Expansion of Steel Plant by expanding Sponge Iron from 1...

Expansion of Steel Plant by expanding Sponge Iron from 1,20,000 TPA to 3,18,000 TPA, MS Billets from 105000 TPA to 3,72,300 TPA, Rolling Mill from 100000 TPA to 300000 TPA, Submerged Arc Furnace (SAF) from 15000 TPA to 30000 TPA & Captive Power Plant from 16 MW to 42 MW including Waste Heat Recovery Boiler (WHRB) At Jamuria Industrial Estate, Village Ikra & Damodarpur, Tehsil Jamuria, District Paschim Bardhaman, West Bengal

Pre-Feasibility Report

Damodar Ispat Limited 1

PRE - FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY

Damodar Ispat Limited is presently operating a 50 TPD (15,000TPA) Direct Reduced Iron unit at

Jamuria Industrial Estate, Jamuria, West Bengal. The sponge iron produced is supplied to various

nearby steel units for further use in steel making. The company has obtained Environment

Clearance from MoEFCC, New Delhi vide letter number J-11011/366/2010-IA.II(I) dated 2nd April,

2012 for expansion of existing unit of 1x50 TPD (15,000TPA) DRI by 3 x 100 TPD DRI (1,05,000 TPA

of sponge iron), 2x15T IF, 1x30T LF (1,05,000 TPA of MS Billets), 310 TPD Rolling mill (1,00,000 TPA

of Rods/bars/light structurals), 1X9 MVA SAF (15,000TPA of Fe–Mn/Si-Mn), 1x5 TPH, 2 X 10TPH

WHRB & 1X32 TPH FBC Boiler and 16 MW Captive Power Plant (7 MW of WHRB and 9 MW of

FBC) and validity extended on 24th May, 2019 till 1st April, 2022. The implementation of this EC is

under process and is expected to be completed within 2 years. Consent to Establish was obtained

from WBPCB vide Memo no. 211-2N-51/2003 & NOCNO159358 dated 15.02.2019.

The status of implementation as per latest Environment Clearance is as mentioned below:-

S. No.

Plant Capacity as per granted EC Dated 2nd April, 2012 & validity

extended till 1st April, 2022

Status of Implementation Expected Completion Time

1. Sponge Iron

120000 TPA (1X 350 TPD DRI Plant)

Under Construction Nov., 2020

2. MS Billets 105000 TPA {2X15 Ton IF (Induction Furnace) & 1X30 Ton LF (Laddle Furnace)}

Order Placed. Construction to begin from Sep., 2019.

Dec., 2020

3. Rolling Mill 100000 TPA (310 TPD of rolled/bars/light

structure)

Order Placed. Construction to begin from August, 2019.

Dec., 2020

4. SAF 15000 TPA (1X9 MVA

of Fe-Mn/ Si-Mn)

Under Planning. Jan., 2021

5. WHRB 7 MW (35 TPH)


6. Captive Power Plant

9 MW (1X 32 TPH FBC boiler)


The company is now proposing expansion of Existing Steel Plant by expanding Sponge Iron from

1,20,000 TPA to 3,18,000 TPA, MS Billets from 105000 TPA to 3,72,300 TPA, Rolling Mill from

100000 TPA to 300000 TPA, Submerged Arc Furnace (SAF) from 15000 TPA to 30000 TPA &

Captive Power Plant from 16 MW to 42 MW including Waste Heat Recovery Boiler (WHRB) at

Jamuria Industrial Estate, Village Ikra & Damodarpur, Tehsil Jamuria, District Paschim Bardhaman,

West Bengal. The following facilities are proposed under the expansion plan:




S. No.

Plant Capacity as per granted EC dated 2nd April, 2012 & validity extension 24th May, 2019 till 1st April, 2022 (Under Planning &

Implementation)

Additional Capacity Proposed

Total Capacity After Proposed Expansion

1. Sponge Iron 120000 TPA (1X 350 TPD DRI Plant)

198000 TPA (1X 600 TPD DRI

Plant)

318000 TPA (1x 350 & 1X 600 TPD DRI

Plant) 2. MS Billets 105000 TPA

{2X15 Ton IF (Induction Furnace) & 1X30 Ton LF (Laddle Furnace)}

267300 TPA {6X15 Ton IF

(Induction Furnace)}

372300 TPA {8X15 Ton IF (Induction Furnace) & 1X30 Ton LF

(Laddle Furnace)} 3. Rolling Mill 100000 TPA

(310 TPD of rolled/bars/light structure)

200000 TPA (625 TPD of

rolled/bars/light structure)

300000 TPA (310 TPD & 625TPD of

rolled/bars/light structure

4. Submerged Arc Furnace

(SAF)

15000 TPA (1X9 MVA

of Fe-Mn/ Si-Mn)

15000 TPA (1X9 MVA

of Fe-Mn/ Si-Mn)

30000 TPA (2X9 MVA

of Fe-Mn/ Si-Mn) 5. Waste Heat

Recovery Boiler

(WHRB)

7 MW (35 TPH)

14 MW (70 TPH)

21 MW (35 TPH & 70 TPH)



10 MW (50 TPH FBC boiler)

19 MW (1X 32 TPH & 50 TPH FBC

boiler) 7. Billet Caster --- 2X2 Strand 2X2 Strand8. Railway Siding with wagon Tippler

* Presently only 15000 TPA Sponge Iron Plant (50 TPD DRI Plant) is operational which will

be dismantled after commissioning of 1X350 TPD. Consent to Establish has also been

obtained for 1X350 TPD only.

The details of all the products are mentioned in the table below:-

Table 1 Name of unit & its product

Name of the Units Name of Product

DRI Sponge Iron Induction Furnace with LF & CCM MS Billets

Rolling Mill Re-bar Submerged Arc Furnace (SAF) Silico Manganese Waste Heat Recovery Boiler

(WHRB)Electricity

Captive Power Plant Electricity




As per EIA Notification dated 14th Sept., 2006 and subsequent amendments, the project falls under

Category “A” S. No. 3 (Material Production), Project Activity ‘3 (a)’ Metallurgical Industries (ferrous

& non-ferrous).

Table – 2 Salient Features of the Project

S. NO. PARTICULARS DETAILS

A. Nature & Size of the Project Expansion of Steel Plant by expanding Sponge Iron from 1,20,000 TPA to 3,18,000 TPA, MS Billets from 105000 TPA to 3,72,300 TPA, Rolling Mill from 100000 TPA to 300000 TPA, Submerged Arc Furnace (SAF) from 15000 TPA to 30000 TPA & Captive Power Plant from 16 MW to 42 MW including Waste Heat Recovery Boiler (WHRB)

B. Category of the Project As per EIA Notification dated 14th Sept., 2006 and subsequent amendments, this project falls under Category “A”, S. No. 3 (Material Production), Project Activity ‘3 (a)’ Metallurgical Industries (ferrous & non-ferrous)

C. Location Details

Location Jamuria Industrial Area

Village Ikra & Damodarpur

Tehsil Jamuria

District Paschim Bardhaman

State West Bengal

Latitude 23041’40.83” N to 23041’59.49” N

Longitude 8705’35.35” E to 8705’35.35” E

Toposheet No. 73M2, 73M1, 73I14

D. Area Details

Total Project Area Existing Plant area is 40.44 acres (16.37 ha). Additional land required for the expansion is 38 acres (15.37 ha). Hence after expansion total plant area will be 78.44 acres (31.74 ha).

Greenbelt & Plantation Area 13.34 acres (5.4 ha) i.e. 33% of the existing plant area has already been covered under greenbelt & plantation. After expansion approx. 33% of the total plant area i.e. 25.88 acres (10.5 ha) will be developed under greenbelt & plantation.

E. Environmental Setting Details within 10 km radius (with approximate aerial distance and direction from the project site)

1. Nearest City Raniganj (~9 km in SE direction)

2. Nearest Town Jamuria ( ~1.3 km in NW direction)

3. Nearest National Highway / State Highway

o NH - 2 (~4.2 km in SSW direction) o NH - 60 (~4.5 km in SE direction)

4. Nearest Railway station o Ikra Junction Railway Station (~2 km in East direction) o Jamuria Railway Station (~2.5 km in NW direction)




S. NO. PARTICULARS DETAILS

5. Nearest Airport Kazi Nazrul Islam International Airport, Andal (~20 km in ESE direction from plant site)

6. National Parks, Wildlife Sanctuaries, Biosphere Reserves, Reserve forest and Protected forest within 10 km radius

No National Parks, Wildlife Sanctuaries, Biosphere Reserves, Reserve forest lies within 10 km radius.

7. Water Bodies within 10 km radius area

• Singaran Nala (2.2 km in East direction) • Damodar Nala (2.9 km in WNW direction) • Punta Khal (6.0 km in WNW direction) • Nonia Khal (7.5 km in SW direction) • Ajay River (8.0 Km in NNE direction) • Damodar River (9.5 km in SSW direction)

8. Seismic Zone Zone - III [as per IS 1893 (Part-I): 2002]

F. Cost Details

Total Cost of the Expansion Project

Rs. 837.19 Crores (Existing project cost – Rs. 549.68 Crores)

Cost for Environment Management Plan

o Capital Cost – Rs 55.5 Crores o Recurring Cost- Rs 5.8 Crores / annum

G. Basic Requirements for the Project

Requirements Source

Existing Additional Total

Fresh Water Requirement (KLPD)

2420 1758 4178 ADDA & Ajay River

Power Requirement (MW) 30 MW 54.3 MW 84.3 MW 42 MW CPP and balance from West Bengal State Power Grid/DVC

Manpower Requirement (Operational phase) (Persons)

Regular 190 218 408 Source: Local & outside areas Contractual 720 875 1595

Total 910 1093 2003

1.2 ENVIRONMENTAL MANAGEMENT PLAN

Air Management

All pollution control systems are connected to energy meters and the records are maintained for run

hours, failure time and efficiency.

Bag filters have been installed to control fugitive emissions at the transfer points and the raw material

handling areas.

Dust settling chambers for settling of coarse particles at the DRI kilns have been installed.




Spark erecter, dust extraction system comprising of pulse jet bag filters have been installed to control

particulate emissions from the rolling mills/induction furnace/ladle furnace and gas cleaning plant.

ESP has been installed to control particulate emissions from the FBC boiler and WHRB connected with

DRI and emissions will be disbursed through stack of adequate height.

Dry Fog system shall install in raw material handling to control the fugitive dust.

Telescopic chute shall install in product dispatch building and ash dispatch area to control fugitive dust.

Dust conveying system shall be installed in all the APC system & send to silo to control the fugitive dust.

Pug mill system shall install at ash/dust silo to control the fugitive dust.

The entire area shall be made in concrete/paved to control the fugitive dust from roads at the time of

vehicle movement.

Water sprinkling is being/will be carried out at suitable intervals to control dust generation. This effort

will be continued along with avenue plantations in-and-around the plant premises. Dust suppression

system (Pulse jet Bag Filter with Silicon coating bags) is adopted to control the fugitive dust emanated

during extra quantity of raw materials unloading operations.

Proper maintenance of vehicles and machineries is being/ will be done and combustion efficiency of

vehicles & machineries is being/ will be tested regularly both by the proponent as well as the

contractors engaged.

33% of the total area is being/will be developed as greenbelt & plantation within premises.

Ambient air quality and stack emission is being/will be regularly monitored to ensure that emission level

is within the ambient air and flue gas emissions quality standards.

The dust generated in the material handling system is being/ will be extracted through suction hoods

located at various drop points.

The hoods will be connected to a common duct which will be provided with a motorized damper for

isolation.

An on-line booster fan will be provided for generating the necessary suction at the suction hoods.

Water Management

The company is/ will be completely based on Zero Liquid discharge.

Rainwater harvesting & ground water recharging by recharge structure for conservation of water

Cooling tower downs are separately treated with standard process and the treated effluent are recycled

to an extent of 70- 75% excess treated effluent are stored in guard pond for further secondary use in the

plant.

Sanitary sewage is treated by septic tank followed by soak-pit.




Efforts would be reuse and re-circulate the water to the extent possible

Storm water/Garland drains would be provided and are linked to the guard pond.

Contaminated waters cleaned and recycled to process. Waste water is being/ will be used in greenbelt &

dust suppression.

Continuous attempt is being/ will be made to optimize/reduce the use of water and to avoid wastage

and leakage of water.

Record of water consumption on daily basis is being/ will be maintained as per present practice.

Non-contaminated and potentially contaminated run-off is being/ will be channelized separately. Non-

contaminated run-off is being/ will be routed to off-site areas via silt traps. Sediment trap is being/ will

be provided to prevent the discharge of excessive suspended solids.

Oil and grease trap are being/ will be provided in plant drainage lines to prevent contamination by

accidental oil spillage.

Noise Management

Time to time oiling and servicing of machines is being/will be done.

Acoustic enclosures for DG sets are provided.

Earmuffs provided to workers while running the equipment of the plant.

Periodic monitoring is being/will be carried out.

Greenbelt of appropriate width inside the plant premises and at the plant boundary has been /will be

developed and same will be maintained in the future.

Sound absorbing material is provided in rooms where both the noise source and plant personal is

present so that the reflecting sound is absorbed.

Fly Ash Management

Fly ash is being/will be supplied to company’s own cement plant and will be used in brick manufacturing.

Solid waste Management

Used oils are industrial lubricating oils are stored in closed barrels with appropriate seal and stored in a

designated HW Facility and is being/ will be sold to companies engaged in oil reclamation business.

Contaminated cotton and wiping clothes collected from all units is sent to Common Hazardous Waste

Treatment, Storage and Disposal Facility (CHWTSDF).

SMS slag is being used for road leveling, road construction and infrastructure development or may be

collected by a subcontractor to be sold externally.

Scrap generated in continuous casting and rolling mills will be used as return scrap in the IF.




Char produced is used in captive power plant boilers, flying dust, wet scrapper dust.

Greenbelt Development & Plantation

The greenbelt & plantation development in 33% area all around and inside the plant helps to attenuate

the pollution level.

Greenbelt is being developed as per Central Pollution Control Board (CPCB) guidelines.

Plantation of selected tree species, which are suitable to area condition, has been done for attenuation

of air & noise pollution.

Native species have been planted in consultation with the local DFO.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

(i) Identification of Project and Project Proponent

Project:-

Damodar Ispat Limited is now proposing expansion of Existing Steel Plant by expanding Sponge

Iron from 1,20,000 TPA to 3,18,000 TPA, MS Billets from 105000 TPA to 3,72,300 TPA, Rolling Mill

from 100000 TPA to 300000 TPA, Submerged Arc Furnace (SAF) from 15000 TPA to 30000 TPA &



West Bengal. The proposed expansion will be done in existing land and in the land acquired

adjacent to the existing plant.

Project Proponent

Damodar Ispat Limited was acquired by SAI Group in mid of FY 18-19 and the said plant is near to

the manufacturing unit of Super Smelters Limited (the Flagship Company of SAI Group) situated at

Jamuria, West Bengal. SAI Group promoted by Shri Sitaram Agarwal and followed by his two sons

Shri Dilipp Agarwal and Shri Deepak Agarwal, is only in the Iron and Steel business and is a

renowned name in manufacturing of intermediary as well as value added iron & steel products.

The Group already has an established brand "SUPER SHAKTI" which is widely accepted in the

construction and infrastructure sector for its consistent quality. The Group has been carrying on its

operations for nearly 3 decades and has created an excellent goodwill among its user due to

delivery of consistent quality of products. The products are sold in various parts of the country

such as West Bengal, Jharkhand, Bihar, Uttar Pradesh, Noida, etc. The group companies of DIL are

Super Smelters Ltd, Supershakti Metaliks Limited and Sai Electrocasting Pvt Ltd. The group

companies are engaged in the manufacturing of Iron and Steel Products. The products are used in

the construction industry, infrastructure sector and other steel & allied industries.




(ii) Brief description of nature of the project

Damodar Ispat Limited is presently operating a 50 TPD (15,000TPA) Direct Reduced Iron unit at

Jamuria Industrial Complex, Jamuria, West Bengal. The sponge iron produced is supplied to

various nearby steel units for further use in steel making. The company has obtained Environment

Clearance from MoEFCC, New Delhi vide letter number J-11011/366/2010-IA.II(I) dated 2nd April,

2012 for expansion of existing unit of 1x50 TPD (15,000TPA) DRI by 3 x 100 TPD DRI (1,05,000 TPA

of sponge iron), 2x15T IF, 1x30T LF (1,05,000 TPA of MS Billets), 310 TPD Rolling mill (1,00,000 TPA

of Rods/bars/light structurals), 1X9 MVA SAF (15,000TPA of Fe–Mn/Si-Mn), 1x5 TPH, 2 X 10TPH

WHRB & 1X32 TPH FBC Boiler, and 16 MW Captive Power Plant (7 MW of WHRB and 9 MW of

FBC) and validity extended on 24th May, 2019. The implementation of this EC is under process and

is expected to be completed within 2 years.

The company is now proposing expansion of Existing Steel Plant by expanding Sponge Iron from





West Bengal.

The details of existing plant operating, capacity as per latest obtained EC, proposed additional

production capacity is mentioned in Table 1.

As per EIA Notification dated 14th Sept., 2006 and subsequent amendments, this project falls

under Category “A”, S. No. 3 (Material Production), Project Activity ‘3(a)’ Metallurgical Industries

(ferrous & non-ferrous).

(iii) & (iv) Need for the project and its importance to the country and or region &

Demand- Supply Gap

Steel is crucial to the development of any modern economy and is considered to be the

backbone of the human civilization. The level of per capita consumption of steel is treated as one

of the important indicators of socio-economic development and living standard of the people in

any country. It is a product of a large and technologically complex industry having strong forward

and backward linkages in terms of material flow and income generation. All major industrial

economies are characterized by the existence of a strong steel industry and the growth of many

of these economies has been largely shaped by the strength of their steel industries in their initial

stages of development.

The mild demand in the country is going at the rate 9-10% (Compound Average Growth rate

CAGR) Particularly in the southern states, due to no. of major infra-structural projects planned by




State/Central Governments and also rapid growth of industries, the demand is likely to be higher

than average for the country. Considering the proximity of the project site to all the three major

Metros, Hyderabad, Bangalore and Chennai and neighbouring states of Orissa, Jharkhand, Bihar

and entire North East states, the growing demand can be met with less transportation costs of

Mild Steel.

The Indian steel industry continued to showcase trends of higher consumption of finished steel.

Currently, the steel consumption in India is second only to China. However, with the steel

consumption in China expected to moderate at around 3%, India is likely to emerge as the fastest

growing steel consuming nation. Further, India's current per capita finished steel consumption at

52 kg is well below the world average of 203 kg. With rising income levels expected to make steel

increasingly affordable, there is vast scope for increasing per capita consumption of steel.

Being a core sector, steel industry tracks the overall economic growth in the long term. Also, steel

demand, being derived from other sectors like automobiles, consumer durables and

infrastructure, its fortune is dependent on the growth of these user industries. The Indian steel

sector enjoys advantages of domestic availability of raw materials and cheap labour. Iron ore is

also available in abundant quantities. This provides major cost advantage to the domestic steel

industry.

The world Gross Domestic Product (GDP) is expected to grow by 3.4% in 2014. With advanced

economies expected to do well in 2015, the global growth projection for 2015 is 5%. (Source: -

IMF & SAIL annual report). This is despite the fact that there was a noticeable slowdown in the

emerging market and developing economies during 2013, a reflection of the sharp deceleration

in demand from key advanced economies. As such, we reckon that while global prospects have

improved but the road to recovery in the advanced economies is still uncertain and volatile.

Steel demand in India has remained sluggish so far in 2014 amidst weak activity and poor

sentiment; however, activity is expected to accelerate modestly in the coming years.

Strengthening domestic consumption and improving external conditions will help underpin the

growth of steel using sectors. From the market analysis data, it is evident that the states of Bihar,

Orissa, Jharkhand, will continue to show an above average growth of demand.

The project offers an excellent opportunity for Damodar Ispat Limited to expand its existing steel

plant by expanding Sponge Iron from 1,20,000 TPA to 3,18,000 TPA, MS Billets from 105000 TPA

to 3,72,300 TPA, Rolling Mill from 100000 TPA to 300000 TPA, Submerged Arc Furnace (SAF) from

15000 TPA to 30000 TPA & Captive Power Plant from 16 MW to 42 MW including Waste Heat

Recovery Boiler (WHRB) at Jamuria Industrial Estate, Village Ikra & Damodarpur, Tehsil Jamuria,

District Paschim Bardhaman, West Bengal.




Following advantages can be obtained from the expansion project

Availability of land

Proximity to sources of main raw materials

Availability of water in close proximity.

Availability of skilled manpower in surrounding area.

Reasonable proximity to end users

Proximity to steel market, Close to high growth of Steel Billets markets for secondary steel

making process in small scale foundries.

Convenient Rail & Road links.

No National Parks and Sanctuaries within 10 Km radius

Using the Eco-friendly clean Technology.

Economies of scale will result in lower operating cost.

Offers freight advantage vis-à-vis competitors.

(v) Imports vs. Indigenous Production

The project is/will utilize locally available raw material and coal will be imported from South

Africa/Indonesia at Dhamra/Haldia/Paradeep ports from where the same is being/ will be brought

in through rail/road.

(vi) Export Possibility

India has enormous potential and necessary resources, capabilities to become a global supplier of

quality steel. Also there exists ample market opportunities in the neighbouring regions of Asia,

Africa and the Middle East. The policy framework while according top priority to meet domestic

demand should also take into account the large export possibilities.

Currently, there are no export plans from the project. Major production is/will be consumed in the

state of West Bengal itself and neighbouring states. Export of finished product to neighbouring

Countries will depend upon opportunities available in future.

(vii) Domestic / Export Markets

Domestic market mainly includes West Bengal, Jharkhand, Bihar, Uttar Pradesh, Noida etc.

(viii) Employment Generation (Direct and Indirect) due to the project

The project will create the additional employment of 1093 people (218 regular + 875 contractual)

during operation & construction phase. Skilled and unskilled people on daily average will be

employed. DIL will give preference to the local people during construction and operation phase of

the project depending upon the skill, job requirement and capability. Several others indirect

employment opportunities will be created in the surrounding areas by transport, business, vehicle




drivers and attendants, workshops, grocery and retails, medical, etc. The overall Employment

detail is:

Description Existing Additional

Total After proposed expansion

Regular 190 218 408

Contractual 720 875 1595

Total 910 1093 2003

3.0 PROJECT DESCRIPTION

(i) Type of Project including interlinked and interdependent projects if any

Project:- Expansion of Steel Plant by expanding Sponge Iron from 1,20,000 TPA to 3,18,000 TPA,

MS Billets from 105000 TPA to 3,72,300 TPA, Rolling Mill from 100000 TPA to 300000 TPA,

Submerged Arc Furnace (SAF) from 15000 TPA to 30000 TPA & Captive Power Plant from 16 MW

to 42 MW including Waste Heat Recovery Boiler (WHRB) at Jamuria Industrial Estate, Village Ikra &

Damodarpur, Tehsil Jamuria, District Paschim Bardhaman, West Bengal.

Interlinked and Interdependent Projects:

Interlinked Project: There is no interlinked project.

Interdependent Project: There is no interdependent project.

(ii) Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates




Figure - 1: Location Map


e Feasibility Report


Figure - 2: Plant Layout


e Feasibility Report


(iii) Key Plan

Figure - 3: Key Plan




(iv) Details of alternative sites consideration and basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

Since, the expansion will be done within the existing plant premises and in the land adjacent to

the existing plant; therefore, no alternative site has been considered.

(v) Size or magnitude of operation

Damodar Ispat Limited is proposing Expansion of Steel Plant by expanding Sponge Iron from





West Bengal.

As per EIA Notification dated 14th Sept., 2006 as amended from time to time, this project falls

under Category “A”, S. No. 3 (Material Production), Project Activity ‘3(a)’ Metallurgical Industries

(ferrous & non-ferrous).

(vi) Project description with process details (a schematic diagram/ flow chart showing the

project layout, components of the project etc. should be given)

The details of existing & proposed units are given in Table below:-

S. No.

Plant Capacity as per granted EC dated 2nd April, 2012 & validity

extension 24th May, 2019 (Under Planning & Implementation)



1. Sponge Iron 120000 TPA (1X 350 TPD DRI Plant)

198000 TPA (1X 600 TPD DRI

Plant)

318000 TPA (1x 350 & 1X 600 TPD DRI

Plant)2. MS Billets 105000 TPA

{2X15 Ton IF (Induction Furnace) & 1X30 Ton LF (Laddle Furnace)}

267300 TPA {6X15 Ton IF

(Induction Furnace)}

372300 TPA {2X15 Ton & 6X15 Ton IF

(Induction Furnace) & 1X30 Ton LF (Laddle

Furnace)}3. Rolling Mill 100000 TPA

(310 TPD of rolled/bars/light structure)

200000 TPA (625 TPD of

rolled/bars/light structure)

300000 TPA (310 TPD & 625TPD of

rolled/bars/light structure

4. Submerged Arc Furnace

(SAF)

15000 TPA (1X9 MVA

of Fe-Mn/ Si-Mn)

15000 TPA (1X9 MVA

of Fe-Mn/ Si-Mn)

30000 TPA (2X9 MVA

of Fe-Mn/ Si-Mn)5. Waste Heat

Recovery Boiler (WHRB)

7 MW (35 TPH)

14 MW (70 TPH)

21 MW (35 TPH & 70 TPH)



12 MW (50 TPH FBC boiler)

21 MW (1X 32 TPH & 50 TPH FBC




S. No.

Plant Capacity as per granted EC dated 2nd April, 2012 & validity

extension 24th May, 2019 (Under Planning & Implementation)



boiler) 7. Billet Caster --- 2X2 Strand 2X2 Strand8. Railway Siding with wagon Tippler

* Presently only 15000 TPA Sponge Iron Plant (50 TPD DRI Plant) is operational which will

be dismantled after commissioning of 1X350 TPD. Consent to Establish has also been

obtained for 1X350 TPD only.

Process Description

A. DRI Plant (1x350 + 1x600 TPD)

The DRI plant will comprise of the following major units:-

Raw material feed system

Rotary kiln

Rotary cooler

Product processing system

Product (DRI) handling & storage system

Waste gas system

De-dusting system

Raw material feed system

Non-cooking coal, iron ore / pellets and limestone / dolomite will be procured as per required

sizes for use in the DRI plant. After screening, the sized raw materials will be conveyed to the

respective day bins at the stock house. The stock house will be provided with requisite number of

bins for separate storage of iron ore, coarse coal, fine coal, dolomite and recycled materials. The

bins will be provided with level measuring for monitoring filling status of bins. For withdrawal of

measured quantities of raw materials from the day bins at pre-set rate, weigh feeders will be

provided at the bottom opening of bins. The raw materials will be discharged on to a common

collecting conveyor and delivered to the feed end of the rotary kiln by conveyor system.

In addition, one bin will be provided near discharge end of kiln for storing coal fines required for

injection into the rotary kiln at the discharge end. Coal fines will be injected pneumatically into the

kiln from the discharge end through feeders and rotary compressors.

Rotary kiln

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

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




controlled DC drive so that the speed of the kiln can be varied as desired by operating conditions.

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

Proper facilities will be provided for air which is required for proper burning of combustibles

inside the kiln and for maintaining the desired temperature profile.

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

fuel, especially during start-up of the kiln and in an emergency. A central oil burner with

combustion air blower will be provided at the discharge end of the rotary kiln for this purpose.

Rotary cooler

The hot product discharged from the rotary kiln will be indirectly cooled in a rotary cooler by

spraying water on the shell of the cooler. The cooler will only be partially lined with refractory’s /

castables. Both main and auxiliary drives will be provided for the cooler. The cooler discharge

materials will pass though product separation and handling system.

Product handling system

The discharge from the rotary cooler will be stored in an intermediate storage bin first and from

there it is conveyed to finished product processing and storage building. The cooler discharge will

be screened at + 18 mm, -18 to 3 mm and – 3 mm fractions. The over sized fraction (+ 18 mm)

will be stored in a bin as reject.

The -18 to 3 mm fraction will be passed through double drum magnetic separator. DRI and non-

magnetic materials (char) thus separated will be stored in separate bins. Undersize (-3 mm)

fraction will also be passed through magnetic separator and DRI fines will be stored in a separate

bin.

Electromagnetic tramp iron separators, belt scales and mechanical hoists will be provided in the

system, as required. The sized sponge iron meant for use in induction furnaces will be stocked

either at the stock house or in the bunkers in the product building. Adequate facilities will be

provided in the system for dust extraction and suppression to contain the level of dust emission.

The system shall be provided with independent associated electrics.

Waste gas system

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

before passing through the after burning chamber (ABC). The ABC will be supplied with additional

air by a fan for burning the combustible matter contained in the kiln off gases.

It is envisaged that the waste gas from the ABC will be used to generate steam in a waste heat

recovery boiler (WHRB) to be installed for the captive power plant. Dry cleaning of waste gas

through electrostatic precipitator (ESP) has been envisaged. The waste gas from WHRB will be

passed through the ESP to bring down the dust contents within acceptable emission levels. Clean




gases from ESP will go through an induced draft (ID) fan before it is released into the atmosphere

through a stack.

Technological Parameters of DRI Kilns and rotary cooler for existing and proposed expansion are

given in table below:

S. No. Description Unit Parameters

A. Rotary Kiln

1. No. of Kilns x capacity TPD 1 x 350 (existing) + 1 x 600 (proposed)

2. Type of kiln - Rotary

3. Diameter of kiln (ID) mm 4200 - 5350 (approx.)

4. Length of kiln m 80 (approx.)

5. Shell thickness mm 25 / 35 / 50

6. Lining thickness mm 230

7. No. of supports Nos. 4

8. Slope % 4

9. Kiln speed RPM 0.07 – 0.70

B. Rotary Cooler

10. Diameter of cooler (D) mm 3440 - 3600 (approx.)

11. Length of cooler m 46 - 50 (approx.)

12. Shell thickness mm 25 – 30

13. No. of supports Nos. 2

14. Slope % 2

15. Cooler speed RPM 1.3

16. Production per day TPD 950

17. No. of working days Nos. 330

18. Annual production of DRI TPA 3,13,500

Electrical system

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

including variable frequency drives for kiln rotation over 11/0.415 – 0.25 kV load centre

substation. Power to 11 kV switch board will be fed from CPP over underground cable feeders.




Figure: 4 Process flow chart of DRI

B. Steel Melt Shop (SMS)

In context of steel industry in India, induction furnace units are categorized as Secondary steel

producers along with Electric Arc Furnaces vis-à-vis Primary Steel Producers comprising of large

integrated steel plants producing steel through blast furnace route. While Primary Steel Producers

use iron ore as raw material and coal and gas as source of power, secondary steel producers are

mainly using electricity as source of power and steel scrap and sponge iron as raw materials.

Induction furnaces in India are mainly producing mild steel or plain carbon steel and have

significant contribution in the production of long products by the secondary steel sector in the

country. About 40% of the steel produced by secondary sector is from induction furnace route.




In term of quality, since induction furnace is basically a melting unit, no refining is possible; the

quality of steel produced mainly depends on the quality of input material. However, considering

the steel grades proposed and quantum of production, steel production through induction

furnace route is an appropriate choice.

Production Facilities

Following facilities are envisaged.

Product Existing Additional After expansion Production unit Production unit Production units

Liquid steel / Hot Metal 2 x 15 T IF + 1 x 30 T LF

6 x 15 T IF 8 x 15 T IF + 1x 30 T LF

Steel Grades - The steel melt shop will produce steel for rebar as per the following grades:

ASTM A 615 Gr40

ASTM A 615 Gr60

DIN 448 (BST500)

BS 4449 Gr460

AISI/SAE1010

The Salient Features of Induction Furnace is given below:

6,000 KW / 500 Hz, 24 Pulse Quick Melt Services Solid State Power Supply Unit with eight

members of 15,000 kg ET steel from melting furnace.

Steel Frame Melting Furnace complete with refractory top & bottom, Copper Coil,

Lamination Packets secured in a Frame Structure, Hydraulic Cylinders and Inlet & Outlet

Sub-Manifolds etc.

Capacitor Rack fitted with Capacitors suitable for above Power supply unit complete with

connecting Bus bars and Capacitor Switch.

D. C. Choke suitable for above Solid State Power Supply Unit.

D. M. Water Circulation Unit complete with Plate Type Heat Exchanger, Non-Ferrous Pump,

Mix- bed Resin Cartridge, DM Water Storage PVC Tank with Pressure Gauge, Valves and

inter-connecting pipeline.

Hydraulic Power Pack consisting of 3 phase Induction Motor, Hydraulic Pump, Oil Storage

Tank, Pressure Gauge, Valves.

Operator Control Desk with stand consisting of On/Off push buttons, Indicators & Meters

for On / Off and Power Control operations from Furnace Platform.

LRF of Capacity 30 T for treatment and temperature adjustment of liquid steel tapped from

induction furnaces will be installed for use as & when required.




The main functions of Ladle Furnace are as below:

Alloying and heating of steel

Homogenization of chemistry

Homogenization of temperature

Desulphurization & inclusion control

To serve as a buffer between IF and caster in case of emergency

Double Strand Medium Speed Modular Billet Caster

2 (Two) strand 6/9/15 MR billet caster suitable for casting billet / blooms between 100 x 100 mm

to 200 x 200 mm. shall be installed. In general 130 mm billets shall be processed.

Salient features of the Billet Caster

- Ladle turret for sequencing casting

- Rigid dummy bar with withdrawal mechanism.

- PLC based automatic secondary spray cooling system

- Automatic mould oscillation & control lubrication system

- Automatic mould level control(Radioactive)

- Aluminium wire feeder

- PLC – SCADA based automation

- 2 Nos. pusher type cooling beds

Utilities & Services

The utilities and services required for the proposed IF & LRF are as follows:

Air Pollution Control System

Air pollution control system has been envisaged for primary pollution control for suction and

cleaning of fumes emanating from the Induction Furnace. The system will collect fumes generated

during different phases of operation of furnaces, treat them through bag filters and let the clean

air go into atmosphere as per anti-pollution norms.

Particulars ParametersFurnace capacity IF-2 x 15 T + 6 x 15 T + 30 T LFFurnace Charging Material Pig Iron, Steel Scrap, Return Scrap, DRI Charging Method PI / Scrap by Magnet / Grab

DRI Continuous by Vibro feederSuction Hood & hood drive: Type Dish Antenna type Fume Capturing Hood (Side Draft) Location On platform (Common for two crucibles) Hood drive Geared Motor Dust collector: Type Cassette FilterFilter design pressure +/- 500 mmwc




Design inlet gas temperature 90˚C – 110˚C Moisture content 0%Inlet dust load 2000–3000 mg/Nm³ Design outlet dust emission: 20 mg/Nm3

Fabric used Polyester needle felt with Antistatic Construction Electricals Power Voltage 400VInstrument Control Voltage 220V Total connected Load 770 kWOthers : ID Fan pressure drop 450 mm WC AC Ratio (Net) 1.08Compressed air requirement Will be met from control CA system

Power Distribution System

The scope envisages the electric power supply and distribution for installation of assets as below:-

8x 15 T (2 in Phase I & 6 in Phase II) Induction Furnaces along with 30T LRF

Auxiliaries and utilities for assets

Power

The Steel Melt Shop will require about ~51 MW maximum demand (phase I: ~16 MW & Phase II:

~35 MW), which will be sourced partly from Captive power plants and partly from DVC.

All electrical work will be done in a neat workmanship strictly conforming to the current Indian

Electricity Rules and IS Codes of Practice.

Water System

Water is pre-dominantly required in the steel plant cooling equipment. In addition, it is used for

process such as steam rising, for collecting and conveying of scales, control of dust and debris, for

drinking and sanitation, for fire fighting and for miscellaneous purposes.

The plant water system shall comprise a makeup water system, drinking water and fire fighting

water system, and individual re-circulating water systems for the proposed facilities, effluent

disposal system as well as emergency water supply system for the vital units of the plant.

Fire Fighting Facilities

Adequate firefighting equipment shall be installed.

C. Rolling Mills

DIL has planned to set up new 0.20 Million TPA Rolling Mill (Re-bar). As per the current EC, the

implementation of Rolling Mill having output capacity of 0.1 Million TPA is under process.

In the proposed rebar mill, 100 - 130 mm Sq. x 3/6/12 m long hot billet from caster shall be

moved to roughing mill which shall consist of 3 Nos., 3 Hi stands, RM1, RM 2 & RM3 arranged in

cross country configuration. Here hot billet get rolled in nine passes through escapement




repeaters installed in between stands RM1 – RM2, RM2 – RM2, RM2 – RM3. & RM3 – RM3 for

Rolling of 8, 10, 12, 16, 20, 25 mm round bars and 32mm round bar get rolled in 7 passes with

addition of a repeater to be installed between stand no. RM2 & RM3. All roughing mill stands

shall be driven by common A.C motor 1100 KW through flywheel, reduction gear box and pinion

stand. Exit bar size from stand RM3 shall be 25 mm Sq., 27.5 mm Sq. or 35 mm Sq. which shall be

moved to 2 nos. disc shears with pinch roll in between for front and back end cutting.

Intermediate mill consists of 4 stands i.e. IM1, IM2, IM3 IM4, alt 2Hi, horizontal, arranged in cross

country configuration in addition with speed increaser, 2Hi Pinion stand between stand # IM2 &

IM3. All intermediate mill stands shall be driven by common D.C. Motor 600 KW through

reduction gear box and pinion stand. The exit bar size from stand IM4 shall be 17 mm / 18.6mm /

20 mm round.

The 25 mm and 32 mm round bar shall be finished from stand # IM2 and 20 mm round bar shall

be finished from stand # IM4.

After intermediate mill a finishing mill consists of 6 stands, Horizontal, alt. 2 Hi (FM1, FM2, FM3,

FM4, FM5 & FM6,) arranged in continuous configuration to roll bar sizes 8 mm to 16 mm round

bar. All finishing stands are driven by individually DC motors of 250 kW each. Before stand # FM1

a flying shear shall be installed, to cut front & tail ends of the bar as well as chopping the bar into

small pieces during the event of cobbling in the successive stands.

In finishing mill 2 nos. vertical loppers with snap shear shall be installed between stand FM2 - FM3

& FM4 – FM5 to ensure tension free rolling in the mill to get better surface quality & grade of

finished product. Finished bar from continuous mill shall be fed to the TMT line via pinch roll # 3

to produce TMT grades of rebar. TMT finished bar then moved to the dividing shear with pinch

roll installed after TMT line in line with the tail break pinch roll and twin channel of cooling bed

to cut the long finished bar as per the 66m lg. x 8.5m width cooling bed length.

These high speed cut bars shall be handled by 2 Nos. tail breaking pinch rolls installed before the

cooling bed & twin channel installed at entry side of cooling bed length. Twin channels stops the

high speed moving bars & drop it on to the rake type cooling bed for slow cooling.

Cooled bars in layer shall be shifted to run out roller table of cooling bed through automatic chain

transfer. These cooled bars then moved towards cold shear to cut into 12 m length measured by a

disappearing stopper installed at a distance 12m from shear blade. After cold shear these bars

then transferred to storage bay through bar transfer / bar bundles &Bundle bending system. The

bundle of bars tied manually. Thus 6m long bar bundles are ready for dispatch to storage yard.

Mill Layout

The following features will be considered while developing the layout of the Rebar mill:-




The Mill, billet storage, finished material storage shall be at ± 0.00level.

The units must be suitably located in the plant premises.

The layout must be compact.

Area must be utilized optimally.

Flow of material should be smooth and uni-directional with in line inspection.

Location of integration facilities must be such that it gives minimum rise to piping and

cabling.

Sufficient space within the shops must be provided for repair, maintenance and storage of

spare parts.

D. Ferro Alloys (Silico Manganese / Ferro Manganese: 2 x 9 MVA)

Ferro alloy refers to various alloys of iron, which are used in the production of mild steel, carbon

steel, special alloy steel and stainless steel. India’s steel production is increasing every year;

thereby the consumption of Ferro Alloys is also increasing. The Indian Ferro Alloy industry has a

capacity of 5.15 million tones. It is accounting for nearly 10%of the world’s ferro alloy production

and is among the 10 largest producers of the material in the world. In the midst of raw material

availability being a key factor for Ferro Alloy industry growth, production is concentrated in a few

pockets. India, South Africa, China and the CIS countries represent a large source for Ferro Alloys.

India’s Ferro Alloy supply constitutes of Ferro chrome about 32%, Ferro Manganese and Silicon

Manganese about 62% and rest others.

DIL has proposed to set up two 1x9 MVA Submerged Electric Arc Furnaces (SAF), one in each

phase. Considering the present feasibility and demand scenario, DIL proposes to produce Silico

Manganese in the SAF. Each 9 MVA furnace will have an output capacity of 15,000 TPA (approx) of

Silico Manganese. The company may also produce Ferro Manganese in the SAF, in case of better

realization and market demand.

Manufacturing Process of Ferro Alloys:

Ferro Alloys are smelted at about 1350 – 1500 deg. C Temperature. This is achieved by a

conventional, Open Submerged Electric Arc Furnace. The three Carbon Electrodes, partially

submerged in the charge, are supported on hydraulic cylinders for upward and downward

movements to maintain the desired electrical parameters.

The body of the furnace is cylindrical in shape, and is lined with Firebricks, Silicon carbide bricks

and Carbon tamping paste. Three tap holes are provided at 120 degree apart for drawing out

both the molten alloy and Slag. During the repair works of one of the tap holes the other will

function as stand by. The Raw materials are conveyed through Conveyors and stored in Day

Bunkers. The charge mix is weighed electronically and it is thoroughly mixed in the proper




proportion before being charged through Skip, Telfer hoist and charging chutes into the Furnace.

The charge is being pushed near to electrodes on Furnace top by a Charging Stoker. As the

charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the

reductants, being heavy, gradually settles at the bottom. At regular intervals the furnace is tapped.

The tap hole is opened by Oxygen lancing pipe and after tapping is completed, it is closed by clay

plugs. The liquid Metal and Slag are collected in a Ladle and Slag will be over flowed to sand

beds. The Metal being retained in the ladle having a Nozzle at the bottom which allows metal

flows on to C.I. Pans. After solidification the cakes are broken manually to required lump size. All

the Ferro Alloys could be produced in the same furnace with minor modifications in Furnace

Equipment.

FURNACE BODY:

The furnace body consists of welded steel shell plates and stiffeners. Bottom of the shell is flat and

rests on a set of parallel beams. The shell is lined with firebricks and carbon tamping paste. The

three tap holes are made of Silicon Carbide bricks. Tapping spouts and Launders are fabricated

with M.S. material, connecting the tap hole to Crane bay. These are also lined with refractory

bricks and Tamping Paste.

HOOD & CHIMNEY:

The Hood is provided over the furnace to collect flue gases. A Gas Cleaning Plant of Filter Bag

House with Pulse Jet type is provided to clean the gas as per State norms. A tall chimney is

provided to release the gases into atmosphere during the short periods of time during furnace

start up after a long period of shut down.

ELECTRODE ASSEMBLY:

Electrode assembly consists of water cooled copper contact clamps with pressure rings,

suspension mantles, slipping collars, bus tubes and cooling water pipes. Three such electrode

assemblies are provided, each housed a soder berg self – baking electrode.

ELECTRODE REGULATION:

Each electrode assembly is supported on two hydraulic cylinders for raise and lower operations.

The movements are controlled by electric signalling and Hydraulic operating system.

ELECTRODE SLIPPING:

Slipping operation of electrodes at regular intervals, depending on the consumptions, are effected

by means of two mechanically controlled and hydraulic operated equipment.

FURNACE TRANSFORMER:




The furnace Transformer is provided in a separate dust protected room on the furnace floor. The

capacity of Transformer is 9,000 KVA and the primary having a line voltage of 11 KV and is

provided with On Load tap Changer to obtain a range of Secondary voltages at the electrodes.

SECONDARY BUS BARS:

Power is fed from Furnace Transformer to the Contact Clamps and Electrodes by means of water

cooled copper tubes arranged in a manner which keeps reactance at minimum. The bus tubes

terminate at the furnace Hood and are connected to a set of copper flexible. Water cooled copper

tubes take off from these flexible up to the electrode contact clamps, making a delta connection.

Compressed Air

Compressed air will be required for the operation of pneumatic devices and for general-purpose

use in the plant. Working and Standby compressors of adequate capacity will be provided at a

discharge pressure of 7 bars. For the supply of instrument grade, dry, oil free air to specific

consumers, a dryer with carbon filter will be provided. Approximately 3650 Nm3/hr of

Compressed Air shall be required for the entire plant operation.

Facilities Nm3 / hr Induction Furnace 300 Billet Caster 1420Rebar Mill – 2 nos. 1000 DRI Plant 479Ferro Alloy (Silico Manganese) 100Power Plants 350

Total 3649 (say ~ 3650)

Power

Power shall be sourced from mainly from Captive power plants. In case of shortfall, power shall be

sourced from DVC.




Figure 5 - Existing Plant Pictures

E. Captive Power Plant – 42 MW (21 MW WHRB & 21 MW CFBC)

DIL has proposed to set up 42 MW Captive Power Plant (existing 16 MW & proposed 26 MW)

which shall be based on WHRB and CFBC technology. Out the total 42 MW, 21 MW shall be

generated from the Waste Heat Recovery Boiler (WHRB) and 21 MW from CFBC Boiler as per

following details




Facility Capacity Unit

Existing Additional After expansion

Captive Power Plant : 16 26 40 MW

- WHRB : 7 14 21 MW

- CFBC : 9 12 21 MW

Availability of Gas:

The basic parameters of the gas generated from the DRI plant are given in table below:

S. No Particulars Parameters1. Gas Quantity ~ 1,04,000 Nm3/Hr / kiln by 350 TPD Kiln

~ 1,90,000 Nm3 / Hr / kiln by 600 TPD Kiln2. Gas Temperature 9500C (11000C momentary peak) 3. Dust load in gas 20-30 gm / Nm34. Density of Gas 1.2242 Kg / Nm3 5. Specific heat of gas 0.3 Kcal / Kg / 0C 6 Volumetric Composition of Gasi) N2 72.33% ii) CO2 2.45%iii) H2O 14.62%iv) SO2 0.07% v) O2 10.88%

Major Facilities:

The power plant will primarily consist of

a) 1 x 35 TPH (Existing) + 1 x 70 TPH (Proposed) Waste heat recovery boilers(WHRB).

b) 1 x 45 TPH (Existing ) + 1 x 50 TPH (Proposed) FBC boilers.

c) 1 x 42 MW Steam turbine generators (STG).

Features of Thermal Cycle

The steam from the boiler will be fed to a common steam turbine generator (TG) rated for an

output of 42 MW at 11kV. The TG will receive steam at 87 ata and 510°C. In order to improve the

thermal cycle efficiency each steam turbine is provided with two bleeds of around 6 to 7 KSCA

and 2KSCA.

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

turbine shaft, through the various thermodynamic processes that is capable of producing the net

heat flow or work when placed between the energy source and energy sink. The heat energy is

derived from burning of some fuels or using heat energy already available in the hot waste gases.

The cycle needs a working fluid and steam is viewed as the most favored working fluid mainly




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

availability at cheaper cost and non toxic nature. Higher thermal capacity of the working fluid

generally results in smaller equipment for the given power output or heat transfer.

Rankine Cycle is described as the combination of the various processes like the isentropic

compression of water in the boiler feed water pumps, reversible heat addition to the working fluid

through the liquid, two phase and super heat states, isentropic expansion of the working medium

in the turbine and the constant pressure heat rejection to the atmosphere through the surface

condenser and the cooling water system. The cycle to be adopted for this proposed power plant

will be a modified Rankine Cycle with the addition of a Regenerative feed water heating. To

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

extracted from the turbine. Because of the size of the plant there are limitations in the use of the

number of stages for heating the feed water, and for this proposed power plant only one stage of

heating is done in a deaerator.

High pressure and high temperature cycles are crucial for increasing the operating efficiency and

the power output from the power Plants. The choice of the level of the pressure and temperature

for the cycle depends on the level of confidence in the plant operators, quality of the feed water

and the water treatment systems available and the cost of the high pressure/temperature boiler

and Turbo generator systems and the financial benefits realizable from the power plant by way of

the sale of the exportable power.

Thermodynamically, energy recovery from the Rankine Cycle is more dependent on the steam

inlet temperature than the pressure and the higher the inlet steam temperature, higher the cycle

efficiency. However, because of the nature of the working medium, which is steam, the pressure

also plays a major role in ensuring the optimum extraction of the useful energy from the working

medium and hence, the increase in the steam temperature should be accompanied by the

matching increase in the pressure. Anyhow, the practically attainable limits of temperatures are

influenced by the metallurgy of the boiler tubing, piping, the turbine components and the

complexity of the Creep fatigue interaction for the materials at higher temperatures.

It is extremely important that the selection of the temperature is done keeping in mind the nature

of the industry. Considerations such as cost, maintainability, provision of adequate safety margins,

the experience of the industry so far and the level of the operating personnel available in the

industry, enable us to select the practical limit on the steam temperature for the plants of the

subject size and nature.

The Waste Heat Recovery Boilers consists of steam drum, economizer, evaporator, super heater,

integral piping, flue gas ducting with expansion joints, supporting structures, platforms and




walkways, soot blowers etc. The WHRB is/will be adequately sized to cater for the momentary

increment in the flow rate and the temperature of the waste gas. The super-heater is/will be

arranged in two stages with a spray type super-heater in between to control the steam

temperature.

Retractable and manual soot blowers are/will be provided to cater to high dust load. HP and LP

dosing are/will also be provided. The dust is being/will be collected at the bottom of the hopper

of the boiler by gravity.

CFBC Power Plant consists of Induced Draft Fans (ID Fan) and Stack, CFBC boilers, Steam and

Water System, Steam Drum, Super Heaters System, Economizer, Air Heater System, Combustion

Chamber, Soot Blowing System, Auxiliary Steam Pressure Reducing & De-super heating Station

(Aux.PRDS), Steam Generator Blow down & Integral Piping, Power Cycle Piping / External Piping

System, Feed Regulating Station, Fuel Feeding System, Bed Material Feeding System, Wall Seal Air

Blowing System, Startup Light Diesel Oil System, Air and Flue Gas System, Electrostatic Precipitator

System, Bed Ash Extraction /Drain System, Fly Ash Removal, Refractories and Thermal Insulation.

Turbo Generators:

a) Steam Trbine:

This Captive power plant envisages ~42 MW Extraction cum condensing turbo generator. DIL may

opt for either 1 or 2 (nos) turbo generator as per convenience.

The turbine will be designed for the operation with the inlet steam parameters at 87 ata and

510Deg.C. The turbine will be a horizontal, single cylinder, single extraction, and condensing type.

There will be four uncontrolled extraction from the turbine. Necessary spray water pressure

reducing station and de-superheater in the exhaust line for maintaining the extraction steam

parameters shall be provided. All casings and stator blade carriers will be horizontally split and the

design will be such as to permit examination of the blading without disturbing shaft alignment or

causing damage to the blades. The design of the casing and the supports will be such as to permit

free thermal expansion in all directions.

The turbine will have solidly forged and machined rotor with integral disks. The rotor after

fullymachined and bladed will be dynamic balanced accurately in the shop and will be given a

over speed test under vacuum. None of the critical speeds of the rotor will fall within the range of

20% above and 20% below the normal running speed of the rotor. The rotor will be designed to

withstand the maximum shock loading that may occur during any power system disturbance. Such

shock loading values will be taken for the design of the generator rotor.

The blading will be designed to withstand all vibrations, thermal shocks, and other loading that

may be experienced during service and system disturbances. The blades will be machined from




forged bars or die forged and the materials used will be chromium steels consistent with proven

experience and standards.

The glands will preferably be of labyrinth type and sealed with steam. The gland packing will be of

13% chromium stainless steel. Required gland steam condenser with the suction fans will be

provided. Steam leaving the glands will be condensed in the gland / vent steam condenser.

The turbine will be provided with liberally rated hydrodynamic radial and thrust bearings. The

radial bearings will be split, for ease of assembly, and of the sleeve or pad type, with steel shell

backed, babbitted replaceable pins and will be positively secured in the axial direction. The thrust

bearing will be of, Mitchell tilting pad type, with steel backed babbitted multiple segment,

designed for equal thrust capacity in both directions. A liberal flow of lube oil under pressure will

be supplied to all the bearings for lubrication and cooling.

A pressure lubrication and control oil system will be furnished for the turbo generator unit to

supply oil at the required pressure to the steam turbine, generator bearings and governing

system. For the hottest ambient conditions of 45 Deg.C, to be encountered at the site the oil

outlet temperature at any bearing will neither exceed the maximum permissible temperature for

the bearing metal nor the maximum safe operational temperature of the oil.

The turbine governing system will be electro hydraulic designed for high accuracy, speed and

sensitivity of response. The electrical / electronic and hydraulic components of the control system

will be selected on the basis of reliability over a wide range of operating conditions. All

components used will be well proven to assure overall system reliability and will be designed for

easy and quick replacement when necessary. The governor will be configurable in the field.

The governing system will have the following important functions:

Speed Control

Over speed Control

Load Control

Steam Pressure Control

As a minimum requirement the turbine will be designed to withstand the external forces and

moments calculated in accordance with the requirements of NEMA SM. 23 or any other equivalent

standards.

The steam turbine and the other high temperature parts, including piping supplied, will be

insulated with low conductivity inert material, where required, reinforced by stainless steel wire

net between applied layers. The insulation will be so arranged that it can be removed for access to

the flange bolting, control valves and other parts that require periodic maintenance.




The reduction gear box between the turbine and the generator will be of proven design preferably

of double helical arrangement with a minimum service factor of 1.3. It will be capable of

transmitting the maximum rating of the set and be able to withstand 20% over speed over a

period of minimum five (5) minutes. The gear box will also be designed for the short circuit

condition of the generator. All bearings of the gear box will be readily renewable and will be

possible to inspect the bearings and the gears readily without disturbing the shaft alignment.

Illuminated sight glasses will be provided to inspect the lube oil drain from each individual

bearing. The gear box design will be as per the requirements of AGMA or any other equivalent

standard.

The flexible couplings between the turbine and the gearbox between and the generator will be of

reputed make. The power rating of the coupling will be at least equal to the turbine rated power

times the service factor in accordance with AGMA 514 or any other equivalent standard. Easily

removable coupling guard will be placed over each of the exposed coupling.

The turbine will be provided with a barring gear of mechanical type driven by an AC motor to

rotate the turbine and generator after shutdown to prevent thermal distortion of the rotor. The

barring gear will be capable of starting the rotor from rest and run it continuously at low speeds.

The barring gear will be interlocked with the lubrication system to prevent its operation without

lubrication.

The system will be capable of manual engagement and automatic disengagement when the

turbine speed goes above the normal barring gear speed. The system will also have facility for

manual turning in case of AC supply failure.

The condenser will be of air cooled Condenser. The condenser will be sized to meet the turbine’s

wide open flow rates. Suitable designed condenser air evacuation system will be provided.

Two numbers hundred percent (100%) capacity condensate extraction pumps to pump the

condensate from the condensate tank will be provided. One of the pumps will be operating and

the other one will be a standby. The pump will be selected for a normal continuous flow rate

equivalent to the maximum steam flow to the condenser under all the operating conditions.

The turbine control will be through the centrally located DCS System, described in another section

of this Report. The control system will provide redundancy for key functions by use of separate

sensors and monitors. The control system will include all the standard control monitoring and

alarming. Only proven equipment that has been used in similar systems before will be provided.

Control panels will be supplied fully wired and complete with all necessary special wiring for

interconnection of panels. Vibration detectors/ proximity meters/ axial position detectors

monitors will be provided for all bearings including the bearings of the generator. Solid state




annunciation units wherever located will be of the first out type. Individual alarm windows will be

provided for all critical points parameters. The alarm sequence will be as per international

standards. Separate windows will be provided for pre-alarm and shutdown with simultaneous

alarm.

Auxiliary for Power Plant

Apart from the above, the power plant will have all necessary auxiliary systems such as feed water

heating and pumping systems, dust handling systems for WHRB and CFBC boilers, Condenser

cooling water system, demineralizing plant, electrical system including power distribution and

evacuation equipment, firefighting system, air-conditioning and ventilation system, cranes etc.

Electric Power System

It is proposed that power will be generated at 11 kV at the power plant utilizing waste heat of DRI

Plant through waste heat recovery boilers (WHRB), CFBC boilers and steam turbine generators

(STG).

11 kV power turbo generator will be fed through11kV cables to 11kV generator breaker which in

turn will feed to 11kV CPP Bus.

Crane for the Turbo generator Building

Two EOT cranes 30 t/10t will be provided for servicing of 42 (16+26) MW TG. This crane cannot be

used for installation of the machines and it could be useful only for maintenance.

Compressed Air System

The requirement of compressed air for instruments and the control systems of the power plant

will be supplied by two (2) instrument air compressors with one (1) working and one (1) standby.

Each of the compressors will be rated for 350Ncu.m/ hr at 7 kg/sq.cm (g). The air compressor will

be provided with accessories like Inter cooler, after cooler, Moisture separators, Air driers, Air

receivers and control panel.

The air compressor will be oil free one (1) stage reciprocating, non-lubricating type with belt drive.

The design of the reciprocating compressor will be in accordance with API 618 or any other

equivalent standard. The rotating parts will be dynamically balanced according to the standard.

The air drier unit will comprise of 2 x 100% absorber towers with one of the towers in operation

and the other one in regeneration mode. The towers will be fabricated with suitable material and

filled with Alumina. The air drier will be provided with sequence timer for automatic changeover

and change over valves. The entire drying system will be skid mounted.

The air receiver capacity will be One (1) Cu.M, fabricated from SA 515 Gr. 70 or IS: 2002 material.

The internal surface will be galvanized. The air receiver will be fitted with all accessories including

safety valves, moisture separators, etc.




Air Conditioning and ventilation System

The main plant control room housing the controls for the boilers and the turbo generator will be

air conditioned with window mounted air conditioners. A dry bulb temperature of 24°C + 1.5°C

and a relative humidity of 60% will be maintained in the control rooms.

The turbo generator station building will be provided with a forced ventilation system. Most of the

areas will be ventilated with exhaust fans mounted on the walls or on the roof.

Fire Protection System

The fire protection system for the proposed power plant will be consisting of:

Hydr

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