PRE - FEASIBILITY
REPORT
FOR
MANUFACTURE
OF
FERRO ALLOYS
WITH AN INSTALLED CAPACITY
OF
1,20,000 TONNES PER ANNUM
IN
Barjora, Dist. Bankura (West Bengal)
Submitted By:
MAITHAN ALLOYS LTD.
4th FLOOR IDEAL CENTRE
9, A.J.C. BOSE ROAD
KOLKATA – 700 017
MAITHAN ALLOYS LIMITED
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CONTENTS
CHAPTER NO. CHAPTER NAME PAGE
PROJECT HIGHLIGHTS 3
COMPANY PROFILE 5
CONSULTANT PROFILE 7
CHAPTER I INTRODUCTION 8
CHAPTER II EXECUTIVE SUMMARY 9
CHAPTER III THE MARKETING ASPECTS 14
CHAPTER IV PROCESS TECHNOLOGY 17
CHAPTER V RAW MATERIALS AND SOURCES 19
CHAPTER VI LOCATION & INFRASTRUCTURE 22
CHAPTER VII PLANT FACILITIES 24
CHAPTER VIII UTILITIES AND SERVICES 27
CHAPTER IX CIVIL AND STRUCTURAL WORK 34
CHAPTER X MANPOWER 35
CHAPTER XI IMPLEMENTATION SCHEDULE 36
MAITHAN ALLOYS LIMITED
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PROJECT HIGHLIGHTS
NAME OF THE COMPANY : MAITHAN ALLOYS LIMITED
DIRECTORS : SRI SUBHAS CHANDRA AGARWALLA
SRI SUBODH AGARWALLA
CONSTITUTION : LIMITED COMPANY
REGISTERED OFFICE : 4th FLOOR, IDEAL CENTRE
9, A.J.C. BOSE ROAD,
KOLKATA - 700 017.
CORPORATE OFFICE : 4th FLOOR, IDEAL CENTRE
9, A.J.C. BOSE ROAD,
KOLKATA - 700 017.
LOCATION : BARJORA, DIST. BANKURA, WEST BENGAL
PROJECT : FERRO ALLOYS PLANT
FINAL PRODUCT : FERRO ALLOYS
PROPOSED CAPACITIES :
➢ FERRO ALLOYS PLANT (4X16.5 MVA
SUBMERGED ARC FURNACES) – TOTAL
1,20,000 TPA FERRO ALLOYS (FERRO
CHROME, SILICO MANGANESE, FERRO
SILICON & FERRO MANGANESE)
➢ SINTER PLANT (2X100 TPD) – 70,000 TPA
MANGANESE ORE SINTER
➢ BRIQUETTE PLANT (2X30 TPH) – 3,00,000
TPA CHROME ORE BRIQUETTE
KEY ADVANTAGES : • READY SOURCE OF MAJOR RAW MATERIALS
• READY MARKET FOR THE FINISHED
PRODUCT
• PROMOTERS WELL EXPERIENCED IN THE
BUSINESS LINE
• USAGE OF PROVEN AND UNIVERSALLY
ACCEPTED TECHNOLOGY.
MAITHAN ALLOYS LIMITED
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MAITHAN ALLOYS LIMITED
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COST OF PROJECT (Rs. In Lacs)
Particulars Total
1. Land & Land Development Cost 1500.00
2. Shed & Building 1457.32
3. Plant & Machinery 16784.15
4.
5.
Miscellaneous Fixed Assets
Interest during construction
390.00 1224.00
6. Provision For Contingencies 1397.36
7. Preliminary & Pre-Operative Expenses
397.77
8. Margin for Working Capital 3906.72
TOTAL 27057.33
MEANS OF FINANCE (Rs. In Lacs)
Particulars Total
1. Share Capital 13457.33
2. Term Loan 13600.00
Total 27057.33
OPERATIONS Year 1 Year 2 Year 3 Year 4
Capacity Utilization 75% 80% 85% 85%
Production (TPA) 45000 96000 102000 102000
Power (lac units) 1710 364 3876 3876
Net Turnover (Rs. in crores) 306 711 815 858
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COMPANY PROFILE Maithan Alloys Limited is a company with its registered office is at 4th Floor, Ideal Centre,
9, A.J.C. Bose Road, Kolkata 700017. The promoters have a rich heritage in the form of
a sound industrial background, with a decade experience in ferro alloys. In addition, the
promoter group has widely varying experience in Coal Mining, Coke Manufacturing,
Refractories, Iron & Steel and International Trade.
The group as a whole currently enjoys a leadership position as far as the manganese
alloys industry is concerned. This new project being undertaken will further consolidate
the group’s position in the entire basket of ferro alloys. The ideal location selected on the
basis of closeness to raw material source, availability of inexpensive quality power and
proximity to the port as well as the upcoming new steel destination of India will render an
advantage so powerful that the company will be able to take all thick and thin in its stride.
BIO - DATA of Sri Subhas Chandra Agarwalla
Date of Birth : 27/11/1951
Present Address : P.O. Salanpur - 713 357, Dist. Burdwan (W.B.)
Educational Qualification : B.Com (Hons.)
Experience Details : 46 Years’ experience in various businesses such as Coal Mining, Coke Manufacturing, Refractories & Ferro Alloys.
BIO - DATA of Sri Subodh Agarwalla
Date of Birth : 12/09/1978
Present Address : P.O. Salanpur - 713 357, Dist. Burdwan (W.B.)
Educational Qualification : B. Tech., M.B.A.
Experience Details : 15 Years experience in Ferro Alloys.
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PAST PERFORMANCE OF MAITHAN ALLOYS LTD
Year Turnover
(Rs. In crores)
EBIDTA
(Rs. In crores)
PAT
(Rs. In crores)
Production
(‘000 Tonne)
2015-16
2016-17
2017-18
1151
1342
1879
131
297
395
79
198
291
206
213
225
MAITHAN ALLOYS LIMITED
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CHAPTER – I
INTRODUCTION
Ferro Alloys are an important component added to Steel for enhancement of its
properties. Alloying elements such as Manganese (Mn), Silicon (Si), Chromium (Cr),
Molybdenum (Mo), Tungsten (W) etc. need to be added to Steel while it is still in molten
state to improve various physico-mechanical characteristics. These elements are
normally added to steel in the form of Ferro Alloys. Besides alloying functions, Ferro
Alloys are very essential for Steel making as it is used for deoxidizing and degassing.
Steels are mainly classified according to its alloying elements such as low alloy, medium
alloy and high alloy Steels.
Submerged Electric Arc Furnace route is being used for Ferro Alloy production since
1951. Though several types of Ferro Alloys are in vogue, the major Ferro Alloys are
Ferro Manganese, Silico Manganese, Ferro Silicon and Ferro Chrome. Production of
Ferro Alloys calls for availability of right type of ore and quality power at the optimum
parameters. India is fortunately endowed with good reserve of ores such as Mn Ore,
Chromite, Quartz, etc, which are suitable for Ferro Alloy production. As such, it is a right
place for ore based Ferro Alloys production. 97% of proven Chrome Ore reserves of
India occur in Sukinda Valley in Jajpur district of Orissa. Barjora is about 400 km from
Chrome ore mines and 250 km from Haldia port (for imports). Good quality power at very
competitive rates are supplied by Damodar Valley Corporation (Power utility) in this area.
Besides, the area has good infrastructural facilities and proximity to other minor
indigenous raw materials, making it an attractive location for a Ferro Alloy plant.
The technology for Ferro Alloy production is available indigenously and plants can be set
up by utilizing indigenous equipment, engineering and know-how.
The demand for Steel is increasing vis-a-vis production in India. Hence, the demand for
Ferro Alloys, which is a necessary addition, is bound to increase. Each tonne of Mild
Steel produced requires a minimum of 8-10 kg of Ferro Alloys. The corresponding
requirement for stainless steel are about 200 kg of ferro chrome and an almost equal
quantity of other ferro alloys.
The Ferro-Alloy industry is predominantly located in Andhra Pradesh, Orissa,
Chhattisgarh, West Bengal, Jharkhand & Meghalaya. There are more than 100 units in
India, with a total capacity of 4-5 million tonnes. Manufacturing of ferro alloys is a power-
intensive process.
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CHAPTER – II
EXECUTIVE SUMMARY
2.1 GENERAL:
M/s Maithan Alloys Limited proposes to set up 4 x 16.5 MVA Submerged Arc
Furnaces along with Sinter Plant (2x100 TPD - 70,000 TPA Manganese Ore
Sinter) & Briquette Plant (2x30 TPH - 3,00,000 TPA Chrome Ore Briquette) at
L.R. Plot No. at Mouza: Basudevpur (North) – 856, 960-964, 972, 974-999, 1001-
1026, 1028-1036, 1063-1066, 1076, 1077, 1080-1083, 1085-1105, 1107-1113,
1117, 1120, 1125, 1128, 1138-1141, 1025/1247, 1065/1174, 1106/1106,
986/1249, 986/1250, 986/1251, L.R. Plot No. at Mouza: Hat-Asuria – 365-379,
381, 382, 385, 1002-1026, 1028, 1035, 1011/2872, 1035/2874, 1806/2871,
372/2672, Village: Hat-Asuria and Basudebpur (North), Mouza: Basudebpur
(North) and Hat-Asuria, P.O. Hat-Asuria, P.S. Barjora, District Bankura, West
Bengal.
2.2 MARKET DEMAND:
Looking at the projection of demand for steel and ferro alloys it can be realised
that there remains a considerable gap between demand and supply of steel/ferro
alloys by 2020-21.
To meet the demand, new capacities have to be created. As such setting up a
ferro alloy plant by M/s Maithan Alloys Limited is commercially suitable.
2.3 PROCESS TECHNOLOGY:
The proposed project shall cover Ferro Alloys production. Four Submerged
Electric Arc Furnaces, of combined daily capacity of about 343 T and an annual
capacity of 1,20,000 T will be set up for production of Ferro Chrome, Silico
Manganese, Ferro Silicon & Ferro Manganese ferro alloys.
2.4 RAW MATERIALS:
The plant shall require friable Manganese Ore, Coke, Coal & Quartz. The annual
requirement of various raw materials is given in Table 2.1:
Table 2.1 Raw Materials requirements
Sl. No. Items Annual Daily
1. Chrome Ore 156000 MT 446 MT
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2. Manganese Ore 102000 MT 291 MT
3. FeMn Slag 42000 MT 120 MT
4. Coke 48000 MT 137 MT
5. Coal 34800 MT 100 MT
6. Quartz 13200 MT 38 MT
7. Molasses 3600 MT 10 MT
8. Lime 1500 MT 4 MT
9. Dolomite 1200 MT 4 MT
10. Light Diesel Oil 600 KL 2 KL
2.5 PLANT LOCATION AND INFRASTRUCTURE:
The project envisages the setting up of a 4 x 16.5 MVA capacity Ferro Alloys
Plant along with Sinter Plant (2x100 TPD - 70,000 TPA Manganese Ore Sinter) &
Briquette Plant (2x30 TPH - 3,00,000 TPA Chrome Ore Briquette) at L.R. Plot No.
at Mouza: Basudevpur (North) – 856, 960-964, 972, 974-999, 1001-1026, 1028-
1036, 1063-1066, 1076, 1077, 1080-1083, 1085-1105, 1107-1113, 1117, 1120,
1125, 1128, 1138-1141, 1025/1247, 1065/1174, 1106/1106, 986/1249, 986/1250,
986/1251, L.R. Plot No. at Mouza: Hat-Asuria – 365-379, 381, 382, 385, 1002-
1026, 1028, 1035, 1011/2872, 1035/2874, 1806/2871, 372/2672, Village: Hat-
Asuria and Basudebpur (North), Mouza: Basudebpur (North) and Hat-Asuria,
P.O. Hat-Asuria, P.S. Barjora, District Bankura, West Bengal. The major raw
materials shall be received by road/rail and the finished products shall also be
despatched by road.
2.6 PLANT FACILITIES:
2.6.1 Raw materials, storage and handling - The raw material storage capacity in the
yard are given below in Table – 2.2.
Table – 2.2
Sl. No. Material No. of Days Storage
1. Chrome Ore 60 days
2. Manganese Ore 60 days
3. Ferro Manganese Slag 60 days
4. Coke 60 days
5. Coal 60 days
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It is assumed that the material shall be received in the yard by truck. Material
from the stockyard shall be conveyed to the day-bins by dumper & pay-loader.
2.6.2 Ferro alloys making – It is proposed to set up 4 Submerged Arc Furnaces of
approximate combined capacity 343 TPD. The plant shall be producing 1,20,000
Tons of Ferro Alloys per year.
• Raw Material Storage & Handling
• Submerged Arc Furnaces
• Ferro alloys storage and handling
• Ladle preparation and drying
2.7 UTILITIES AND SERVICES:
2.7.1 Water Supply Facilities:
Requirement of water – The estimated additional requirement of water for various
purposes is indicated in the following Table – 2.3.
Table – 2.3 : Water requirement
1.
2.
3.
Circulating Water
Make-up Water
Drinking Water
2400 KL
600 KL per day
50 KL per day
The total requirement of fresh water to meet process make-up and drinking
needs shall be 650 cubic meters per day. The water shall be made available by
Local Gram Panchayat and/or WBIDC water supply system.
Necessary facilities shall be provided for supply of industrial water, soft water as
per requirement.
2.7.2 Compressed air facilities – Facilities has been provided for supply of industrial
quality compressed air and dry quality instrumentation air as per requirement.
The total requirement of air shall be as follows:
• 200 Nm3 per min industrial quality air at 7kg per cm2.
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2.7.3 Other Gas facilities – Oxygen and acetylene shall be required for opening of tap
holes prior to tapping and for maintenance jobs.
2.7.4 Power supply and distribution – The estimated total power demand and annual
energy consumption are as follows in Table - 2.4:
Table – 2.4 : Power
Power Demand (MVA) 64 MVA
Annual Energy Consumption (Million KWhr) 456.00
The above requirement is for 100% capacity utilization.
The power shall be required at plant site at 132 KVA and will be stepped down
suitably for various purposes. Necessary arrangement shall be made for supply
of emergency power to critical equipment.
2.7.5 Instrumentation – Adequate instrumentation has been foreseen for better process
control. All inputs from instruments shall be available in the control room.
2.7.6 Quality control facilities – A quality control laboratory has been foreseen for the
following function:
• Analysis of raw materials
• Analysis of product
• Testing of water and gas samples.
2.7.7 Ventilation and air conditioning – Building and shops will generally be provided
with natural ventilation. The control rooms of plants shall be provided with window
type air conditioner to maintain the temperature as per requirements.
2.7.8 Fire protection facilities – To combat fire internal and yard hydrants shall be
provided at suitable locations. Besides portable fire extinguishers shall be kept at
strategic locations. A firepost with one fire attendant has been foreseen.
2.7.9 Pollution control facilities – All measures have been provided to contain water air
and noise pollution inside plant premises to acceptable limits.
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2.8 MANPOWER:
The category-wise break-up of manpower that shall be required is given below in
Table – 2.5:
Table – 2.5: Manpower Requirement
Sl. No. Category No. of Employees
01 Managerial 17
02 Supervisory 45
03 Skilled 72
Sub Total (Direct) 134
04 Semi – Skilled 72
05 Unskilled (furnace handling) 144
06 Unskilled (metal handling) 200
07 Security Personnel 20
Sub Total (Indirect) 436
Total 570
2.9 PROJECT IMPLEMANTATION SCHEDULE:
The time of implementation shall be as follows:
4 Ferro Alloy Furnaces of 16.5 MVA each along with Sinter Plant (2x100 TPD -
70,000 TPA Manganese Ore Sinter) & Briquette Plant (2x30 TPH - 3,00,000 TPA
Chrome Ore Briquette) - 30 months
2.10 PROJECT COST:
The Total project cost comes to about Rs. 271 crores
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CHAPTER – III
THE MARKETING ASPECTS
3.1 Increase in global steel production:
The global steel production has increased continuously over the last few years
and this trend is expected to continue in the years to come. The production of
crude steel for last few years and future production as projected is given below in
Table – 3.1:
Table – 3.1
Year Production of Steel (million tonnes)
2010 1394
2011 1491
2012 1510
2013 1578
2014 1636
2015 1596
2016 1625
2017 1711
As can be seen from the table above, the global crude steel output has been
growing at about 5% and is expected to grow at a similar rate overall. The steel
growth in India has been higher and is expected to grow @ 7% till 2030 by when
the production is expected to reach about 230 million tonne. This consistent
growth of crude steel production will have a direct correlation with the demand for
ferro alloys i.e. Ferro Chrome, Silico Manganese and Ferro Manganese
3.2 Change in Production Pattern of Steel i.e. its Mix:
Manganese-intensive steel accounts for 13% of the global steel production and
this proportion is expected to rise. Similarly, stainless steel (consuming high
quantities of ferro chrome) is rising due to demand of higher quality steel for both
industrial as well as domestic applications. The bulk of steel production
comprises multi-purpose low carbon steels containing only 0.15% to 0.80%
manganese while high strength steels with yield strength over 500 MPa contain
MAITHAN ALLOYS LIMITED
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over 1% manganese but represent only 3 to 4% of the tonnage of the steel
produced today.
The latter leverage the austenitic transformation temperature to obtain a fine
ferrite structure. Micro-alloying additions reinforce the structure through carbide or
nitride precipitates which are evenly distributed in the ferrite matrix. These steels
are widely used for oil/gas pipelines, shipbuilding and in transportation equipment
to reduce weight without compromising strength.
Engineering steels comprise either HSLA or heat-treated grades; either pure
chromium-manganese grades, or with nickel, chromium, molybdenum, vanadium
additives and often 0.6 to 0.8% manganese. A few grades containing 1.0% to
1.5% manganese (as well as chromium or boron) are popular with the automobile
industry.
Stainless steels represent less than 2% of total world steel production and
contain about 1% manganese. Special manganese-stainless steels, where nickel
is replaced partly or entirely by manganese, have a manganese content of 4 to
16%. An example of the same is the series 200 stainless variety.
Any overview of high manganese steels must include Hadfield steel which
contains 13% or more manganese. Its unique properties make it indispensable
for applications requiring toughness and wear resistance. Among these can be
cited gyratory crushers, jaw-crusher plates, railway points and crossover
components, teeth for earth-moving equipment, etc. High manganese (10-12%)
non-magnetic steels are used for such products as retainer rings for turbo
alternators and collars on oil rigs. Grades with a similar chemistry are used as
cryogenic steels.
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3.3 Demand for Ferro Alloys
Demand for Ferro Alloys is directly linked to steel production level. Looking at the
projection of demand for steel and ferro alloys it can be realized that there
remains a considerable gap between demand and supply of steel as well as ferro
alloys by 2020-11. To meet the demand, new capacities have to be created.
The production of ferro alloys is concentrated in a few pockets like India, China,
South Africa and the CIS. South African production has been hampered due to
logistics, power and political considerations. China is the biggest producer of ferro
alloys in the world but its government is discouraging exports due to the power
intensive nature of the product with an export duty of 20%. India enjoys a number
of advantages that make it a favourable location for global supply.
3.4 The Indian ferro alloy advantage
Low production cost: India has abundant supply of low cost manpower (skilled
and unskilled), which is an edge in a business that requires about 10 people for
every MVA of production.
Favourable location: With three-fourths of India’s landmass accessible by sea,
India is favourably located to export to various destinations across continents.
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Abundant industrial power availability: The industrial supply of power is
available at reasonable rates in India, an edge in a power-intensive industry over
China and South Africa. China is conserving its energy and has imposed an
export duty on ferro alloys, while South Africa is experiencing a power crisis.
Ore edge: India possesses the sixth largest quantity of manganese ore deposits
in the world, representing adequate backward integration.
Large domestic market: India enjoys the advantage of a growing domestic
steel market. India’s steel production is expected to increase from an estimated
100 MT in 2017-18 to 230 MT in 2030-31 (Source: Ministry of steel).
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CHAPTER – IV
PROCESS TECHNOLOGY
4.1 General
Process technology selection and manufacturing route are very crucial for
achieving efficiency and economy. This project envisages setting up of a Ferro
Alloy plant wherein suitable and sized material shall be procured. As such the
process technology area relates to only ferro alloy production.
This plant shall be designed for production of Ferro Alloys (Ferro Chrome, Silico
Manganese, Ferro Silicon & Ferro Manganese). The standard grade of Ferro
Chrome has Cr content of ~60% and Silico Manganese has Mn content of ~60%
and Si content of 14-15%.
The production of Ferro alloys is a continuous slagging process. The oxides of
chromium, manganese, iron, silicon, phosphorous etc. contained in the ore is
reduced by the carbon present in coke/coal in a submerged electric arc furnace.
The reduction of oxide is accompanied by evolution of gases at furnace top.
4.2 Silico Manganese / Ferro Chrome
Silico Manganese is an alloy of manganese with silicon & iron. Ferro Chrome is
an alloy of chromium with iron & silicon with silicon present in smaller quantities.
Ferro alloys are widely used in metallurgy as a complex reducer and alloying
additive in making various grades of steel, with ferro chrome usage limited largely
to stainless steel production, but in significantly higher quantities.
The concept of the use of Silico manganese instead of ferro manganese and
ferro silicon pure into the steel is due to its cost effectiveness, as ferro
manganese and ferro silicon require purer raw materials, which are costlier.
Moreover silico manganese goes for production of refined grades of Ferro
manganese i.e. low and medium carbon ferro manganese. Ferro manganese, on
the other hand is used where Si content in the finished steel has to be controlled
accurately as is the case in steel flat products (sheets and plates).
Silicides of Manganese are more stable compounds than manganese carbides.
Therefore, the higher the Si content in manganese alloys, lower is the carbon
content.
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Ferro alloys are produced by reduction of ores by the carbon contained in coke
and coal.
The chemical reactions taking place are as follows:-
Decomposition: 4 MnO2 => 2 Mn2 O3 + O2 (at 430oC)
6 Mn2O3 => 4 Mn3O4 + O2 (at 950oC)
Reduction: Mn3O4 + C => 3 MnO + CO
MnO + C => Mn + CO (at 1430oC)
2 Cr2O3 => 2 Cr + 3 O2 (at 1780oC)
SiO2 + C => Si + CO2 (at > 1500oC)
The Cr, Mn and Si thus formed join the alloy.
The excess SiO2, AI2O3, oxides of calcium and Magnesium get generated during
the process and join the slag. 0.7 – 1.0 Tonne of slag produced per tonne of
alloy. This would be sold for land filling purposes. Fluxes may be added to
control the slag fluidity.
Metal (Alloy) and slag are tapped simultaneously 3 - 4 times per shift.
Selection of Plant Capacity
H.C. Silico Manganese and H.C. Ferro Chrome are typically smelted in 5000 -
18000 KVA closed top submerged electric arc furnaces with transformer
secondary voltage 100 – 200 V. The plant will have 4 submerged arc furnaces of
16.5 MVA working for 350 days in a year and 3 shifts per day.
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PROCESS FLOW-CHART
INPUT OF SIZED & GRADED RAW
MATERIAL
HANDLING BY PAYLOADER &
DUMPERS
FEED IN DAY BINS THROUGH
BELT CONVEYOR
BATCH PREPARED BY COMPUTERISED
WEIGHMENT
TAPPING IN CAST IRON LADLES
DISCHARGE OF MOLTEN METAL
REACTION IN
FURNACE
CHARGE INTO
FURNACE
NATURAL COOLING OF
INGOTS
SIZING, GRADING
& PACKING
INSPECTION
DESPATCH
DISCHARGE
OF SLAG
RE-USE AND/OR
LAND FILLING
MAITHAN ALLOYS LIMITED
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CHAPTER – V
RAW MATERIALS AND SOURCES
The quality of raw materials is key factors for effective plant operation.
The raw materials, required for manganese alloys production are:
For Ferro Chrome / Silico Manganese
- Chrome Ore / Manganese Ore / Ferro Manganese Slag
- Coke & Coal
- Dolomite & Quartz
For Ferro Silicon
- Coke / Coal / Charcoal
- Quartz
The sources for raw materials have to be critically selected to get the required product.
Chrome Ore:
Mn - 35-40%
P - 0.10% (typical)
Size - 0-6 mm
This would be procured form Sukinda Valley in Jajpur district of Orissa and would be
transported 400-450km in trucks. The ore would be friable in nature and would contain
about 90% 0-3mm. The fines would need to be agglomerated in a briquetting plant using
LDO for drying and molasses and lime as binders.
Manganese Ore (Imported):
Mn - 35-46%
P - 0.10% (typical)
Size - 10-75 mm
Mn Ore of highest quality would be imported from Australia / Africa in lots of about 4000-
8000 tonnes to Haldia port.
Manganese Ore (Domestic):
Mn - 26-35%
P - 0.20% (typical)
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Size - 10-75 mm
The domestic ore would be sourced from Barbil, Nagpur or Bellary sector based on
actual need.
Ferro Manganese Slag:
MnO - 30-35%
P - ~0.02%
Size - 20-80 mm
The above material would be generated during the in-house production of ferro
manganese in the company’s plant at Kalyaneswari. If sufficient quantities are not
available in-house, it could be procured from indigenous sources or even imported.
LAM Coke (Imported):
Ash - 14-18%
Size - 5-25 mm
Metallurgical coke shall be imported in bulk from China, Ukraine or Colombia depending
on the comparative cost.
Coke (Domestic):
Ash - 30-32%
Size - 5-25 mm
The above coke shall be procured from small coke plants in Dhanbad which is about
150km away.
Coal:
Ash - 25-30% (max)
Size - 20-50 mm
The Coal of above quality is available in South-Eastern Coalfields of CIL in nearby
Chhattisgarh. Coal received from mines shall be crushed to the above size at the plant.
Quartz:
Quartz of below-mentioned quality is available in Keonjhar / Sundargarh dist. of Orissa.
SiO2 - 96% (min)
Size - 25 – 75mm
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Dolomite:
CaO + MgO - 50%
SiO2 - < 4%
Dolomite of this quality is available from Sundergarh District, Orissa. It shall be used in
small quantities as and when required depending upon metallurgical parameters.
The daily and annual requirement of raw materials for production of 60,000 TPA Ferro
Chrome and 60,000 TPA Silico Manganese is given in the following Table – 5.1.
Table – 5.1: Raw Material requirement
Sl. No. Items Annual Daily Raw Material
per Tonne of Fe-Cr
production
Raw Material
per Tonne of Si-Mn
Production
1. Chrome Ore 156000 MT 446 MT 2600 kg/MT NIL
2. Manganese Ore 102000 MT 291 MT NIL 1700 kg/MT
3. FeMn Slag 42000 MT 120 MT NIL 700 kg/MT
4. Coke 48000 MT 137 MT 400 kg/MT 400 kg/MT
5. Coal 34800 MT 100 MT 180 kg/MT 400 kg/MT
6. Quartz 13200 MT 38 MT 20 kg/MT 200 kg/MT
7. Molasses 3600 MT 10 MT NIL
8. Lime 1500 MT 4 MT NIL
9. Dolomite 1200 MT 4 MT 20 kg/MT NIL
10. Light Diesel Oil 600 KL 2 KL NIL
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CHAPTER – VI
LOCATION AND INFRASTRUCTURE
Location: The project envisages the setting up of 4 x 16.5 MVA Submerged Arc
Furnaces for production of Ferro Alloys along with Sinter Plant (2x100 TPD - 70,000 TPA
Manganese Ore Sinter) & Briquette Plant (2x30 TPH - 3,00,000 TPA Chrome Ore
Briquette) at L.R. Plot No. at Mouza: Basudevpur (North) – 856, 960-964, 972, 974-999,
1001-1026, 1028-1036, 1063-1066, 1076, 1077, 1080-1083, 1085-1105, 1107-1113,
1117, 1120, 1125, 1128, 1138-1141, 1025/1247, 1065/1174, 1106/1106, 986/1249,
986/1250, 986/1251, L.R. Plot No. at Mouza: Hat-Asuria – 365-379, 381, 382, 385, 1002-
1026, 1028, 1035, 1011/2872, 1035/2874, 1806/2871, 372/2672, Village: Hat-Asuria
Basudebpur (North), Mouza: Basudebpur (North) and Hat-Asuria, P.O. Hat-Asuria, P.S.
Barjora, District Bankura, West Bengal.
MAITHAN ALLOYS LIMITED
25
Fig : 6.1 Location of the Project Site
The proposed project site is located at Village: Hat-Asuria Basudebpur (North),
Mouza: Basudebpur (North) and Hat-Asuria, P.O. Hat-Asuria, P.S. Barjora, District
Bankura, West Bengal. Its geographical co-ordinates are Latitude 23024’11.00”N and
Longitude 87017’50.00”E with above mean sea level (AMSL) 257 ft. The four corners
of the proposed project site are as follows:
Co-ordinates of all four corners of Project Site:
Four Corners Latitude Longitude
Top Left Corner 23°24’18.47”N 87°17’59.75”E
Top Right Corner 23°24’15.03”N 87°17’49.18”E
Bottom Left Corner 23°24’12.06”N 87°17’36.49”E
Bottom Right Corner 23°24’02.83”N 87°17’52.68”E
The project site already has proper road linkage for transport of materials and
equipment. The nearest Railway Station Durgapur is 10.3 km from the project site.
Nearest town Kharagpur is about 3.0 km from the project site. Important Town like
Barjora is about 3 kms from the project site and Bankura (District H.Q) is about 30
km from project site. Good road connectivity because of SH-9 is located at a distance
of 2.4 kms from the project site. Hatasuria Pakhanna road is located at a distance of
0.5 kms from the project site. Kolkata city is located at a distance of about 120 km
from the project site. The nearest airport is Kolkata which is about 144 km from the
project site. River Damodar is passing approx. 6.0 km distance in north-east direction
w.r.t the project site.
There is no National Park, Reserve Forest & Wildlife Sanctuary within 10 km radius
of the Project Site.
Land: The land requirement for the total unit shall be around 40 acres (16.19 Ha).
The land shall be fairly flat and suitable for industrial purpose.
Power
Power requirement of the proposed plant would be around 64 MVA which shall be
drawn at 132 KV and will be supplied by Damodar Valley Corporation (DVC).
Water
MAITHAN ALLOYS LIMITED
26
650 KLD water will be required for the project. Such water which will be made
available by Local Gram Panchayat and/or WBIDC water supply system.
Transportation
The site is well connected by road. It is situated 2.4 km from state highway. Besides,
a railway siding is close by for goods movement and Haldia port is about 250 km
away for handling import and export cargo. Durgapur railway station is only 10.3 km
away for passenger movement.
Raw Materials
All raw materials shall reach the plant by trucks, transported from the nearby railway
siding, Haldia port or directly from the mines (as the case may be).
Layout: The plant layout has been already developed considering the below factors:-
1. Mode of receipt of raw materials.
2. Amount of material to be stored.
3. Raw materials preparation.
4. Handling methods to be adopted for proportioning.
5. Charging methods.
6. Technological units.
7. Product handling, treatment & dispatches.
8. Logistics and movement.
The plant layout will be developed looking into the placement of technological and
services units so that there is no interference and the movement of man and material
is easy and minimum.
MAITHAN ALLOYS LIMITED
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CHAPTER – VII
PLANT FACILITIES
7.1 Raw Material Receipt and Storage
Incoming raw material i.e. Mn Ore, Quartz, Coke, Dolomite and Coal shall be
received by trucks and stacked separately in the stockyard. The material shall be
procured in required size range and quality.
The requirement of raw materials and storage capacity to be proved in the yard is
given in the following Table – 7.1.
Table – 7.1 : Raw Materials requirements
Sl. No.
Items Annual Daily Remarks
1. Chrome Ore 156000 MT 446 MT By truck from mines
2. Manganese Ore 102000 MT 291 MT By truck from siding/port
3. FeMn Slag 42000 MT 120 MT By truck
4. Coke 48000 MT 137 MT By truck
5. Coal 34800 MT 100 MT By truck from mines/port
6. Quartz 13200 MT 38 MT By truck from mines
7. Molasses 3600 MT 10 MT By tanker
8. Lime 1500 MT 4 MT By truck
9. Dolomite 1200 MT 4 MT By truck from mines
10. Light Diesel Oil 600 KL 2 KL By truck
7.2 Raw Material feeding system
Raw Material shall be fed to a ground hopper by dumpers. The material shall be
drawn from ground hopper to screening station where fines shall be removed.
The screened material shall be conveyed to the Bunker house having 32 day
bunkers for different materials. The bunkers shall be fed with reversible
conveyors.
Each bunker shall be provided with vibratory feeder. Each set of 4 bunkers shall
have one set of weigh hopper. Material from each bunker shall be withdrawn and
weighed separately in the weigh hoppers and dumped to a common surge
hopper provided with a vibratory feeder through a conveyor.
MAITHAN ALLOYS LIMITED
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The weight of raw materials in required quantity from the surge hopper shall be
fed to the feed hopper provided at the top platform. The material from feed
hopper shall be conveyed to 7 charging bins and 1 correction bin, which will be
located around the circumference of the furnace. These charging bins shall feed
the raw material mix through chutes and slide gates into the furnace.
For smelting of raw materials a submerged arc furnace of following specifications
shall be commissioned.
Mechanical
Shell diameter - ~ 9000 mm
Shell height - ~ 5000 mm
Electrode diameter - ~1150 mm
Electrical
Furnace transformer rating - 1 nos. 16.5 MVA 3-phase per furnace
Method of tap changing - O.L.T.C.
The furnace shell shall be lined with graphite paste inside. Layers of high heat
duty firebricks and insulation bricks will back this. Tapping holes (3 nos at 120o)
will be provided at the hearth level in the refractories. The bottom lining will be
thick layer of tamping paste and layers of high alumina brick of 55%, 45% and
35% Al203 and suitable castable refractories. Silicon carbide bricks will be used
for tap hole lining.
Primary parameters of the Ferro Alloy Furnaces are given in Table – 7.2.
Table – 7.2 : Primary Parameters of Ferro Alloy Furnaces
Sl. No. Parameters Unit Value/Features
01 Ferro Alloy production t/yr 120000
02 Daily Production TPD 343
03 No. of furnace No. 4
04 Type of furnace - Submerged Arc Furnace
05 Transformer rating MVA 16.5 MVA 3-phase
06 No. of electrodes No 3 in each furnace
07 Type of electrode - Self baking Soderberg
MAITHAN ALLOYS LIMITED
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The furnace shall be provided with water-cooling system for:
- Cooling of current conducting pipes and contact clamp.
- Cooling of electrode holder ring
- Cooling of electrode shell
- Cooling of supporting framework exposed to heat from furnace top.
For furnace tapping, tap hole arcing device (moving around the furnace) shall be
provided. Electrical connection to the arcing device shall be made manually after
positioning.
The flue gases from the furnace are sucked through an inter-connecting ductwork
and gas cleaning system by induced draft fan and exhaust to chimney. The gas is
first cooled from 300OC to 120OC in a heat exchanger. The cooled gases will pass
through a bag fitter for dust removal before letting it out through the chimney.
The tapping fumes are also cleaned through bag filters before letting it out.
7.2 Hot Alloy handling
The hot metal tapped from the spout will be collected in a ladle. The slag will be
collected in C.I. Pots.
The liquid metal from the ladle will be poured to CI mould with the help of a crane.
The thin casting, which is cast in mould, will be transferred to a crushing and
packing area by dumpers. Thereafter, manual breaking and packing shall be
carried out for dispatch.
MAITHAN ALLOYS LIMITED
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CHAPTER – VIII
UTILITIES AND SERVICES
The following services and utilities shall be required.
8.1 WATER SUPPLY FACILITIES
• Requirement of water – The estimated requirement of water for various plant
units is indicated in Table – 8.1.
Table 8.1 Requirement of Water
Table 8.1 Water requirement
1.
2.
3.
Circulating Water
Make-up Water
Drinking Water
2400 KL
600 KL per day
50 KL per day
The total requirement of fresh water to meet process make-up and drinking
needs shall be 650 cubic meters per day.
Such water which will be made available by Local Gram Panchayat and/or
WBIDC water supply system.
Industrial water re-circulation cycle shall comprise supply water pumps, cooling
towers, swamp, interconnection piping and necessary instrumentations.
Emergency overhead tank shall be provided for critical units.
8.2 COMPRESSED AIR FACILITIES
A compressed air system has been provided to cater to the needs of service
requirements of various units. This also caters to the need of instrument air of
specific quality for various consumers. The requirement of compressed all shall
be as follows:
• Industrial quality at 7 Kg per cm2-200 Nm3per min.
Necessary facility for air compressors and air dryer with receiver has been
envisaged.
MAITHAN ALLOYS LIMITED
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8.3 ELECTRIC POWER SUPPLY AND DISTRIBUTION:
8.3.1 Power Requirement
The estimated power demand and annual energy consumption for units under are:
Power Demand (MVA) 64 MVA
Annual Energy Consumption (MKWH) 456.00
The above requirements are for 100% capacity utilisation.
The plant shall receive the power from Damodar Valley Corporation (DVC) to meet
its requirements initially.
8.3.2 Basic Design Parameters
System Voltage
Distribution to MCC - 3.3KV, 3ph, 50Hz and 415V, 3 ph, 50Hz
For Illumination - 230V, 1ph, 50 Hz
8.3.3 Power Distribution Facilities
HT Switchgear:
The 33 KV Switchgear would be of outdoor type with minimum oil circuit breaker,
with three-phase symmetrical short circuit rating of adequate capacity. The circuit
breakers would be electrically operated (battery operated type) and operated
from 24V DC control source.
Transformer:
The transformer would be mineral oil filled with ONAN cooling. It would be
designed for temperature rise not exceeding 50OC in winding and 40OC in oil over
ambient temperature.
Substation facilities:
Complete substation facilities and accessories such as battery banks and
associated battery charging equipment, DC distribution board, fire fighting
equipment, ventilation equipment and complete earthing will be provided.
MAITHAN ALLOYS LIMITED
32
8.3.4 Cabling
Power inside the plant would be distribution by insulated cables, which would be
generally laid underground. The cables used for LT power distribution would be
of 1100V grade, heavy duty with Aluminium conductors. All control cables shall
be of 2.5 sq. mm copper.
8.3.5 Motor control center
Drives:
AC motors will normally be used in all areas of plant except in places where the
speed control and torque requirements call for DC motors. Slip-ring induction
motor would be considered for intermittently running drives requiring frequent
switching operations and for heavy-duty drive application requiring speed control.
In all other cases, squirrel case induction motors have been considered. The
motors would be suitable for direct on line starting with full voltage on.
Controls:
The control systems would be confirmed as a distributed hierarchical concept
with the following three control levels.
• Individual drive control level
• Functional group control level
• Technological plant control level
For this purpose the contractors and relays techniques would be adopted for
individual drive control at the bottom level in hierarchical structures. These will
essentially take care of the connection (ON), disconnection (OFF) and individual
error signaling of a drive.
Automation:
The automation of operations shall be achieved through programmable logic
controllers (PLC) from the central control room. It shall be possible to operate any
motor in remote mode from the control room. To monitor the state of all drive
motors VDU’s shall be provided in the control room. The technological drives
shall be grouped in logical control blocks for the purpose of sequence of
operation, monitoring and fault annunciations. Mimic display of the status of
various drives is also foreseen.
MAITHAN ALLOYS LIMITED
33
Earthing and lightning protection
All electrical equipment would be provided with two district earth connections as
per Indian electricity rules. A ring main earthing system shall be provided for each
shop/unit for this purpose. All buildings would be provided with necessary
lightning protection arrangements. GI strips/flats and GI electrodes will be used
for earthing and lightning protection.
Illumination
The illumination level envisaged for the different areas indoor and outdoor will be
as per international norms for industrial production units to ensure comfort and
safety. High-pressure sodium vapor lamps with reflectors will be used or high bay
lighting and road lighting. Flood lighting will be used for open storage areas.
Florescent lamps with will be used for low bays of production departments, office
building, electric rooms, laboratory and stores. Emergency lights along with
batteries will be provided for strategic units and control rooms to ensure safety.
Instrumentation
Adequate instrumentation has been foreseen for better process control. Both field
and onboard instruments shall measure various process parameters and transmit
to the control room for taking measures to correct process disturbances in time.
The instrument shall be computer compatible so that a computer can read the
values and in turn the computer shall provide various process trends to affect the
process control.
VENTILATION AND AIR CONDITIONING:
Building and shops will generally be provided with natural ventilation. Mechanical
ventilation shall be provided where adequate ventilation cannot be provided by
natural means. The control rooms of plants shall be provided with window type air
conditioner to maintain the temperature as per requirements.
FIRE PROTECTION FACILITIES:
In order to combat any occurrence of fire the following fire protection facilities
have been envisaged for the plant. Internal and yard hydrants along with hose
boxes and hoses complete in all respects at suitable intervals. Adequate number
of suitable types of portable extinguishers shall be provided in all the units as per
the nature of fire. A fire-post with one fire attendant shall be deployed to extend
necessary assistance required for fighting fire in any of the plant units.
MAITHAN ALLOYS LIMITED
34
POLLUTION CONTROL FACILITIES:
With increasing environmental awareness, it is imperative that due attention is
paid to this aspect right at the planning stage. Of the three major identified areas
of pollution viz. air, water & noise, the extent of water pollution & noise pollution in
ferro alloy manufacturing units is negligible.
As regards air pollution, while gaseous emission are naturally well within the
stipulated limits, necessary control measures will be put in place to ensure that
particulate emission from the furnaces are also well below acceptable/prescribed
safety norms.
8.6.1 Air pollution control
Particulate emission consists mainly of manganese ore dust, coal & coke fines
emanating mainly from the furnace exhaust gases & transfer points of conveying
and handling equipment. The gas emanating from the furnace will be picked up in
the ‘Hood’ above the Furnace and is sucked into the system by negative
pressure. It is shall be first passed through a heat exchanger wherein it shall be
air cooled. The air coming out of the cooler at a temperature of about 120oC shall
be then passed through a modular type ‘Pulse Jet’ Bag Filter where fine dust
particles will be separated and clean filtered air having emission less than 50
mg/Nm3 will be vented out through the stack via an ID fan.
The dust collected in the bag house would primarily consist of fines of
manganese ore, coke, coal and other raw materials fed to the furnace. This would
be processed by the briquetting and/or sintering plants and would be fed back to
the furnaces.
The main areas of fugitive gas emission are:
a) Above the open hearth of the furnace.
b) At the Slag Port and Tapping spout. But the fumes here are negligible.
However control measures to maintain the ambient air quality will be
incorporated.
General Mitigative measures
▪ Stack height of all the APCS will be minimum of 30 m as per CPCB
norms.
MAITHAN ALLOYS LIMITED
35
▪ Green belt along the boundary and inside the premises will be developed
to arrest the dust from fugitive emissions.
▪ Water sprinkling will be done in vehicle movement, loading and unloading
areas. Also all roads within the premises will be made pucca.
▪ Enclosures will be provided for noise generating equipments
▪ Eco-friendly and silent DG sets will be installed.
8.6.2 Water pollution
The water is used for 2(two) purposes, i.e.:
a) Cooling the various equipments in the furnace and gas cleaning system.
b) Domestic consumption.
The water used for cooling purpose is recycled back via the Cooling Tower,
where the scales/dusts carried over by such cooling water invariably and easily
settles down at the Cooling Tower Pond.
Adequate waste water handling, treatment and reuse measures will be taken to
conserve water in the plant. Wastewater, after treatment in the wastewater
treatment facility, would be reused for green belt development and water
sprinkling in other areas within the premises.
The water used for domestic purposes will be divided in 2(two) parts, viz :
a) General Domestic uses for washing, bathing etc.
b) Domestic effluent from Toilets.
The domestic wastewater will be passed through a septic tank – soak pit as
standard practice.
General Mitigative measures
▪ Recycle and reuse of water to conserve the sources.
▪ Implementation of rain water harvesting system for recharge of ground
water or use in the plant
8.6.3 Noise pollution control
To avoid noise pollution, the DG sets and compressors shall confirm to laid down
norms of the pollution control board.
MAITHAN ALLOYS LIMITED
36
8.6.4 Thermal pollution control
There will also be no Thermal Pollution as the entire heat generating equipments
are water cooled and/or thermally insulated with Refractory materials. Hot gas
from furnace cools down in the Gas Hood due to dilution with ambient air.
However, the operational area around the furnace will be hot to warm up to a
distance of 3-5 Meters.
8.7 AIR-CONDITIONING & VENTILATION
Ventilation fans would generally be installed in enclosed premises. Supply ducts
and grills on the ventilation and air conditioning system would be suitably sized
for minimum noise level.
8.8 QUALITY CONTROL FACILITIES
The plant shall have its own quality control laboratory for following functions:
- Analysis of raw materials
- Analysis of products
- Testing of water and Gas samples
The laboratory shall have following sections:
- Sample preparation unit
- Wet chemical analysis section
- Instrumental analysis section
MAITHAN ALLOYS LIMITED
37
CHAPTER – IX
CIVIL AND STRUCTURAL WORK
9.1 Civil Work
The civil work shall comprises of site preparation, design and construction of
building structures, under ground structures, foundation for equipment and
structures, floors, surface and underground drainage, underground tunnels,
roads, boundary wall, fencing etc.
The civil design shall be carried out based on the site contour and soil
investigation report. These activities need to be carried out before
commencement of civil engineering work.
9.2 Structural Work
Steel structural work shall cover the building structures, conveyor galleries,
pipeline supports, roof and side sheeting work and painting.
MAITHAN ALLOYS LIMITED
38
CHAPTER – X
M A N P O W E R
The operation and maintenance needs for the plant coming up under the proposed
project calls for deployment of proper manpower.
The category-wise break-up of manpower that shall be required for the plant is given
below in Table – 10.1.
Table – 10.1 : Manpower Required
Sl. No. Category No. of Employees
01 Managerial 17
02 Supervisory 45
03 Skilled 72
Sub Total (Direct) 134
04 Semi – Skilled 72
05 Unskilled (furnace handling) 144
06 Unskilled (metal handling) 200
07 Security Personnel 20
Sub Total (Indirect) 436
Total 570
The above estimates have been based on production technology proposed, level of
mechanization and automation, number of operating shifts etc.
About 60% of personnel may need other on-job training or training by plant suppliers due
to operational needs.
MAITHAN ALLOYS LIMITED
39
CHAPTER – XI
IMPLEMENTATION SCHEDULE
The project envisages installation of 4 Nos. Submerged Electric Arc Furnaces, each of
rating 16.5 MVA for production of Ferro Alloys along with Sinter Plant (2x100 TPD -
70,000 TPA Manganese Ore Sinter) & Briquette Plant (2x30 TPH - 3,00,000 TPA
Chrome Ore Briquette).
The above facilities shall also include its associated auxiliary & utility units. The total time
of implementation for the project shall be 30 months from the zero date. The zero date
for the project has been considered as the time when land allocation & other formalities
are completed and civil work can be started.
The detailed implementation schedule is as follows:
PARTICULARS START COMPLETION for 1st furnace
COMPLETION for last furnace
Civil Works Zero date 18 months 24 months
Plant and Machinery
a. Placement of Orders 3 months 20 months 26 months
b. Fabrication 6 months 20 months 26 months
c. Erection & Installation 15 months 22 months 28 months
Trial Production 23 months 29 months
Commercial Production 24 months 30 months
Projected Implementation
It will be imperative to complete many of the project activities before the zero date and
soon afterwards. These include:
• Basic Engineering
• Preparation & Issue of tender document for major technological units.
• Placement of orders for major technological units.
• Financial tie-ups, if any.
• Finalisation of terms with overseas agencies if any.
MAITHAN ALLOYS LIMITED
40
• Clearance from statutory authorities.
• Land acquisition.
• Site survey and soil investigations.
• Site preparation / leveling work.
• Enabling work like construction of water line, power line and sewerage, labour
camp and communication facilities.
It will be necessary to ensure selection of capable and reputed construction and erection
agencies and mobilization of requisite resources of men, material and construction
machinery as well as construction and erection expertise on modern and advance
trends, to adhere to the proposed schedule. It will also be necessary to ensure timely
availability of the site infrastructure of the work execution at site.
MAITHAN ALLOYS LTD.WBSECL
HA
RIN
AG
OR
E G
RA
M
GATE
21.65
3
21.93718.166 7.972
7.651 10.639 5.563 20.37825.839
16.617
9.007 10.999
64.307
10.41
7
23.328 7.290 7.080 15.243 6.5283.474
3.6447.573
4.2626.584
4.4323.008
8.164
4.716
3.271 7.986
17.268
9.642
8.4523.336
5.431
9.157
3.619
16.85
4
4.2985.257
5.6333.815
3.242 6.352 7.773
7.113
3.787
11.03511.340
2.8486.798 4.947
53.232
14.14
0
4.862
5.57014.819
2.7254.048
8.241
12.1084.6397.461
10.96
6
9.190
3.789
8.38715.041
8.657
3.621
2.8277.467
5.1887.2517.367
10.8327.161
7.327
6.977
7.141 6.439 7.368 15.78710.565
1.4972.138
20.00
0
46.964
17.985
11.90110.132
7.79028.60320.004
16.644
12.83
2
6.475
6.371
15.259
11.08112.751
8.64615.759
9.390
6.27114.224
18.486
10.232
3.762 3.1
02
7.02911.477
7.265
28.2877.21148.121
22.802
3.46414.3635.6877.364
47.40831.349
30.201130.981
206.878
17.228
241.4
89
51.791
LAYOUT PLAN
CRAN
E B
AY
BREA
KING
AND
PAC
KING
BAY
CRAN
E B
AY
BREA
KING
AND
PAC
KING
BAY
AUTOTRANSF
AUTOTRANSF
AUTOTRANSF
AUTOTRANSF
FUR.BREAKER
FUR.BREAKER
FUR.BREAKER
FUR.BREAKER
35.45
35.45
6.98
51.48
7.50
51.50
10.65
24.00
21.00
12.00
16.00
7.00
4.75
4.75
5.75
5.75
4.75
4.75
5.75
5.75
4.75
4.75
7.50
4.75
4.75
5.75
5.75
4.75
4.75
5.75
5.75
4.75
4.75
7.00
4.75 4.75 4.75 4.75
19.00
85.00
35.00
18.00
22.00
7.50
30.00
28.50
10.00
6.755.50
1.635.50
1.635.50
1.635.50
1.63 8.25
5.00
12.00 8.00 12.00 12.00
6.00
6.00
6.00
6.00
6.00
30.40
L.T. ROOM
L.T. ROOM
L.T. ROOM
D.G. ROOM
AUX. TRNSF.
MECH W/S
MECH W/S
ELEC. OFFICE
ELEC. W/S
ELEC. W/S
CASING W/S
CASING W/S
CASING W/S
MECH STORE
ELEC. STORE
67.00
6.00
6.00
30.00
11.00
30.00
11.00
W.B.
SUB-STATION
SUB-STATION
COOLING TOWER AREA & SUMP
H.T. LINE
TEMPLE
81.98
APC -3
APC -4
BARJORA UNIT -4LAYOUT PLAN OF 4X16.5 MVA SUBMERGED ELECTRICARE FURNACE
SCALE:-1:650DATE -26/04/2018
REV.
06DRAWN CHECKED APPROVED
REST ROOM
12.00
FILTER & SOFTENER
PUMP HOUSE
RAW
WAT
ER T
ANK
COAL CRUSHER40.00
0
50.000
APC -2B
12.00
20.00
APC -2A
6.00
12.00
APC -1A 6.00
12.00
APC -1B
12.00
20.00
8M WIDE INTERNAL ROAD 8M WIDE INTERNAL ROAD8M WIDE INTERNAL ROAD
8M W
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8M WIDE INTERNAL ROAD
8M WIDE INTERNAL ROAD
8M WIDE INTERNAL ROAD
MAIN
ROA
D GATE
6.00
11.92
40.00
0
50.000
SLAG CRUSHER
N 00.00
N +20.00
N +40.00
N +60.00
N +20.00
N +80.00
N +120.00
N +140.00
N +160.00
N +180.00
N +200.00
N +220.00
N +240.00
N +260.00
N +280.00
N +300.00
N +320.00
N +340.00
N +360.00
N +100.00
N -40.00
N -60.00
N -20.00
N -80.00
N -120.00
N -100.00
E -0
0.00
E +2
0.00
E +
40.00
E +6
0.00
E +8
0.00
E +1
00.00
E+12
0.00
E +1
60.00
E +1
80.00
E +2
00.00
E +2
20.00
E +2
40.00
E +2
60.00
E+32
0.00
E +3
00.00
E +2
80.00
E -1
80.00
E -1
60.00
E - 1
40.00
E -1
20.00
E - 1
00.00
E -8
0.00
E-60
.00
E -4
0.00
E -2
0.00
E -2
00.00
E -2
20.00
E -2
40.00
E -2
60.00
W.B.
PLANT OFFICE
QUALITYCONTROL
12.00
12.00
12.00
48.00
0
COKE
SHE
D
12.50012.50012.50012.500
BRIQUETTING PLANT & SINTER PLANT
RAW MATERIAL YARD
157.00
105.0
0
6M WIDE INTERNAL ROAD
17.54
6.00
&
6M WIDE INTERNAL ROAD 6M WIDE INTERNAL ROAD
TOILET & WASH
TOILET
WASH
2 & 4 WHEELER PARKING
50.00
12.00
STORE STORE STORE STORE STORE STORE
16.00 8.0012.00 12.00 12.00 12.00 12.00 12.00
8.008.00
10.00 OFFICEADMIN.OFFICE
CRECHE
AUTO MOBILE PARKING
OXYGEN
18.00
12.00FABRICATION SHED
10.00 18.50
STORE
TANK
48.00
0
COKE
SHE
D
12.50012.50012.50012.500
9.00
4.36
6.00
CYCLE STAND6.0010.00
E+34
0.00
60.00
ROOM
12.00CANTEEN
15.00AMBULANCE
6.00
TOILET4.00
4.00
COMPRESSORROOM
COMPRESSORROOM
DRINKINGWATER
E +1
40.00
18.00
12.00TRANSFORMER SHED
15.00
AUTO
MOB
ILE W
/S
6.00
24.00
30.00
12.00