Argon/nitrogen gas will be



introduced through a porous plug fitted at the bottom of the ladle for stirring the liquid

steel during treatment.

Continuous casting machine The billet caster is installed in the continuous casting shop. The caster is equipped with

ladle car to facilitiate sequence casting and to improve the surface and internal quality of

cast billets.

The casting machine along with tundish cars, casting platform etc. Is located in the

casting aisle undish preparation facilities as well as mould testing facilities for the caster

are also located adjacent to the caster

Scale pit is located close to the caster in casting bay. Scale is removed from the scale pit

by a grab attached to the crane and disposed by truck.

The main features of the casters are as follows:

No. of machines : 2

No. of strand : 2

Type : Low hear curved type 6/11 m

Radius

Steel grades that are cast : Construction steel, carbon

Steel.

Nominal heat size : 30/40 Ton

Ladle handling : Ladle car

Type of ladle : Bottom poured with slide gate

Machine equipped to cast : Billets : 100 x 100

Section, mm : 160 x 160 & 130 x 130

Cutting device : Automatic gas cutter

Cut length, m : 6-9

Method of discharge : Roller tables for each strand

and common cooling bed

suitable for billet handling by

crane for storage.



5.6.10 Annual requirement of major raw materials

The annual requirement of major raw materials estimated by taking into consideration

225720 tons per year liquid steel production and a charge mix of approximately 30% hot

metal about 70% DRI/sponge iron and about 4% scrap will be as given in Table 5.9.

TABLE 5.9

ANNUAL REQUIREMENT OF MAJOR RAW MATERIALS

Item Quantity / year

Pig iron (tons) 71,200

DRI/Sponge iron (Tons) 1,66,320

Scraps 9,504

5.6.11 Handling facilities

DRI handling

DRI will be brought from DR plant by dumper to SMS building. DRI storage bins will be

of concrete construction. The storage capacity of DRI will meet about seven days

requirement.

Ferro Alloy and additive handling

Ferro alloys and additives will be received at the LF area and kept in earmarked bins.

Automatic weighing, batching and conveying system will be provided. The ferro alloy

and additive charging system will be operated from a remote control panel.

Liquid steel handling

Liquid steel from IF will be tapped into a preheated ladle mounted on a transfer car. Each

ladle will be equipped with a slide gate system with a porous plug at the bottom for inert

gas stirring. The steel in the ladle will be tapped slag free as far as practicable. The

transfer car will transport the ladle to the LF aisle and place it under LF hood for

treatment. After LF treatment, the ladle will be moved out and the heat will be placed on

the ladle turret of the CCM.

On completion of casting, slag in the ladle will be dumped on the ground in a specified

area. The ladle will then be placed on the ladle transfer car to take it back where it will be

placed on the ladle stand for slide gate and porous plug setting and preheating.

Slag handling

It is estimated that the annual generation of slag in the IF will thus be about 40,000 tons.

In addition, about 3,500 tons of slag will be generated in LF. The total quantity of slag to

be handled in the steel melt shop will amout to 43,500 tons per year.



The IF slag will be poured through the slag door on the ground and disposed to the dump

yard by heavy duty loaders and road transport.

The slag remaining in the steel ladle after casting, will be dumped on the ground in a

specified area of the LF aisle. It will then be sent to the dump yard in the similar manner.

5.6.12 Ladle preparation, roof relining and other facilities

Facilities for various ladle preparation activities such as, deskulling, debricking and

relining, ladle preheating, will be provided, along with slide gate nozzle & porous plug

setting facilities for roof preparation etc. One crane will be used for these activities.

Refractories for relining the ladle will be received in trucks and stored by the relining

pits.

About 2,37,600 tons per annum of billets shall be available from proposed steel melt

shop.

5.7. FERRO-ALLOYS PLANT - PROPOSAL OF CHANGE IN

PRODUCT –MIX:

M/s. JAI BALAJI INDUSTRIES LIMITED (Unit I) proposes for Change in number of

Products of the existing Ferro-Alloys plant, keeping the total installed capacity same as

per the existing CTO

There will be no change in pollution load, plant & machineries and plant layout on

account of the above proposal.

Proposal of M/s. JAI BALAJI INDUSTRIES LIMITED (Unit I) for Change in number of

Products of the existing Ferro-Alloys plant, at G-1, Mangalpur Industrial Estate, P.O.

Bakhtarnagar, P.S. Raniganj, District – Burdwan, undertakes:

✓ There will be no change in total quantity of Ferro-Alloys production (i.e. 2,513

Tons/Month)

✓ There will be no change in pollution load as prescribed in the obtained Consent to

Operate, Ref. Memo No. 546 WPBA/Red(Bwn)/Cont(332)/2002, dated

05.05.2017.

✓ There will be no change in plant & machineries.

✓ There will be no change in plant layout.

✓ No further investment is also required



OPTIMISATION OF PRODUCT MIX – PROPOSAL

FACILITY PRODUCT MIX & CAPACITY

EXISTING PROPOSED

FERRO

ALLOYS

Total Capacity :

2,513 Tons / Month

(CTO obtained)

Product Mix:

• Ferro Manganese - 1,298

Ton/month

• Silico Manganese- 1,215

Ton/month

Total Capacity :

2,513 Tons / Month

Keeping the total Ferro-Alloys

production Capacity 2,513 Tons /

Month unchanged; product mix

capacity will be optimized, or

combination thereof.

Product Mix:

Either

• Ferro Manganese - 2,513

Ton/month (capacity

optimized)

Or • Silico Manganese- 2,430

Ton/month (capacity

optimized)

Or

• Ferro Chrome – 2,000

Ton/month (capacity

optimized)

5.7.1 List of rawmaterials with quantity:

RAW MATERIAL QUANTITY

(Ton/month)

either, Ferro Manganese – 2,513 Ton/month

Mn Ore 5,780

Coke 1,319

Dolomite 628

or, Silico Manganese – 2,430 Ton/month

Mn Ore 4,252

Coke 1,580

Quartz 365

Dolomite 365

Fe-Mn Slag 1,216

or, Ferro Chrome - 2,000 Ton/month

Briquette 4,000

Chrome Ore 800

Coke 1,080

Quartz 400



5.7.2 Manufacturing process of each product

The Ferro alloys section will make following three types of alloys:

1. Ferro-manganese (high carbon)

2. Silico-manganese

3. Ferro-Chrome

The facilities within the ferro alloy plant comprise of the following major units:

1. Raw material handling system

2. Furnace feeding system

3. Submerged arc furnace

4. Furnace tapping and casting

5. Product handling system

6. Electrical system

7. Gas cleaning plant

Two numbers of conveyor system will be envisaged to feed the day bins for different

ferro alloy production. Day bins will be for Ferro manganese, Silico-manganese and

Ferro chrome. Vibrating feeders located below each ground hopper, which transport the

material on a vibratory screen through conveyor. In order to store the materials in

individual bunker a reversible shuttle conveyor has been provided on top of bunker.

Furnace feeding system

A conveyor has been provided to collect the seighed mixture of material from surge

hopper on ground level and dump the same in to a feed hopper. The material from this

hopper is collected by a conveyor and transported to a rotating unidirectional conveyor

mounted on the rails. By way of rotation this conveyor gets aligned with charging bins

and correction bins, which are located around the circumference of this rotation. The

charging bins extends further in the form F.A. chute, up to the furnace. Pneumatically

operated slide gates has been provided in each chute. These gates is operated from the

central control desk.

Submerged arc furnace

Two submerged arc furnaces of capacity 7 MVA each have been established. The

furnaces are equipped with charge feeding hoppers, chutes, transformer, electrodes and

gas cleaning plant.

Furnace tapping and casting

The furnaces are tapped at an interval of about two and half hours considering eight

numbers of heats per day. The tap hole is opened by tap hole drilling machine. Oxygen

lancing is resorted for piercing the solidified metal/slag in the tap hole for proper flow of



metal and slag from the furnace. Tap hole closing device has been provided for closing

the tap hole after tapping. Skimmer/ladle tapping arrangement is provided. The liquid

metal is cast in moulds or in sand bed. The slag from the furnace is collected, cooled and

disposed at suitable area allocated for slag disposal.

Product handling system

The solid cakes are broken in to smaller pieces manually in to required sizes. Suitable

adjustment of breaking can change the product sizes to suit customer’s requirement.

The products, classified according to sizes and grades of different three ferro alloys will

be stored in the dedicated storage areas. Sized product is weighed, packed and kept ready

for dispatch.

Metallurgical Reactions involved during production of Ferro-manganese & Silico-

manganese:

• 2MnO2 + C → Mn2O3 + CO

• 3 Mn2O3 + C → 2Mn3O2 + CO

• Mn3O2 + C → 3MnO + CO

• MnO + C → Mn + CO

• Fe2O3 + 3C → 2Fe + 3CO

• SiO2 + 2C → Si + 2CO

• P2O5 + 5C → 2P + 5CO

The main Metallurgical Reactions involved during production of Ferro-chrome :

• Fe2O3 + CO → 2FeO + CO2 (at 800°C)

• FeO + C → Fe + CO (at 1200°C)

• Cr2O3 + 3C → 2Cr + 3CO (at 1400°C)

• SiO2 + C → SiO + CO (at 1600°C)



5.7.3 Mass Balance for each product:



5.7.4 Water Aspects:

Water Consumption Details (KL/Day) :

Propose

Existing Water

Consumption

Water Consumption

Break up after change

in product mix

Proposed Additional Water

Consumption

INDUSTRIAL

No additional water

consumption

Process + APCM

Boiler

Cooling 300 300

Washing

Gardening

Other

Total Industrial 300 300

Domestic 2 2

5.3 Water Balance Diagram (with reuse/recycle if any):



5.7.5 Effluent Generation (KL/day) :

Purpose

Existing

Effluent

Generation

Effluent

Generation after

proposed change

in product

mix

Mode of Disposal &

Ultimate

Receiving Body

INDUSTRIAL

Dust

suppression/greenery

purpose

Process + APCM

Boiler

Cooling 100 100

Washing

Other

Total Industrial 100 100

DOMESTIC 2 2

5.7.6 Effluent Gas Emission:

Sr.

No.

Stack attached

to

Fuel

Existing Fuel

Consumption

Proposed Fuel

Consumption

Stack Height

1. Submerged Arc

Furnaces

Electricity 11.2 MW 11.2 MW 1 Stack of 30

mtrs height

5.7.7 Process Emission:

Stack

No.

Stack attached to

Stack

height in

meter

APCM

Parameter

Permissible

Limit

1 Submerged Arc

Furnace (SAF) - 1

& 2

30 Heat

Exchanger

& Bag Filter

PM – 46.58

mg/Nm3

50 mg/Nm3

5.7.8 Hazardous Waste Generation :

In the existing operation, negligible quantity of Used Oil is being generated, which will

remain within the same level after the proposed change in number products.

Stack

No.

Type of

waste

Category (as

per schedule

Generation per year (No

Change)

Permissibl

e Limit

Source of

Generation

Mode

of

Storage

Mode of

Treatment

& Disposal

Existing After change

in product

mix

- - - - - - - - -



5.7.9 Proposal for reduction / recovery / reuse / recycle / sale of waste:

Solid Waste Type Quantity Management

Ferro manganese

Slag

25,632 TPA

Ferro manganese Slag will be used as raw

material for Silicon Manganese production.

Silicon Manganese

Slag

24,780 TPA Silicon Manganese Slag will be used for low

land filling.

Ferro-chrome slag 20,400 TPA ❖ Chrome will be recovered from Ferro-

chrome slag at Chrome recovery plant.

❖ After chrome recovery, the tailing

material will be used as stone chips (8 to

25 mm) & land filling purpose (0 to 8

mm).

❖ TCLP Test shall be carried out all

around the storage area on regular basis.

5.7.10 Ferro-Chrome Slag Generation :

Arround 20,400 TPA Ferro-Chrome Slag generations is estimated per annum in case of

Ferro Chrome production reaches 24,000 Tons/Annum (optimized capacity).

Chrome concentration in the Ferro-Chrome slag obtained from Jai Balaji Industries

Limited is found 2.6 mg/Kg, therefore, Ferro-Chrome Slag obtained shall not be

characterized as Hazardous Waste.

However, Jai Balaji Industries Limited, have some specific programmes for the Ferro-

Chrome slag generated as followings:

- Recovery of Chromium (metal) from Ferro Chrome Slag.

- After Metal Recovery from slag, the balance tailing material will be used as stone

chips (8-25 mm) in civil work and land filling (0-8 mm ).

5.7.11 Chrome Recover – Process Description:

Ferro Chrome Slag of size fraction (+0 - 300 mm) will be received on Feed Hopper,

which will be discharged from the bottom opening through a Rod Gate and Reciprocating

Feeder.

Reciprocating Feeder will discharge the Slag to the Primary Jaw Crusher through Feed

Conveyor to feed it to the Primary Jaw Crusher.

Jaw crusher shall crush the slag to (-) 65 mm and discharge the crushed material to

Double Deck Sizing Screen Feed Conveyor to feed it to Double Deck Sizing Screen.



+25mm material from the Surge Hopper will be fed through Rod Gate and Vibrating

Feeder to the Secondary Jaw Crusher.

Secondary Jaw Crusher will crush the slag down to -25mm.

The crushed (-) 25mm product will also be discharged to the Double Deck Sizing Screen

via Double Deck Sizing Screen Feed Conveyor .

The overflow (+8 to 25 mm) from the Bottom Deck of Double Deck Sizing Screen will

be discharged to Surge Hopper for Coarse and the underflow (+0 to 8 mm) from the

Double Deck Sizing Screen shall be discharged to Surge Hopper for Fines.

Jig will produce 3 (Three) types of Products.

i) Concentrate (Pure Metal)

ii) Middlings (Remelt)

iii) Tailings (Slag)

✓ Middling will be discharged on to the Middling Conveyor for onward ground

storage.

✓ Tailings will be discharged on to the Tailings Conveyor for onward ground

disposal.

Provision will be kept to further crush the Middling in the Secondary Jaw Crusher.

Clarified water from the tailing settling pond will be recycled back to Jig water feed

sump

5.7.12 Ferro-Chrome Slag Storage:

An area near to Ferro-Chrome Plant area have been identified for storage of Ferro-

Chrome Slag (metal recovered). The Slag Storage area will have R.C.C. flooring and a

garland drain will be constructed at this storage area.

TCLP test will be carried out all around the storage area on regular basi.

5.8 AUXILIARY FACILITIES

Repair and maintenance shop:

The plant repair and maintenance facilities will be centralised to take care of regular

maintenance work. Tool room, hydraulic and pneumatic equipment repair, welding

section, office, toilet etc will be suitably located.



General store:

A single bay building will keep equipment spares, hardwares, wearing parts and

consumables.

Laboratory Facilities

Facilities will be provided for collection of various samples and carrying out necessary

analysis as required for operation of the plant.

Other Facilities

Besides the repair and maintenance shop, and general stores, other auxiliary facilities

like general administrative building, first aid station, canteen will also be provided.

5. 9 ELECTRIC POWER

This section presents the estimated power requirements for the proposed new plant, the

characteristics of plant loads, the source of power and the proposed power distribution

arrangement. The major electrical equipment as envisaged such as switchgear,

transformers, motors and controls as well as plant lighting system, instrumentation and &

automation system and plant communication system are also discussed.

ESTIMATED OVERALL PLANT POWER REQUIREMENTS OF

NEW FACILITIES.

Sl. No. Facility Required Power

1 DRI Plant ( 5 X 100 TPD ) 1.5 MW

2 Iron ore Beneficiation Plant ( 0.6 MTPA ) 4 MW

3 Pellet Plant 2.5 MW

4 Induction Furnace 32 MW

5 Coal Washery 0.5 MW

3 Ancilliary units of Captive Power Plant

(22MW )

2 MW

Total: 42.5 MW

5.9.1 Power arrangement:

JBIL ( UNIT – I ) is well planned in arrangement of power for project operation.

Presently the Captive Power Plant ( 18.3 MW ) is catering power to its operational units.

For the proposed projects additional 42.5 MW power will be required. Out of the total

44.2 MW rewuirement 22 MW power will be supplied by proposed 20 MW captive

power plant and balace 20.5 MW will be met from DVC, DPL



5.10 WATER SYSTEM

Water is predominantly required in the steel plant for equipment cooling. In addition, it is

used for process use; steam raising; for collecting and conveying of scales, control of dust

and debris; for drinking and sanitation; for fire-fighting and for other miscellaneous

purposes.

5.9.1 Water requirement

The existing plant water requirement for operational unit is 570 m3/day and additional

water requirement for the proposed expansion project is about 1175 m3/day. Thus, the

total water requirement will be 1745 cu.m/day. The break-up of water required for

proposed Units is given in Table-5.4.

TABLE – 5.4

WATER REQUIREMENT FOR EXPANSION Sl. No. Plant / Section Water (m3/day)

1 4x15 T Induction Furnaces 110

2 DRI Plant ( 5 X 100 TPD ) 65

3 Coal Washery 50

4 Iron Ore Beneficiation Plant ( 0.6 MTPA ) 540

5 Pellet Plant (0.6 MTPA) 100

6 Captive Power Plant( 20 MW ) 275

7 Domestic Water 35

NET MAKE UP REQUIREMENT 1175

It is considered that requisite amount of make up water supply shall be made available by

the supply of Asansol Durgapur Development Authority ( ADDA ).

5.9.2 Plant water system

The plant water system comprises a make-up water system, drinking water and fire-

fighting water systems, individual recirculating water systems for the proposed facilities,

effluent disposal system as well as emergency water supply system for the vital units of

the plant.

The different water systems, their respective consumers and broad facilities provided for

each system are indicated in the following Table 5.4, which reflect a conceptual water

distribution scheme.

TABLE – 5.4

MAJOR WATER SYSTEMS

Sl.

No.

System Main consumers Main facilities

1. Make-up water

system

Cold well of various recirculating

waster systems of plant, drinking

Water storage tank,

make up water pump



water and sanitation system, fire-

fighting water system, softening

and DM plants.

house with storage,

pumps, distribution

pipework and

chemical dosing

system

2. Drinking Water

System

Plant personnel and laboratories Drinking water

facilities including

filtration unit,

chlorinating unit,

pump, overhead tank

and distribution pipe

network and disposal

facilities including

sewage treatment

plant.

3 Fire-fighting Water based fire-water system. Fire-fighting water

fighting system

pumps, storage

reservoir of required

comprising

yard/capacity, fire

fighting water network

shop fire hydrants

covering yard and

shop comprising

distribution mains,

landing valves, hoses

nozzles etc. including

jockey pumps.

4 Demineralistation

water supply system

Closed recirculating system of

units comprising captive power

plants.

Demineralisation

plant, storage, pumps

and pipework.

5. Direct reduction

plant water system

DR Plant consumers requiring

primarily closed circuit cooling

involving ICW system etc.

Pumping instllation,

cooling tower,

pipework and

chemical dosing.

6. Captive Power Plant

recirculating system.

Captive power plant (gas based

unit and coal and char based unit)

Pumping installation

cooling tower,

chemical dosing

system, pipeworks etc.

7. Iron Ore Benficiation

Plant

Process Washing.



5.9.3 Waste water and faecal sewage management

Waste water generated from the different areas of the plant will be treated to the desired

extent in suitable treatment facilities and recycled back to the process, as far as

practicable, facilitating adequate reuse of-water in the respective recirculating systems

and economizing on the make-up water requirement. Sewage generated from toilet blocks

etc shall be treated in a sewage treatment plant and the treated effluent shall be collected

in a sump, located in a low lying area, where bleeds from the several clear water

recirculating cycles shall also be collected. The water thus collected shall be used for dust

suppression at raw material handling system, landscaping etc. The excess effluent with

quality parameters conforming to norms stipulated by statutory authorities shall be

allowed to be drained out to nearby watercourse/drains.

5.9.4 Electrics, instruments and controls

The requisite instruments and controls as well as audio- visual alarms and safety

interlocks will be provided for safe and efficient operation of the water system which will

be complete with necessary sensing devices, transmitters, actuators, control valves,

instrument panel, impulse piping and other accessories. The electrical equipment required

for catering to the water system equipment are considered separately under the relevant

portion pertaining to section on electrics.

5.9.5 Drainage

Open drains are envisaged for the plant storm water drainage. The drains will be laid by

the side of the roads close to plant units. The space between the drain and the building

apron will have gentle slope towards the drain. The outfalls of plant drains will be located

at low lying areas near the plant boundary wall adjacent to natural nullahs.

5.10 UTILITY SYSTEM

This section discusses the requirements and facilities proposed for various utilities viz.,

fuel oil, Oxygen plant and instrument air. In addition, air pollution, ventilation and air

conditioning and fire protection systems envisaged have also been discussed.

5.10.1 Fuel oil system

Fuel oil is required to start-up the kiln and for emergency requirements in the Kiln, and

DG set operation.

It is envisaged that LDO will be brought in road tankers and unloaded into respective

storage tanks through unloading pumpsets. The oil storage tank has been considered for

Kiln and DG set operation. The tank will be provided with standard auxiliaries such as

conservative vent valve, flame arrestor, drain connection. Oil from these tanks shall be

transferred to the respective consumer units by 2 x 100 per cent fuel oil transfer pumps



through filters. Return oil, if any, shall be discharged back to the storage tank. The tank

farm will be provided with dyke wall and suitable fencing all around according to

statutory requirement.

5.10.2 Cutting fuel gas system

LP gas shall be used for general purpose cutting and gas welding. The requirements of LP

gas shall be met by gas cylinders. Necessary facilities including cylinder banks,

manifolds and associated pipework shall be provided near the respective consumption

points.

5.10.3 Oxygen system

Oxygen required for general purpose welding and cutting operations shall be met by

oxygen cylinder which shall be provided near the respective plant units. The cylinders

shall be provided with necessary cylinder valve and suitable manifold to a distribution

piping network upto the respective consumption points.

5.10.4 Plant and instrument air system

Compressed air will be required for general service purpose, cleaning of bag filters used

in fume/dust extraction systems for DR kilns and various furnaces, other process users

and for instrumentation.

5.10.5 Ventilation systems

The ventilation systems proposed to achieve desired conditions in different areas are as

follows:

- Switchgear rooms, cable tunnel, cable basement, oil and hydraulic cellars:

Mechanical ventilation system using fan-filter units for supply and exhaust fans.

- Compressor Building, Transformer Rooms: Mechanical ventilation system

using exhaust fans.

Natural ventilation arrangement will be adopted in most of production

buildings.

5.10.5 Air conditioning system

The air-conditioning system is proposed to be designed to maintain the following

conditions in the spaces serviced:

25 + 2oC dry bulb temperature and 55 + 5 percent relative humidity for control rooms,

control pulpits, computer rooms, PLC rooms, laboratory etc.



To meet the above requirement, air handling units using chilled water, package type air

conditioning unit complete with compressor, condenser and ductwork are envisaged. AC

units/AHUs shall be installed in separate rooms adjacent to various conditioned spaces

served. Conditioned air from AC units to the spaces served shall be provided by

plenum/ductwork. Wall mounted window model air conditioners have also been

envisaged in some areas for the purpose of air conditioning.

5.10.6 Fire protection system

In addition to the yard fire hydrant system, the fire protection systems envisaged for the

plant are as follows:

- Internal fire hydrant for storied buildings to be tapped-off from the outdoor

fire water header.

- Fire detection and alarm system for electrical rooms, cable basements/cellars,

cable tunnels, selected oil/ hydraulic cellars.

- Portable fire extinguishers such as CO2, foam and dry chemical powder in all

areas of the plant with fire hazard.



CHAPTER - 6

CONTROL MEASURES FOR ENVIRONMENTAL POLLUTION

6.1 Intruduction

The proposed expansion will follow Environment Friendly operation. The

recovery of energy in the form of electricity from DR kiln waste gas makes this

production process more attractive. However, there would be some

environmental pollution in respect of land, air and water that need to be

controlled. This chapter accordingly gives an outline of the principal types of

pollution, its sources and also highlights the proposed environmental pollution

control measures that form an integral part of the proposed project concept.

6.2 Pollution potential sources

The sources and types of pollution can be assessed from the project concept

described in the earlier chapters. It may be seen from the earlier chapters that the

major sources of pollution in the proposed plant are from the (i) Raw material

handling (ii) DRI production by using non-coking coal in rotary kiln. Apart from

these there would be Captive Power Plant to generate power using Waste heat

from DRI Kilns in Waste Heat Recovery Boilers and Dolo-char/Washery Rejects

in CFBC Boiler. Each of these production units would contribute to air, water

and land pollution of varying nature and degree. The sources of pollution from

the proposed project and type of environmental pollution likely to occur are

summarized in Table 6.1.

Table – 6.1

Sources of pollution due to proposed expansion

Proposed

production

facilities

Process operation Pollutants released Type of

environmental

pollution

Raw material

handling yard

Stockpilling, crushing,

screening, conveyor

transfer and charging

Fugitive dust

emission

Air pollution

Noise pollution

Iron ore

beneficiation Plant

Stockpiling, crushing,

screening, conveyor

transfer

Iron ore dust, waste

water containing

fine ore

Air pollution

Water pollution

Iron ore Pellet

Plant

Stockpiling, crushing,

screening, conveyor

transfer

Iron ore / Coal dust. Air pollution



Proposed

production

facilities

Process operation Pollutants released Type of

environmental

pollution

Rotary kiln Direct reduction of iron

ore at 900 °C

TSP, CO2, SO2,

NOX and thermal

heat from emissions

of combustion flue

gases at 900-1000

°C

Air pollution

Thermal pollution

Induction Furnace Production of liquid

steel at around

temperature of 1100 °C

followed by secondary

refining of steel in LF

and billet casting

Waste gas

containing

particulates

Discharge of hot

water from the

pollution cooling

circuit

IF & LF slag land

pollution

Waste water

containing iron

scales, oil and

grease discharge of

hot water.

Air pollution

Noise pollution

Water pollution

Solid Waste

Water pollution

Ferro-Alloys Plant Production of Ferro-

Alloys in Submerged

Arc Furnace at around

temperature of 1600 °C

Discharge of hot

water from the

pollution cooling

circuit

Ferro-Manganese /

Silico Manganese /

Ferro-Chrome Slag

Water Pollution

Solid Waste

Captive power

plant

Generation of power

from plant fuel gas, coal

middlings and char

TSP, SO2, NOX &

CO

Generation of ash

Air pollution

Land pollution

The air pollution will take place due to emission from stacks attached to various units in

the complex.



6.3 Pollution prevention and control measures

In consideration of the above stated pollution potential of the proposed steel plant, the

following mitigation schemes are envisaged in order to control environmental pollution

within the permissible norms and keep the environment fairly clean.

6.3.1 Air environment protection

a) Raw material handling area

The raw material handling section would be provided with dust suppressing (DS) by

water sprinkling at the open stockyard and multiple dust extraction DE) systems within

the closed work zone for various dust generation points. The DE system shall consist of

bag filter units complete with ducts, extraction fans and stack of appropriate height.

b) DRI kiln

The exhaust gas from the kiln generated at a temperature of 900 to 1000 °C and

contaminated with dust particulates, sulphur dioxide, oxides of nitrogen and carbon

monoxide would be cleaned by dry gas cleaning system (ESP/bag filters). The DR kiln

off gas would pass through after burning chamber to burn out CO in the flue gas before it

is taken to the waste heat recovery boiler for generation of power. The product separation

unit would be provided with DE system to arrest the dust emission.

c) Captive power plant

The flue gas generated from combustion of char and coal middlings would be taken

through an ESP or bag filter to arrest the fine dust particulate matter. The clean gas would

be vented into the atmosphere through a tall stack of adequate height.

d) Iron ore beneficiation plant

The air and water pollution from various technological units is controlled by employing

suitable pollution control systems for source reduction of pollution and effluent is treated

before they are let out if any. All the conveyors transfer points are equipped with dust

extraction system(s) as required.

There is no effluent let out from the iron ore beneficiation plant. Water from the tailings

is also reclaimed and reused in the process.

e) Iron ore Pellet plant

All junction houses and transfer points are dust generating sources. To control the dust

two numbers of ambient dust catching system will be installed in the pellet plant. The

dust content after dust catcher shall not be more than 50 mg/Nm3. Finally dust will be

controlled by the ESP before discharge through stack.



f) Steel Melting Shop

In this shop, air pollution would be primarily due to emission of dusts, CO and NOX.

The essential pollution control measures would be the arresting of dust emissions to the

atmosphere from the EAF and the LF. The IF would be provided with in-built after

combustion chamber for CO removal and dust separation from the waste gases by bag

filters.

The water required for cooling of the billets would give rise to hot fumes containing

mostly vapours of water. This would be collected by suitable FE system and taken

through a condenser to separate out the steam condensate and the spent gas would be let

out theough a roof top stack into the atmosphere.

6.3.2 Water environment protection

The waste water generated in the Iron ore beneficiation plant containing fine iron ore

would be passed to tailing pond of desired capacity. The clear water from the pond would

be re-circulated for further use.

The plant sanitary waste water including canteen effluent would be treated in a modular

type sewage treatment plant for separation of floating oil and reduction of BOD. The

treated waste water would be collected in a pond within the plant to be used for dust

suppression and the maintenance of plant green belt.

6.3.3 Work zone pollution control

As stated earlier, the work zone pollution would be mostly fugitive dust, heat and noise.

The fugitive dust emission in open area would be controlled by DS and DE system as

described earlier.

The work zone noise would be mostly fluid noise from the rotary equipment and

machinery like fans, blowers, compressors and pumps. Propose selection of low noise

prone equipment and the grouting of this equipment will be made free from vibrations.

The work zone nose exposure of the operating personnel would be avoided by remote

operation from the control rooms.

6.3.4 Solid waste disposal

The solid waste produced due to the proposed plant would be DR kiln char, treatment

plant sludge’s, fly and bottom ash, flue dust etc. coal ash would be collected and

temporarily stored in the ash disposal area for onward transporting to nearby Cement

manufacturing unit / brick manufacturing units.



6.3.5 Pollution control equipment for the steel complex

The pollution control equipment are given in the following Table 6.2

Table – 6.2

POLLUTION CONTROL EQUIPMENT

FOR FUGITIVE AND STACK EMISSIONS IN STEEL COMPLEX

Probable Pollution Sources Mitigation Measures

DRI Plant

Loading / Unloading of Raw Materials and Finished

Products

Sprinklers / Fogging / Mist

Raw Material Handling System for DRI Plant Bag Filters

Product handling during discharge and intermediate

and product bins

Bag Filters

DRI Kiln off Gases ESP (Electro Static

Precipitator)

Iron ore Beneficiation Plant

Stock piles

Dust Extraction system. Material Transfer points on Conveyors

Power Plant

Unloading of Raw Material Sprinkler / Fogging / Mist

Raw Material Handling System for Power Plant Bag Filters

Boiler Flue Gases ESP

SMS

Raw material handling system for Steel Melting

Section

Bag Filters

IF & LF off Gases Fume Extraction System with

Bag Filters

PELLET PLANT

Process E.S.P & Bag Filters

The cost of pollution control equipment is given in the following table, which forms part

of main investment.

Table – 6.3

Cost of equipment/facilities for pollution control

Location/ Plant Air pollution

control equipment

to be deployed

Specification

(If possible)

Tentative cost

( Rs in crore )

Coal Washery Bag-filters 100mg/m3 0.40

Induction Furnace Bag-filters 100mg/m3 1.80



Pellet Plant Bag-filters, Silo 100mg/m3 3.20

Sponge Iron ESP, Bag-filters,

GCT

100mg/m3 20.00

Power Plant (20

MW)

ESP, Silo, Bag

filters.

100mg/m3 5.00

Iron Ore Beneficiary Dust Extraction

system

100mg/m3 3.00

Total 33.40

6.3.6 Plant safety

Plant safety measures would form an integral part of the environment protection plan of

the proposed plant. Workers safety would be of highest degree of concern so as to avoid

any form of personal injury or untoward accident. In-built safety features of the plant and

machinery would be made adequate in order to avoid hazardous events causing damage

to the life and property.

6.3.7 Green belt and landscaping

Jai Balaji Industries Limited has already earmarked 16.2 acres of land for Green Belt

Development within its existing plant at Raniganj, part of which has already been

developed.

Pertaining to the proposed expansion the Company proposes to increase area for green

belt development by 28.5 acres, which will be 33.72 % of the total proposed project area

of 85.5 acres.

• Green belt development is planned to be completed within 5 years by planting

about 500-600 saplings per acre.

• It is also proposed to build a green belt at the solid waste disposal sites.

• Plantation along the road will attenuate noise level, arrest dust and improve the

environment in surrounding.

• This would improve the plant aesthetics as well as prevent the fugitive dust

emissions

• The plant species will be selected as per CPCB guidelines.

6.3.8 Design targets for environmental protection

Stack emissions :

Particulate matter 100 mg/Nm3

SO2 emission Would be permitted within the

carrying capacity of the site

environment NOX emission

Work zone environment :

Dusts 10mg/cum (max) in a handling Closed area and 500 mg/cum (max)



and transport of raw materials and

finished product

in an open area within 20 to 30 m

aerial coverage

Thermal pollution 2.5 KW/m2 (max) for 40 sec.

Noise maximum 85 dB(A) for a period of 8 hours

exposure

Waste water discharge :

pH 6 to 9

Total suspended solids 100 mg/l

BOD 5 (20 °C) 30 mg/l

COD 250 mg/l

Oil and grease 10 mg/l

Iron (as Fe) 3 mg/l

6.4 Environmental monitoring

Routine environmental monitoring of stack emission, ambient air quality, work zone air

quality, noise level, waste water and surface water stream would be carried out. The

monitored data would be recorded and necessary corrective measures to be implemented

to avoid any con compliance of statutory regulations.

6.5 Land use planning

It is estimated the total area required for the proposed facilities is 86 Acres. The land use

planning of the same is as follows:

The built up area details combined for existing and expansion are as follows:

1. DRI PLANT (5 X 100TPD) = 20 acres

2. CPP (20MW) = 10 acres

3. IRON ORE BENEFICIATION PLANT = 6 acres

4. IRON ORE PELLET PLANT = 6 acres

5. SMS DIVISION = 4 acres

6. ASH POND = 5 acres

7. MAIN WATER STORAGE TANK = 4 acres

8. MISCELLANEOUS = 2 acres

9. GREEN BELT = 28.5 acres

TOTAL = 85.5 acres

6.6 Waste water management

A. Domestic waste water

No residential accommodation is planned within the plant premises. However, large

manpower 800 persons will require 40 cum/day of drinking/sanitary water. This will be

treated before releasing to the environment for plantation etc.



B. Industrial waste water

The Industrial waste water will be treated and recycled.

6.7 Solid waste management

The solid wastes generated by the expansion plant will be as follows :

Particulars TPA Remarks

1. Dolo-Char from DRI Plant 60,000 Will be utilized in CFBC

Boiler for Power

generation.

2. Dust from DRI Plant through WHRB

boilers

18,000 Will be given to the

Pellet Plant.

3. Fly Ash from 10 MW Thermal power

station

40,000 Will be sold to the

Cement Plants / Brick

manufacturing

4. Bottom ash Power Plant 10,000 To be disposed in

abandoned mines

ESP Dust from Power Plant 10,000 To be disposed in

abandoned mines

5. Tailings from Iron ore beneficiation plant 2,20,000 To be disposed in

abandoned mines

IF Slag 40,000 Land Filling

LF Slag 3,500 Land Filling

Ferro-Chrome Slag 20,400 After chrome recovery,

the tailing material will

be used as stone chips (8

to 25 mm) & land filling

purpose (0 to 8 mm).

Ferro-Manganese Slag 25,632 Ferro manganese Slag

will be used as raw

material for Silicon

Manganese production.

Silico Manganese Slag 24,780 Silicon Manganese Slag

will be used for low land

filling.



CHAPTER - 7

MANPOWER REQUIREMENTS

This chapter deals with assessment of manpower requirement for the proposed expansion.

The requirement of additional manpower for the proposed expansion, its auxiliaries and

services will be 800.

Breakup of the additional manpower requirement is given in the following Table.

Category wise break up of additional manpower

The category wise break down of additional manpower requirement if indicated in the

following Table.

CATEGORY WISE BREAK-UP OF ADDITIONAL MANPOWER

Category Number of persons

Managerial staff 10

Executive staff 40

Skilled staff 200

Non - skilled staff 500

Office staff 50

Total 800

JAI BALAJI INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.

TEFR for Steel Complex Expansion 8-1

CHAPTER - 8

CAPITAL COST ESTIMATES

This chapter presents the estimate of project cost for installation of steel complex

(expansion) with 5 X 100 TPD Kilns, 0.6 MTPA Iron Ore Beneficiation Plant,

0.6 MTPA pellet Plant, 4 X 15 T Induction Furnace and 22 MW Captive Power

Plant.

8.1 CAPITAL COST ESTIMATE

a) Plant cost

The plant cost covers the cost of all facilities as described in Chapter 5 & 6. It

includes the cost of civil and structural work and equipment as erected within the

plant boundary. It also includes the expenses for technical services, design,

engineering and administration during construction.

i) Civil and structural work

The cost of civil and structural work includes expenses towards all civil works

and structural steelworks for factory buildings of main and auxiliary services.

The cost of civil work has been based on prevailing prices of building materials

and existing rates of construction work for similar plant and equipment. The cost

of structural steel work has been estimated on the basis of current prices of steel

structurals and the prevailing rates of fabrication and erection work. The

quantities of civil structural steelwork have been estimated based on preliminary

design concepts and layouts of the major departments.

ii) Plant and machinery

The cost of equipment is based on prevailing prices with manufacturers and

vender.

Technical services, design and engineering fees and administration during

construction

A provision has been made towards technical services, design and engineering

fees, administration and interest during construction. The overall project cost

becomes Rs 332 crores as shown in the following Table 10.1.

JAI BALAJI INDUSTRIES LIMITED ( UNIT – I ) G-1, Mangalpur Industrial Complex, P.O.-Baktarnagar, District – Burdwan, West Bengal.

TEFR for Steel Complex Expansion 8-2

TABLE – 8.1

TOTAL PROJECT COST

Sl.No. Particulars Rs. Crores

1 DRI Plant ( 5 X 100 TPD ) 60.00

2 Captive Power Plant ( 20MW ) 110.00

3 Iron Ore Beneficiation Plant ( 0.6 MTPA ) 12.00

4 Pellet Plant 100.00

5 Induction Furnace 40.00

4 Land & site development 10.00

TOTAL *332.00

*-Including cost of environment pollution control equipments / systems.

TABLE – 8.2

MEANS OF FINANCE

Sl.No. Particulars Rs. Crores

1 Term Loan 232.00

2 Equity / Internal Accruals 110.00

TOTAL 332.00

jai balaji industries limited · 2006 approved the merger of shri ramrupai balaji steels limited,...

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