DEC 2018 JOURNAL - steelscenario.com€¦ · Sumit Roy Gopal Ghosh ... Sameer Kundu Editorial...

DECEMBER 2018

C O N T E N T S VOL 28/M05

SECTION : SEMINAR PAPER

Steel-concrete Composite Construction& Life Cycle Costing - Debashish Dutta 1

Visakhapatnam Metropolitan Region Development Authority (VMRDA) - P. Basanth Kumar IAS 8

The views and data given by the authors are their own and Steel Scenario Journal is not responsible for their authenticity

Printed and Published by Ms. Sakuntala C.Chanda on behalf of Spark Steel & Economy Research Centre (P) Ltd.

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DATA BANK 43

SECTION : ARTICLE

Processes Routes for HRC Production - Sanat Bhaumik 32

Iron Ore Beneficiation - P. S. Bhattacharya 39

Pelletization - P. S. Bhattacharya 41

EDITOR’S NOTE

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Steel Structures – Satyajit Mohapatra 17

Steel Structures

Advantages of steel structures in Civil infra structures – Abhai Sinha 24

Usage of Steel in Mass Transit Systems - K K Rao 25

GLIMPSES OF “WHY STEEL?” SEMINAR AT VISAKHAPATNAM, 2018

2019 will change the momentum for Steel Industry

With minimal new steel capacity expected to be commissioned until 2021 in India, robust

steel demand -- especially from the construction, infrastructure and automotive sectors --

will keep end-product prices high, even as rising costs for key inputs, coking coal and iron

ore profitability. It appears that the expectation of a prolonged turnaround in the global

steel market fuelled by consumption growth, higher levels of production and capacity

utilisation and rising steel prices has been cut short and the happenings in the next few

months on which there is a great deal of uncertainty would determine the fate of the steel

industry for 2019 and beyond that.

Meanwhile, India's steel sector consolidation will drive improvement in the industry’s

capacity utilisation levels and mute the pressure on profitability. India will be the brightest

spot for the steel sector over the next 12-18 months, according to Moody's Investors Service. The first half of the calendar

year 2019 will be a strong period for the steel industry globally, said TV Narendran, managing director of Tata Steel. He

also added that apart from some concern on trade flows, the fundamentals are strong and growing in China, India, US and

Europe is good.

Asian steel demand will remain steady over the next 12 months to June 2019, because solid growth in 2018 will offset a

likely softening in 2019. Demand in the ASEAN region is expected to resume its growth momentum backed by

infrastructure programmes in 2019 and onwards. Risks are largely related to rising trade tensions between the US and

China, currency volatility and political instability. India has already committed US$94 b to infrastructure up to 2020,

which will see robust steel production and usage growth rates.

Throughout 2019, Steel Scenario Journal will regularly cover various topics connected to steel awareness among end

users, case studies of steel usage in numerous projects connected to infrastructure, housing, roads, mass transit systems,

etc. We start our editorial calendar with a focus on various Public Enterprises which has played an important role in giving

India its due momentum inspite of major economic crises and change in economic policies intermittently by various

ruling governments. As we acknowledge the contribution of Public Sector Undertakings we cannot overlook the

contribution by various Private Enterprises who have to lead the country to greate heights and gave India a recognition in

the global development map.

2019 will remain a year of great expectations from all domains of the industrial sectors and steel will not be an exception.

After a long dwelling crisis that was chocking the industry, by and large, this is the year to turn around and look forward.

Let the whole fraternity come together to bring this major change in the mind set of users which is the only way of

bringing the significant change in steel consumption in India.

DECEMBER 2018

EDITOR’S NOTE

“Steel is the Future Metal” - the outcome of WHY STEEL? Seminar in Visakhapatnam

Steel Scenario Journal in support of Ministry of Steel

completed its 2nd Seminar on WHY STEEL in

Visakhapatnam on 12th December. The Seminar was

well attended from the user segment who are main

users of the steel industry. Various departments from

urban development, municipal corporation, Smart City,

Panchayati Raj, architects, NHAI, builders from Indian

Building Congress, CREDAI, Airport Authority and town

planning were all present in the Seminar to discuss

various pertinent issues concerning steel usage in their

various projects.

Though the users understood the requirement to use steel in more quantity in various projects, they have

major challenges in terms of cost of the project going up, difficulties in finding the adequate quantity and

quality of steel for various projects. President of Indian Building Congress Shri Abhai Sinha spoke about the

requirement to use more of steel in various building projects and WHY STEEL should be used and should be

the future metal for building construction.

The Seminar started with a Keynote Address by Shri Debashish Dutta from INSDAG who spoke about “Steel

Concrete Composite Building & LCA”. He emphasized on the solution for the building industry through Steel-

Concrete Composite. This is applicable not only to rural houses but also in urban houses for a cost-effective way

of building sustainable houses.

The Seminar was divided into another three Sessions, “Usage of Steel in Infrastructure, Usage of Steel in Urban

& Rural Houses and Usage of Steel in Public Utilities & Mass Transit System”. The Session had very senior

representatives from various segments as well as steel producers who deliberated on various projects

happening under their departments and the requirement of steel for these projects. Shri P Basant Kumar,

Commissioner VMRDA gave a detailed presentation of the various projects that are in pipeline and the steel

museum they have constructed in record time with steel replacing concrete. During the Seminar Session

discussion, Airport Authority Director Shri G Prakash Reddy, requested steel producers to submit a quotation

and time frame for a three-tier car park project for the Visakhapatnam Airport.

The outcome of the Seminar was very impressive with many user segment organisations and state government

departments requesting steel producers to come for further discussions to be part of the projects in the state.

It is in-evident, that the mission of WHY STEEL was achieved to a great extent in this Seminar.

Sakuntala, Editor - Steel Scenario

DECEMBER 2018

Prashant Mishra, NHAI

Niranjan Reddy, Panchayat Raj & Rural Dev.

Debashish Dutta, INSDAG

A. Prabhu, SAIL

Satyajit Mohapatra, Essar Steel

P. Murali Krishna , R&B Circle, Vizag

K. V. L. Sreeram, Amaravati City Dev. Corp.

P. Basanth Kumar, VMRDA

GLIMPSES OF “WHY STEEL?”

Pradeep Mittal, Indian Building Congress

Abhai Sinha, Indian Congress

Building

P. Koteswara Rao, CREDAI, Vizag

Ar. Y. Narasimha Rao, IIA - Vizag

G. Prakash Reddy, Airport Authority of India

Col. Harsha, Smart City - Vizag

K.K. Rao, Vizag Profiles

K. V. L. Sreeram, Ama

Corp.

ravati City Dev.

SEMINAR AT VISAKHAPATNAM, 2018

DECEMBER 2018

• India transforming from developing to developed country

• Upsurge in construction activities

• Recent statistical studies show Indian subcontinent and Far East becoming more vulnerable to natural hazards

• Proper selection of technology helps building our nation with more sustainable & durable construction & structures could withstand natural calamities

• Popular method of selection followed abroad Life Cycle Cost Analysis (LCCA)

• From value of LCC, function of construction w.r.t. strength, durability, longevity, disaster resistance etc. i.e. Life Expectancy could be well assessed

• From LCCA, Scientific evaluation of different proposals would be easier

• LCCA may indicate lesser LCC even when direct construction cost is more

• If fast track technology, Steel-Concrete composite methodology adopted, due to the lesser construction period, the saving in interest burden on borrowed capital & early generation of revenue also reduces Net Construction Cost, also LCC

• Life Cycle Management is required to ensure Sustainable Growth, Hollistic Development and upgradation towards more scientific living

Steel-concrete Composite Construction& Life Cycle Costing

by - Debashish Dutta, Assistant General Manager, INSDAG

Section : SEMINAR PAPER

1DECEMBER 2018

• Steel-Concrete composite construction more resistant ADVANTAGES OF STEEL-CONCRETE COMPOSITE against accidental loadsCONSTRUCTION

• Composite sections have higher stiffness compared to only • Effective utilisation of materials viz. concrete in compression

steel construction and hence experience lesser deflection and steel in tensionthan the non-composite steel sections

• High ductility of steel leads to better seismic resistance of the composite section

• Large column free area. More usable space. Area of composite column < area of RCC column

The study extends further to compare 7 options – one with • Faster construction by rolled / pre-fabricated components, conventional RCC with brick walls and the six (6) others with quicker return on the invested capitalsteel-concrete Composite options having variations in storey • Quality of steel assured since produced under QAP in factory. height and type of cladding material including conventional Hence, more use of steel ensures better quality control bricks and lighter cladding materials• Cost effective, based on LCCA since steel structures can be

maintained easily and less frequent repairs required for steel structure

• Steel is more durable, highly recyclable and hence environment friendly

• For same span/loading, smaller sections reqd compared to non-composite construction

• Reduction in overall weight of the composite structure, lesser foundation costs

• Cost of formwork is lower compared to RCC construction

• Cost of handling & transportation less because major part is fabricated in workshop

INSDAG’s study of LCC on a (B+G+20) storeyed residential

building with both RCC and Steel-Concrete Composite options

Done in 2003 & updated in 2011 (Applicable Kolkata rates)

Some examples on buildings have been worked out

considering Direct Construction Costs of different proposals.

For item rates of repair and maintenance and weightage

thereof IS 13174 – Part 1 & 2 (Annex C & D) and DSR 2007 with

Cost Index referred. For assessment of LCC Table 10 of IS 13174

(Part 2): 1994 followed. Reference made to various aspects as

stipulated in the US Code ASTM E 917

Though Steel construction is costlier than RCC structure,

outcome of the study shows that Steel-Concrete Composite

construction give encouraging results even in direct

construction cost & in LCC

Series 1 : For sales price of Rs. 2500/- per sq. ft. and rental charge of Rs. 10/-per sq. ft.

OPTION NO. 1 2 3 4 5 6 7

FRAME TYPE RCC COMP COMP COMP COMP COMP COMP

FL TO FL HT (M) 3.15 3 2.85 2.85 2.85 2.85 3

B+G+ 20 20 21 20 20 21 20

CLADDING TYPE BRICK BRICK BRICK BRICK M2 M2 M2

DIRECT CONSTRUCTION COST 22.540 20.450 20.820 19.850 18.350 19.180 18.710

(Rs. in Crores)

TOTAL SQ. FT. 161500 161500 169182.6 161500 161500 169182.6 161500

COST PER SQ. FT. 1396.00 1266.00 1230.00 1229.00 1136.00 1134.00 1159.00

BREAK-UPS OF COST VARIATIONS

[MAJOR VARYING ITEMS - % CHEAPER

FRAMING 0 17.23 12.79 17.83 17.87 13.69 18.33

CLADDING 0 -7.40 -3.05 1.15 23.29 20.19 17.54

FOUNDATION 0 18.02 15.32 18.02 24.92 20.34 21.80

:- OTHER ITEMS VARY NEGLIGIBLY]

OVERALL COST COMPARISON

% CHEAPER THAN OPTION NO. 1 0 9.27 7.63 11.93 18.59 14.91 16.99

OF DIRECT CONSTRUCTION COST

IDC @ 11.75% (1.5 YRS.) 4.087 3.708 3.775 3.599 3.327 3.478 3.393

(Rs. in Crores)

RENTAL EARNING (Rs. in Crores) 0.00 1.29 1.35 1.29 1.29 1.35 1.29

(Rs. 10 per sq. ft.)

[CONSIDERING 8 MONTHS SAVING

BY COMPOSITE CONSTRUCTION]

NET COST(Rs. in Crores) 26.627 22.866 23.242 22.157 20.385 21.304 20.811

TOTAL RENTAL EARNING / YEAR 1.938 1.938 2.030 1.938 1.938 2.030 1.938

(Rs. in Crores)(Rs. 10 per sq. ft.)

Y.P. [PAYBACK PERIOD] 13.74 11.80 11.45 11.43 10.52 10.49 10.74

DECEMBER 20182


From the above Table Comparison in Direct Construction Cost reveals:-

• The cost of RCC building is 22.50 Crores having a covered area of 1,61,500 sq.ft.

• The storey height of RCC building is 3.15 m to accommodate the designed beam conforming to the Municipal by laws

• The Steel-Concrete Composite Option with brick wall storey height 3m is 9.27% cheaper than the RCC option with brick wall

• The Composite Option with brick wall of storey height of 2.85 m and an additional floor, costs 7.63% cheaper than RCC options

• Composite Options with brick wall and storey height of 2.85 m, costs 11.93% cheaper than RCC Option

• Composite option with lighter cladding material (M2 Panel, Aerocon Block, Gyperete etc) and storey height of 2.85 m, costs 18.59% cheaper than RCC

• Composite option with lighter cladding material and storey height of 2.85m and one additional floor, costs 14.91%cheaper than RCC

• Composite option with lighter cladding material and storey height of 3.0 m, costs 16.99%cheaper than RCC

Comparison of total Direct Cost for RCC & Composite Options

Net Cost = Direct Construction Cost + IDC - Rental charges over the saved period of construction time

An apartment area is categorized as under:

• Carpet Area - Apartment clear area only

• Covered Area - Apartment area including wall

• Super-built up Area - Apartment covered area

+ undivided (apportioned) share of land

+ Amenities + Facilities

•

•

•

• For worst case, it is considered that over period of saved construction time the building is rented out instead of selling it out at an early date

For IDC an interest rate of 11.75% has been considered because the promoter / developer is supposed to borrow money at an interest rate as minimum equal to the Prime lending rate (PLR) of the commercial bank, which was at time of study about 12%

A possible reduction in PLR is considered (11.75%)

IDC over period of construction is considered on average basis because lending organizations disburse loan in stages

Super Built-up Area

97.1

129.5136.6 136.9

157.5 158.1152.2

65.6

90.7 96.4 96.7

113.6 114.1 109.3

41.9

61.6 66.5 66.780.8 81.2 77.2

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

160.0

180.0

1 2 3 4 5 6 7Various Options

Chart 4 : Showing profit % for various options with 30% superbuilt-up area

Series 1

Series 2

% o

f P

rofi

t

74.4

103.1109.3 109.6

127.8 128.3 123.1

46.5

68.7 73.8 74.0

88.9 89.4 85.1

25.6

43.0 47.3 47.459.9 60.3 56.7

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0


Chart 2 : Showing profit % for various options with 15% superbuilt-up area

Series 1

Series 2

% o

f P

rofi

t

51.6

76.682.0 82.2

98.1 98.594.0

27.4

46.751.1 51.3

64.3 64.7 61.0

9.2

24.3 28.0 28.2

39.1 39.4 36.3

0.0

20.0

40.0

60.0

80.0

100.0

120.0

1 2 3 4 5 6 7

Various Options

Chart 1 : Showing profit % for various options without superbuilt -up area

Series 1

Series 2

% o

f P

rofi

t

82.0

111.9118.4 118.7

137.7 138.2132.8

52.8

76.081.3 81.6

97.1 97.6 93.2

31.0

49.2 53.7 53.866.9 67.3 63.6

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

160.0


Chart 3 : Showing profit % for various options with 20% superbuilt - up area

Series 1

Series 2

% o

f P

rofi

t

0

5

10

15

20

25

30

12 21 65 125

TOTAL HEIGHT (M) OF BUILDING

Series1

Series2

Series 1: RCC OptionsSeries 2: Composite Options

Series 1 : For sales price Rs. 2500/- per sq. ft. and rental charge Rs. 10/-per sq. ft.Series 2 : For sales price Rs. 2100/- per sq. ft. and rental charge Rs. 8/-per sq. ft.Series 3 : For sales price Rs. 1800/- per sq. ft. and rental charge Rs. 6/-per sq. ft.


3DECEMBER 2018

Life Cycle Cost (LCC) includes:-

TABLE 5UNIFORM PRESENT WORTH FACTORS (upwf) WITH RESPECTIVE DISCOUNT RATE AND SPECIFIED NUMBER OF YEARS

NK (1 – K ) 1 upwf = -------------------- where K = --------------------

(1 – K) (1 + 0.01 x DR)

• Repairs (occasional ) cost & Maintenance (regular) cost

required to make the Structure operational till its Life

Expectancy

• In this study assumed 80% of present Net Construction Cost

is spent in future for maintenance & minor repairs over

expected life of building

• 20% of the present Net Construction Cost is spent at every th10 year as major repair cost over same period

• Considered Straight-line method of Depreciation

• Cost for a new building replacement to make budget for a

Sinking Fund

• Residual value at the end of the study period

• 2 study periods considered - 80 yrs & 100 yrs the - life

expectancy of RCC structure is about 70 years and for

Steel-Concrete Composite Options it is about 100 years

Present Worth (PW) Method or Net Present

Value (NPV) Method has been adopted

In this method all direct expenses incurred at beginning of

project and at different times over life of project are discounted

to present value at base year of life cycle cost study & added

together to arrive at the Net Present Value of a project

alternative

If ‘S’ is the cost incurred in a project at ‘t’th year then with a

discounting factor of ‘i’ the present value of that future cost

will be given by

= Present Worth Factor (pwf)( As per IS 13174 (Part 2): 1994 Annex A or Table 4)

TABLE 4

PRESENT WORTH FACTORS (pwf) WITH RESPECTIVE DISCOUNT RATE AND SPECIFIED NUMBER OF YEARS

1pwf = ------------------------------

N (1 + 0.01 x DR)

•

• 2 tables preferred with 5.5% and 10% discounting rates for

each 80 years and 100 years of study periods

CPI (this year) – CPI (last year)

Rate of Inflation of consumer prices (%) =------------------------------------------- x

100

CPI (last year)

IS 13174 (Part 2): 1994 suggested 2 methods for assessing Life

Cycle Cost (LCC):-

1. Present Worth Method (PW)

2. Annualised Cost Method (AC)

Rate of Inflation on book 5.5% whereas market inflation at

actual is assessed to be 10%

In the Present Worth Method the initial investment and all the

future expenses incurred to keep the asset functioning are

converted to the present value whereas the Annualised Cost

Method ammortises all costs over the life of the item or

project. Arithmetically both the methods are identical

In INSDAG study

St P = ------------ where 1 / (1+i)

t (1+i)

Series 1: RCC OptionsSeries 2: Composite Options

Year (N) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

8 3.99 4.62 5.21 5.75 6.25 6.71 7.14 7.54 7.9 8.24 8.56 8.85 9.12 9.37 9.6 9.82

9 3.89 4.49 5.03 5.54 6 6.42 6.81 7.16 7.49 7.79 8.06 8.31 8.54 8.76 8.95 9.13

10 3.79 4.36 4.87 5.34 5.76 6.15 6.5 6.81 7.1 7.37 7.61 7.82 8.02 8.2 8.37 8.51

11 3.7 4.23 4.71 5.15 5.54 5.89 6.21 6.49 6.75 6.98 7.19 7.38 7.55 7.7 7.84 7.96

12 3.61 4.11 4.56 4.97 5.33 5.65 5.94 6.19 6.42 6.63 6.81 6.97 7.12 7.25 7.37 7.47

13 3.52 4 4.42 4.8 5.13 5.43 5.69 5.92 6.12 6.3 6.46 6.6 6.73 6.84 6.94 7.03

14 3.43 3.89 4.29 4.64 4.95 5.22 5.45 5.66 5.84 6 6.14 6.27 6.37 6.47 6.55 6.62

15 3.35 3.78 4.16 4.49 4.77 5.02 5.23 5.42 5.58 5.72 5.85 5.95 6.05 6.13 6.2 6.26

16 3.27 3.69 4.04 4.34 4.61 4.83 5.03 5.2 5.34 5.47 5.58 5.67 5.75 5.82 5.88 5.93

Discount Rate (%) (DR)

Year (N) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

8 0.68 0.63 0.58 0.54 0.5 0.46 0.43 0.4 0.37 0.34 0.32 0.29 0.27 0.25 0.23 0.22

9 0.65 0.6 0.55 0.5 0.46 0.42 0.39 0.36 0.33 0.3 0.28 0.25 0.23 0.21 0.19 0.18

10 0.62 0.56 0.51 0.47 0.42 0.39 0.35 0.32 0.29 0.26 0.24 0.22 0.2 0.18 0.16 0.15

11 0.59 0.54 0.48 0.43 0.39 0.35 0.32 0.29 0.26 0.23 0.21 0.19 0.17 0.15 0.14 0.12

12 0.57 0.51 0.45 0.4 0.36 0.32 0.29 0.26 0.23 0.21 0.18 0.16 0.15 0.13 0.12 0.1

13 0.54 0.48 0.43 0.38 0.33 0.3 0.26 0.23 0.2 0.18 0.16 0.14 0.13 0.11 0.1 0.09

14 0.52 0.46 0.4 0.35 0.31 0.27 0.24 0.21 0.18 0.16 0.14 0.12 0.11 0.1 0.08 0.07

15 0.5 0.43 0.38 0.33 0.28 0.25 0.22 0.19 0.16 0.14 0.12 0.11 0.09 0.08 0.07 0.06

16 0.48 0.41 0.35 0.31 0.26 0.23 0.2 0.17 0.15 0.13 0.11 0.09 0.08 0.07 0.06 0.05

Discount Rate (%) (DR)

DECEMBER 20184


LCC Summary Tables for 100 years @ 12%

Series 1 : LCCA Study Period 30 Yrs. Rate of Inflation 8%




SOME LIVE EXAMPLES OF STEEL-CONCRETE COMPOSITE BUILDINGS DESIGNED BY INSDAG

HANDLOOM HOUSE (2005)

COMMERCIAL CENTRE OF PRABHAT GROUP At Borivali, Mumbai

• Client – CPWD (Nomination basis)

• Site Location – Janpath New Delhi

Total Structural Steel consumed about 1400 Tonnes

Reinforcements consumed about 700 Tonnes

0.000

5.000

10.000

15.000

20.000

25.000

30.000

1 2 3 4 5 6 7

Series1

Series 3

0.000

5.000

10.000

15.000

20.000

25.000

30.000

25.940 22.610 23.019 21.946 20.288 21.205 20.686

Series1

Series2

Series3

Series4

100 YEARS

12 %

SL

.N

O.

OP

TIO

N

TO

TA

LC

ON

ST

RU

CT

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CO

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(RS

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12%

PE

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12%

PE

RA

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UM

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LN

PV

(RS

.IN

CR

OR

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)

CH

EA

PE

RB

Y%

1 RCC 22.54 70 0.322 0.258 2.147 0.644 0.306 24.99 0

2 COMP 1 20.45 100 0.205 0.164 1.363 0.409 0.194 22.01 11.94

3 COMP 2 20.82 100 0.208 0.167 1.388 0.416 0.198 22.41 10.35

4 COMP 3 19.85 100 0.199 0.159 1.323 0.397 0.189 21.36 14.53

5 COMP 4 18.35 100 0.184 0.147 1.223 0.367 0.174 19.75 20.99

6 COMP 5 19.18 100 0.192 0.153 1.279 0.384 0.182 20.64 17.41

7 COMP 6 18.71 100 0.187 0.15 1.247 0.374 0.178 20.14 19.44

FOR A YEAR OF

DISCOUNT RATE


5DECEMBER 2018

INDIRA PARIYABARAN BHAWAN, NEW DELHI (2010)

• Client – CPWD (Nomination basis)• Site Location – Jorbagh, New Delhi

Total Structural Steel consumed about 645 TonnesProfiled Deck Sheet consumed about 3192 sq m

Guest House-cum-Marriage Hall at Howly, Assam

Data Centre Office Building at Shillong, Meghalaya

DECEMBER 20186


• As thumb rule, 1 tonne of CO2 emitted to produce 1 the investment of public / private money

tonne of Concrete; 1.8 tonnes of CO2 evolved to produce • LCCA will help policy makers to take decisions with due 1 tonne of Steel consideration of Cost Benefit Ratio of projects

• Over last 50 years, Steel industry could reduce its energy • Environment aspects of sustainability is also ensured by this consumption per tonne produced by 60% methodology

• Through “Climate Action Recognition Programme” of WSA,

expected to reduce more• B+G+20 Storeyed Residential Building with Steel-Concrete

• Improvised carbon capture technology, in nascent stage, Composite Option – published by Institute for Steel

reduce carbon footprints in climate in futureDevelopment & Growth (INSDAG), 2003, edited D. Datta and

• For High strength-to-weight ratio, small Steel could replace G. Chakrabortylarge Concrete to withstand typical loading condition.

• Multistoreyed Residential Building (B+G+20) with Steel-Hence, comparative sustainability is achieved by use of

Concrete Composite Construction – published by Institute more Steel in Structures

for Steel Development & Growth (INSDAG), 2010, edited D. • Use of Steel ensures Reduce, Reuse & Recycle of material, Datta

supports sustainable development • Life Cycle Cost Analysis of Buildings – published by Institute

Technologies are required to be developed not only to give the for Steel Development & Growth (INSDAG), 2010, edited D. immediate economic and strength impact but also to offer Dattarational and responsible choices with respect to life cycle costs

• Sustainability of steel in transition to a low carbon economy, and the long-term environmental effects on the community to

edited D Dattaensure sustainable development

• Lawson R M “Composite Structure Cost of Modern

Commercial Buildings”, SCI Publication, 1993.• Through LCCA proper comparison of invested sum would be

• Bandyopadhyay T K, “Basic Concepts in Composite easily assessedStructures”, Refresher Course on Composite Construction

using Structural Steel, 17-21 January 2000, organized by

• It is desirable that the concerned authorities of Government Institute for Steel Development & Growth (INSDAG) and / Private sectors ask contractors to submit the LCCA of their Jadavpur University, Kolkataproposals because the least bidder with respect to Direct

• Finance Management by I M PandeyConstruction Cost may not necessarily be the least bidder

with respect is the Life Cycle Cost

• Today’s extra expenditure may save future expenditures,

thereby an overall benefit could be achieved with respect to

References:-

CONCLUSIONS:-

Net Value = L1 Price + Life Cycle Cost


7DECEMBER 2018

VMRDA PROFILE

Promote & secure planned development

PROJECTS

FUNCTIONS OF VMRDA

Ø Plan - Preparation of Visakhapatnam Metropolitan Region Development Plan

Ø VMRDA is Constituted under the Andhra Pradesh Ø Metropolitan Region and Urban Development

Authorities Act, 2016 (Act No. 5 of 2016) on 05-09-2018.

Ø Co-ordinate with line departments - give directions to Ø Declared the ‘Development Area’ for Visakhapatnam other departments, whereas VUDA is an Metropolitan Region to an extent of 6501.65 Sq. Kms.independent agency and planning apex body.

Ø The VMRDA will be governed under the monitoring Ø of the VMRDA Board and the Executive Committee.

Ø ImplementØ Management and administration of the affairs of the Authority shall vest in the Executive Committee. Ø

Ø The full board of the Metropolitan Region Ø Develop high quality infrastructure.Development Authority is yet to be constituted to

Ø guide and steer the development of the Metro Region. The orders appointing Chairperson officers dealing with Transportation, R&B, Energy, Environment and experts in the areas of Urban Governance / Planning, Conservation, Environment and Transportation as members are yet to be issued.

Ø As per Section 5, the Apex Policy Body is vested with the following functions encompassing all spheres of development including economic development

Development Control - to monitor progress of development in Visakhapatnam as per its Metropolitan Region Development Plan

Monitor/Supervise

VMRDA undertakes investment plan in addition to infrastructure and land use plan where as VUDA undertakes only land use plans

Visakhapatnam Metropolitan Region Development Authority (VMRDA)

COST

Ongoing Project -Rs.150 Cr

Proposed Projects Rs.1190.00 Cr

Commercial Complexes/ Auditoriums / Kalyanamandapams Rs.33.09 Cr.

Markets / Rythu Bazars Rs.7.32 Cr.

Sports Complexes Rs.6.00 Cr.

Other Development works Rs.5.74 Cr.

Total Rs.1568.42 Cr.

by - P. Basanth Kumar IAS, Metropolitan Commissioner

DECEMBER 20188


On Going Projects: Construction of Flyover at NAD Junction,

Visakhapatnam

Construction of Flyover at NAD Junction, Visakhapatnam

Construction of Flyover at NAD Junction,

Visakhapatnam

Purpose: To overcome the Traffic problems with

sustainable urban junction solution for a seamless

Pedestrian and Vehicular movement, at the

Intersection

Ü Estimate Cost: Rs.150.00 Crores.

Ü Tender Approval : G.O Rt No. 699 MA&UD (H2) Dept

dated: 06-10-2017.

Ü N a m e o f t h e

Contractor : M/s

V i j a y N i r m a n

Company Pvt Ltd.,

Visakhapatnam

Ü Agt No. & Date:

09/2017-18 dated:

18.11.2017

Ü Agt Amount: Rs.

113, 60,82,310/-

Ü Date of Completion

: 17.11.2019

Ü Proposed to construct Multi Level Rotary’s separately

for LMV’s, HMV’s and Pedestrians.

Status:

Ü The Contracting Agency is constructing the arms of the

upper level rotary after making necessary traffic

diversions and barricading the site.

Ü Agency has established Ready Mix concrete plant,

laboratory and casting yard for girders at Vepagunta

Ü The agency has completed 17 foundations and 11 pier

caps out of total 64 piers.

Ü The agency has completed 12% of the work.

Ü Proposals for additional RoB submitted by Railways to

head office at Bhubaneswar in Nov,2018. AIRPORT ARM


9DECEMBER 2018

Construction of Flyover at NAD Junction, Visakhapatnam

1. Development of IT City at Madhurawada

Proposed Projects

Status:

The project is proposed in the vacant VMRDA land at

Madhurawada to promote IT & ITES development in

Visakhapatnam.

Ü Area of land available – 22.12 Acres

Ü Proposed IT & ITES space – 5 Million Sqft

Ü Other developmental activities – Commercial,

Residential, Entertainment etc

Ü MOU signed with IT

Dept, Govt of A.P for

rental guarantee on

26-02-2018.

Ü Mode of development

– Trough Specia l

P u r p o s e Ve h i c l e

(SPV).

Ü Consultant – Andhra Pradesh Urban Infrastructure

Asset Management Ltd (APUIAML)

struction of one tower of 18 floors

along with trunk infrastructure will be invited shortly.

Ü Master plan finalized for the site.

Ü Conceptual design of proposed IT towers are under

finalization.

Ü Cost of the project

about Rs. 1000 Cr.

Ü O r d e r s o n

formation of SPV

VIEDCO issued on

29.10.2018.

Ü RFP for the soil

excavation under

soil monetization mode to form the Roads is invited in

Nov, 2018. The last date was extended from

06.12.2018 to 21.12.2018.

Ü Tenders for con

NSTL ARM

GOPALAPATNAM ARM

MARRIPALEM ARM

DECEMBER 201810


2. Proposed integrated museum & tourism complex

in beach road with underground parking

Proposed to develop an Integrated Naval Museum

together with an underground parking for parking about

700 (4-wheelers) in the Beach Road for the facility of

visitors.

Ü The conceptual designs integrating all facilities like

TU-142, Proposed Sea Harrier with Museum,

Submarine Museum etc., are prepared.

Ü Public opinion is invited for finalization of the best

design as per the directions of the Hon’ble Chief

Minister.

Ü Comments received from the public during meeting

on 09.10.2018 are being considered in the

finalization of the conceptual designs.

Ü Considering various aspects and public opinion

Revised plan prepared deleting under passage.

Ü Public Representatives gave their consent on

24.11.2018 for the Revised plan.

Ü Proposed to take up the renovation of Rajiv Smruthi

Bhavan and Sea Harrier museum in first phase.

Ü Detailed plans prepared in consultation with Navy

officials (INS Hansa, Goa) on 27.11.2018. Estimates

under preperation.

Ü Tentative project cost of Phase – I is about Rs. 10 cr in

the over all project cost of about Rs.80 Crores

Way Forward:


11DECEMBER 2018

3. COMPREHENSIVE DEVELOPMENT OF ‘YARADA HILLS’ WITH STAR HOTELS, RESORTS ETC.

Slope Analysis Ü The site Lies on the ridge of the hill and about 53% of

the site is good for development. VMRDA in possession of 1394 acres at Yarada Hill, aspires for Comprehensive Development with Ü 21% of the site should not be developed and requires special focus on Tourism preservation of slopes.

Ü Promotion of Eco-Tourism, Star Hotels, Resorts, Golf Courses, Botanical Gardens with focus on basic infrastructure development, attracting private investments

Ü Innovative tourism facilities connecting Yarada Beach with other recreational facilities

Ü RFP invited in July 2018 for providing consultancy services for Master plan & Comprehensive Development of Yarada Hills.

Ü The entire assignment is bifurcated in to four activities Viz Master Plan preparation, DPR for the selected mode (PPP/BOQ), Tender evaluations and Agreements etc.

Ü Seven eligible consultants have submit the Technical presentation before the committee on 29.10.2018. The consultants have submitted a broad Master Plan for development of Yarada Hills as per their expertise.

Ü Technical evaluation of the 7 bidders is Completed.

Ü Evaluation of bids completed - LOA to be issued.

Ü Selected Consultant will prepare detailed master plan after detailed analysis of the site.

Ü Some of the concepts suggested by the consultants

are as follows for information.

Developable Zone Area (Acres)

%

No Development 295 21

Moderate Development

353 25

Good for Development

745 53

Total Area 1394 100

BOTANICALGARDEN

ADVENTURE/BIKE TRAILS

HOSPITALITY /HOTELS

CITY CENTRE/ COMMERCIAL

BOTANICALGARDEN

RESORTS/STAR HOTEL

ECO TRAILS / NATURE/ FARMS

GOLFWEEKEND HOMES

VILLAS/WEEKEND HOMES

SPORTS/ PARKS/ RECREATION

AMENITIES FOR VILLAS

ZONING DIAGRAM 1. Golf Course

2. Botanical Garden

3. Club House

4. Wellness Resort

5. Villas / Time Share Apartments

6. Town Center

7. Walking and Biking Trails

8. Eco Cottages

DECEMBER 201812


4. Development of Mudasarlova Park: 5. Restoration & Re-development of 380 Ac

Kailasagiri Hill Park As per the orders of the Govt, VMRDA proposes to

develop the park as international tourist destination in Restoration and Re-Development of 380 Acres of the city. Kailasagiri Hill top park is being taken up by VMRDA

Ü Area to be developed – 20 Acres. under Andhra Pradesh Disaster Recovery Project

(APDRP).Ü Project Cost – Rs.50.00 Crores.

Ü Administrative Sanction: G.O.RT No. 64 Revenue (DM) Ü AP Urban Greening & Dept Dated 04-05- 2016B e a u t i f i c a t i o n

Ü Cost of project : Rs. 40.00 Crores.Corporation Ltd was

requested to finalize Ü Consultant for preparation of DPR and Supervision of the detailed designs works : M/s SAI Consulting Engineers Pvt., Ltd,

and drawings for Ahmedabad

d eve l o p m e nt o f Ü Agt No. & Date: 07/2017-18/CE/ VMRDA Dated: 31-park. 07-2017.

Ü A r c h i t e c t u r a l Ü Agt value: Rs. 3,65,75,500/-consultant – M/s.

Design Accord, New Ü The consultant submitted final conceptual Master Delhi

plan drawings on 30.10.2018. Ü The Hon’ble Chief Minister of A.P has approved the

Ü VMRDA reviewed the proposals on 06.11.2018 and components proposed by the design consultant

suggested certain revisions/improvements.

Ü The World Bank officials reviewed the concept plan on

a. Entrance Plaza, 28.11.2018.

Ü The consultant will submit the final master plan in this b. Adventure walk,

week.c. Heritage walk with shops,Ü Stakeholders meeting is expected to be conducted in

d. Landscaping and fountains, the next week

e. Restaurants, Ü Final DPR will be submitted in Dec’2018.

f. Children’s play area,

g. Amphi theatre,

h. Parking facilities.

Ü The VMRDA Board

meeting held on

10.08.2018 approved the components to be taken up

to an amount of Rs.19.00Crores in this financial year.

Ü Tenders for Gate complex, Signature pavilion etc., are

invited with last date of submission as 14.12.2018.

Status:

Major components:

Status:


13DECEMBER 2018

6. Development of Multi-Level Car Parking

& Instit. complex

Proposed to construct Multi level car parking and

institutional complex with a holistic approach duly taking

the parking requirement of UDYOG BHAVAN, HSBC,

GURAJADA, Children Arena etc.

Ü Area of land available – 1.35 Acres

Ü Consultant: M/s. Andhra Pradesh Urban

Infrastructure Asset Management Ltd.

Ü Master plan prepared with 5 floors parking and 6

floors for commercial use.

Ü Detailed designs and estimates are under progress.

Ü EOI is being invited for taking up the project under

PPP mode parallelly.

Status:

Restoration & Re-development of 380 Ac Kailasagiri Hill Park

# Description

1 Net Plot Area

Parking Area No.of 4W No.of 2W

Basement Floor 1 - Area 52337.20 Sq m 145 -



Stilt Floor - Area 3401.57 Sq m - 792

Floor 1 above Stilt - Area 3197.95 Sq m 75

Total Parking Floors BUA 22611.12 Sq m 510 792

Total ECS achived

Commerical Development Floors Area

Each Typical Floor Area

Total Commercial Development

Floors Area - ( 6 x 2158.60 )

4 Total BUA (Parking + Commercial)

3

2

2158.60 Sq m

12951.60 Sq m

Details

35562.72 Sq m

708

AREA STATEMENT

6288.92 Sq m

DECEMBER 201814


7. Commercial Complexes, Auditoriums & Kalyanamandapams

1. Shops near RTC complex opposite to City Central Park

Ÿ Total Cost : Rs. 235.00 Lakhs

Ÿ No. of shops : 42 No’s(G+1)

Ÿ Each shop size : 9 x 12

2. Commercial Complex at Pitapuram Colony

Ÿ Total Extent : 947.50 Sqm

Ÿ Total Cost : Rs.760.00 Lakhs

Ÿ No. of floors/Total area: G+3 (1847.80sqm)

Ÿ Parking Area : 649.70sqm

3. Commercial Complex at Ramnagar Site-1 & 2

Ÿ Total Extent : Site-1: 2432.30 Sft &

: Site-2: 602.39 Sft

Ÿ Total Cost : Rs.1350.00lakhs

Ÿ Total floor Area(G+3) : Site-1: 2811.24 Sqmt &

: Site-2: 1312.40 Sqmt

Status: Estimate revised as per 2018-19 rates –

Tenders will be invited shortly

4. Kalyanamandapam at Chinmushidivada VMRDA

Layout, Ground floor+ 1st floor, Visakhapatnam

Ÿ Total Extent : 53915 Sft (Ac.1.23 cts)


Ÿ No. of floors : (G+1)

5. Proposed construction of Community Hall /

Kalyanamandapam / Meeting Hall at Thadichetlapalem,

Dharma Nagar, Ward No.35 Visakhapatnam



6. Development of Open Auditorium at Gajuwaka

Ÿ Total Extent : Ac.1.56 cts


7. Construction of Kalyanamadapam for Christian minorities

at Chinagadili Village, Visakhapatnam

Ÿ Total Extent : 575 Sqm


Status: Finishing works in progress – 90% completed.

Status: Work is in progress – 75% Completed.

Status: Work is in progress – 15% completed.

Status: Work is under progress – Plinth beams under progress.

Status: Roof truss under progress.

Status: Foundations under progress.

IN PROGRESS

IN PROGRESS

IN PROGRESS

IN PROGRESS

IN PROGRESS

IN PROGRESS


15DECEMBER 2018

Markets / Rythu Bazars

1. Construction of Modern fish market opposite VMRDA

City central park,Visakhapatnam.


Ÿ No. of floors : (Cellar+silt+2)


Status: About Rs.1.74 crores is deposited by Fisheries department for the project. No Response to the 1st call Tenders - to be recalled.

Sports Complexes

Other Development works

1. Indoor sports complex infrastructure facilities at Z.P.High School

Gopalapatnam



1. Construction of Ground floor and 1st floor building for Fire Station

at Suryabaugh, Visakhapatnam.



2. Construction of RDO Office at Anakapalli.


Ÿ No. of floors : Rs.320.00lakhs

Status: Roof slab completed.

3. Construction of framed structure for school building (G+2) for

shifting of Adarsh Public School at Pedagantyada, Visakhapatnam.

Ÿ Total Extent : 14758 Sqft


Status: Work completed.

Status: 1st floor Brick Masonry work is in progress.

Status: Columns up to plinth level completed and remaining work is in progress.

Existing market

Completed

IN PROGRESS

IN PROGRESS

IN PROGRESS

DECEMBER 201816


India's Steel Sector: Strong Outlook

Overall Steel Consumption by Segment in India

Focus Sectors promising Steel Demand

Steel Structuresby – Satyajit Mohapatra

General Manager –Technical Marketing (Marketing & Sales), Essar Steel

Auto Sector poised to grow from US$ 74 Bn in 2015 to US$ 260-300 Bn in 2026

Anything which is low can only go UP!


17DECEMBER 2018

Infrastructure Investment Drivers

Indian Infrastructure: Powering Ahead

DECEMBER 201818


Demand from India's ever-expanding Highways Why Steel?

Ÿ Over 100,000km of National Highways in India

Ÿ New Road construction Target @41 Kms per day

Ÿ Major demand for Coated steel for usage in Bridges, Crash

Barriers, and for General Engineering

Port Developments

As part of Sagarmala Programme, more than 577 projects (Cost: Rs. 8.57 Lacs Cr.)

have been identified for implementation, during 2015-2035, across the areas of

port modernization & Newport development, port connectivity enhancement,

port-linked industrialization and coastal community development.

As of 31-Mar-2018, a total of 492 projects (costing around Rs. 4.25 Lac Crore)

wereunder various stages of implementation, development and completion.


19DECEMBER 2018

Steel Grades –Product Criticality

Essar's Initiative Defence…Make In India

DECEMBER 201820


Make In India -Supplies to Critical Projects

Make In India-Exports to Prestigious Projects


21DECEMBER 2018

Product Positioning –Essar's Branding Initiative

Essar Steel –SC network

DECEMBER 201822


Why Essar is a preferred supplier ?

Roadmap to achieve 300 Million tons

Ø Dedicated port infrastructure –ease of movement for raw material & finished goods

Ø Raw material security with largest pellet capacity in India

Ø Wide product mix.

Ø Presence across all segments

Ø Express Deliveries –Geographical Advantage.

Ø Customer centric approach


23DECEMBER 2018

NINL Registers Highest Single-day Sinter Production

Odisha's Kalinga Nagar-based Neelachal Ispat Nigam Limited (NINL) set another benchmark in production with highest ever single-

day Sinter output of 5680 ton on 28th December, 2018 surpassing the previous best of 5640 ton recorded in 2013.

Mr. S.S. Mohanty, Vice-Chairman & MD, NINL, congratulated the team and all concerned in and around.

Earlier, Brahmani, the Blast Furnace of the company, registered 110 percent of the rated capacity on 15th December, 2018 with

highest single-day Hot Metal output of 3412 ton.

NINL resumed billet production earlier this month by restarting its state-of-the-art Steel Melting Shop which is the second

milestone, the company has planned for the turnaround of the plant. NINL had achieved the first milestone with the completion of

the Blast Furnace and expects to achieve the third milestone with operation of its captive iron ore mines towards the end of the

present Financial Year. The company has also plans to produce TMT Bars and Wire Rods soon.

Advantages of Steel Structures

Uses

Constructability

Cost Effectiveness

Safety

? No porosity, hence no entry for mold and mildew.

? Offsite fabrication and fast component assembly.? High tensile strength.

? Endlessly recyclable.? High strength per unit mass, so light structure, cost

saving in design of foundation.

? For large span structure, steel sections will be small. ? For Skyscrapers, agriculture buildings and garages.

? Steel frames are with CAD accuracy and offer Arch ? Attractive building options from start to finish- design, planning and design flexibility. Sustainable, Affordable and durable.

? Steel in concrete to offer tensile strength. ? Suitable for hybrid construction works.

? Steel structures are with high strength, stiffness, ? It can be used at any stage of construction framing, toughness and ductile property with integrity. floor joists, roofing materials.

? Most suitable for Industrial and Commercial buildings. ? Steel is cheaper/lighter than wood.

? Most durable and least maintenance cost. ? Faster construction which is high quality controlled, no

scope for human error as projects/sections are factory

finished with less impact on surrounding.? Can Be fabricated into endless variety of shapes

? Saves money, labor, decreased construction time, less ? Faster construction at site due to bolting and welding.

maintenance cost and less repair/replacement cost.? Distribution of compression and tensile forces in beams

? No Construction waste at site.offers Architectural freedom in design of spaces and

? Steel structures are having unrivaled ability to with last-minute changes.stand high speed winds, heavy snow loads, fire and

seismic activities, pests and decay, less insurance cost.

? Due to Standardization, steel structure sections are ? It can be moulded in any shape.easy to erect after fabrication.

? Any roofing pattern with wood-like siding.? Shorter Construction period-less duration of

? It can afford any artistic imagination without disturbance in vicinity.

compromising any inherent property.? Steel prices are dipping continuously and uninterrupted

? Highly energy efficient structure.supply at site.

? Complete sealed buildings.

? Roofing panels can be primed or made cool metal

? Non-Combustible with fire resistant coating. roofing to decrease solar heat gain, which increases

energy efficiency.? Water resistant coating so no corrosion.

Steel StructuresAdvantages of steel structures in Civil infra structures

by – Abhai Sinha, Former D.G, C.P.W.D, National President, IBC

DECEMBER 201824


THE 4 MASS TRANSIT SYSTEMS

STEEL IN SHIPS & PORTS

Usage of Steel in Mass Transit Systems

by - K K Rao, Director, Steel Exchange India Ltd.

Bulk Carrier Ship

Oil tanker ship

Container ship

Passenger ship

SHIPSMeasures for enhancing steel consumption

Encourage river and coastal shipping.

More ships and vessels to be built in India; for international & coastal shipping as well as Navy.

Produce more steel plates of ship hull quality.

Ship internals need normal grade steels too - plates, structurals, pipes and hollow sections.

Encourage installation in ships, of stainless steel tanks, fittings, railings and furniture etc


25DECEMBER 2018

Visakhapatnam Port

Coal berths

Layout of berths

Dredging

GANGAVARAN PORT

PETRONET LNG LTD

PETRONET LNG LTD

DECEMBER 201826


PORTS

Steel used for RCC, berths, buildings, sheds, conveyors, rail lines, roads and parking areas.

Measures for enhancing steel consumption

Berths, buildings, storage sheds and conveyor systems: These are all constructions at site.

Cargo &mobile crane: Purchased/outsourced.

Tugs, boats, vehicles, fire tender: Purchased Replacement of rails, if situation so warrants.

Storage facilities: Open yards and large sheds. Construction of steel shelters in bus stops etc.

Use of steel lighting poles for streets & parks.

Construction of new major and minor ports.

Construction of rail lines to the new ports.

Construction of steel buildings in future ports.

Services: Stevedoring, dredging and transport.

Goods transport: Rail and road (truck/ trailer) Encourage usage of steel- ---------------------------------------------------------------

Coated sheets for roofs and cup boards.

Stainless Steel: Railings, benches, chairs etc.

AIR PLANES AND AIR LINES

STEEL IN PLANES & AIR PORTS


27DECEMBER 2018

Pre-engineered steel buildings be preferred for

aircraft hangers and cargo storage sheds.

AIR PORTS

(Construction - RCC & Steel, SS, Al, PVC, glass,

granite and tiles)

Units: Main building, runway, traffic control tower,

hangers, aero bridges, loading & towing m/c s, fuel

& fire tenders and water &fuel tanks.

Encourage usage of steel –

Sheets for roofing, cupboards /storage devices.

SS: Hand railings, passenger benches, chairs etc.

Start construction of approved new airports.

Main building houses offices, check in counters,

security checks, boarding gates, waiting lounges,

food courts & shops and passenger amenities.

Prefer steel buildings over RCC constructions.

Lattice structure in front enhances appearance.

Lighting, air conditioning, fire detection, lifts,

escalators, baggage scanners, belt conveyors,

display & public address systems are installed.

Roads, parking, public conveniences provided.

Measures for enhancing steel consumption.

Delhi T3 Terminal

Visakhapatnam Airport

AIRPORT STRUCTURES

AIRPORT STRUCTURES

DECEMBER 201828


STEEL IN TRAINS & RAILWAY STATIONS

OUR TRAINS – ON LIGHTER SIDE

Indian Railways Logo Solar Panels on train New model train Advertisements

Secunderabad

Victoria Terminus (VT), then Chennai Central Chapatrapati Sivajji Terminus (CST)

VIJAYAWADA RAILWAY JUNCTION VISAKHAPATNAM RAILWAY STATION


29DECEMBER 2018

RAILWAY STATIONS

Signal cabins, goods shed and misc. buildings.

Construction material: RCC, steel, granite, tiles, wood

and glass.

Measures for enhancing steel consumption

Houses offices of station master, staff; ticket counters,

vending m/cs, RPF, waiting halls & rooms, cloak room

and food court & kiosks etc.

Require more RCC sleepers, steel poles, rails, foot over bridges and

barriers between tracks.

Platforms, stairs, escalators, foot over bridges,

fans, lights, benches, chairs, potable water,

display boards and public address systems.

Country needs more express and goods trains- i.e., more engines,

bogeys and wagons.

Expeditious construction of new railway lines, track doubling and

electrification works.

Approach roads, parking and water tanks etc.

Preference be given for items made of steel –

Coated sheets, cupboards and storage devices.

SS: Hand railings, platform benches, chairs etc.

Use of Galvanized Reinforcement

Reinforcement used in the white concrete shells and also the binding wires was entirely galvanized so as to prevent the long-term effect of rusting. S i n c e g a l v a n i z e d reinforcement for concrete is seldom used in India, several tests were carried out to ensure that the mechanical properties of reinforcement did not become adversely affected due to galvanizing. Sandblast ing done to reduce pickling time and also to avoid hydrogen embrittlement.

Cold Twisted Deformed (CTD) steelbars used for reinforcement.

Prior to galvanizing, bars preheatedto 100 Deg C to drive out moisture.

Lotus Temple, New Delhi Completion - 1986

Steel buildings are better for seismic zones.

They can be constructed faster than your imagination.The 30 storey Arc Hotel , Changsha (CHINA) built in just 15 days!

REINFORCEMENT STEEL High Strength Deformed Bars & Wires

for Concrete Reinforcement

High strength deformed bars and wires

for concrete reinforcement

[IS 1786 - 2008 not specific to any process]

TOR/CTD: Hot rolling followed by cold working.

TMT: Thermo Mechanical Treatment

[Hot rolling of bar/ coil, rapid quenching after

exit stand and tempering on cooling bed]

Micro Alloying: Cr, Mo and V

Strengthening elements: Nb, V,B and Ti

Low alloy steels: Cr, Cu, Ni, Mo and P

DECEMBER 201830


TEMPCORE COOLING

High strength deformed steel bars

Beware!

All steels sold in market may

not meet quality standards.

Be aware of steel application

needs and desired quality

specifications.

Make sure, you get steel of

right quality, right quantity

and in right time.

Insist on manufacturer’s test

certificate, especially when

quantity is reasonably high.

Make cross check, if need be.

Steel Product

Physical Properties

Chemical Properties

Sectional weight

Dimension Tolerances


31DECEMBER 2018

TATA STEEL ADVT

INTRODUCTION

Production of hot rolled steel coils involves hot rolling process

which requires rolling of steel slabs at a high temperature

(typically at a temperature more than 9250C or 17000F), which is

above the re-crystallization temperature of steel. When steel is

heated above re-crystallization temperature, it can be shaped

and formed easily. Hot rolling process uses this property of steel

for production of hot rolled coils.

There are mainly five process routes for production of hot rolled

coils (HRC) and these are:

1. Steckel Mill route,

2. Conventional Hot Strip Mill (HSM) route

3. Thin Slab Casting & Rolling Mill (CSP® or fTSR or QSP) route For the same strip width of 1650mm, a thin slab casting & rolling

4. Endless Strip Production (Arvedi ESP) route andmill (CSP® or fTSR/QSP) will be able to produce 1.4 - 1.5mtpy

5. Direct Strip Casting (DSC, HSBC, BCT, CASTRIP) route with a single casting strand and the production capacity can be

doubled by adding a 2nd casting strand in future. The CSP® Selection of right production process depends on the product

(Compact Strip Plant) or fTSR (Flexible Thin Slab Rolling / QSP mix (strip thicknesses, widths & steel grades), product quality

(Quality Strip Production) route can produce minimum strip and production capacity of the plant.

thickness of 1.2mm on regular basis and is being produced by For example, a 2-stand Steckel mill will be able to produce about

many plants worldwide but some of them are also claiming 0.90 – 1.00 million tons of HRC per year if we consider 1650mm

production of even 1.0mm thickness.maximum width strips. Again, such steckel mills cannot produce

An Arvedi ESP (Endless Strip Production) can produce ultra thin good quality HRC of less than 1.80mm strip thickness on

HRC of 0.80mm thickness and undoubtedly the best technology consistent basis. Even with implementation of latest

available for production of ultra thin HRC on consistent basis automation hardware and software systems, the thickness and

with very good thickness and shape tolerances. However, an flatness tolerances on output HRC from Steckel mills will be

Arvedi ESP will be able to produce maximum 1.5 – 1.6mtpy HRC below market average considering the outputs from other units

for 1650mm maximum width but there is no possibility of any like conventional HSM, CSP®/fTSR/QSP or ESP.

major production capacity expansion of the same plant in Conventional Hot Strip Mill (HSM) can produce minimum strip

future.thickness of 1.2mm but the optimum production capacity will be

With a few pilot plants in operation, Direct Strip Casting (DSC) approximately 3.8 to 4.0mtpy of HRC if we consider 1650mm

technology has probably reached a stage from where it may be maximum width strip. Annual production capacity of less than

feasible process route for HRC production. DSC process consists 2.5mtpy for commercial grade steel will make such plant

of a caster in which liquid steel is fed on an intensively cooled economically unviable.

Hot Rolled Coils at the Delivery Section of a HSM

Processes Routes for HRC Productionby- Sanat Bhaumik, Director (Sales & Marketing), Steel Plantech India

DECEMBER 201832

Section : ARTICLE

revolving belt (see Figure 1). After solidification in protective every complete pass. Output coils from Steckel mill will be

atmosphere, the cast strip is about 10-15mm in thickness which normally of minimum strip thickness of 1.8mm. A shearing

is directly hot rolled without reheating. The development of DSC mechanism is also provided in this mill to cut the irregular head

process should be viewed in the context of other near net shape and tail of the incoming slab.

casting developments like twin roll strip casting carried out by

European steel companies to produce new steel grades with

improved mechanical properties at reduced overall cost.

Before we reach a final conclusion for the best production route

for HRC production, let us have a look through these five process

routes and technology. In the Steckel mill, several passes have to be taken to get the

desired thickness reduction. The Steckel mill has quality

problems due to temperature losses during these passes. The A Steckel mill also known as a reversible finishing mill except

rated production in a Steckel mill is also lower than a that two coiler furnaces are used to feed the material through conventional HSM.the mill. One coiler is on the entry side and the other on the

In India, Steckel mills are mainly used for production stainless or exit side. The coilers pull the material through the rolling mill alloy steel strips primarily for low production capacity. Jindal stand. The material is fed back and forth through the mill until Stainless (JSL), a leading producer of stainless steel in India, the desired thickness is reached, much like a reversing rolling started with a Steckel mill in Hisar plant and then installed a mill (see Figure 2). conventional HSM in Odisha both for higher capacity and HR

Steckel mils process slabs to produce hot rolled coil (HRC). The strip quality.Steckel mill allows the rolling of a large slab by providing heated

reels (Steckel Furnaces) on both sides of the mill to store the

increased length produced during rolling. The primary function of the Hot Strip Mill (HSM) is to reheat

These Steckel furnaces are used for additional heat retention semi-finished steel slabs nearly to their melting point, then roll

and thermal consistency in the rolled piece, which in turn them thinner and longer through successive rolling mill stands

produces improved uniformity throughout the rolled product. A driven by motors, and finally coiling up the lengthened steel

furnace is provided in both sides of the mill, which covers the strip for transport to the next process (see Figure 3).

mandrels each in one side upon which the slab is rolled after

STECKEL MILL

Two-stand Steckel Mill in Operation

CONVENTIONAL HOT STRIP MILL (HSM)

Figure 1: Schematic Drawing of a Direct Strip Caster

Figure 2: Schematic Diagram of a 2-stand Steckel Mill

Section : ARTICLE

33DECEMBER 2018

Reheating Furnace for a Hot Strip Mill

Tunnel Furnaces of a fTSR plant

For such plants there are three commercially proven solutions:

(1) CSP® or the Compact Strip Plant developed, patented and

implemented in about twenty eight plants worldwide by SMS

Siemag AG, Germany, (2) fTSR or Flexible Thin Slab Rolling

developed and implemented by Danieli Italy for about ten plants

and (3) QSP or the Quality Strip implemented by JP Steel

Plantech Co. (SPCO), Japan for only one plant in Thailand.

CSP® is a compact plant concept comprising a two or single

strand casting machine, a roller-hearth furnace or tunnel

furnace (160 to 220 meters long) and a 6-stand rolling mill The HSMs in India roll slabs weighing up to 35 tons between

train. Thin slabs, 55 - 90mm thick, are cast and fed directly to 800mm and 2250mm width. Steel slab 200mm to 250mm thick

the CSP® rolling mill after temperature equalization in the and up to 10 – 11 meters long is rolled into strip as thin as 1.6mm

roller-hearth furnace and then rolled to the finished strip (may be 1.20mm) and up to 500 meters in length. Coils are

gauge (see Figure 4). This roller-hearth furnace is also used as a produced with a 762mm inside diameter ('eye') on one of coilers,

buffer for storing the slabs during roll changes in the mill with outside diameter limitations of 2200mm, corresponding to stands.1000 pounds-per-inch-width (PIW) or 22kg/mm width.

For a 1650mm wide HSM the optimum production capacity will

be about 3.8 - 4.0mtpy and such conventional HSMs will be able

to produce highest quality HRC with precise control of gauge,

thickness and crown. However, installation of new HSM for

production of 1650mm wide HRC is rare now and almost all

present day HSM installations are mainly for 1850mm to

2250mm wide strip production with annual capacity varying

between 4.5 to 5.5mtpy.

The compact CSP® process makes it possible to produce hot strip

with a homogeneous microstructure and constant mechanical

and physical properties over the entire length and width of the

strip. Additional features are the close tolerances with regard to

gauge, width, profile, contour and flatness. These can be

achieved by the homogeneous temperature distribution in the

thin slab and to the low temperature losses between the roller

THIN SLAB CASTING & ROLLING MILL (fTSR, CSP® or QSP)

Figure 3: Schematic Diagram for a conventional HSM

Finishing Mill train of MHI Hot Strip Mill in Operation

DECEMBER 201834

Section : ARTICLE

hearth furnace and the rolling mill. These conditions result in an There is only one fTSR under implementation in India and it is at

extremely stable rolling process at constant rolling speeds and NMDC Nagarnagar and on completion this plant will be quite

temperatures. similar to MMK Atakas plant in Turkey.

The first CSP® in India was installed in Ispat Dolvi (now JSW Ispat JP Steel Plantech Co., Japan has only one QSP (see Figure 6)

Dolvi Works) in 1998 and presently there are 3 more plants are installation at G-Steel, Thailand. The concept of this QSP is very

under operation – these are at Bhushan Steel & Power (Odisha), good and with a coil box separating the roughing mill train from

Essar Steel (Hazira) and Tata Steel (Jamshedpur). Out of these finishing mill train. It can compete with almost all product grades

plants, the CSP® at Essar Steel is for production of 3.5mtpy HRC from conventional HSM. This QSP is equipped with Sumitomo

with three casting strands. Caster, MHI Mill stands and other equipment from SPCO (Tunnel

Furnace, Descaler, Crop shear, Laminar Cooling and Delivery

section equipment, etc).

But considering the number of installations worldwide and

overall performance records, CSP® of SMS AG is more reliable

than the fTSR of Danieli, Italy. Since QSP of SPCO is implemented

only in one plant (G-Steel Thailand), we cannot judge its

performance considering only one installation and again, it is not

properly utilized to its fullest potential to produce high end steel

grades. Over the years G-Steel has been producing commercial

grade hot rolled coils only.

fTSR (see Figure 5) or Flexible Thin Slab Rolling is a concept

implemented by Danieli in almost ten plants. It has two

differences from the CSP® of SMS Siemag and these are (1)

Vertical curved caster in place of full vertical caster and (2)

Roughing and Finishing Mill trains are separated in place of all

mill stands in a single cluster (see Figure 5).

Mill Section of a Compact Strip Plant or CSP®

Figure 4: Schematic Diagram for a Compact Strip Plant or CSP®

Figure 5 : Schematic Diagram for a Flexible Thin Slab Rolling Plant or Danieli fTSR

Figure 6 : Schematic Diagram for JP Steel Plantech QSP in G Steel, Thailand

Section : ARTICLE

35DECEMBER 2018

For 1650mm wide strips, annual production capacity of a single produce up to 1.2 – 1.5million tons of HRC per year (depending

casting strand CSP® or fTSR/QSP will be about 1.4 - 1.5mtpy and on product mix) and the minimum strip thickness can be as low

adding a second strand in future, the capacity can be increased as 0.8mm.

to 3.0mtpy. Overall line length in all three cases will be about 480 Presently two Arvedi ESP Lines are in operation in Italy and five in

to 500 meters.Rizhao Steel, China.

The Arvedi ESP was developed and implemented by Siemens VAI

Austria (now Primetals) with Acciaieria Arvedi SpA, Italy. This ESP

produces hot rolled strip in a combined, continuous and

uninterrupted casting and rolling process (see Figure 7). In this

type of plant, the energy consumption and the associated costs

are up to 40 percent lower than those of conventional hot strip

mills or casting and direct rolling processes. This also means a

significant reduction of CO2 emissions. With a length of just 180

– 200 meters, the plants also have considerably more compact

dimensions than conventional casting and rolling mills like CSP®,

fTSR or QSP. A wide range of high-quality and ultra-thin steel

grades can be produced with the endless cast-rolling process.

Due to the highly compact ESP line arrangement with a total

length of only 180 – 200 meters combined with the direct linkage

of the casting and rolling processes, lower investment (CAPEX) With increasing competition in global steel market, strip casting

and operating costs (OPEX) will be incurred in comparison with technology (Figures 8, 9 &10) potentially offers an efficient,

conventional HSM or thin-slab-casting and direct-rolling plants.

economical, and environment friendly approach to produce hot The endless rolling operations allow strip production with

rolled coils. There are various strip casting initiatives that have uniform and repeatable mechanical properties along the entire

been carried out in the past as well as present. Twin Roll Casting strip length and yield losses are reduced to a minimum because

(TRC), Horizontal Single-Belt Casting (HSBC) or Belt Casting head- and tail-end strip crops are virtually eliminated. Another

Technology (BCT) and Near-Net-Shape-Casting are some of decisive advantage is that with continuous rolling operations,

these emerging technologies.the roll gap and pressure adjustments are constant during the

entire rolling process – resulting in a longer roll lifetime – as The CASTRIP® facility at Nucor Steel Crawfordsville, Indiana can

compared to the discontinuous and wear-intensive rolling of produce ultra thin cast strip products of 0.8mm to 1.5mm

discrete transfer bars.thickness which can be used as replacement of many cold rolled

sheets. This process essentially consists of two counter rotating An Arvedi ESP line for 1650mm maximum wide strips can

ENDLESS STRIP PRODUCTION (Arvedi ESP)

DIRECT STRIP CASTING

Arvedi ESP in operation at Acciaieria Arvedi SpA Italy

Figure 7: Schematic Diagram for an Arvedi ESP

DECEMBER 201836

Section : ARTICLE

rolls as shown in Figure 9. The molten steel delivered from the The commercialization of Horizontal Single Belt Casting (HSBC)

top solidifies on the surface of the casting rolls. This results in the or Belt Casting Technology (BCT) is still to be established. In

formation of two separate shells which are joined together at general both these technologies have good potential to compete the roll nip to form a continuous solid strip. with thin slab casting & rolling solutions but still a long way to go

reach the stage CSP® or fTSR reached today. The HSBC The CASTRIP® process has many inherent advantages over technology may be suitable for integrated steel plants while the conventional casting and rolling technologies. These include a

TRC technology is suited only for mini mills.smaller footprint, lower capital cost, simpler and more flexible

operating plants, etc.

However, till today these processes could not be fully

established for commercial applications and many steel At the beginning of this paper we observed that there are four

producers in Europe, Japan and USA are making efforts to make established and one developing process routes for production of

the strip casing technology commercially viable for hot rolled hot rolled coils and subsequently, we have briefly described

coil production. these processes.

We also found that selection of most suitable production

process depends on the product mix (strip thickness, width &

steel grades), product quality and production capacity of the

plant.

These observations are summarized below (with respect to a

plant to produce 1650mm wide strips):

Ÿ Maximum production in a Steckel mill will be 0.90 – 1.00mtpy

and output quality of HRC may not be as good as other plants

using alternative process.

Ÿ Output HRC quality of conventional HSM is good but the

optimum production capacity should be 3.5 – 4.0mtpy to opt for

this option. Conventional HSM can produce all steel grades The commercialization of Horizontal Single Belt Casting (HSBC) including HRC for automotive skin panels and CRGO.or Belt Casting Technology (BCT) is still to be established. In

Ÿ Considering the number of installations worldwide and general both these technologies have good potential to compete

overall performance till date, CSP® is more reliable than the fTSR with thin slab casting & rolling solutions but still a long way to go

or QSP. However, till now this process is mainly established for reach the stage CSP® or fTSR reached today. The HSBC

production commercial grade HRC.technology may be suitable for integrated steel plants while the

Ÿ Arvedi ESP may be the best option if the plant capacity is TRC technology is suited only for mini mills.

OUTLOOK & CONCLUSION

Figure 8: Schematic Diagram for evolving Strip Casting Processes

Figure 9: Schematic of the CASTRIP Twin Roll Caster

Section : ARTICLE

37DECEMBER 2018

limited to 1.5mtpy and for phase II expansion another identical integrated steel plants. In fact, if we look into last 20 years' mill

Arvedi ESP line will have to be installed. Obviously, the Capex will installations worldwide for hot rolled steel coil production, we

be more but it will add more flexibility of operation. find at least two-thirds of the total production comes from the

conventional HSM route. But the Thin Slab Casting & Rolling Ÿ Strip Casting technologies (HSBC or BCT) are yet to be proven

technologies are putting up very tough competition depending commercially effective when compared with other processes

on the selected product mix, production capacity and product like Steckel Mill, conventional HSM, CSP®, fTSR or QSP.

applications. TSCR process is constantly challenging the

convention HSM to optimize on its Capex and Opex. However, for

After analyzing all these points for each of the described integrated steel plants HSM is a clear winner as far as the

processes, we may infer that, for HRC production the production capacity, product diversity and product qualities are

conventional HSM route still may be the best option for large concerned.

Figure 10: Schematic Diagram of BCT Pilot Caster at Clausthal

Laminar Cooling Section of a HS

DECEMBER 201838

Section : ARTICLE

Iron and steel industry grew exponentially during the last decade. On the basis of growth witnessed the National Steel policy 2008 revised the estimated domestic steel production to 180 million tonnes by 2019-2020.Iron ore is the basic raw material for iron and steel making. Of total

Domestic consumption of iron ore 98% is accounted for pig iron and sponge iron industries.

Lumpy iron ore (-30 +10mm) and agglomerates like sinter and pellets form the production of pig iron in blast furnace, where as steel scrap, lumpy iron ore ( -18 + 6mm) or pellet are the feed for sponge iron production. Hematite and magnetite are the most prominent iron ores found in the country .Of these, hematite is considered to be most important iron ore because of its high grade quality and lumpy nature which is consumed by a large number of pig

1. Most of the iron ore mines in India have been operated and sponge iron industries in India. Magnetic deposits are by selective mining for maintaining high grade iron ore.not are not exploited so far for domestic use on account of

poor lumps (-40% Fe) However it can be used after 2. To maintain high grade iron ore low grade lumps and beneficiation a finer size followed by pelletisation. laterites are rejected. Generally classifier fines (-10

to.15mm) are not processed any further and hence As per United Nations Framework classification (UNFC) as used in sinter making.on 1.4.2010 the total resource in the country is estimated

to be 28.5 billion tonnes out of which hematite iron ore 3. The current industrial practice of iron ore washing is account for 62.7% and magnetite 37.3%.Almost all present oriented towards product with 2.5 to 3.0 Al2O3, in day production come from hematite reserves. The overall lumps and around 5% Al2O3 in Sinter plant.hematite reserves is of medium grade (+62% Fe) and

4. The present iron ore processing circuits produce slimes account for 28% of total iron ore resources of the country,particles below 0.15mm (-100 mesh) which are

Domestic iron ore production mainly in the form of lumps discarded as waste. Generation of slimes is in the tune and fines is in the ratio of 2:3. Of these domestic of 20 to 25 %.consumption in iron and steel making is only around 40-

5. Present industrial practice causes huge loss of iron 45%in the form of lumps and sinters, the remaining is values in process/mine rejects and then stacking has exported. The bulk (around 90%) of iron ore fines get adverse effects on environment causing economical exported as they cannot be used in Iron making without imbalance.agglomeration. A close look at the beneficiation

/processing practised in India reveals the following: 6. Low grade ores are exploited.

Iron Ore Beneficiationby - P. S. Bhattacharya, Editorial Consultant

Section : ARTICLE

39DECEMBER 2018

Processing is a must as any ore in general has impurities. In 4. In magnetite processing plant the process of flotation is many cases presence of deleterious impurities like silica, replaced by magnetic separation. The minerals are Alumina, sulphur and phosphorous beyond desired limits conveyed to the permanent magnetic dewatering tank make the ore unsuitable for use in BF or adversely affect for concentrate and then concentrate will enter productivity and quality. permanent magnet drum for a second magnetic

separation. The concentrate after filtration and drying Efficient and economic production of pig iron in blast are conveyed to ware furnace depends on a large extent on appropriate raw

material quality. There has been a change particularly for Advantagesiron ore i.e. from totally lump oriented feed to use of

1. In crushing it adapts to additional 2 stages and closed higher sinter and pellets in blast furnace burden. Therefore

circuit system for ideal fineness. Jaw crushers have fine requirement has gone up. Hence, emphasis on

large crushing capacity.enriching the quality of fines through techno economically viable beneficiation is essential. 2. In grinding and classification with characteristics of a

large processing capacity and small floor area superfine Higher grade lump ore reserves are limited and hence lamination autogenously mill can save energy up to 85%.optimum utilisation of locked up valuables in sub grade

iron ore resources are essential for industries to survive 3. In classification hydro cyclone and vibrating screens can and grow and achieveing through appropriate enhance classifying effects.beneficiation technology. A short description of process is

4. It adapts the third generation tailings dry stacking depicted below.

technology which can save energy by 60 to 80%. The lower grade sources of iron ore generally require Furthermore it can protect the environment and build a beneficiation, using techniques like crushing, milling, base for green mine.gravity or heavy media separation, screening and silica

Major iron ore beneficiation equipment are jaw crusher, froth floatation to improve the concentration of the ore cone crusher, vibrating screen , ball mill spiral classifier, and remove impurities. This results in high quality fine ore hydro cyclone, flotation machine, magnetic separator, powder known as fines. The process of beneficiation efficient thickener , press filter, slurry pump feeder, depends on the nature of ore i.e. HG, MG or LG. Typical agitation tank, belt conveyor etc.process is as given below:

Iron ore beneficiation plants in India1. Raw iron ore for primary crushing are fed into a jaw

crusher by plate feeder and reduced to secondary Such plants are highly adequate in India (i.e. 52 crushing. The cast iron ore is then sent to vibrating concentrators cater to the need of iron production of screen for classification. about 220 mtpa (mines 316) of these 50% are in Goa

region ( 33 mtpa, mines 72) dedicated totally for exports After classification with below mesh size shall be

and not for domestic consumption.transferred away as final products and the balance will return to the cone crusher thus forming a closed circuit. Present status and proposed action planAs per the requirement the size of products can be

The Indian mining industry currently is being run in combined and graded.

fragmented lease holds and operated by captive and non 2. The smaller crushed iron ore is fed to ball mill for captive consideration, producing iron ore in the ratio of

grinding; the crushed iron ore will grind the ore to about 1:4. The non captive sectors are sources of high quality 2mm with 3inch steel balls. lumpy ores (within -18 + 6mm) to coal based DRI plants,

leaving behind the huge stock of fines (-6mm) at the mines 3. The iron ore slurry is pumped to agitation tank and

head and are being exported.finally pumped to flotation machine with the final

However, these fines are ideal feed for value addition sulphide ore (-0.074mm) going to froth flotation cells through beneficiation for sintering / pelletisation.for recovery of iron.

DECEMBER 201840

Section : ARTICLE

Pelletization is a process of compressing or moulding Typical properties of pellets are:-

material in the shape of a pellet. A wide range of different

materials are pelletized including chemicals, iron ore

animal compound feed etc.

For iron and steel industry pelletization is one of the

agglomeration processes. It is the process of converting

iron ore fines into uniform sized iron ore pellets, which has

better tumbling index as compared to that of parent ore

which can be charged directly to a blast furnace (as

substitute for iron ore) or into a furnace used in the

production of DRI. The process involves mixing very finely

ground particles of iron ore fines of size less than 200 mesh

with additives like bentonite and shaping them into

oval/spherical lumps of 8 to 16 mm in diameter by

pelletizer and hardening the balls by firing with a fuel.

Pelletization process, leads to substantial economic gains

over time and given the shortage of quality iron ore lump

(which setting up a pellet plant can well alleviate), have led The two most accepted process of pelletization are to a paradigm change in the domestic market. compared below:

Low grade iron ore, iron ore fines and iron ore

tailings/slimes accumulated over the years at mine heads

and generated during the existing washing processes,

need to be beneficiated to provide concentrates of

required quality to the Indian steel plants. However, these

concentrates are too fine in size to be used directly in the

existing iron making processes. For utilizing this fine

concentrate, pelletizing is the only alternative available.

There are 4 stages of pellet preparation:

a) Raw material preparation

b) Formation of green balls or pellets

c) Induration of the pellets

d) Cooling, storage and transportation of the pellets

Pelletizationby - P. S. Bhattacharya, Editorial Consultant

Chemical Analysis On dry basis Unit Value Tolerance

Fe 65 Minimum % 65 Minimum

FeO % 0.3 Maximum

Si O2+Al2O3 % 5 Maximum

CaO % 0.03 +/-0.01

MgO % 0.06 +/-0.01

Basicity % 65 Maximum

Phosphorus % 0.05 Maximum

Physical properties

Bulk density t/cum 2.2 +/-0.2

Tumbler Index % 93 Minimum

Abrasion index % 3 Max+/- 0.5%

Cold crushing strength AV Kg/p 250 minimum

Size Analysis

8-16mm 94 Minimum

-5mm % 2 Maximum

+16mm % 4 Maximum

Metallurgical properties

Porosity % 2 Minimum

Reducibility % 62 Minimum

Sl no. Straight travelling grate process Grate kiln process

1 Drying, preheating induration and

cooling cycle carried out in a single

unit

Carried out in different units

2 Green pellets remain undisturbed

during the process

Entire process takes place in 3 equipments

travelling gate, rotary kiln and circular

cooler. Hence pellet transfer takes place.

3 Grate car moves in the same speed

in the drying, induration and

cooling zones

Independent control at 3 zones. So better

operational flexibility

4 Fines generation is negligible as

there is no material transfer

Higher generation of fines due to material

transfer

5 There is no strength requirement

of intermediate product

Before transfer to kiln green pellets have

to be sufficiently hardened.

6 Process availability is higher. Lower process availability

7 Higher specific energy Lower specific energy consumption

8 Lesser maintenance Higher maintenance

9 Lower dust generation Higher dust generation

10 Higher investment cost Lower investment cost

11 Suited both for hematite and

magnetite ores

Process is more suitable for magnetite

ores

Section : ARTICLE

41DECEMBER 2018

Advantages of Pellets 6. The chemical analysis is uniform since it gets controlled during benification process. Fe content varies from 63 to Iron ore pellets is a kind of agglomerated fines which has 68% depending on iron content in ore fines. Absence of LOI better tumbling index when compared with iron ore and is another advantage.can be used as a substitute for the same both.

7. Pellets have high and uniform mechanical strength and 1. Pellets have good reducibility since they have high can be transported to long distances without fine porosity(25 to 30%).Normally pellets are reduced generation. Further it is resistant to disintegration. High considerably faster than sinters as well as iron ore mechanical and uniform strength of pellets is even under lumps. High porosity also helps in better metallization in thermal stress in reducing atmosphere.DRI production.

2. Their spherical shapes and containing open pores, gives Due to mining of iron ore, large chunk of fines have been them good bed permeability. generated at mines which becomes an environmental

hazard. In order to utilise these fines, pelletisation is one of 3. Pellets have uniform size 8 to 16mmm.the technologies where the fines cannot be changed

4. Pellets have spherical shape and open pores which gives directly to iron making, hence, pelletisation is required. it better bed permeability.

With installation of larger BFS in India, utilisation of pellet 5. Pellets have low angle of repose which is a draw back as in the change mix will be further enhanced. it creates uneven binder distribution.

India's leading steel producer and global steel giant, Tata Steel has awarded CMI Industry METALS a contract for three

state of the art processing lines: 2 Continuous Galvanizing Lines (CGL) & 1 Continuous Annealing Line (CAL). All three

high-end lines are to be supplied to the client's site at Kalinganagar in the Jajpur district of Odisha. The order placed

with CMI for three processing lines, that are to provide the client with the very latest technology, will allow Tata Steel to

produce skin panels for car outer bodies, helping it retain leadership among domestic suppliers to high-quality

segments like the auto and white goods sectors. As such, all three lines are central parts of the phase two expansion of

the client's steel plant, and are to increase the annual galvanized steel production by 1 million tons.

Decisive factors for choosing CMI for this project were the company's extensive experience in steel processing lines, but

also the high process security of the plant concept, which features the full spectrum of CMI's process technologies:

Multi-stage cleaning section, Vertical annealing furnace (incl. CMI's L-Top math model and jet cooling system), Air-Knife

system, APC Blowstab low vibration cooling system, Inline skin pass mill and Tension leveler, Chemical roll-coat post

treatment, Side trimmer, Exit shear. The material grades will range from deep-drawing steels, hot-formed and high-

strength steels, to dual-phase and complex-phase steels. Besides the traditional Gi coating, one of the new lines is

designed to also process aluminized (AluSi) coatings, while the second line is to also apply galvannealed (Ga) coatings. The

order covers the engineering, procurement and supply, as well as the supervision of the erection and commissioning.

João Felix Da Silva, President of the CMI Industry Sector and Chairman – Board of Directors CMI FPE Limited stated, “We

are honored to be part of the expansion plans of a long-lasting business partner like Tata Steel, and we are very proud to

be able to assist our client in their reach for the highest steel quality and the related leadership in high-end segments

like the automotive and white goods industries.” This is the 3rd contract that Tata Steel entrusts to CMI Industry

METALS in the past 6 years. After the recent modernization of SEGAL, Tata's high-end automotive line in Belgium, this is

the second order that Tata places with CMI in the framework of its automotive steel production. Another project that

further strengthens CMI's leading position for the complete supply of high-quality automotive processing lines.

CMI receives contract from Tata Steel

DECEMBER 201842

Section : ARTICLE

Item SizeAmount per MT

( Main Producer)

Amount per MT

Local

4. M.S.Tor Steel 10 mm 43350/- 39350/-

5. M. S. Tor Steel 12 mm 43350/- 39350/-

6. M. S. Tor Steel 25 mm 43350/- 39350/-

7. M.S.Angle 50x50x6 41350/- 36550/-

8. M.S.Angle 75x75x6 40350/- 37350/-

9. R. S. Joist 125x70 X 37350/-

10. R. S. Joist 200x100 38550/- 37550/-

11. M.S.Channel 75x40 43250/- 37550/-

12. M.S.Channel 150x75 43250/- 37550/-

13. M.S.Plate 6 mm 40500T'-

14. M.S.Plate 10 mm 40500/-

15. M.S.Plate 12 mm 40500/-

16. M.S.Plate 25 mm 40500/-

17. H. R. Coils 2.00 mm 42500/-

18. H.R. Coils 2.50 mm 41250/-

19. H. R. Coils 3.15 mm 41250/-

Date-15.12.2018KOLKATA MARKET PRICES (In Rs.)

1. Some materials price has been decreased.

2. The Materials prices are increased due to sale down in market

3. The main producers are benefited due to increase/decrease the price of the materials.

Section : DATA BANK

43DECEMBER 2018

Total Crude Steel Production

DECEMBER 201844

Section : DATA BANK

Section : DATA BANK

45DECEMBER 2018

DECEMBER 201846

Section : DATA BANK

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