annexure i location map (topo map & administrative set-up) · 2018-03-13 · be of light scrap...

Annexure JR Metal - Amirthamangalam 1

List of Annexures Annexure I Location Map (Topo Map & Administrative Set-up)

Annexure II Survey Nos. – Combined Sketch

Annexure III Site Photographs

Annexure IV Plant Layout

Annexure V Manufacturing Process

Annexure VI Details of disposal of Solid & Liquid Wastes

Annexure VII Drainage & Water Bodies Map

Annexure VIII Water Balance Diagram

Annexure IX Raw Material Consumption

Annexure X Stack Characteristics

Annexure XI Air Pollution Control Measures


Annexure I

Location Map


Annexure II Combined Sketch

Annexure JR Metal - Amirthamanagalam

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Annexure III

Site Photograph


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Site Photographs


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Annexure IV

Plant Layout


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Plant Layout


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Annexure V

Manufacturing Process


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Sponge Iron Plant

The plant consists of raw material preparation unit where iron ore and non-coking

coal are crushed and screened to obtain the required sizes. These required sizes are

conveyed to stock house for storing in the respective bins. No crushing is envisaged

for dolomite/limestone, as it is received mostly in 0-4 mm size form. This limestone

is conveyed to its respective bins. The sized materials stored in bins at stock house

are charged in rotary kiln with predetermined feed rates with the help of weigh

feeders, volumetric feeders, and conveyors.

The iron ore is preheated, and reduced to sponge iron in the rotary kiln at the

required and controlled temperatures and pressure. Carbon and volatile matter in

coal is utilised and converted into char. Dolomite is used for desulfurization, and in

the process becomes dolochar. Sponge iron, char and dolochar travel from kiln to

cooler and are cooled to about 80ºC by indirect cooling, using water as medium.

The material cooled and discharged from the cooler, is conveyed to product

separation system. A junction house is provided in between cooler & product

separation system, to take care of any eventualities occurring due to the breakdown

of the product separation system, which may happen due to breakdown of

equipment etc. The cooler discharged material is screened, and separated with the

help of magnetic separators. Sponge iron lumps and sponge iron fines are taken to

their respective bins. Dolochar, and char which are non magnetic are taken to a

single bin.


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Fig 1.0 Manufacturing process of Steel division

TMT bars, Wire rod coils, Rounds, Structural products


14

Details of Steel Production Units Steel melting Shop

The Steel Melting Process can be subdivided into the following stages:-

Stage 1: Production of Liquid Metal from Induction Furnace.

Stage 2: Transfer of Liquid Steel to the Ladle Furnace

Stage 3: Continuous Casting.

Induction Furnace Scrap and Direct Reduction Iron (DRI) are the main raw materials for melting in the

Induction Furnace. The scrap and DRI will be brought into the steel plant premises

by Tipper / Dumpers / Trucks and unloaded either in the open scrap yard where it

will be intermittently stored or directly into the scrap bay, whereas, Sponge Iron is

produced within the Plant at Sponge Iron Plant. The usage of scrap and DRI in the

Steel Melt Shop is in the ratio of 56:44.

Raw Materials

Qty. in % fed in charge

Recovery

Qty. fed TPA for 6,00,000

Scrap + Cast iron Pieces

56% 96%

3,36,000

DRI 44% 82% 2,64,000

The capacity in the scrap bay of scrap and DRI will be in the same ratio. The scrap

bay will store the scrap and DRI in bins. In the scrap bay the trucks will be unloaded

by EOT cranes, and the tippers will tip the scrap / DRI into the bins directly.

From the bins in the Melting Bay EOT cranes will load the scrap in to a scrap bucket

which will be charged in to the Induction Furnace by EOT Crane. The first charge will

be of light scrap + cast iron pieces of about 3 T followed by DRI to be fed in 2-3

installments. The balance of heavy scrap is charged towards the end of the heat.


15

Fe metal C Si Mn P S

92.1% 0.25% 0.35% 0.5 % 0.03% 0.04%

The DRI will be mainly Coal based and will be in lumps with size range of 3 mm to 20 mm with a bulk density of about 2100 kg/ cum. The typical chemical composition of coal based DRI is:

Metallization Fe Total P S C Si

92% 94% 0.045% 0.02% 0.1% 1.8

Melting

The Induction Furnaces are Melting Units. The heat, and stirring in a coreless

Induction Furnace is caused by magnetic forces which result from the interaction of

the electrical current flowing in the induction coil, and in the molten bath itself melts

the metal and can increase the bath temp. to required temperature of 1600°C to

1650°C. Slag formed is taken out in the process.

The first charge of 3 t will consist of scrap and cast iron pieces only. DRI will be fed

in two or three installments. Frequent deslagging will be done to take the slag out. A

mechanical poker is provided to compact the scrap during feeding and to avoid the

formation of a bridge. The scrap mix used is shredded scrap, HMS, Cast Iron and

coal based DRI. Induction Furnace liquid steel output quality is dependent on the

quality of charge mix.

There will be 2 x 40 T Electric Induction Furnaces and 1 x 30 T Electric Induction

Furnace. The tapping temperature is maintained to approx. 1620°C.


16

The final chemistry of Liquid Metal from the induction furnace is:

C P S Temp.

0.30 max. 0.070 max 0.05 max. 1620 Deg.C

One heat in one Induction Furnace is estimated to take about 120 minutes on an

average. There will be two Induction Furnaces of 40T capacity + 1 No. of 30 T. The

Melting Bay has to therefore handle 48 heats every 24 hours.

Slag handling

The slag generated during melting will be to the extent of 10%. De-slagging will be

done by tilting the IF forward during the process while the power is reduced to a

minimum for 1-2 min. During the process of deslagging by forward tilting will be

done 5 - 6 times every heat. The slag will fall into in a slag box parked below the

Induction Furnace. The slag pot capacity will be 10 T to take care of the slag of each

heat. The slag pot will be lifted by the EOT crane and either be emptied in a dumper

or at the end of the bay. From there the slag will be taken to the slag dumping area.

Continuous Casting Machine

Liquid steel from ladle furnace is now placed in the Turret of the Continuous

Casting Machine. The Turret shall be moved and positioned over the tundish into

which the liquid steel will flow. From the tundish the liquid steel will flow into the

mould which shapes and forms the billet. The required starting ladle temperature

for the manufacture of billet for TMT rebars, wire rod, rounds, structural / grade at

the CCM is about 1650° C.

The hot billet goes through a water spray cooling chamber and comes to a

straightening cum withdrawal machine which is a set of individually driven rollers

with hydraulically pressed rollers.


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The withdrawal machine also varies the speed of the billet to keep the level of the

mould constant as the steel flow into it varies as the metering nozzle erodes with

time. After the withdrawal machine is the oxy-fuel cutting machine which cuts the

billets into 6 m / 12 m length.

The billet by the time it reaches the cutting machine has no liquid core. The billets of

the 2 strands then come out onto a run out roller table and go into the run-in roller

table of the cooling bed. The transportation of the billets together from the run-in

roller table onto the cooling bed is done by an over head cross transfer for further

pushing of by a billet pusher on a skid Bank cooling bed.

A non-sequence casting cycle is as follows:

Placement of ladle on the Ladle turret : 2 min.

Moving the turret on position : 2.min.

Opening of the slide gate to start flow of : 1 min.

steel into the tundish

Opening the tundish metering nozzle : 1 min.

Start and end of casting including

slow start /slow finish : 25 min.

Total : 31 min.

Machine preparation : 20 min. After every sequence the CCM will have to be prepared again. The final output from

the CCM is 200 mm sq. billets in 6 m/ 12 m length.

Rolling Mill

The DRI – IF – CCM – RM route is considered for the integrated plant under

consideration, which is suitably supported by the Captive Power Plant. The main

technological facilities in different processing steps for production of rolled products


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in DRI-SMS-RM route are as follows.

S.No Processing step Technological facility

1. Iron making Direct Reduction Plant

2. Steel making Induction Furnace

3. Casting Billet Caster

4. Rolling of Billets/ Blooms Rolling Mill

The Billets from Steel Melting Shop after Quality inspection are charged into

reheating furnace and at discharge end uniformly heated billets at a temperature of

about 1050OC – 1250OC (depending upon grade of Steel being rolled) are discharged

by an Ejector.

The heated billets are fed to different rolling mills to produce required size of

finished products.

The rolled product after last stand is transferred to Turnover Cooling Bed, and cut to

specified length and after Quality inspection and requisite Color Coding, bundling

etc. is shifted to despatch section.


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WASTE HEAT RECOVERY – POWER GENERATION The process of sponge iron making by the DRI route produces a large quantity of

flue furnace gas. About 3500 N.Cu.m of flue gas with a calorific value of 900

K.Cal/N.Cu.m will be generated per ton of hot metal produced. It is estimated to

generate about 15 tons per hour of steam, which inturn generates about 8000 KW

power per kiln, and hence total Power Generated for 2-kilns together will be 16 MW.

In addition to above, it is proposed to make use of the Dolachar generated in Kilns

alongwith some quantity of coal in the AFBC boiler to generate additionally 16MW

of power, thus resulting in a total of 32MW power generation.

The Power plant will consist of a boiler house, steam turbine and generator along

with accessories such as condensers, deaerators, boiler feed pumps, controls and

instrumentation.

Process flow sheet for captive power plant is as shown in the following page.


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Flow Diagram for Captive Power Plant

WHR / FBC BOILER

FLUE GAS

FROM ROTARY KILN & DOLACHAR/COAL

STEAM

TURBINE

GENERATOR

A

I

R

P

R

E

H

E

A

T

E

R

AIR

WATER

FLUE GAS

AIR

AIR COOLED CONDENSOR WATER OUT

DEAERATOR FLUE GAS TO CHIMNEY THROUGH ID FAN

32.0 MW

STEAM


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Annexure VI

Details of Solid and Liquid Waste generation and disposal method


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Solid Wastes

The solid waste generated will be slag from melting, and dolochar from sponge iron

plant.

Flyash and Bottom ash will be generated from Power Plant.

The quantity of solid waste that would be generated in the proposed plant are as

follows

S. No. Description Quantity Generated (T/D) Mode of Disposal

1. Slag 130 Ground slag will be given to

Cement manufacturers

2. Fly ash 27.65 Will be given to Cement

manufacturers

3. Bottom ash 6.91 Will be given to Brick

manufacturers

4. Dolochar 57 Will be used in AFBC Boiler

Waste water generated LIQUID WASTE MANAGEMENT

Description of effluent generated Qty (KLD)

Boiler Blow Down 18

DM. Plant Regeration Waste 15

Induction Cooling Blowdown 20

Rotary Kiln Cooling Blowdown 110

Concast Cooling Blow Down 10

TMT Cooling Blow Down 12

Sewage 9

Total 194


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Annexure VII

Drainage & Water bodies Map


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25

Annexure VIII

Water Balance Diagram


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Water Balance Diagram

All values are in KLD.

Raw Water 325

Induction Furnace 1 & 2 Cooling

Concast Cooling

Rolling Mill Cooling

Boiler Water Make-up (AFBC)

Boiler Water Make-up (WHRB)

Rotary Kiln Cooling

Evaporation Loss – 40



60

30

30

10

10

160

12

10

20

9

9

Green Belt

Cooling Pond I

Cooling Pond II

170

Guard Pond



110

Coal Dust Suppression /

Ash Dyke

7

D.M. Plant Regeneration

15 15

Domestic Consumption

10 9

STP 9

37

Rec

ycle

d

14

8

Har

vest

ed R

ain

Wat

er/

Bo

rew

ell

17

7

325

Neutralization Pit

RO Plant

185

RO Reject

148

30

15


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Annexure IX

Raw Material Consumption


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RAW MATERIAL REQUIREMENT

Annual requirement of raw materials on the basis of achievable production is as follows:

FOR SPONGE IRON PLANT

Sl.

No.

Raw Material Quantity (TPA)

1.

2.

3.

Iron-Ore

Coal

Dolomite/Limestone/ Quartz

5,40,000

2,70,000

14,900

FOR INDUCTION FURNACE / (BILLET)

Sl.

No.

Raw Material Quantity (TPA)

1.

2.

3.

4.

Sponge Iron

Melting Scrap

Ramming Mars

Refractories

2,15,000

4,32,000

1,200

620

FOR RE-ROLLING MILL

The Billet produced by the Steel Melt Shop will be the Raw Material for Re-Rolling Mill

Sl.

No.

Raw Material Quantity

1.

2.

Coal for

Producer Gas

Furnace Oil

23,000 TPA

4 KL/day

FOR POWER PLANT

Sl.

No.

Raw Material Upon Expansion

1.

Imported Coal

384 TPD


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Annexure X

Stack Characteristics


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Stack Characteristics

Stack No 1 2 3 4 5 6 7 8

Material of Construction M.S M.S M.S M.S M.S M.S M.S M.S

Stack attached to Rotary Kiln 2 x 350TPD

Induction Furnace

40T

Induction Furnace

40T

Induction Furnace

30T

Re-Heating Furnace

40T

Power Plant

16 MW (AFBC – 65

TPH)

D.G. Set 750 KVA

D.G. Set 625 KVA

Stack height Above the ground level, in m

30.0 30.0 30.0 30.0 30.0 110.0 9.0 9.0

Stack top Round or Circular

Circular Circular Circular Circular Circular Circular Circular Circular

Inside dimensions of the stack at top, mm

1350 200 200 200 350 1500 180 150

Gas quantity – m3/hr 110000 1080 1080 1080 1080 500400 1500 1200

Flue gas temperature, oC 176 70 70 70 70 140 300 250

Exit velocity of the gas, m/s 22.0 10 10 10 10 21.0 19 19

Emission concentration, mg/m3

SO2 284.0 --- --- --- 462 240.11 432 420

NOx 113.6 --- --- --- 210 97.40 72 60

SPM 100 150 150 150 11 6.95 2.4 3

Emission rate, g/s

SO2 8.68 --- --- --- 0.1386 33.36 0.18 0.14

NOx 3.47 --- --- --- 0.063 13.54 0.03 0.02

SPM 3.06 0.045 0.045 0.045 0.0033 0.97 0.001 0.001


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Annexure XI

Air Pollution Control Measures


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Air Pollution Control Equipments

The sources & process of pollution, the pollutants and their respective control measures of the

proposed plant are as follows

Sl. No. Source of Pollution Process of

Pollution

Pollutants Control Measures

1 Rotary Kiln (2 x 350 TPD) DRI Process SO2, NOX, SPM ESP/Stack

Use of Limestone

2 Electric Induction Furnace

40 T

Melting of Scrap SPM Cyclone/ Wet

Scrubber / Chimney


40 T

Melting of Scrap SPM Cyclone/ Wet

Scrubber / Chimney


30 T

Melting of Scrap SPM Cyclone/Bagfilter/

Chimney

5 Re-heating Furnace

40 T

Annehealing of

Billets

SPM Producer Gas used /

ID Fan / Stack

6 AFBC (65 TPH)

[Power Plant (16 MW)]

Fuel (Coal)

Burning

SO2, NOX, SPM ESP / Low NOX

Burner / Use of

Lime Stone / Stack

7 D.G. Set (750 KVA) Fuel burning ie.

HSD

SO2, NOX, SPM Stack as per CPCB

8 D.G. Set (625 KVA) Fuel burning ie.

HSD

SO2, NOX, SPM Stack as per CPCB


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Fugitive Emissions

i. Iron Ore / Coal Dust Extraction and Suppression

Iron-Ore/Coal handling plant is provided with set of bag filters for extraction of dust

emanating during transfer of Iron-Ore/coal from one conveyer to another. Bag filters are

provided at all junction towers, where Iron-Ore/coal is transferred from one conveyor to

another. Bag filter is also provided at the discharge point from conveyor belt to a shuttle

conveyor at the top of the bunker. Bag filter is also provided at the transfer of Iron-Ore/coal

from shuttle conveyor to the bunker.

The roads in the entire plant site will be asphalted.

ii. Iron-Ore / Coal Handling &Preparation plant Truck Unloading hoppers Dust Suppression System

Belt Conveyor Provided with Steel Hoods to Eliminate spillage & dust nuisance

Conveyor Tunnel Below Truck unloading hopper

Dust Extractor & Bag filter

Open Iron Ore / Coal stock pile

Provided with water sprinkler spray System. Eliminates spontaneous Combustion of coal thereby loss of coal & pollution due to burning of coal.

iii. Sponge Iron Screening & Handling Plant Sponge Iron Screening/Crusher and Bunker

Dust extractor connected to Bag filter.

Loading equipment Dustless soft loading equipment.

Conveyor/Transfer Point All conveyor & transfer points are provided with dust extractor/Bag filter.

Belt Conveyor Continuous hooding along length of Belt Conveyor.

Suggested control measures for arresting fugitive dust emissions along with the envisaged

pollution control equipment are adequate and will help to have a healthy and cleaner

environment inside the plant thereby improve the productivity and the efficiency of the

workers as well as that of plant machinery.

annexure i location map (topo map & administrative set-up) · 2018-03-13 · be of light scrap...

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