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Pre-Feasibility Report

Project Mini Blast Furnace (65 m3) & Sinter Plant (12 m2)

Project Proponent Purulia Metal Casting (P) Ltd.

(Pig Iron Division)

Project Location Village : Bongabari

P.O. : Vivekanandanagar

District : Purulia

Pin : 723147

West Bengal

October 2016

Contents CHAPTER DESCRIPTION PAGE

1 Project Summary 1

2 Background Information 2

2.1 Project Rationale 2

2.2 Justification of the Proposed Project 2

2.3 Project Proponent 3

2.4 Project Site 3

3 Project Description 5

3.1 Project Facilities 5

3.2 Sinter Plant (12m2) 6

3.2.1 Raw Materials (Sinter Plant) 6

3.2.2 Manufacturing Process (Sinter Plant) 7

3.3 Mini Blast Furnace (65 m3) 8

3.3.1 Raw Materials (Mini Blast Furnace) 8

3.3.2 Manufacturing Process (Mini Blast Furnace) 9

3.4 Pig Casting Machine 9

3.5 Utilities & Services 10

3.5.1 Water Re-circulation System 10

3.5.2 Fuel Oil Storage & Distribution System 11

3.5.3 Compressed Air System 11

3.5.4 Laboratories & Quality Assurance System 11

3.5.5 Electrical Power Supply & Distribution System 12

3.5.6 De-dusting System 12

3.5.7 Internal Roads & Drainage 14

3.6 Main Plant & Equipment 14

4 Project Schedule 15

4.1 General 15

4.2 Steps Involved in Implementation 15

4.3 Project Implementation Schedule 15

4.4 Commissioning of Plant 16

4.5 Procurement of Equipment & Installation 16

4.6 Civil Work 16

4.7 Structural Steel Work 16

4.8 Equipment Erection 16

4.9 Wiring, Lighting, Water & Utilities Including Piping Works 17

4.10 Project Management 17

5 Manpower Requirement 18

6 Project Cost & Financial Analysis 19

6.1 Project Cost 19

6.2 Production Cost Estimate of Sinter 20

6.3 Production Cost Estimate of Molten Metal 21

Plant Layout 22


Mini Blast Furnace (65 m3) & Sinter Plant (12 m2)

Project Location Village : Bongabari, P.O. : Vivekanandanagar, District : Purulia, Pin : 723147, West Bengal

October 2016

Purulia Metal Casting (P) Ltd. (Pig Iron Division)

Page 1

C H A P T E R 1 Project Summary

PROJECT SUMMARY

Proposed Project Mini Blast Furnace (65 m3) and Sinter Plant (12 m

2)

Project Proponent Purulia Metal Casting (P) Ltd. (Pig Iron Division)


Latitude : 23°21'1.72" N ; Longitude : 86°22'58.30" E

Main Plant

Unit

Production Capacity

Ton Per Day

Working Days

per Year

Product

Total Production

Ton Per Annum (TPA)

Mini Blast Furnace (65 m

3) 162.5 365 Molten Metal 59,310

Sinter Plant (12 m2) 300.0 170 Iron Ore Sinter 51,000

Product Pig Iron : 59,310 Ton Per Annum (TPA)

Raw Materials

Mini Blast Furnace (TPA) Sinter Plant (TPA)

1. Iron ore 47,450 1. Iron ore fines 40,800

2. Iron ore (Sinter) 50,415 2. Mill scale 6,630

3. Coke 41,518 3. Limestone 5,100

4. Limestone 6,524 4. Coke Breeze 3,060

5. Dolomite 6,524 5. Flue dust 1,530

6. Quartz 2,965 6. Return fines 21,420

Land Area Total Land : 5.0 Acres ; Proposed Greenbelt : 1.65 Acres

Project Cost Rs. 25.50 Crores

Pollution Control Cost

Capital Cost : Rs. 2.0 Crore ; Recurring Cost : Rs. 14.0 Lakhs / Annum

Make-up Water

Consumption Proposed Total : 345 KLD

(Mini Blast Furnace : 260 KLD ; Sinter Plant : 80 KLD : Domestic : 5 KLD)

Source : Supply Water, Borewell & Rain Water Harvesting

Power Requirement Total : 2,050 kVA ; Mini Blast Furnace : 1,500 kVA ; Sinter Plant : 550 kVA

Source : Damodar Valley Corporation (DVC)

D.G. Set : Mini Blast Furnace : 2 X 250 kVA ; Sinter Plant : 2 X 250 kVA

Manpower Proposed Total : 60

Air Pollution Control System

Source Pollution Control System

Mini Blast Furnace Dust Catcher, Dust Cyclone & Bag Filter

Sinter Plant Bag filter

Solid Waste

Blast Furnace Slag : 11,270 TPA will be used in cement plant.

Dust from Air Pollution Control System : 1,530 TPA will be recycled in the process.

Applicability of EIA Notification 2006

Category A [3(a) : Metallurgical Industry (Ferrous & Non Ferrous)]

Environmental Clearance is required from Expert Appraisal Committee (Industrial Projects –1), Ministry of Environment, Forest and Climate Change, Govt. of India, New Delhi.




October 2016


Page 2

C H A P T E R 2 Background Information

2.1 Project Rationale As one of the developing countries of the world, India has taken stride to up lift its industrial status in

multifarious disciplines in parity with the upr ising trend of economic growth rate all through the

world. In STEEL SECTOR all through the world a phenomenon growth is observed in last five years.

India is also in that league and has sustained more than 15% growth rate in this sector.

STEEL SECTOR in Eastern India worth special mention. Being one of the largest reservoirs of iron ore

this part of India has contributed the highest to this growth. In recent years many steel plants have

come up in this region. These helped, in turn, development of steel melting industries in this region.

Furthermore, the massive infra-structural development in the country has further boosted up local

demand of finished steel products. Such scenario attribute to the fact that a lot of entrepreneurs

coming forward to set up mini / midi steel plants of all known methods, continuous casting and rolling is

most effective. With recent growth of the rolling mill sector the gap is widened between demand and

supply. With the growing up of steel Industries in the Country, other supporting ancillary industries like

sponge iron and ferroalloy units are also coming up gradually. Also, with country’s infra-structural

development, requirement of building material like cement and reinforced bar is gaining momentum.

The product Pig Iron will be used in the Induction Furnaces as one of the raw materials.

2.2 Justification of the Proposed Project

1. The proposed plant will feature a Mini Blast Furnace (65 m3) and a Sinter Plant (12 m2).

2. Iron Ore Sinter will be produced in the Sinter Plant.

3. The feed to the Mini Blast Furnace will be sinter from Sinter Plant & fluxes etc. and liquid metal

will be produced in the Mini Blast Furnace.

4. The liquid metal from Mini Blast Furnace will cast in the Pig Casting Machine to produce Pig

Iron.

5. The major portion of Pig Iron will be used as a raw material to the Induction Furnace of the

existing Secondary Metallurgical Unit of Purulia Metal Casting (P) Ltd.

6. In the existing Secondary Metallurgical Unit the molten metal from induction furnace are being

charged to existing CCM & then to Rolling Mills.

7. The Project because of its nearness to the different industrial areas in Durgapur, Asansol and

Bokaro will benefit from basic infrastructure facilities such as good roads, water supply, power

lines and availability of raw materials for Sinter Plant and Mini Blast Furnace.

8. As the promoters are already established in the field of steel sector, major portion will be

consumed in house and rest of the materials will be sold to the other industries.

9. The process and the equipment will be selected in such a way that the product can meet most

of the international standard. This will help the company to bid for supplying steel to high

valued projects.

10. As the product Pig Iron will be for captive plant so as such there will be no issue of competition

and it will help to gain cost reduction substantially in the production.




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2.3 Project Proponent Purulia Metal Casting (P) Ltd is a Private Limited Company, incorporated under the Companies Act,

1956 with the registrar of Companies, West Bengal. The registered office of the Company is situated at

4D1 & 4D2, 4th Floor, 31, Ganesh Chandra Avenue, Kolkata – 700013, West Bengal. The Directors are

Shri Goutam Kumar Sen and Shri Bhabani Prasad Mukherjee. There will also be very experience

professional those will run the Organization on day-to-day basis.

2.4 Project Site The project site for the proposed project Mini Blast Furnace (65 m3) & Sinter Plant (12 m2) is at Village : Bongabari, P.O. : Vivekanandanagar, District : Purulia, Pin : 723147, West Bengal.

Purulia is the westernmost district of State of West Bengal. It acts as a gateway between the

developed industrial belts of West Bengal and Jharkhand. Midnapore, Bankura and Burdwan district of

West Bengal and Dhanbad, Bokaro, Hazaribagh, Ranchi, West Singbhum, East Singbhum district of

Jharkhand State bound this district.

The site is in close proximity of the substation within a distance of 2 km from where power shall be

provided at 33 kV to the proposed plant. It is well connected by road with Kolkata and other metropolis

of the country. The site is near to Durgapur, the well-recognized steel city of West Bengal. It can

therefore be seen that the site is ideally situated from the point of view of industrial infrastructure

facilities needed, management control, ancillary support and co-ordination with other unit of the

company.

Project Site : Latitude : 23°21'1.72" N ; Longitude : 86°22'58.30" E




October 2016


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October 2016


Page 5

C H A P T E R 3 Project Description

3.1 Project Facilities Purulia Metal Casting (P) Ltd. (Pig Iron Division) now have decided to go for setting up a Mini Blast

Furnace with 162.5 TPD capacity along with matching Sinter Plant of 300 TPD Capacity to produce Hot

Metal (i.e. Liquid pig iron). Hot Metal will be casted as solid Pig Iron in the Pig Casting Machine. The

salient feature of the plant capacity, general layout viz. storage and handling of the major input

materials and locations of the Mini Blast Furnace, Sinter Plant, Pig Casting Machine, Product Storage

Yard and De-dusting unit with respect to all the requisite facilities have discussed here. In developing

the plant general layout, the following factors have been taken into consideration:

Economical and uninterrupted receipt of incoming raw materials and supplies including inter

departmental dispatch of in process materials up to finishing stage and disposal of plant wastes with minimum counter flow of materials particularly inside the shops.

Logical location arrangement of production units, plant services and ancillary facilities to ensure minimum capital and operating costs both during the initial stage and future expansion.

Compactness of plant layout minimizing the distance of internal communications and inter plant handling of processing materials without sacrificing operational efficiency.

The plant general layout has been developed with rational disposition of production and auxiliary

facilities, plant utilities, services and ancillary buildings. A properly designed layout is essential for

operational efficiency, economical capital and production cost.

Mini Blast Furnace & Sinter Plant is a material intensive process, employing various plant and

equipment. To ensure an efficient and economically favourable operation, it is essential that the layout

of the shop provide easy access to all operational areas and unimpeded movement of input materials

and manufactured products. Unidirectional flow of materials is of consequence. The major production

facilities are receiving and storage of essential raw materials, such as iron ore, lime stone, dolomite,

coke breeze, fuel oil etc. and miscellaneous supplies.

The manufacturing facility of hot metal comprises of one (1) Mini Blast Furnace of 65 m3 capacity with

blast heating system, blowing system, raw material handling system, slag granulation system, ladle

preparation system, ladle transportation system, pig casting machine & auxiliary services with plant de-

dusting units. The Sinter Plant Comprises of one (1) 12 m2 Sinter machine, Raw material handling

system, Burden preparation unit, Mixer unit, Screening & crushing station, transportation of sinter to

Blast Furnace. This is supported by services and utilities for water and compressed air, electric power,

fuel, ancillary facilities ablution block, drainage, roads, sewerage, de-dusting etc. Taking the above

factors into consideration and major plant equipment involved in the process, general area layout has

been developed. The production facilities including storages of major input materials such as iron ore,

lime stone, dolomite, coke breeze, fuel oil, refractories, fuels etc. have been considered. Sinter shall be

kept in a storage shed for use in the Blast Furnace. The other materials received by trucks / tankers shall

be unloaded at the respective storage area.




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3.2 Sinter Plant (12m2) Sinter Plants agglomerates iron ore fines with other fine materials at high temperature to create a

product that can be used in a Blast Furnace. The final product, a Sinter, is a small, irregular nodule of

iron mixed with small amounts of other minerals. The process, called sintering, causes the constituent

materials to fuse to make a single porous mass with little change in the chemical properties of the

ingredients. The purpose of sinter is to be used for converting iron into steel. The Technical

Parameters of 12 m2 Sinter Plant are :

Sinter Plant (12 m2)

Sl. No. Item Unit Index

1. Design Scale Set X m2 1 X 12 m2

2. Annular Sinter Machine

Effective Sintering Area m2 12

Usage Factor t/m2·hr 1.62

Working Days d 170

3. Working Days of Whole Plant d 170

4. Production per Day T 19.5

5. Working Hours per Day hr 20

6. Production per Day T 390

7. Screening Factor % 23

8. Final Production per Day T 300

9. Annual Production T 51,000

3.2.1 Raw Materials (Sinter Plant) Raw material will be required for sintering are Iron ore, Limestone and Coke Breeze. Apart from this,

Flue dust & Returns fines will be generated in the Sinter Plant itself. The requirement of raw materials

for production of iron ore sinter under the proposed technology are:

Details of Raw Materials for Sinter Plant (12 m2)

Sl. No.

Raw Materials Quantity Ton / Ton

Total Requirement

Ton per Day (TPD)

Total Requirement

Ton per Annum (TPA)

1. Iron Ore Fines 0.80 240 40,800

2. Mill Scale 0.13 39 6,630

3. Limestone 0.10 30 5,100

4. Coke Breeze 0.06 18 3,060

5. Flue Dust 0.03 9 1,530

6. Return Fines 0.42 126 21,420

https://en.wikipedia.org/wiki/Agglomerate

https://en.wikipedia.org/wiki/Iron_ore#Beneficiation

https://en.wikipedia.org/wiki/Sintering




October 2016


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3.2.2 Manufacturing Process (Sinter Plant) Iron ore (sinter) is the major raw material required for Blast Furnace. The raw materials (i.e.; Iron ore,

Limestone & Coke Breeze) will be received in the same ground hopper through dumpers. There will be a

Dust Suppression System above the ground hopper. The different raw materials will be received in cyclic

manner to avoid mixing. At the bottom of the hopper there will be a vibro-feeder which will discharge

the material in to a bifurcated chute with a flap gate. Through one leg of the chute Iron ore & Limestone

(flux) will be carried to a belt conveyor through the other leg Coke Breeze will be taken into screen. The

screen under flow will be discharged on a belt conveyor & the other size i.e. (+) 10 mm will be taken into

the Mini Blast Furnace raw material section. This conveyor will discharge into a trifurcated chute with

flap gates. Through one leg of this chute only Iron Ore will be carried to a reversible conveyor & finally

into 2 Raw material storage bin for Iron Ore fines. Through other legs of the chute Limestone & Coke

Breeze will be carried to two (2) dedicated crusher for Lime Stone & Coke Breeze through deflector

gates. Both of the crushed material will be discharged into a common vibrating screen. The undersized

crushed materials (-4mm) will be received in a reversible conveyor to deliver specific materials into their

dedicated storage bunker. The screen over size materials (+4mm) will be recycled through the crusher.

All the storage hoppers/ bunkers will have a weigh feeder at the bottom opening for exact quantity of

raw materials extraction into the conveyor which will discharge the material into a mixer. Little water is

added here to achieve proper micro pelletizing of the raw mix. The raw mix is then transferred to raw

mix bin through a conveyor. There are another two bins for Sinter bedding materials received through a

conveyor & Coke from a hopper. These are fed into the sinter machine through vibro feeder & conveyor.

Bedding materials is initially taken in sinter

machine for protection of machine grates.

Above this bedding raw mix is packed &

leveled. Finally a coke layer is spread

above raw mix for proper & uniform

burning. Burners are initially ignited by

LDO. After burning of raw mix is complete,

the total mix becomes Sinter.

The hot sinter is first crushed & then

conveyed to sinter cooler through

Conveyor. Air is blown to the sinter cooler

through a blower. The hot air passing out

of sinter cooler is de-dusted in a bag filter

before it is let out to atmosphere through

stack & ID fan.

The crushed cooled Sinter is then taken

into a double deck screen. The overflow is the final product which will stored in storage bin at Mini Blast

Furnace (MBF) area through conveyor. The under size of the screen is recycled to return fines bin

through another conveyor. The dust accumulated in the bag filter is also fed to return fines bin through

conveyor.




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3.3 Mini Blast Furnace (65 m3) The purpose of a Mini Blast Furnace is to chemically reduce and physically convert iron oxides into liquid

iron called ‘hot Metal’. The Blast Furnace is a huge, steel stack lined with refractory brick, where raw

material from stock house are dumped into the top and preheated air is blown into the bottom. The raw

materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final

product as liquid slag and liquid iron. These liquid products are drained from the furnace at regular

intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds

after going through numerous chemical reactions.

Purulia Metal Casting (P) Ltd. (Pig Iron Division) has decided to install and commission a 65 m3 Mini

Blast Furnace. Technical Parameters of 65 m3 Mini Blast Furnace are :

Mini Blast Furnace (65 m3)

1. Design Volume of Mini Blast Furnace 65 m3

3. Productivity on working vol. T/d/m3 2.5

4. Available working day in a year 365

5. Annual production T (Hot Metal) 59,310

7. B F Slag generation (TPA) 11,270

8. Hot Blast Flow 13,500 Nm3/ hr

9. Hot Blast Pressure (Bustle Pr.) 1 - 1.1 kg/cm2

10. Hot Blast Temperature 1000 - 1200 oC

11. Furnace Top pressure 0.3 - 0.4 kg/cm2

3.3.1 Raw Materials (Mini Blast Furnace) The raw material required for producing molten metal is iron ore, sinter, limestone, dolomite, coke,

quartz. The requirement of raw-materials for production of steel under the proposed technology are :

Details of Raw Materials for Mini Blast Furnace (65 m3)

Sl. No.

Raw Material Quantity Ton per Ton

Total Requirement

Ton per Day (TPD)

Total Requirement

Ton per Annum (TPA)

1. Iron Ore 0.80 T 130 47,450

2. Iron Ore Sinter 0.85 T 138 50,415

3. Coke 0.70 T 114 41,518

4. Limestone 0.11 T 18 6,524

5. Dolomite 0.11 T 18 6,524

6. Quartz 0.05 T 8 2,965




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3.3.2 Manufacturing Process (Mini Blast Furnace) Iron ore, Lime Stone, Dolomite, Coke will be stored in a stockyard and from where the same will be feed

to a ground hopper by pay loader. Below the ground hopper there will be extractor which will discharge

the material to a conveyor. This conveyor will feed to the tripper conveyor in a junction house. Product

sinter from Sinter Plant will feed to the tripper conveyor through sinter conveyor. Over size coke from

Sinter Plant will also feed to this tripper conveyor. The tripper conveyor will discharge material to

twelve numbers day bins (in stock house measuring 25 m X 9 m wide double bay in construction. From

the day bins the same will feed to a conveyor through vibrating screens / vibro feeders. This conveyor

will feed another conveyor which will feed the material to Mini Blast Furnace.

The Fe content of iron ore should

preferably be 30% and 35% iron ore

(sinter) and above with a Laterite content

under 10%, in respect of coke, fixed

carbon should be 75% or higher with ash

not more than 25%. Limestone, which is

used desulfurizing agent should have CaO

contents> 45%. The charge mix is an

important part of the Blast Furnace. The

success of production process in the

furnace mostly depends on it. Another

product of the iron making process, in

addition to molten iron and slag is hot

dirty gas. These gases exit the top of the

Mini Blast Furnace and proceed through

gas cleaning equipment where particulate

matter is removed from the gas and gas is cooled.

This gas has a considerable energy value. So it is burnt as a fuel in the ‘Hot Blat Stoves’ which are used

to preheat the air entering the Mini Blast Furnace to become ‘’Hot Blast’’ and turbo blower that

generates the compressed air known as ‘Cold Blast’ that comes to the stoves. After the hot gas back to

the blast furnace and dirty air out of the stove into a stack. The slag from the Mini Blast Furnace will be

guided to a water pond with a ramp. The guide channel for the slag will be lined with heat resistance

bricks. The hot slag when comes in contact with the water in the pond become granulated. The

granulated slag will be periodically removed mechanically / manually and will be sold to Cement Plant.

3.4 Pig Casting Machine Hot metal produces in the Mini Blast Furnace, whenever not used directly in the steel melting shop is

cast into pig iron in the Pig Casting Machine (PCM) to small pieces. Small sizes of pig iron pieces are

produced in PCM by pouring the hot metal into the mould having small pockets. There the hot metal is

solidified by cooling with air followed by water cooling. The PCM stand is an endless chain carrying the

pig moulds. The strands are placed at an inclination. The level of the inclination is decided on the height

required for receiving the hot metal and for discharging the cast Pig Iron into the car.




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3.5 Utilities & Services The utilities and services comprise the electric power supply and distribution, water supply and re-

circulation system, compressed air and fuel oil storage and distribution system, etc. and these are

suitably located with respect to their storage facilities and specific uses in the shop.

3.5.1 Water Re-circulation System Suitable water circulation system for production units have been duly considered as per requirement.

Water system for Mini Blast Furnace shell cooling, water seal of Sinter Machine, Mixer and Dust

Suppression System comes under one circuit because of water quality as well as terminal pressure also.

One separate circuit has been considered for hydraulic valves, blowers for cooling. A common pump

room measuring 12m X 8m has been planned to accommodate all the pumps, cooling tower necessary to

run the circulation system.

All the reservoirs will be of RCC construction and the pump room will be brick building with R.C. roofing.

One (1) PVC construction overhead reservoir has been considered for feeding water during emergency

to different consuming sectors. Compressors will be housed in a compressor room. While developing the

system design for mechanical utilities and electrical services as mentioned above, various guiding

factors, viz. sources of availability, storage, consumption, terminal condition and losses in circulation as

required by individual services have been duly considered. Water is required for cooling of different equipment and components of the above production units. To

economize consumption of water it is proposed to adopt a re-circulation system for different circuits,

which enables re-use of water in-cycle and replenishing the losses by feeding make up water in the

circuit. Considering operational requirement, duly condition involved in different re-circulation systems

have been proposed as raw water for Mini Blast Furnace shell cooling, Sinter Machine, Mixer & Plant De-

Dusting Unit and soft water for hydraulic valves & blowers. Source of make-up water supply and storage of the same for all the above system have been made

common. Quantity of water in circulation, quality required, terminal pressure related to different service

points are given in the Table.

Equipment Quality

Quantity in Circulation

(m3/hr)

Terminal Pressure

Kg./cm2g

Rate of

Loss

(%)

Make up Feed

(m3/hr)

A. Raw Water Clear suffered 230 4.0 2.83 6.51

B. Soft Water Dematerialized water 285 4.0 1.00 2.85

C. Domestic water Clear & chlorinated 5 - - 5.00

Total 14.36

Total Make-up Water Consumption = 345 KLD

It is apparent from the above table that the continuous supply of make-up water to compensate the

losses will be required at 14.36 m3/ hr. i.e. 345 KLD.




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System Description : The water system will have two circuits, one for cooling of hydraulic valve system

& other for Blower House. This closed circuit will require soft water. The other circuit for MBF shell

cooling with raw water. Raw water will also be required for Dust suppression, Sinter mixer & water seal

of Sinter Machine. Raw water at the battery limit will be collected in raw water reservoir. There will be

two pumps (1W+1S) with valves, reducers etc. which pump water from this reservoir. The pumped out

water will be distributed to the circuit 1 & 2.

Circuit-1 for Soft Water : The raw water will be fed to a RO Plant for softening & the soft water will be

collected in water tank. Two pumps each with valves & reducers are connected to the soft water tank.

The pumps (1W+1S) will pump soft water to Hydraulic Station & House, all for cooling purpose. The hot

water outlet from Hydraulic Station & Blower House will be collected in hot water tank from where the

hot water will be pumped to the cooling tower tank & back to soft water tank.

Circuit-2 for Raw Water : The raw water by pump will be taken to hot water tank in circuit 2 (as make

up after initial filling). From here raw water will be pumped to the cooling tower in this circuit. The cold

water from cooling tower basin will be pumped (1W+1S) for MBF shell cooling & hot water will be

collected back in the hot water tank. One pump will be pumping water to emergency overhead tank.

Another part of raw water will be directly given for dust suppression in Sinter Mixer Machine & Sinter

Machine. Blow down from RO Plant, soft water tank, circuit-2, cold water tank & hot water tank will all

be collected in the slag granulation pond.

Emergency Supply of Cooling Water : With a view to maintain continuity in supply of water during

power failure, an overhead tank has been provided in the system design to combat the emergency

situation. Certain important zones of Mini Blast Furnace shell cooling system comes under purview of

such emergency feeding of cooling water under gravity from the overhead water tank.

Drinking & Sanitary Water System : Drinking and sanitary water system has been separately considered

in this project. For this purpose water of required quantity will be supplied from raw water reservoir to

the Iron removal Filter and will by-pass softening plant. The filtered water will thereafter be supplied

the tip of overhead tank through chlorination Plant. From the overhead tank drinking and sanitary water

will be supplied to different service terminals under gravity.

3.5.2 Fuel Oil Storage & Distribution System LDO will be required for Sinter Machine Burners in Sinter Plant and Stove Burners in Mini Blast Furnace. The LDO system will comprise of fuel tank, dual fuel burners, pumps, storage tank, distribution pipelines, valves, fittings, instruments, pressure regulations at service terminals and accessories.

3.5.3 Compressed Air System Compressed air shall be required for the pneumatic systems used in Sinter Plant & Mini Blast Furnace

area and general cleaning purposes. To meet the requirement of compressed air, two air compressors of

100 cfm at 100 psig complete with after cooler and a common air receiver has been considered.

3.5.4 Laboratories & Quality Assurance System Equipment in Chemical & Physical Laboratory will be provided for Quality Assurance System.




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3.5.5 Electrical Power Supply & Distribution System The power supply at 33 kV, 50 Hz. 3 phase overhead supply will be available from utility. 33 kV power

will receive by 2.5 MVA, 33/0.433 kV power transformer. Diesel Generator set of 2 X 250 kVA for Mini

Blast Furnace and 2 X 250 kVA for Sinter Plant are intended to cater to emergency loads during power

failure/ restricted periods. 33 kV supply from utility substation will be received to the blast furnace &

stove unit. Power Transformer of rating 33/0.433 kV, 2.5 MVA will convert power to 433 Volt level &

feed to Main LT panel via LT bus duct.

3.5.6 De-dusting System

Sinter Plant

Bag Filter : There will be suction hoods in all transfer points of conveyors, hoppers, chutes in stock

house building, mixing building, sinter machine building and junction houses. The dust generated in all

transfer points will be sucked by suction hoods and will transfer to the filter bags, so they are remained

on the surface of the bags and then the clean flue gas sent to stack of 30 meter height through ID fan.

With the procession of the dust remover, dust remained on the surface of the filter bags become more

and more, the resistance of the bags increases, when the resistance of the bags reaches upper

threshold, the system will open the purge-valve automatically in order to send the cleaning gas into the

pressure static box, which makes the filter bags changed from a state of deflated to a state of expansion

so that the dust absorbed on the surface of the filter bags will fall into the dust hopper at the bottom of

the box and the dust in the hopper will be cleaned by the ash valve. When the resistance of the filter

bags reaches down threshold, the system will close the purge-valve to stop cleaning, as so the dust

remover works again. Maximum filtering rate is 1.0 - 1.5 m3/minute and the gas temperature is 50 OC.

The dust content in the flue gas through the stack will be < 50 mg/Nm3. Service life of fabric bags is

generally up to two years.

Mini Blast Furnace

Dust Catcher : Gas cleaning is based on the gravity separation principle and is used for the removal of

large particles of the dust. It is the dry separation of dust particles in the Mini Blast Furnace top gas

before Bag Filter and is commonly done by a gravity dust catcher. In this stage all the coarser particles

are removed. The objective is to remove as much dust as possible in a dry condition for reuse and

recycling. The dust removal efficiency of the separator is dependent on the particle size distribution, on

the separation mechanism (i.e. gravitational or centrifugal force) and, to a lesser degree, on the inlet

dust loading. The separated dust is normally of size greater than 10 micrometers and is collected in the

dust storage hopper, which is usually sized for one and half days of dust accumulation, and emptied via

a dust discharge system. The dust catcher is a large cylindrical structure normally with a large diameter

and with the required height. It is usually lined to insulate it and prevent the condensation of moisture

in MBF gas so that the dust remains dry and does not ball up and flow freely into the conical portion of

the dust catcher at its bottom for its periodical removal.

The gas is sent to the dust catcher by a single down comer and enters through the top by a vertical pipe

that carries the gas downward inside the dust catcher. This pipe flares at its lower extremity like an

inverted funnel, so that as the gas passes downward its velocity (and thus its dust carrying potential)




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decreases, and most of the coarser dust drops out of the gas stream and is deposited in the cone at the

bottom of the dust catcher. Since the bottom of the dust catcher is closed, and the gas outlet is near the

top, the direction of the travel of the gas must reverse 180 OC. This sudden reversal in the direction of

flow causes more of the dust to get settle down.

Dust Cyclone : In the cyclone dust catcher the raw Mini Blast Furnace gas is introduced by one or two

tangential inlets with a velocity to force the dust particles to the wall and separate them from the gas

stream. The cyclone dust catcher can have different type of internal construction. One type of cyclone is

completely empty, while other type has a complicated inlet dome and replaceable guide vanes. The

higher separation of dust inside the cyclone is linked to the centrifugal forces and high circumferential

velocities inside the cyclone. The higher velocities inside the vessel require a special protection of the

surfaces inside the vessel. A dust catcher is very often operated without any protection of the inner

surfaces due to the low gas velocity, but the cyclone technology requires a protection of these surfaces

in order to avoid wear.

The cyclone dust catcher is usually with vortex finder, apex, flow cone and a dust collection hopper with

a dual dust outlet. The collection efficiency of the cyclone depends very much on particle size

distribution. Particles below 5 micrometers are not removed due to their small mass; Particles between

5 micrometers to 30 micrometers are partially separated and particles larger than 30 micrometers are

completely separated in the cone dust catcher. Overall separation efficiency of cyclone dust catcher is

better than the gravity dust catcher.

Bag Filter : The gas that after initial separation get into the dust catcher and dust cyclone from the

bottom of the dust remover, and larger particles fall on the ash bucket by their own weight, and the

smaller particles dispersion in the room of the filter bags, so they are remained on the surface of the

bags and then the clean gas is sent to the users. With the procession of the dust remover, dust

remained on the surface of the filter bags become more and more, the resistance of the bags increases,

when the resistance of the bags reaches upper threshold, the system will open the purge-valve

automatically in order to send the cleaning gas into the pressure static box, which makes the filter bags

changed from a state of deflated to a state of expansion so that the dust absorbed on the surface of the

filter bags will fall into the dust hopper at the bottom of the box and the dust in the hopper will be

cleaned by the ash valve. When the resistance of the filter bags reaches down threshold, the system will

close the purge-valve to stop cleaning, as so the dust remover works again. Maximum filtering rate is 1.0

to 1.5 m3/minute and the gas temperature is 50 OC to 280 OC (the system can also operate stably

(reliably) for 2 hours at gas temperature of 300 OC). The normal dust content of Mini Blast Furnace gas

after cleaning is usually not more than 3 mg/ Nm3. Service life of fabric bags is generally up to two years.

Set of bag filter with ID Fan & Stack will be provided to control the air pollution to comply with the

emission norm. The amount of dust will be sucked by hoods from different material handling facilities &

through bag filter it will be released to the atmosphere through stack. The flue gases from furnace will

be sucked through an interconnecting ductwork by induced draft fan & exhaust to the chimney. The

system will meet the emission standards during operation of the plant and ensure clean plant operation.

The fume exhaust hood with duct will be provided around the furnace circumference to capture the

fumes generated during operation. The cleaning will be off line & will take place after tapping operation

is over. Emission level at the outlet of Bag House through stack will be less than 50 mg/ Nm3.




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3.5.7 Internal Roads & Drainage The Internal roads will be 6m wide. A drainage system will be provided along the roads and buildings for

disposal of plant and storm water. Brief details of factory and other buildings are given in Plant Layout.

3.6 Main Plant & Equipment

List of Main Plant & Equipment

Sl. No. Description

Blast Furnace : 65 m3

1. Ground Hopper

2. Day Bins

3. Conveyors

4. Tripper Conveyor

5. Vibrating Screen

6. Vibro Feeder

7. Blast Furnace, 65 m3

8. Dust Catcher

9. Dust Cyclone with Hopper

10. Bag Filter

11. Stove

12. Blower

13. Multi Stage Blower

14. Pig Casting Machine

15. Water Circulation System

16. Air System with Accessories

17. Hydraulic Power Pack with Motor

Sinter Plant : 12 m2 1. Ground Hopper

2. Day Bins

3. Conveyors

4. Screens

5. Crushers

6. Mixer Machine

7. Sinter Machine, 12 m2

8. Sinter Cooler

9. Water Circulation System

10. Air System With Accessories

11. Thickener & Flocculator

12. Gas Cleaning Station

General 1. De-dusting Unit for Sinter Plant & Mini Blast Furnace




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C H A P T E R 4 Project Schedule

4.1 General Considering the delivery period of major equipment and time required for construction of

buildings and miscellaneous items as well as for installation of machinery and equipment, a project

implementation schedule has been developed. The factors involved in the execution of this schedule are

as follows :

4.2 Steps Involved in Implementation The major steps involved in the implementation of the proposed plant are :

Arrangement of the requisite financing for the project.

Finalization of the layout for the proposed plant.

Design of all plant buildings, auxiliary and ancillary buildings, utilities and services.

Issue of tender documents and specifications for all equipment, selection of equipment suppliers and placement of orders.

Finalization of arrangements for the construction of the substation for the electric power supply system / gas distribution system. For the construction and commissioning of the plant the following major steps are needed :

Setting up an organization for the execution of the job.

Arrangement of all construction facilities at the plant site.

Procurement of bulk of steel, cement and other constructional materials and their progressive delivery in accordance with the construction schedule.

Obtaining foundation load and other relevant data of furnace, gas generator etc.

Preparation of tender documents for construction.

Issue of tender documents and selection of contractors for handling civil, structural, mechanical and electrical jobs and equipment installation.

Erection of equipment, power supply & distribution system, water system and other utilities.

Securing staff for the operation of the plant.

Arranging for the necessary raw materials and services.

Trial runs and commissioning of the individual units and finally the entire plant.

4.3 Project Implementation Schedule Based on the delivery schedule of major equipment and volume of all construction jobs, construction

planning has been made on the basis of a total time of completion of the proposed plant as 18 month

from the go-ahead signal. A construction schedule broadly indicating the sequence of major activities

such as preparation of specification / drawing, issue of tenders, placement of orders, delivery schedule

of the major items of equipment, civil and structural construction of all buildings, test trial runs of

various items of equipment and commissioning of the plant is shown in a Bar chart.




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4.4 Commissioning of Plant It has been planned to complete the installation and commissioning of the entire plant within 18

months of go-ahead. The construction schedule has been prepared on the basis of the delivery periods

of the major items of equipment and the volume of civil, mechanical and constructional jobs involved.

In view of long delivery period of some of the major items, it is imperative to finalize the orders for all

such equipment at the initial stage of the project. Completion of the project on time can concern, in

accordance with delivery of plant and equipment.

4.5 Procurement of Equipment & Installation The equipment comprises one Mini Blast Furnace and Sinter Plant, the delivery period of which is

normally 4-5 months. The order for it should be placed. The delivery period of the crane, electrical

equipment, etc. will be about 3-4 months. Therefore, pending the delivery of the Sinter Plant, all

necessary electrical jobs and water supply arrangement should be executed as far as practicable. The

arrangements for installation of the Mini Blast Furnace, Stock House, Stoves and Sinter Plant should be

initiated along with structural jobs for the project to facilitate easy installation of Mini Blast Furnace.

The entire water circulation system should be ready by the time the test / trial run commence.

4.6 Civil Work The drawings for foundations of the columns for production buildings should be started immediately

after the go-ahead signal and action taken for the procurement of cement and reinforcement rods.

The construction of production sheds can proceed simultaneously. On receipt of foundation load and

other data, lying of foundations for the Mini Blast Furnace, transformer and all other equipment can

be taken up simultaneously before the equipment arrive at the site. The laying of internal roads and

drainage system should be completed expeditiously to facilitate transportation of structural materials,

equipment, raw materials, etc. Work on the construction of ancillary buildings and facilities should

proceed simultaneously.

4.7 Structural Steel Work

An appropriate and economic structural design of plant buildings will be developed and the required

quantity of structural steel and other building materials should be procured in stages after the go-

ahead decision has been taken. Adequate steel materials should be made available by the time

structural fabrication commences and the drawings should be released in stages. A contractor should

be fixed. The fabrication of columns, roof trusses, etc. can be started along with the civil work. The

fabrication and erection of structural steel work including roofing and cladding should be completed

within the allocated time.

4.8 Equipment Erection Arrangements for procuring the equipment should commence immediately after the go-ahead signal

has been given. Equipment data (foundation, electrical, utilities, etc.) have to be taken from the

suppliers. The erection of the induction furnaces should preferably be carried out under the guidance




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and supervision of the personnel deputed by the equipment supplier, who will also be responsible for

commissioning the equipment and demonstrating the fulfillment of the performance guarantee. In the

case of staggered delivery of the components of an individual item of equipment, the erection should

follow the schedule. Piping, electrical work and lying of refractory have to be kept in view. As cooling

water of the desired specification will be necessary, the jobs relating to water treatment and its

cooling should be completed in time.

4.9 Wiring, Lighting, Water & Utilities Including Piping Works

Preparation of specification for these facilities should be taken up after the data from the equipment

suppliers received and it is to be so planned that these are installed at the sight will in advance of

commissioning of the equipment. Permanent power and water supplies will have to be arranged

before the test trial commences. The source of water and its analysis should also be available to

enable selection of the proper water treatment facilities.

4.10 Project Management It will be necessary to fix the responsibility for project management on suitable persons headed by a

Chief of the project who will monitor the progress of work and apply midterm correction to ensure its

timely implementation.

Project Implementation Bar Chart

Sl. No. Activity Time In Month

1. Land Development and Road Construction, Drainage etc. 1 to 2

2. Finalization of Master Plan 1 to 1

3. Road and Sewerage Construction 2 to 2

4. Civil and Structural Drawings 2 to 6

5. Piling Earth Cutting etc. for the Shed and Civil 3 to 6

6. Structural Construction of Sheds 3 to 9

7. Preparation of Tender Documents for Main Equipment 2 to 5

8. Design of Utilities on the Basis of Main Equipment 9 to 12

9. Selection and Procurement of the Equipment 6 to 12

10. Preparation of Drawings Mechanical and Electrical Utilities 9 to 12

11. Erection of Equipment 9 to 14

12. Selection of Manpower for Different Activity 9 to 12

13. Commissioning of the Plant 14 to 16

14. Performance Test and Commencement of Regular Production 16 to 18




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C H A P T E R 5 Manpower Requirement

Sl. No.

Section & Trade Shifts

Extra Total Grade G A B C

1 PLANT OPERATION

1.1 General

a. Works Manager 1 - - - - 1 Executive

Total of Item 1.1 1

1.2 Mini Blast Furnace Area

a. Shift Foreman - 1 1 1 - 3 Jr. Manager

b. Furnace Operator - 2 1 1 - 4 Highly Skilled

c. Assistant - 2 1 1 - 4 Skilled

d. Helper - 1 1 1 - 3 Un-skilled

e. Charging Crane Operator - 1 1 1 - 3 Skilled

f. Sling Man - 2 2 2 2 8 Un-skilled

g. Labour - 2 1 1 - 4 Un-skilled

Total of Item 1.2 29

1.3 Blast Furnace Stock House Area

a. Shift Foreman - 1 1 - - 2 Jr. Manager

b. Operator - 1 1 1 - 3 Highly Skilled

c. Helper - 2 2 1 - 5 Semi-skilled


1.4 Sinter Plant Area

a. Shift Foreman - 1 1 - - 2 Jr. Manager

b. Sinter Machine Operator - 1 1 1 - 3 Highly Skilled

c. Helper - 1 1 1 1 4 Semi-skilled

d. Gas Cutter - 1 1 - - 2 Skilled

e. Crane Operator - 1 1 - - 2 Skilled


2. SERVICE AND MAINTENANCE

a. Chief Engineer 1 - - - - 1 Sr. Manager

b. Shift Supervisor (Mech. & Elec.) - 1 1 1 - 3 Supervisor

c. Electrical Engineering 1 - - - - 1 Jr. Manager

d. Electrician - 1 - - - 1 Skilled

e. Helper - 1 - - - 1 Semiskilled

Total of Item 1.4 7

Total Manpower Requirement = 1 + 29 + 10 + 13 + 7 = 60 Additional unskilled labour on contract basis = 80




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C H A P T E R 6 Project Cost & Financial Analysis

6.1 Project Cost

Indian steel demand rose 4.5 per cent in the financial year 2015-16, a slightly better growth rate than in

the previous year. Accordingly, even though challenges remain, the steel sector’s fundamentals have

started to improve. Purulia Metal Casting (P) Ltd. is presently operating Secondary Metallurgical Unit

having Induction Furnaces, Continuous Casting Machine and Rolling Mill producing finished steel

products. To make finished steel products even more economically viable in the present fluctuating

market, Purulia Metal Casting (P) Ltd. has decided to go for a Mini Blast Furnace (65 m3) and Sinter Plant

(12 m2) to produce Pig Iron which will be used as one of the raw materials in its existing Secondary

Metallurgical Unit to withstand the present market situations.

The technology involved in the proposed project is well recognised and reliable. Such types of plants are

successfully operating all over the country. The combination of dynamic management and experienced

professionals is quite capable of managing the business. Regarding operation and maintenance of the

plant, well experienced professional manpower are available in this region. The proposed project will

have good financial and social benefits to the local people by way of direct & indirect employment.

Preference will be given to the local people considering the requisite skill and qualification criteria. The

unit does CSR activities in the area like supply of drinking water during summer, help to pour peoples,

financial aid to local schools, clubs etc. In future, after commissioning of the proposed project, the unit

will carry out different CSR activities also.

There will be complete integration right from the beginning to finished products. The feasibility of

proposed project has been examined from 3 angles, which are backbone of any sustainable project i.e.,

Commercial and Financial Feasibility, Pre and Post Project scenario in which company will operate and

Environmental feasibility and the results show positive feasibility.

The total Project Cost will be Rs. 25.50 Crores. The following is the breakup of the proposed project cost.

Capital Cost for Pollution Control System will be Rs. 2.0 Crores. The Recurring Cost for Pollution Control

System has been considered as Rs. 14.00 Lakhs / annum. Also there will be an adequate fund towards

Corporate Social Responsibility.

Sl. No. Item Total Cost

(Rs. In Crores)

1. Land & Site Development 3.00

2. Mini Blast Furnace 7.00

3. Sinter Plant 3.75

4. Refractory & Other Initial Requirement 3.00

5. Civil & Structural 3.50

6. Erection & Commissioning 3.25

7. Pollution Control System 2.00

Total 25.50




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6.2 Production Cost Estimate of Sinter

Basis : One Sinter Plant for 170 Days of Operation in a Year Producing 51,000 T of Sinter

Sl. No.

Items Rate / Price / T

(Rs.)

Consumption / T

(kg)

Cost / T of Sinter (Rs.)

A Raw Materials

1. Iron Ore Fines 800.00 800.00 640.00

2. Mill Scale 0.00 130.00 0.00

3. Limestone 3500.00 100.00 350.00

4. Coke Breeze 12000.00 60.00 720.00

Total 1710.00

5. Flue Dust 0.00 30.00 0.00

6. Return Fines 0.00 420.00 0.00

Total 0.00

Total of A 1710.00

B Utilities & Consumables

1. Power (Kwh) 4.18 60.00 250.80

2. Fuel Oil (L) 25.00 1.00 25.00

3. Refractories & Consumables for Sinter Machine

100.00

4. Miscellaneous consumable 25.00

Total of B 400.80

C Indirect Expenses

1. Labour & Supervision 200.00

2. Repair & Maintenance 40.00

3. Administrative Expenses 50.00

4. Miscellaneous Factory Expenses 50.00

Total of C 340.00

Cost per Ton of Sinter Production = (A+B+C) 2450.80




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6.3 Production Cost Estimate of Molten Metal

Basis: One Mini Blast Furnace for 365 of Days Operation in a Year Producing 59310 T of Molten Metal

Sl. No.

Items Rate / Price / T

(Rs.)

Consumption / T

(kg)

Cost / T of Sinter (Rs.)

A Raw Materials

1. Iron Ore 3300.00 850.00 2805.00

2. Iron Ore Sinter 2554.00 850.00 2170.90

3. Coke 12000.00 700.00 8400.00

4. Limestone / Dolomite / Quartz

l

3500.00 225.00 787.50

Total of A 14163.40

B Utilities & Consumables

1. Power (Kwh) 4.18 60.00 250.80

2. Refractories & Consumables for MBF Machine

100.00

3. Miscellaneous consumable 25.00

Total of B 375.80

C Indirect Expenses

1. Labour & Supervision 216.00

2. Repair & Maintenance 40.00

3. Administrative Expenses 50.00

4. Miscellaneous Factory Expenses 50.00

Total of C 356.00

Cost per Ton of Molten Metal Production = (A+B+C) 14895.20




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