API Ispat & Powertech Pvt. Ltd. -...
Transcript of API Ispat & Powertech Pvt. Ltd. -...
API Ispat & Powertech Pvt. Ltd. [Expansion of Steel plant]
Vil lage: Siltara, near Phase – II, Siltara Industrial Area,
Tehsil and District: Raipur
Chhattisgarh
PRE-FEASIBILITY REPORT
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Contents
Chapter – 1: Executive Summary ...................................................................... 1
1.1 About Project Proponent ................................................................. 1
1.2 About the Proposed Project .............................................................. 1
Chapter – 2: Introduction of the Project / Background Information ....................... 3
2.1 Identi fication OF Project and Project Proponent ................................... 3
2.2 Brief Description of Nature of Product ............................................... 3
2.3 Need for the Project and importance to the Region ............................... 3
2.4 Demand – Supply GAP ................................................................... 4
2.5 Employment Generation (direct & indirect) ......................................... 5
Chapter – 3: Project Description ........................................................................ 6
3.1 Type of the Project ......................................................................... 6
3.2 Location of the Project .................................................................... 7
3.3 Details of the Alternate Sites ............................................................ 8
3.4 Size OR Magnitude of Operation ...................................................... 8
3.5 Manufacturing Process: ................................................................... 9
3.5.1 Pelletization Unit: .......................................................................... 9
3.5.2 Induction Furnace: ........................................................................12
3.5.3 Rolling Mill Unit: .........................................................................15
3.5.4 Ferro Alloys Manufacturing Unit: ....................................................17
3.6 Raw Material Requirement .............................................................18
3.7 Water requirement and its Source .....................................................20
3.8 Solid Waste Generation and its Disposal:...........................................20
Chapter – 4: Site Analysis.................................................................................21
4.1 Connectivity ................................................................................21
4.2 Land use......................................................................................21
4.3 Topography .................................................................................22
4.4 Existing land use pattern.................................................................22
4.4 Existing infrastructure....................................................................22
4.5 Climatic data from secondary sources ...............................................22
Chapter – 5: Planning Brief ..............................................................................23
5.1 Planning Concept ..........................................................................23
5.2 Population Projection.....................................................................23
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5.3 Land use Planning .........................................................................23
5.4 Amenities / Facilities .....................................................................23
Chapter – 6: Proposed Infrastructure ................................................................24
6.1 Industrial Area (processing Area) .....................................................24
6.2 Residential Area (non Processing Area) .............................................24
6.3 Green Belt ...................................................................................24
6.4 Social Infrastructure ......................................................................25
6.5 Connectivity:................................................................................25
6.6 Drinking Water Management ..........................................................25
6.7 Sewerage System ..........................................................................25
6.8 Industrial Waste Management .........................................................26
6.9 Solid waste Management & its Disposal ............................................26
6.10 Power Requirement & Its Source .....................................................26
Chapter – 7: Rehabilitation & Resettlement (R & R) Plan ....................................27
Chapter – 8: Project Schedule & Cost Estimates .................................................28
8.1 Project Schedule ...........................................................................28
8.1 Project Cost .................................................................................28
Chapter – 9: Analysis of Proposal......................................................................29
9.1 Financial and Social Benefits ..........................................................29
9.2 Socio-economic Developmental Activities .........................................29
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Chapter – 1: Executive Summary
1.1 About Project Proponent
API Ispat & Powertech Pvt. Ltd. [here in after referred as APIIPPL] company is in
steel business and having good reputation in the market, which was gained with
good business experience. Looking forward in prospects of Steel sector, APIIPPL
propose to go for expansion of steel plant in Raipur District of Chhattisgarh State.
1.2 About the Proposed Project
API Ispat & Powertech Pvt. Ltd. is existing steel plant at Siltara village, near Phase
– II, Siltara Industrial Area, Tehsil and District: Raipur, Chhattisgarh. Now as a part
of expansion, APIIPPL is planning to enhance the capacity of Induction Furnace,
Rolling Mill and establish new unit of Pellet plant, EAF and Ferro alloys. Following
is production capacity and plant configuration:
Table 1: Unit Configuration
Sr. No.
Unit Existing CFE awarded Proposed Expansion
After Expansion Implemented To be
commissioned
1. Iron Ore Beneficiation and Pelletization Plant
--- --- 1 x 2000 TPD or
2 x 1000 TPD
= (0.6 Million TPA)
1 x 2000 TPD or
2 x 1000 TPD
= (0.6 Million TPA)
2. DRI Kilns
(Sponge Iron )
1 x 350 TPD
= (105,000 TPA)
1 x 350 TPD
= (105,000 TPA)
---- 2 x 350 TPD
= (210,000 TPA)
3 Steel Melting Shop
a Induction Furnace with CCM (MS Ingots/ billets/ blooms)
2 x 12 Tons = (86400 TPA)
--- 3 x 15 Tons = (162000
TPA)
2 x 12 MT & 3 x 15 MT = (248400
TPA) b Electric Arc Furnace with
AOD/ VOD & Caster (MS
and SS Ingots/ billets/ blooms)
--- --- 2 x 20 MVA = (120000
TPA)
2 x 20 MVA = (120000
TPA)
4. Rolling Mill --- 1 x 322.5 TPD +
1 x 161.7 TPD = (145250 TPA)
1 x 650 TPD
= (200000 TPA)
1 x 322.5 TPD,
1 x 161.7 TPD & 1 x 650 TPD & = (345250 TPA)
5. Ferro alloys [2 x 9 MVA] --- --- 2 x 9 MVA 2 x 9 MVA
i. Ferro – Silicon --- --- 12600 TPA 12600 TPA
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or or or ii. Silico–Manganese --- --- 28400 TPA 28400 TPA
or or or iii. Ferro–Manganese --- --- 37000 TPA 37000 TPA
6 Power Plant–WHRB based 8 MW 10 MW --- 18 MW
7 Power Plant–FBC based 7 MW --- --- 7 MW
97.75 acres of land is in possession of management and proposed expansion will
be taken up the existing plant premises.
Total project cost envisaged for the proposed expansion project is Rs.240 Crores.
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Chapter – 2: Introduction of the Project / Background Information 2.1 Identification of Project and Project Proponent
API Ispat & Powertech Pvt. Ltd. [here in after referred as APIIPPL] company is
engaged in steel business and having good reputation in the market, which was
gained with good business experience. Looking forward in prospects of Steel
sector, APIIPPL propose to go for expansion of steel plant in Raipur District of
Chhattisgarh State.
2.2 Brief Description of Nature of Product
The company after assessing the market potential of the steel industry thoroughly
decided to go in for iron-ore pellets. The highly encouraging response received
on market survey also ruled favorably for the said project. Promoters are well
experienced entrepreneurs and are well supported by technical personnel
experience to run such unit.
Presently, most of the coal based sponge iron plants in India uses iron ore lumps.
The requirement is generally 1.8 t/ t of sponge iron. This high requirement is
mainly due to the fines generated in handling the purchased ore from the source
to the plant. This reduces the kiln campaign length and increases ore fines lost.
Use of pellets with better physical and metallurgical properties for sponge iron
production reduces the accretion formation in the kiln and the pellets
consumption is about1.6 t/t. Further, the production from the kiln is expected to
increase by 25% to 30%.
In view of the above, API Ispat & Powertech Pvt. Ltd. proposed to go for
expansion of steel plant at Siltara village, near Phase – II, Siltara Industrial Area,
Tehsil and District: Raipur, Chhattisgarh.
2.3 Need for the Project and importance to the Region
Utilization of low grade ore and fines has to play an important role. In India partly
due to the sponge iron sector; the overall percentage of lumps usage in steel
making (47%) is higher than most other countries. As hard ore reserves is
depleting day by day, lump generation suitable for blast furnace operation is
coming down resulting in production of large amount of surplus fines. Alternative
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iron making processes for production of steel may lead to changing pattern of use
material inputs and feed stock causing significant shift in respective share of
lumps and agglomerated iron ore (pellets) and will also enable the use of ores
which could not be utilized earlier. As fines forms considerable part of iron ore
resources, value addition to the iron ore fines through various activities such as
beneficiation, Pelletization is the need of the hour.
2.4 Demand – Supply GAP
With the rapid development of Infrastructure and manufacturing sector, the Iron
and steel industry is poised for an accelerated growth. Steel demand in the
country is increasing at an average rate of 10% and is likely to remain in 10-12%
range at least for the next decade. In order to meet the steadily growing steel
demand in the country, domestic steel producing capacity is required to be higher
than 110 mtpa within next three years and, 150 mtpa by the year 2016-17. Indian
economy is growing at more than 10% rate, steel demand and supply will grow in
the same way. As good quality iron ore deposits are depleting fast beneficiation
technologies will have to be adopted to meet iron ore demand. Therefore good
yield of beneficiation process generally around 70 % will make this technology
economically viable.
Agglomeration technologies such as Pelletization will have to be added to DRI
Plant / Steel Plant so that concentrates can be used as feed material. Recycling of cheaper raw material (fines) by beneficiation and pelletization process as feed material will result in better Return on Investment as
compared to using Iron ore as feed material.
With superior reducibility behavior of pellets compared to lump ore efficiency
of DRI production improves.
It can be concluded from results obtained by conducting various tests on
manufactured pavement blocks that substitution of iron ore tailings for sand or quarry dust shows better compressive strength without much change in water absorption.
In the Indian context, by the year 2020, India’s production of steel is expected to
touch110 Million Tonnes and it is imperative that the fines generated in the
mining of iron ore be utilized for the production of steel. The Indian steel industry
which predominantly uses expensive lump ore is gradually moving towards usage
of iron ore pellets.
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The present Indian raw material scenario offers an opportunistic disposition
towards pellet making owing to the availability of large quantities of sub grade
fines, slimes and blue dust etc. at different mine heads. These materials are not
suitable for sinter making. Pelletization is the only possible route for salvaging
these, otherwise waste but valuable materials. Recent techno-economic studies
indicated favorable indices for installation of pellet plants, both small and large
scale. The demand supply analysis also underlines the need for Pelletization.
2.5 Employment Generation (direct & indirect)
PHYSICAL INFRASTRUCTURE
Once the proposed activity is commissioned, the socio-economic status of the
local people will improve and there by infrastructure facilities like communication
systems will improve. Most of the villages at present do not have protected
water supply. After the implementation of the project, the affordability of the
public to spend on water treatment, supply & distribution will more along with
the aid from the state government.
EMPLOYMENT POTENTIAL
The proposed project creates employment to 100 people during construction and
50 people during operation of the proposed expansion.
Sr. No. Category Nos. of employment 1. Skilled 15
2. Semi skilled 15
3. Un-skilled 25
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Chapter – 3: Project Description 3.1 Type of the Project
API Ispat & Powertech Pvt. Ltd. is existing steel plant at Siltara village, near Phase
– II, Siltara Industrial Area, Tehsil and District: Raipur, Chhattisgarh. Now as a part
of expansion, APIIPPL is planning to enhance the capacity of Induction Furnace,
Rolling Mill and establish new unit of Pellet plant, EAF and Ferro alloys. Following
is production capacity and plant configuration:
Sr. No.
Unit Existing CFE awarded Proposed Expansion
After Expansion Implemented To be
commissioned 1. Iron Ore Beneficiation and
Pelletization Plant --- --- 1 x 2000 TPD
or 2 x 1000 TPD
= (0.6 Million TPA)
1 x 2000 TPD or
2 x 1000 TPD
= (0.6 Million TPA)
2. DRI Kilns
(Sponge Iron )
1 x 350 TPD
= (105,000 TPA)
1 x 350 TPD
= (105,000 TPA)
---- 2 x 350 TPD
= (210,000 TPA)
3 Steel Melting Shop
a Induction Furnace with CCM (MS Ingots/ billets/ blooms)
2 x 12 Tons = (86400 TPA)
--- 3 x 15 Tons = (162000
TPA)
2 x 12 MT & 3 x 15 MT = (248400
TPA) b Electric Arc Furnace with
AOD/ VOD & Caster (MS
and SS Ingots/ billets/ blooms)
--- --- 2 x 20 MVA = (120000
TPA)
2 x 20 MVA = (120000
TPA)
4. Rolling Mill --- 1 x 322.5 TPD +
1 x 161.7 TPD = (145250 TPA)
1 x 650 TPD
= (200000 TPA)
1 x 322.5 TPD,
1 x 161.7 TPD & 1 x 650 TPD & = (345250 TPA)
5. Ferro alloys [2 x 9 MVA] --- --- 2 x 9 MVA 2 x 9 MVA
i. Ferro – Silicon --- --- 12600 TPA 12600 TPA or or or
ii. Silico–Manganese --- --- 28400 TPA 28400 TPA or or or
iii. Ferro–Manganese --- --- 37000 TPA 37000 TPA
6 Power Plant–WHRB based 8 MW 10 MW --- 18 MW 7 Power Plant–FBC based 7 MW --- --- 7 MW
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3.2 Location of the Project
Proposed Project is located at Siltara village, near Phase – II, Siltara Industrial
Area, Tehsil and District: Raipur, Chhattisgarh. 97.75 acres of land is in possession
of management and proposed expansion will be taken up the existing plant
premises.
Topographical location of project site is shown below:
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3.3 Details of the Alternate Sites
No alternative sites have been considered as proposed expansion will be taken up
in the existing plant premises.
3.4 Size OR Magnitude of Operation
As a part of expansion, APIIPPL is planning to enhance the capacity of Induction
Furnace, Rolling Mill and establish new unit of Pellet plant, EAF and Ferro alloys.
Following is production capacity and plant configuration:
Sr. No.
Unit Existing CFE awarded Proposed Expansion
After Expansion Implemented To be
commissioned 1. Iron Ore Beneficiation and
Pelletization Plant
--- --- 1 x 2000 TPD
or 2 x 1000 TPD = (0.6 Million
TPA)
1 x 2000 TPD
or 2 x 1000 TPD = (0.6 Million
TPA)
2. DRI Kilns (Sponge Iron )
1 x 350 TPD = (105,000
TPA)
1 x 350 TPD = (105,000 TPA)
---- 2 x 350 TPD = (210,000
TPA)
3 Steel Melting Shop
a Induction Furnace with
CCM (MS Ingots/ billets/ blooms)
2 x 12 Tons
= (86400 TPA)
--- 3 x 15 Tons
= (162000 TPA)
2 x 12 MT &
3 x 15 MT = (248400
TPA)
b Electric Arc Furnace with AOD/ VOD & Caster (MS and SS Ingots/ billets/ blooms)
--- --- 2 x 20 MVA = (120000
TPA)
2 x 20 MVA = (120000
TPA)
4. Rolling Mill --- 1 x 322.5 TPD + 1 x 161.7 TPD = (145250 TPA)
1 x 650 TPD = (200000 TPA)
1 x 322.5 TPD, 1 x 161.7 TPD & 1 x 650 TPD & = (345250
TPA) 5. Ferro alloys [2 x 9 MVA] --- --- 2 x 9 MVA 2 x 9 MVA
i. Ferro – Silicon --- --- 12600 TPA 12600 TPA or or or
ii. Silico–Manganese --- --- 28400 TPA 28400 TPA
or or or iii. Ferro–Manganese --- --- 37000 TPA 37000 TPA
6 Power Plant–WHRB based 8 MW 10 MW --- 18 MW 7 Power Plant–FBC based 7 MW --- --- 7 MW
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3.5 Manufacturing Process: 3.5.1 Pelletization Unit:
The iron ore Pelletization unit comprises of following sections:
a. Drying & Prepn. of Iron Ore Fines b. Grinding c. Mixing and Blending
d. Pelletization e. Screening f. Travel Grate Furnace g. Rotary Kiln h. Cooler
i. Stacking j. Recovery of Dust and Spillage
a. Drying & Preparation of Iron ore Fines:
Generally Iron Ore Fines, Lime Stone and Dolomite fines available, contain
more than 6-7% moisture and require drying before grinding. The drying is
carried out in Rotary Drum Dryer. The moisture content in the dry material
is controlled. The low grade Iron Ore Fines is feed in a screen for
separation. Oversize/ under size moves to the primary grinding circuit.
b. Grinding
Iron Ore Fines, Dolomite and Lime Stone are mixed in required proportion
and fed into a Ball Mill. The fineness of the product is controlled as may be
necessary for particular ore and Pellet quality.
c. Mixing and Blending
Iron Ore powder blended with Bentonite and other binding materials in
desired proportion. Small quantity of water is added during blending
operation. This raw mix is ready for Pellet making and store in feed
hopper.
d. Pelletization
Controlled quantity of raw mix is fed on disc Pelletizer. Some amount of
water is sprinkled for producing Pellets. These Pellets are passed through
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oversize and undersize screens. Sized Pellets are then sent to sintering
section.
e. Screening
Pellets produce in Pelletization sections are passed through oversize and
undersize screens. Rejects Pellets are sent back to raw mix silos sized
Pellets are fed in to Indurations Furnace.
f. Travel Grate Furnace
A Travel Grate Furnace is used for indurations of Pellets. This is divided
into 3 sections (Drying–Preheating–Heating). Hot Pellets at around 950ºC
to 1000ºC from this Travel Grate are dropped into the Kiln for further
strengthening.
g. Rotary Kiln
Rotary Kiln receives Pellets from the Indurations Furnace where Pellets
have to withstand at high temperature approx. 1050ºC – 1200ºC. Here the
Pellets gain more hardness due to high temperature. Furnace Oil /
Producer Gas will be used as a fuel inside the Kiln. After the Kiln the Pellets
are passed to the Grate Cooler.
h. Cooler
Grate Cooler receives hot Pellet with temperature up to 1200ºC coming
from Rotary Kiln. Cooler has its own blowers to blast the air from bottom.
The hot air from the first zone is used as a combustion air in kiln. The hot
blast of the second zone is used in the pre-heating zone-1 of travel grate
and the air from the 3rd zone is discharged to the atmosphere through
chimney as its dust concentration is well within the permissible limits of
pollution norms. Volume of cooling air in all the three zones is regulated
automatically through the temperature control loops as per the
requirement. Cold Pellets at about 100ºC are discharged on conveyors and
they are quenched by the cold water for further cooling and then
conveyed to the stock pile/ loading hoppers.
i. Stacking
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The screened Pellets of required size duly cooled at air cooler and
subsequently natural cooling are transported to Bunkers
j. Recovery of Dust and Spillage
Spillage from drying zone and preheating zone of traveling grate, dust
from the wind box of traveling grate and dust collected through de-duster
of technological process shall meet and will be sent to dust bin via belt
conveyor, after they are ground together with iron ore concentrate at
grinding mill. Spillage (dry Pellets) produced at the discharge end of
traveling grate will be fed into the kiln from the feed chute of the kiln feed
end by bucket elevation. Almost all the dust and spillage are re-circulated
and recovered.
Process flow diagram
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3.5.2 Steel Melting Shop
Semi-finished steel in the form of Steel Ingots & Billets is manufactures through
Induction Furnace with Concast that works on the principle of induction melting
of scrap/ Pig Iron with the help of electric power. An alternating electromagnetic
field induces eddy current in the metal so that the electrical energy converts into
heat whose quantity depends on the resistively of the charge. If the charge
consists of the metal scrap, chips other metal rejections then the eddy currents
arise between separate pieces of charge because high contact resistance. So small
charge pieces required increase frequency of current that feeds the induction
heater in order to speed up melting of the charge. Induction furnaces operate on
current of commercial frequencies (50 HZ) or on current of higher frequencies
from 500 to 2000 Hz. Induction furnaces are beneficial in steel making for low
melting loss.
An Induction furnace constitutes a single larger primary coil made of water-
cooled copper tube. The working voltage impressed across the terminals of the
coil. These furnaces have a great much application for melting of iron, Steel and
Nonferrous. This type of furnace has a rammed lining. The ramming mantel silica
mass contains should more than 96% silica and minimum of Al2O3 & Fe2O3. Before
ramming the material a steel template kept inside the furnace and rammed the
material between the template and the insulated coil of the induction heater. To
minimize the consumption of electric power and cut down the melting period the
crucible wall must be as thin as possible. During running the furnace one must
keep watch on the state of lining because it operates under most unfavorable
condition. The inside of crucible lining is in contact with liquid metal while its
outside surface contacts the water-cooled induction.
Charging: -
The pieces of scrap should be kept on the bottom gently to avoiding impacts into
a compact heap. The scrap pieces / Pig Iron should be in small size that provide
good compacting of the batch without leaving spacing between the charge and
crucible wall. This offer an advantage of quick melting of the charge with a
minimum power spent in the stage for the heat.
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The zone of a highest temperature during the meet lies in the power part of the
crucible therefore it is practical to place first high melting scrap on the crucible
bottom. Large and high melting pieces should stand parallel and close to the
crucible was while low melting components should be in the middle of the large
crucible. Small capacity furnaces are loaded manually and the large capacity
furnaces with the aid of buckets.
Melting: -
At the beginning of the melting the furnace works for 5 to 10 minutes on low
power until the surge of current fed from the generator disappear. The furnace
power is then brought up to a maximum. The charge melts with the crucible held
closed. When the charge approaches the fluid stages then the solid pieces are
pressed backed with a crow bar. The furnaces is then loaded to its capacity by
adding small size of scrap as soon as the charge melted, the stag is formed to
protect the metal from oxidation and to avoid reduce the melting loss. If the slag
generate in excess it should be skimmed off periodically, at the last to deoxidized
the metal with Ferromanganese, Silico-manganese and Ferro-silicon. Now the
metal is ready tap for either in ingot or billet casting.
Casting in Ingot mould: -
For casting ingot the metal temperature should be around 1560ºC/ 1570 ºC in
ladle. Liquid metal tap from furnace to ladle by the help of crane then the ladle in
the centered on the trumpet metal flows from the ladle bottom and filled the
ingot mould. Thus the ingot is ready.
Casting in B.C.M: -
Steel for making billet, the temperature of liquid metal from furnace to ladle, the
final metal temperature in ladle should be 80ºC. superheat from liquidious. Liquid
metal is storage in tundish through ladle then the tundish metal passes from the
various section of mould jacket that is as per requirement (100 X 100 mm, 125 X
125 mm, 160 X 160 mm, 200 X 200 mm) this is a continuous process, length of
billet of is cut as par requirement. Process flow chart is enclosed.
Plant facilities for Continuous Casting Machine
Billet caster:
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The billet caster shall be complete with ladle stand, mould assembly, strand guide
segments and supports withdrawal and straightening system, mould cooling
system, Cut off equipment including length measuring device, Marking machine
etc. Requisite dummy bar and facilities for Dummy bar disconnecting and a
dummy bar receiver will be included.
Auxiliary equipment :
The auxiliary facilities required for the Billet caster will be included. This will
include operating platform, cooling bed, ventilation system for spray chambers,
equipment for collection and disposal of crop-ends, Repair and assembly facilities
for moulds, and segments, Tundishes, Tundish preparation facilities including
tundish drying station, Hydraulic system and Centralized lubrication system, scale
handling system.
Electrical Equipment:
The electrical equipment for the caster will include the drives, HT switchgear, LT
switchgear, control desks, cabling and accessories.
Instrumental and automation:
A modern DCS process automation system shall be provided for control of process
function, sequencing and interlocking and to execute safely controls. Specific
features shall include mould level control, computer aided quality control, and
process field instruments comprising measuring units, transmitters, load cells,
actuators, Programmable controllers and PCs and communication system.
Plant facilities for Ladle Furnace
The LF installation will be single station system with provision for arc heating,
inert gas stirring, and addition of ferroalloys and additives. The LF will be
complete with transformer, Ladle stirring system Aluminum wire feeder, Carbon
injecting device, additives storage and addition system, Sampling and
temperature measuring device. A fume extraction and cleaning system consisting
of bag filters, ID fan and chimney with the related ductwork will be provided.
Auxiliary equipment:
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The auxiliary facilities required for the LF will be included the transfer cars, slag
handling facility, hydraulic and lubrication systems, Electro nipping station.
Argon oxygen decarburisation unit (AOD) / Vacuum degassing/ Vacuum oxygen
decarburisation (VD/VOD)
One AOD/VOD converter of replaceable shell design will be installed for
production of different grades of stainless steels. Treatment of the liquid stainless
steel at AOD/VOD, stainless steel requiring vacuum treatment will be brought to
vacuum degassing unit. After tapping heat from AOD/VOD, alloy steel requiring
vacuum treatment will be brought to vacuum degassing unit.
Ladle will be placed inside the vacuum tank after which tank will be sealed with
tank cover. Vacuum pump will be switched on and argon gas will be
simultaneously purged in the liquid steel during entire vacuum treatment. Sample
will be taken and, if necessary, alloying elements will be added through vacuum
lock hopper to get the desired chemical composition. Vacuum degassed steel will
be shifted to ladle turret for casting into billets.
3.5.3 Rolling Mill Unit:
Rolling mill unit comprise of Re-heating furnace, Roughing Mill, Intermediate Mill,
Finishing Mill, Finishing Section and Auxiliary Equipments.
Reheating furnace
A pusher type furnace has been envisaged for the heating of billets. The furnace
will be end charging and side discharging. It will have single row as well as double
row charging facility. In priority rolling mill will be operated on hot charging basis
i.e. ingots/ billets will be directly rolled in rolling mill without heating. In case
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heating will be required then the Producer gas will be utilized as primary fuel and
Furnace oil will be utilized as secondary as well as auxiliary fuel in pusher type of
re-heating furnace of rolling mill. The furnace combustion system will comprise of
air blowers, coal/ FO storage, supply and preheating system and other associated
facilities. The product of combustion will leave the furnace at charging end and
exhausted through underground flue tunnel and passed through a metallic
tubular recuperator before finally let off to a self-supporting steel chimney of
sufficient height. A set of instrument will be used for smooth operation of the
furnace.
Bar and round mill
A cross country type mill has been envisaged for the plant. The stands have been
grouped into roughing, intermediate and finishing groups. Roughing group will
have 4 (four) stands, intermediate group will have 8 (eight) stands and finishing
mill will have 8 (eight) stands. Roughing group of stands will be driven by one
motor. 4 nos. of intermediate stands will be driven by two motors and balance 4
nos. will be driven by a separate motor. Each stand of finishing group will be
driven by single motor. Necessary guides and troughs will be provided at entry
and exit of mill stands.
One wire rod out let has been provided in the mill. The wire rod line will have 4
stand block driven by a single motor through gear box. Coil forming and handling
of coil is provided.
Automated tilting, drop type tilter and feeding arrangement will be provided in
roughing group of stands. Repeaters have been provided in roughing /
intermediate stands as necessary.
Design provision has been made for introduction of slit rolling facility in future to
roll 8 mm, 10 mm & 12 mm rebars in two strands. The rebars discharged from the
mill will pass through a water cooling system comprising cooling pipes with high
pressure water nozzles for rapid water quenching. At the cooling pipes the bar
skin temperature will be reduced to about 600ºC. The core of the bar still
remains hot. This entrapped heat tempers the bar. This thermo-mechanical
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treatment of the bars increases tensile strength without adversely effecting
weldability and elongation properties. This process eliminates requirement of
cold twisting of bars for production of rebars.
A dividing shear, to cut the products to cooling bed length, will be located
immediately after the water cooling system. This shear will divide all products to
cooling bed lengths. Rake type cooling beds have been envisaged to receive the
rolled product. Cooling bed will be provided with incoming and outgoing roller
tables. One cold shear has been provided to cut the bars coming out of cooling
bed into commercial length of 6 to 12 m. The bar products will be formed into
bundles and will be strapped by strapping machine manually.
The finished products will be removed by overhead EOT crane and stored in the
storage area or dispatched through road vehicles.
3.5.4 Ferro Alloys Manufacturing Unit:
In Ferro alloy plant, Silico Manganese (Si-Mn), Ferro Manganese (Fe-Mn) and
Ferro Silicon (Fe-Si) is produced by smelting of Manganese ore with coke, coal,
quartz and dolomite. The smelting is a continuous process which will be done in
submerged arc furnace with a line voltage of 70-170V. The raw material premix
will be charged into the furnace near the electrodes through chutes. The
electrodes used are of self-baking type in which a series of cylindrical steel casings
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welded on the top of each other forms the electrode column in which solid green
carbon ‘paste’ blocks are added periodically from the top of the column. This
system takes advantage of the electric power used for the process to bake the
electrodes in place. The smelting process thus in submerged arc furnace produces
the ferro alloys.
Manufacturing Process Flow Chart is as below:
3.6 Raw Material Requirement
Raw material required for the proposed expansion is as followed:
a. For Iron Ore Pellet Plant (0.6 million Tons/ year):
Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
1. Iron ore fines 663060 Local / Orissa
Sector
By Rail & Road through
covered trucks 2. Coke 21450 Indonesia / South
Africa / Australia Through sea route / rail
route / by road
3. Limestone 9020 Chhattisgarh / Madhya Pradesh
By Rail & Road through covered trucks
4. Bentonite 6800 Gujarat By Rail & Road through covered trucks
Submerge Electric
Arc Furnace
Feeders (for proper proportion)
Quartz
Manganese Ore Coke
Ferro Alloys
Slag
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b. For Induction Furnace unit (3 x 10 MT = 90000 TPA)
Sr.
No.
Raw Material Quantity
(TPA)
Source Mode of
Transport 1. Sponge Iron 13500 In house generation ----
2. Scrap 19125 Chhattisgarh By road through covered road
3. Ferro Alloys 2025 In house generation ----
cc.. FFoorr RRoolllliinngg MMiillll ((11 xx 665500MMTT == 220000000000 TTPPAA))
Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
1. Billets / Ingots 216600 In house generation ----
dd.. FFoorr FFeerrrroo SSiilliiccoonn uunniitt ((22 xx 99 mmVVAA))::
Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
1. Quartz 16890 Chhattisgarh / Andhra Pradesh
By Rail & Road through covered
trucks
2. Pet coke 5600 Chhattisgarh / Bihar By Rail & Road through covered
trucks
3. MS Scrap 350 Chhattisgarh By Road through covered trucks
4. Electrode paste
840 Andhra Pradesh (Vizag)
By Rail & Road through covered
trucks
ee.. FFoorr SSiilliiccoo MMaannggaanneessee uunniitt ((22 xx 99 mmVVAA))::
Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
1. Manganese Ore 31780 MOIL / OMC By Rail & Road through covered
trucks
2. Mn. Slag 18000 In house generation ----
3. Quartz 7800 Chhattisgarh / Andhra Pradesh
By Rail & Road through covered
trucks
4. Pet coke 3160 Chhattisgarh / Bihar By Rail & Road through covered
trucks
ff.. FFoorr FFeerrrroo MMaannggaanneessee uunniitt ((22 xx 99 mmVVAA))::
Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
1. Manganese Ore 53400 MOIL / OMC By Rail & Road through covered
trucks
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Sr. No.
Raw Material Quantity (TPA)
Source Mode of Transport
2. Pet coke 30780 Chhattisgarh / Bihar By Rail & Road through covered
trucks
3. MS Scrap 2060 Chhattisgarh By Road through covered trucks
4. Electrode Paste 6160 Andhra Pradesh (Vizag)
By Rail & Road through covered
trucks
3.7 Water requirement and its Source
Water required for the proposed expansion project will be 1400 KLD. Water
required will be supplied by Chhattisgarh Ispat Bhumi Ltd.
3.8 Solid Waste Generation and its Disposal:
Sr. No.
Type of Solid waste Quantity (in TPD)
Disposal Proposed
1. Ash / Dust generated from Pellet plant
= 27 Will be recycled in pellet making process.
2. Tar generated from Producer gas plant
= 2 Will be given to coal tar distillation units
3. Slag from SMS = 90 Slag generated from SMS will be given to slag crushing units.
4. Mill scales from Rolling mill
= 50 Reused in SMS
5. Slag from Fe-Mn = 100 To be reused in manufacture of Silico
Manganese as it contains high MnO2 and Silicon
6. Slag from Fe-Si = 13 To be used in cast iron foundries.
7. Slag from Si-Mn = 103 To be used for road construction / slag cement manufacture
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Chapter – 4: Site Analysis
4.1 Connectiv ity
The proposed site is well connected with Road – Rail network. The following
table gives brief regarding connectivity of the proposed site:
Component Description
Road = NH – 200 = 2.4 km Rail = Nearest station – 7.3 km (Mandhar RS) Mumbai-Howrah mail line
Air = Raipur Air Port – 23 Kms.
Sea Port = Vishakapatanam – 505 Kms.
The location has a big advantage in its closed proximate to its market.
Traditionally, iron manufacturing units have tendered to cluster in the eastern
zone of India namely in the state of Jharkhand, Orissa and Chhattisgarh because
of easy availability of major raw input iron-ore and coal. Infrastructural and
other utility services are easily available. Skilled and un-skilled laborers are also
available easily.
Below mentioned table gives brief regarding environmental setting of the project
site
Sr. No. Particulars Distance from the site
1. National Park = No national Park is situated within the 15 km radial distance periphery
2. Wild life sanctuaries = Nil 3. Eco Sensitive Areas = Nil
4. Forests = Nil
5. Surface water bodies = Kharun River – 1.8 Kms. Kulhan nala – 7.8 Kms.
6. Costal Regulation Zone [CRZ] = Nil
7. Industrial Area = The unit is located adjacent to Phase – 2 of Siltara Industrial Area, Raipur
4.2 Land use
Existing plant is located adjacent to Phase # 2, Siltara Industrial Growth Centre.
The terrain of the land is almost plain.
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4.3 Topography
The topography of the land is flat without undulations.
4.4 Existing land use pattern
APIIPPL is an existing plant, partly located in Siltara Village, adjacent to Phase # 2,
SIltara Industrial Area, and its adjacent Village Sondra, Raipur Tehsil & District,
Chhattisgarh. Private owned land is diverted for Industrial purpose. 97.75 acres of
land is in possession of management and proposed expansion will be taken up in
the existing plant premises.
There are no ecologically sensitive places like national park, sanctuary,
biosphere reserve, reserve forest etc. around 10 Kms. radius of the site. There
is no route of migratory animals within the project site. The site satisfies the
criteria stipulated by the Ministry of Environment & Forest, Government of India
for setting up of industries.
4.4 Existing infrastructure
Water supply in most of the villages is available. Inter-village transport facility is
available only for the selected villages. While educational facilities & health
facilities are not encouraging in most of the villages. There is well established
road connection.
4.5 Climatic data from secondary sources
Raipur has a tropical wet and dry climate, temperatures remain moderate
throughout the year, except from March to June, which can be extremely hot. The
temperature in April–May sometimes rises above 48 °C (118 °F).These summer
months also have dry and hot winds. In summers, the temperature can also go up
to 50 °C. The city receives about 1,300 millimetres (51 in) of rain, mostly in the
monsoon season from late June to early October. Winters last from November to
January and are mild, although lows can fall to 5 °C (41 °F).
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Chapter – 5: Planning Brief
5.1 Planning Concept
API Ispat & Powertech Pvt. Ltd. is existing steel plant at Siltara village, near Phase
– II, Siltara Industrial Area, Tehsil and District: Raipur, Chhattisgarh. Now as a part
of expansion, APIIPPL is planning to enhance the capacity of Induction Furnace,
Rolling Mill and establish new unit of Pellet plant, EAF and Ferro alloys
5.2 Population Projection
The project will be providing direct employment to nearly 100 workers. The local
persons will be given preference in employment as per the qualification and
technical competencies. Necessary training will be given to train the unemployed
youths of the nearby villages as per the qualification and technical competencies.
Indirect employment opportunities will be created in the periphery of the project
automatically as the project started operation in the region. In order to
operate and maintain the plant facilities, including its technical general
administration needs, the manpower for the proposed expansion will be 100.
The above manpower covers the top management, middle and junior level
executives and other supporting staff including workforce.
5.3 Land use Planning
APPIIPL is an existing plant. Land is converted for Industrial purpose. 97.75 acres
of land is in possession of management and proposed expansion will be taken up
in the existing plant premises.
5.4 Amenities / Facilities
Facilities like canteen, rest room and indoor games facilities has already been
provided in the existing plant as basic facilities to workers. No other additional
facilities are proposed.
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Chapter – 6: Proposed Infrastructure
6.1 Industrial Area (processing Area)
The main plant area comprises of iron ore handling area, storage area, crushing
sizing area, iron ore beneficiation unit etc.
The major equipment and facilities envisaged for the pelletizing plant are
described below
The pelletizing plant will mainly consist of the following sections:
Storage and handling of iron ore fines
Storage, handling and preparation of binder and additive
Iron ore improvement
Proportioning and mixing
Balling, in duration and cooling
Finished product storage
6.2 Residential Area (non Processing Area)
No colonization is proposed; however facilities like canteen, rest room and indoor
games facilities will be provided in the proposed plant and one Admin building is
also proposed.
6.3 Green Belt
More than 1/3rd
of total land available is reserved for plantation i.e. greenery.
Greenbelt development plan
Local DFO will be consulted in developing the green belt.
Greenbelt of 33% of the area will be developed in the plant premises as
per CPCB guidelines.
15 m wide greenbelt is being maintained all around the plant.
The tree species to be selected for the plantation are pollutant tolerant,
fast growing, wind firm, deep rooted. A three tier plantation is proposed
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comprising of an outer most belt of taller trees which will act as barrier,
middle core acting as air cleaner and the innermost core which may be
termed as absorptive layer consisting of trees which are known to be
particularly tolerant to pollutants.
6.4 Social Infrastructure
Social infrastructure will be developed as per need based in the Villages of the
close vicinity of the project.
6.5 Connectiv ity:
The proposed site is well connected with Road – Rail network. The following
table gives brief regarding connectivity of the proposed site:
Component Description
Road = NH – 200 = 2.4 km Rail = Nearest station – 7.3 km (Mandhar RS) Mumbai-Howrah mail line
Air = Raipur Air Port – 23 Kms.
Sea Port = Vishakapatanam – 505 Kms.
The location has a big advantage in its closed proximate to its market.
Traditionally, iron manufacturing units have tendered to cluster in the eastern
zone of India namely in the state of Jharkhand, Orissa and Chhattisgarh because
of easy availability of major raw input iron-ore and coal. Infrastructural and
other utility services are easily available.
Skilled and un-skilled laborers are also available easily.
6.6 Drinking Water Management
It is estimated that 20 KLD of water will be required for domestic purpose during
operation of expansion project.
6.7 Sewerage System
Domestic effluent collected through toilet blocks and other areas will be collected
through well designed sewer network and send to Septic tanks followed by soak
pits. No effluent will be left-out after Soak pits.
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6.8 Industrial Waste Management
Closed circuit system will be adopted in the proposed expansion project. Hence
zero effluent discharge will be maintained. Only waste water generated will be
sanitary waste water, which will be treated in septic tank followed by soak pit.
6.9 Solid waste Management & its Disposal Sr.
No.
Type of Solid waste Quantity
(in TPD)
Disposal Proposed
1. Ash / Dust generated
from Pellet plant
= 27 Will be recycled in pellet making
process. 2. Tar generated from
Producer gas plant = 2 Will be given to coal tar distillation
units
3. Slag from SMS = 90 Slag generated from SMS will be given to slag crushing units.
4. Mill scales from Rolling mill
= 50 Reused in SMS
5. Slag from Fe-Mn = 100 To be reused in manufacture of Silico Manganese as it contains high MnO2 and Silicon
6. Slag from Fe-Si = 13 To be used in cast iron foundries.
7. Slag from Si-Mn = 103 To be used for road construction / slag cement manufacture
6.10 Power Requirement & Its Source
Power required for the proposed project will be sourced from captive and nearby
grid.
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Chapter – 7: Rehabilitation & Resettlement (R & R) Plan
No rehabilitation and resettlement is required as there are no habitations in the
existing plant site.
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Chapter – 8: Project Schedule & Cost Estimates
8.1 Project Schedule
The plant will be implemented in 18 months from the date of receipt of
Environmental Clearance from the Hon’ble MoEF & NOC from CECB.
8.1 Project Cost
The estimated cost for the proposed expansion project will be Rs.240 crores.
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Chapter – 9: Analysis of Proposal
9.1 Financial and Social Benefits
With the implementation of the proposed project, the socio-economic status of
the local people will improve substantially. The land rates in the area will improve
in the nearby areas due to the proposed activity. This will help in upliftment of
the social status of the people in the area. Educational institutions will also come-
up and will lead to improvement of educational status of the people in the area.
Primary health centre will also be developed by us and the medical facilities will
certainly improve due to the proposed project.
9.2 Socio-economic Dev elopmental Activ ities
The management is committed to uplift the standards of living of the villagers by
undertaking following activities / responsibilities as the part of Corporate Social
Responsibility.
Health & hygiene
Drinking water Education for poor Village roads Lighting
Health & Hygine
Personal and domestic hygiene, Maintaining clean neighborhood, Weekly health camps offering free-check up & medicines Ambulance services
Education & drug de-addiction, aids.
Drinking Water
Making drinking water available at centralized locations in the village,
Supporting Education
Providing books to all poor children, Conducting annual sports festival in the village schools, Providing amenities like fans, lavatories, Maintain play ground etc.
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