ssl project profile

THE INDUSTRY One of the most useful and versatile material, steel is considered to be the backbone of human civilization. As the steel industry has tremendous forward and backward linkages in terms of material flow, income and employment generation, the growth of an economy is closely related to the quantity of steel used by it. With the present emphasis on creating physical infrastructure, massive investment is planned during the Tenth Plan from year 2008 to year 2013. The future and sustained growth of this industry is intimately linked to the growth of the economy in general and to the performance of the industrial sector and the construction activities, in particular. Construction is the largest end-use sector of steel, accounting for nearly 85% of steel consumption. Further, abysmally low per capita consumption of steel at 27 kilograms (Kg) in Bangladesh as compared to global majors (China has a per capita consumption of 128 Kg while the US averages around 472 kg and the European Union 428.6 kg.) suggests that there is a tremendous potential for greater demand. The steel industry comprises of two main types of producers - i.) Integrated steel plants (ISP) or primary producers, which manufacture steel mainly through the blast furnace route from Iron Ore; and, ii). Mini steel plants (MSP) or secondary sector which manufacture steel through the electric arc furnace (EAF) or induction furnace route. BUSINESS The Company has been recently incorporated with a view to manufacture TMT Steel Reinforced Bar or Rebar with a capacity of 63,000 MTPA, from M.S Billets . The company needs a captive power Plant of capacity 4 MWe to run the plant smoothly The billets will be outsourced from different billet suppliers specially targeting the suppliers in India, Vietnam and Pakistan for geographic localization and shorter haulage distance b sea route. The plant for the above activities is located at Gazipur, Dhaka. There is good potential for the Company, as in the eastern , mid and western region there is substantial gap between demand and supply of finished steel and the Company plans to sell their maximum production within the state of Dhaka, Rajsahi, Barisal, Khulna, Comilla and Rangpur. The commercial production of the Phase-I of the Company will commence in June 2013. The demand for TMT bars/ structural is set to increase due to growth in construction and infrastructural activities. SUMMARY OF ASSETS & LIABILITIES AS RESTATED

(BDT in lacs)

Particulars

As at 31.06.2012 30.06.2013

Fixed Assets: Gross Block 218.53 4,319.6

Less: Depreciation 0.10 8.20 Net Block 218.43 4,311.4

Less: Revaluation Reserve -- -- Net Block after adjustment for Revaluation Reserve 218.43 4,311.4

Capital work-in progress 253.21 304.26 Pre-operative Expenses (Pending Allocation) 20.71 76.40 Total Fixed Assets (A) 492.35 4,692.1

Current Assets, loans and Advances: Inventories -- -- Sundry Debtors -- -- Cash & Bank Balances 576.75 108.92 Loans and Advances 0.40 1,938.2

Total (B) 577.15 2,047.2 Liabilities and Provisions:

Secured Loans -- 752.26 Unsecured Loans -- 1,000.0

Current Liabilities and Provisions 3.27 493.35 Deferred Tax Liability -- -- Total (C) 3.27 2,245.6

Net worth (A+B-C) 1,066.23 4,493.7 Represented by

Share Capital 470.00 3,120.0 Share Application Money 600.00 1,400.0 Equity (E) 1,070.00 4,520.0 Reserves -- --

Less Revaluation Reserve -- -- Reserves (Net of Revaluation Reserves) (F) -- -- Miscellaneous Expenditure (To the extent not written off

3.77 26.27

Net Worth (E+F-G) 1,066.23 4,493.7

BOARD OF DIRECTORS OF THE COMPANY

Name of the Director Designatio Mr. Saifuddin Quader Chowdhury Chairman and Managing Director

Mrs. Selina Quader Chowdhury Whole time Director Sadat Quader Chowdhury Whole time Director Saquib Quader Chowdhury Whole time Director Mr. X foreign company share holder as director Non Executive Independent Director Mr. X foreign company share holder as director Non Executive Independent Director

The Bangladeshi Directors of the company are hailed from the renowned business family and who has an established a business portfolio of more than 70 years of business operation initially the directors of Bangladesh for Saif Steel will be the 100% owner of the business registered as a Private Limited Company and they have a plan to sell their 10 stock to the Foreign Steel Rerolling company to get foreign investment directly in Bangladesh The registered office of the Saif Steel will work in the following address effective from March, 2013. A. CAPITAL STRUCTURE Share capital as at the date of filing of the Draft Prospectus with SEBI (before and after the Issue) is set forth below.

(BDT. In lacs, except share data)

Share C it l

Nominal Value Aggregate

Value A. Authorized Capital

80,000,000 Equity Shares of BDT. 10 each 8,000.00 B. Issued, Subscribed and Paid Up Capital

Equity Shares of BDT 10/- each fully

3,920.00

3,920.00

C. Present Issue 37,120,000 Equity Shares of BDT 10/- each 3,712.00 3,712.00

I Out of Which

a) 6,000,000 Equity Shares of BDT. 10/- each as

Promoter and Promoter’s Group

600.00

600.00

b)

1,556,000 Reserved for Employees Equity Shares of BDT. 10/- each fully paid up

155.60

155.60

II Net Offer to the Public 29,564,000 Equity Shares of BDT 10/- each 2,956.40 2,956.40

a) Out of Which 10% to be compulsorily allotted to QIB’s 2,956,400 Equity Shares of BDT 10/- each 295.64 295.64

b) Remaining to all other categories of Public 26,607,600 Equity Shares of BDT 10/- each 2,660.76 2,660.76

D. Paid Up Share Capital After Issue 76,320,000.0 Equity Shares of BDT 10/- each 7,632.00 7,632.00

E. SHARE PREMIUM ACCOUNT Before the Issue 0 After the Issue 0

NOTES FORMING PART OF THE CAPITAL STRUCTURE

1. Details of the increase in authorised capital

Sr. No. Particulars of Increase Date of Meeting in which the resolution was 1 BDT. 5 Crores Incorporatio

2 From BDT. 5 Crores to BDT. 30 Crores 15th April, 3 From BDT. 30 Crores to BDT. 50 Crores 22nd August, 4 From BDT. 50 Crores to BDT. 80 Crores 25th October,

The current authorised capital is sufficient to meet the requirement of the fresh issue

2. The existing share capital of the company has been subscribed and allotted as under Date of

Allotment/ made

fully paid

Number of equity shares

Face Value (BDT

)

Issue Price (BDT)

Consideration (Cash,

bonus, other than cash)

Remarks No.of Equity Shares

(Cumulative

Paid up Equity Capital (BDT)

08/02/200

50,00

10/-

10/-

Cash

Allottment to the Subscribers to

50,00

500,00

31/03/200

4,650,00

10/-

10/-

Cash

Allottment to Promoter Group and PACs

4,700,00

47,000,00

30/04/200

23,570,00

10/-

10/-

Cash

Allottment to Promoter Group and PACs

28,270,00

282,700,00

31/08/200

2,930,00

10/-

10/-

Cash

Further Allotment to Promoter Group

31,200,00

312,000,00

30/11/200

8,000,000

10/-

10/-

Cash

Further Allotment to Promoter Group

39,200,00

392,000,00

OBJECTS OF THE ISSUE The net proceeds of this Issue after deduction of Underwriting and Management fees, Selling fees and all other Issue related expenses payable by us is estimated at BDT [*] lacs. We intend to utilize the entire net proceeds of this Issue towards part funding of our proposed Integrated Steel Plant at Kutch, Gujarat. In case of surplus if any, the same shall be utilized for general corporate purpose of Saif Steel. The Company intends to utilize the proceeds of this Issue towards the following purposes: 1. To part finance the integrated Steel Plant consisting of the following modules:

PHASE I PHASE II 63000 TPA Billet to TMT rebar production line with furnace, shearing section completed with all auxiliary equipment

4 Diesel/Heavy fuel powered MW Captive Power Plant completed with substation

2. To meet the working capital requirements 3. To utilize funds for general corporate purposes. The general corporate purpose also includes the repayment of any unsecured loans raised, if any, for the purpose of the proposed project, which will be repaid from the proceeds of the Public Issue 4. To meet the public issue related expenses. The main object clause and objects incidental or ancillary to the main object clause of the Memorandum of Association of the Company enables the Company to undertake the existing activities and the activities for which the funds are being raised through the present issue. We, further confirm, that the activities of the company carried out until now are in accordance with the object of the Memorandum of Association of the company. Integrated Steel Plant The company is setting up a Green field project at Gazipur , Dhaka. . The cost of the project is estimated to at BDT. 1150 lacs. The various modules of the project, their individual capacities and their current status are given below.

Module

Particulars

Capacity

UoM Cost

(BDT)in lacs Phase I

1

2

Steel Melt Shop: M.S. Billets (1- Induction Furnace each with continuous caster Re-Rolled Products Common Costs including Land, Bldg, Site Devlpt, Misc. Fixed Assets and Soft Costs including Margin for Working Capital, Pre-operative Expenses, etc.

65000

MTPA 450 200

Sub Total (A) 650 Phase II

1 Captive Power Plant1 4 MW 500 Sub Total (B) 500

Total Project Cost (A) +(B) 1150 Public Issue Expenses [*] Grand Total [*]

The Phase I of the project has already been on the proposal stage with consent of directors. It is in stage of initial investment collection and would be operational by June 2013. The project has been appraised by Bangladesh Bank, where the Project comprised the setting up of 4 MW Captive Power Plant using Diesel/HFO. This 4 MW Multiple slow speed turbine Power Plant was found technically and economically fit by the Company to generate 4 MW power if Diesel/HFO is used as fuel. Additionally, such arrangement was also within the estimated costs stated in the report.

MEANS OF FINANCE

The Project is proposed to be funded from Promoter’s Contribution, Public Issue of equity shares, Term Loans from Bank and Financial Institutions. The proposed means of the finance for the Project is as under:

( Rs. In lacs.) Particular

Phase I Phase II Total

Promoters Contribution 750 - 750 Foreign Share - 0 0 Sub Total (Equity) 550 200 750 Debt (Banks/ Financial Institution) 200 200 400 Sub Total (Debt) 200 200 400 Total Project Cost 750 400 1150 Public Issue Expenses - [*] [*] Grand Total 750 [*] [*]

SWOT ANALYSIS

Strength Saif Steels Limited is incorporated with a view to set up a vertically integrated steel plant at Gazipur, Dhaka, Bangladesh. This integrated steel plant will produce 63000 TPA of TMT ebar from M.S. Billets and a Captive Power Plant of 4 MW capacity.

• Vertical Integration

The in-house consumption of billets, which would further be rolled into TMT bars along with installation of captive power plant utilizing the waste heat from the sponge iron plant would improve the overall profitability of the project making it financially more viable. The integrated nature of the plant provides cushion against fluctuation in the supply and prices of inputs required for its Billet and Re- rolling division.

• Captive Power Plant The project envisages a 4 MW captive power plant, which would ensure uninterrupted power supply and would eliminate the dependence on the State Electricity Board to a large extent. Further, on account of the captive power plant, power would be available to the unit at a cheaper cost, which in turn would improve the company’s profitability.

The waste heat gases emitted out of the sponge iron plant and MBF will be utilized for generating power, thereby removing the need for installation of pollution control equipment’s. The company will be generating power from Non-conventional resources and hence may be eligible for carbon credits under the Clean Development Mechanism (CDM). This will also result into substantial economic benefits to the company in the long term. The WHRB based power plant is comparatively less capital intensive than other conventional methods due to small size of the plant. The Company has initiated the process for procuring the necessary approvals for the same. For further details on advantages of CPP please refer to page no. 69 of this Draft Prospectus.

• Proximity and availability of raw materials

Billet and fuel, the major raw- materials required for the manufacturing of steel will be imported from Vietnam, India and Pakistan. and other countries. As the Chittagong port and Mongla port are near to the plant, import of these raw materials will be less time consuming and comparatively very cheaper due to saving on cost of freight.

The Company is in proximity to major raw materials like limestone, which is available in abundance in the Sylhet Region. The raw materials required for generation of Power i.e. lDiesel/HFO is again available locally in abundance. • Domestic Demand There is good potential for the Company, as in the western region there is substantial gap between demand and supply of finished steel and the Company plans to sell their maximum production within Division of Dhaka, Rajsahi and Sylhet. The demand for TMT bars/ structural is set to increase due to growth in construction and infrastructural activities especially in the region of Kutch and adjoining areas affected by earthquake. • Promoters background and experience The promoters are experienced in the steel sector and their existing distribution & marketing network will ensure that the finished goods of the company are sold with minimum efforts. • Promoters Participation and Firm Loan tie-ups The promoters have already have the land connected with main highway costs around 150 Lacs taka in BDT and hence has in the process of secured enough capital for Building Construction and furnace purchase. • Fiscal Incentives • As per the provisions of Section 80IA of the Income Tax Act 1961, the Company is eligible to claim a benefit with respect to deemed profit derived from power project @100% for a period of ten

consecutive assessment years commencing from initial assessment year of Company’s choice which shall fall beyond the fifteenth assessment year starting from the previous year in which the undertaking generates power. • Refund of Excise Duty: Under the Incentive Scheme, the plant should commence its manufacturing operations on or before 31st December 2013 (Notification N. 55/2004-CE dt, 9.11.04). If the conditions are met, the refund of Excise Duty paid on finished product will be available for a period of 5 years for an unlimited amount. • Sales Tax Exemption: Benefit under Sales Tax Exemption would also be available to the extent of 100% of the eligible investment (fixed assets) for a period of 10 years from the date of commencement of commercial production. These benefits would enhance the viability of the project and will provide partial safeguard against drop in sales realization, if any. • Commencement of Commercial Production The commercial production for all the basic source units viz. MS Billets, Steel Melt Shop and Rolling Mill is scheduled to commence in the month of June 2013 itself. Weaknesses • The final products of the company – TMT bars are mainly used for construction activities and are susceptible to price and demand volatility. However, the promoters are well experienced, having 70 years’ experience in marketing, manufacturing, logistics, shipping, trading and commodity import will be able to handle the adverse price and demand movements. Opportunities • The demand for TMT bars/ structural is set to increase due to growth in construction and infrastructural activities. • The company has acquired 3.5 acres of land and this is considered sufficient for their future expansion plans also. Threats • There could be an oversupply position due to capacity expansion and setting up of new projects in the steel industry. • The domestic demand & supply scenario is expected to be balanced even though many new projects/capacity expansion are expected to be implemented over the next 2-3 years. In such a scenario, the players with lower production cost would be in a position to utilize the capacities optimally. SSL enjoys cost advantages, as the essential input for TMT bars would be imported from the most cheaper source, which would enable it to withstand competition. The company is fast in implementing the project and would be in a position to complete the project earlier than other similar projects. SSL also proposes to set up a 4 MW CPP based on Diesel/HFO, which would enable it to produce power and utilize it for its billet and rolling mill division at very low cost. Further, the company would also be eligible for certain fiscal benefits by the way of exemption of excise duty upto 16% and sales tax to the extent of 4% excluding the Value Added Tax of 15%.

ABOUT THE COMPANY INDUSTRY OVERVIEW One of the most useful and versatile material, steel is considered to be the backbone of human civilization. As the steel industry has tremendous forward and backward linkages in terms of material flow, income and employment generation, the growth of an economy is closely related to the quantity of steel used by it. Steel is an integral part of a country’s infrastructure and industrial development. It includes hospitals, schools, townships, offices, houses and other buildings; urban infrastructure (including water supply, sewerage, drainage); highways, roads, ports, railways, airports; power systems; irrigation and agriculture systems; telecommunications etc. Covering as it does such a wide spectrum, steel becomes the basic input for socio-economic development. Global steel demand is rising on the back of accelerated infrastructure activity in China, Bangladesh and India, housing boom in USA, and white goods resurgence in Europe. During the recent recessionary phase, the industry is going through consolidation phase in terms of ownership as well as mothballing of inefficient capacities. Steel prices continue firming up. Looking at the Indian scenario, there has been emphasis on creating physical infrastructure for which massive investment is planned during the Tenth Plan (2008 to 2013). The steel industry would play a crucial role in this regard and has to gear itself to meet the challenges. The future and sustained growth of this industry is intimately linked to the growth of the economy in general and to the performance of the industrial sector and the construction activities, in particular. With the macro indicators looking up in almost all areas, the demand prospects of this industry look bright. GLOBAL SCENARIO For the first time in last 20 years, there is demand growth all over the world for steel. The demand supply gap is expected to increase and this will drive steel prices northwards, even as the global steel industry is not prepared for this demand onslaught. In India, China and other Asian countries the demand is led by emphatic investment activities in infrastructure. China is consuming steel like never before for its infrastructure with investments such as Three Gorges project on Yangtze as well as part of its build up to the Beijing Olympics in 2008 and the Shanghai Expo in 2010. In US, the demand is led by the booming housing industry. Additionally the auto industry is showing signs of recovery as auto sales hit their strongest levels for the year in July even as US posted a 2.4% GDP growth. In Europe, there is demand from a buoyant housing and white goods industry according to industry sources. Facts and Figures • In 2004 World Crude Steel output at 1.05 billion metric tons was 8.7% more than the previous year. (Source: World Steel Dynamics) • China remained the world’s largest Crude Steel producer in 2003 also (220.12 million metric tons) followed by Japan (110.51 million metric tons) and USA (91.36 million metric tons). India occupied the 8th position (31.78 million metric tons). (Source: IISI)

• Asia accounts for about 40% of global demand, which is expected to reach 50% in the next few years as demand growth is projected to be more in this region. BANGLADESH SCENARIO The steel industry witnessed a remarkable turnaround, buoyed by a spurt in the international prices. The domestic industry capitalized on this buoyancy, with a sharp surge in exports, particularly to China. In the domestic market, user industries like automobiles, housing and infrastructure sector and the consumer durable sectors continue to report strong growth. As per the estimates of Tenth Five-Year Plan (2008 to 2013), the construction sector (housing and commercial, infrastructure and industrial) is set to grow at around 12%. It is estimated that the domestic demand for steel will remain buoyant at around 8-10% during 2005-06, promising good fortunes for the players. Indian steel producers performed well during the fiscal 2003 and 2005, despite the global industry being faced with one of the most challenging operating and business environments in the last decade. With improved pricing and worldwide demand growth of steel products, most of the Indian steel manufacturers reaped the benefits of increased exports, reporting substantial improvement in profitability and overall financial position. Facts and Figures • Steel industry was delicensed and decontrolled in 1991 & 1992 respectively. • Bangladesh is the 19th largest recycler of steel in the world. • In 2004-05, production of finished carbon steel was 1.8385 million tonnes (Prov).

MEANS OF FINANCE The Project is proposed to be funded from Promoter’s Contribution, foreign direct investment , Term Loans from Bank and Financial Institutions. The proposed means of the finance for the Project is as under:

FUTURE OUTLOOK

Bangladesh steel sector is expected to witness growth in next few years backed by domestic drivers such as infrastructure and automobile demand along with close co-relation with the rising global trend. The growth in the steel industry will be mainly on account of the increased focus on infrastructural development. Infrastructure development has gained momentum over past two years, led by government initiative and opening up of the sector for private participation. The government has initiated various programmers to develop infrastructure activity in various sectors such as national highways, ports, railways, and power.

The Government stepped up investments in infrastructure over the past few years in the face of rising deficits, through private participation and innovative ways of funding. The assessment of projects in key infrastructure sectors like roads, ports, railways and power plants, indicates prospective investments of BDT. 1,19,600 crores over the next five years. Government has adopted innovative means for financing the proposed projects like levying cess on petrol and diesel, raising funds from multilateral agencies such as the World Bank and Asian Development Bank, encouraging private participation on Build-operate-transfer basis, etc., encouraging the banks and institutions to lend for the infrastructural projects, etc.

Further, abysmally low per capita consumption of steel at 27 kilograms (Kg) in Bangladesh as compared to

global majors (China has a per capita consumption of 128 Kg while the US averages around 472 kg and the European Union 428.6 kg.) suggests that there is a tremendous potential for greater demand. Therefore the steel industry is all set to witness growth in the coming years.

INDUSTRY STRUCTURE

LONG PRODUCTS

The construction sector consumes over 1 million tonnes of steel annually, mostly comprising long products. Thrust on infrastructural development projects like roads, fly-overs and boom in commercial and housing development gave a boost to demand for long products. The construction sector accounts for 70 per cent of long product consumption and the manufacturing and engineering sectors account for 30 percent.

The prices of long products are also expected to increase with a steady growth in demand at 7 per cent CAGR during the same period from the infrastructure and housing sectors; and with an increase in input prices. Long product prices in 2003-04, kept on increasing until they peaked in May 2004 at around BDT.27, 000 per tonne. In June 2004, however, the prices came down from their peak as a result of start of monsoon and decline in raw material prices. Prices increased as a result of the following reasons;

• Higher demand from domestic markets

• Strained supply due to raw material shortage and high operating rates

• High prices of raw materials like scrap, billets, and coke.

The domestic prices in April’05 of long products have increased by 9-18% over their Apr’011 levels and stand in the range of BDT.64000-66000 per tonne. Their prices in the coming year are expected to remain more at the current levels.

STEEL BILLET INDUSTRY

Steel billets are manufactured either by ingot casting and rolling through blooming & billet mills or by forging or by continuous-casting of billets directly from liquid steel. The billet being a semi-finished product is used for further processing for production of suitable products. It is used as a feedstock to rolling mills for production of long products like wire rods, bars/rods and light structural.

BARS AND RODS

Bars and rods constitute 70-75% of the total long products production and consumption. Construction and infrastructure –two high growth sectors in the country- are the primary consumers of bars & rods. CRIS INFAC expects construction investments to increase by 11 per cent over the Tenth Five Year Plan, as compared with 12 percent during the Ninth Five Year Plan. Bars and rods are available in various sizes ranging from 6 mm to 140 mm in diameter, the major segment being 6 mm to 25 mm. Rods of smaller diameters (5.5-12 mm) are generally produced in coil form. These are termed wire rods.

BUSINESS OVERVIEW

Saif Steels Limited (SSL), a closely held public limited company, will incorporate in February 2012 at Chittagong. SSL has been promoted by Mr. Saifudin Quader Chowdhury, Selina Quader Chowdhury Sadat Quader Chowdhury Saquib Quader Chowdhury, and foreign investing firm.

GML has been incorporated with a view to set up a plant in Kutch, Gujarat, to manufacture Sponge Iron, M.S. Billets, Re-Rolled products (TMT bars) with a captive power plant. The proposed project is envisaged to have the following manufacturing facilities.

Sr. no. Details Capacity

I Steel Melt Shop M.S. Billet 63000 per annum (15 MT * 1 – Induction Furnace each with continuous caster)

II Rolling Mill TMT Bars 63000 MT per annum Ill Captive Power Plant 4 MW (from Waste heat and lignite)

The process route selected for manufacture of steel is

Sponge Iron Plant -+ Induction Furnace -+ Continuous Caster -+ Re-Rolled products

The project is proposed to be implemented in two phases as under:

Phase Details Expected Commercial Operation Date

I • 15T * 1 Induction Furnaces • 63000 TPA Re-rolling Mill

May 29th, 2013

II • 4 MW Captive Power Plant October

The project is proposed to be implemented in two phases and the entire project would be fully completed by October 2011 SSL has appointed M/s Indenture Bangladesh and SMT India as its technical consultant for the proposed Roll Mill Industries Limited for the Rolling Mill Division and Energypack Bangladesh for the captive power plant. The technical consultant has been appointed for the rolling mill will also work for steel melt shop as the company proposes to use the conventional manufacturing process, which does require specific technical know-how.

The in-house consumption of billets, which would further be rolled into TMT bars along with installation of captive power plant utilizing the waste heat from the rolling mill plant would improve the overall profitability of the project making it financially more viable. The integrated nature of the plant provides cushion against fluctuation in the supply and prices of inputs required for its Billet and Re-rolling division.

LOCATION OF THE PROJECT

SSL proposes to set up the steel plant Gazipur Dhaka. SSL has acquired 3.5 acres of land at the site.

The registered office of the company is at QC Logistics 6th Floor CNF Tower, Seikh Mujib Road, Agrabad, Chittagong Bangladesh, which enjoys benefits available under Special Fiscal Incentives for Sales Tax and Excise Duty declared under Incentive Scheme 2001 for Economic Development of, which was declared by Government after the Fiscal year of 2010. Under the Incentive Scheme, the plant should commence its manufacturing operations on or before 31st December 2013 (Notification No. 55/2004-CE dt.9.11.04). If the conditions are met, the refund of Excise Duty paid on finished product will be available for a period of 5 years for an unlimited amount. In addition, benefit under Sales Tax

Exemption would also be available to the extent of 100% of the eligible Investment (Fixed Assets) for a period of 10 years from the date of commencement of commercial production

The proposed project also has the required Infrastructural facilities:

Availability of Raw Materials

Proximity to major raw materials like Lignite and limestone, presently both these raw materials are available in abundance in the south region of Bangladesh which is very much near to location. .

Connectivity

The site is well connected with all type of transportation.

National Highway The site adjacent with highway having a wide face of the plot located beside the National highway

Railway Station The site is around 1 KM away from Gazipur Railway Station Railway Siding The Plant is located opposite to local Railway statio the station can be used to carry

billets from beanpole, Chittagong or Bhomra by wagon and also supplying TMT rebar all over Bangladesh

Sea Port Chittagong port is 290 KM away from the location and Mongla port at Khulna is 330 KM away from the location

Air Port Dhaka Shah jalal International Airport is 40 KM from the location Manpower

Manpower both skilled and unskilled is easily available as many steel and other companies have put up/proposed to put up the manufacturing facilities around Dhaka and Narayangong region and also available in Chittagong region.

Proximity to Market

There is good potential for the Company, as in the western region there is substantial gap between demand and supply of finished steel and the Company plans to sell their maximum production within the divison of Dhaka, Sylhet, Rajsahi and Khulna. The demand for TMT bars/ structural is set to increase due to growth in construction and infrastructural activities. The company’s plant is located in close proximity to the market leading to savings in freight cost, which in turn would fetch SSL a higher selling price.

MANUFACTURING PROCESS

1. STEEL MELT SHOP (MS BILLET) The project envisages steel making facility through Induction Furnace route along with Ladle refining furnace and continuous casting machine. The process involves charging mix of raw material, mainly Sponge iron (50%) and C.I. Scrap/M.S. Scrap (50%) into molten bath with constant power track, by which, heat transfers into molten bath at constant voltage and KW to melt the Iron and Steel at a temperature of 1550o C.

I. ROLLING MILL (TMT BARS)

Thermo Mechanically Treated (TMT) bars are protected by past rolling thermo process. There are two known technologies, which were independently developed in Europe and later recognized globally.

These are the Thermo and Temporal Processes. Thermo processing of steel bars results in higher strength with better ductility than that offered by the Cold Twisted Deformed Process.

The process involves converting the shape stock viz. Ingots/billets to desired finished section in hot condition by way of passing the material between a pair of grooved rolls and providing suitable draft at various stages. The whole operation is conducted at a particular temperature range and within a limited time span. The stages of rolling operation are comprised of heating of feed stock to rollable temperature, rolling the feed stock ion different mill stands, cropping the hot bar during process of rolling between stands as applicable and subsequently finishing in the form of hot rolled deformed bar in straight length. The hot bar coming out of last pass is then conveyed through TMT line and collecting in a cool bed after shearing. The bars at almost ambient temperature are sheared to commercial length stored and kept ready for dispatch.

In TMT process, hot bars are subjected to quenching by means of an intense cooling installation (cooling installation specially designed water spray system). Due to quenching, the surface layer will hardens to martensite while the core structured remains austenite. When the bar is free of water chamber heat flows from core to surface and surface gets tempered to structure called Martensite. In the cooling bed due to atmosphere cooling, the hardened zone is tempered by temperature homogenization in the cross section and the austenite core is transferred to Ductile-Ferrite- Pearlite core. A dual combination of micro structural features in the cross-section of the bar gives it excellent yield strength along with superior ductility and weld-ability. Since the desired level of strength in TMT is achieved by heat treatment and not be increasing carbon content, it offers excellent weld-ability, ductility and earthquake resistance. Due to the stability of the microstructure of the bars at high temperatures, these bars exhibit good fire resistance.

PROCESS FLOW FOR MANUFACTURING TMT BARS

CUTTING OF BILLET TO DEFINITE LENGTH

PREHEATING THE BILLETS IN DOUBLE ROW REHEATING

FURNACE

ROLLING OF PREHEATED SOAKED STOCKS THROUGH NUMBER OF

PASSES TILL THE REQUIRED NOMINAL DIAMETER OF BAR IS ATTAINED

CONTROLLED SURFACE QUENCHING OF THE BAR IN THE TMT QUENCHING LINE

SHEARING OF THE BARS WITH FLYING SHARES

COOLING OF THE BARS ON COOLING BED

SHEARING OF BARS TO MARKETABLE LENGTH

SIZE WISE STACKING OF ROLLED TMT BARS

DISPATCH

IV. CAPTIVE POWER PLANT

Waste Heat Recovery Boiler

The waste heat recovery boiler will generate 1 TPH of steam with the outlet parameters of 67 Ksc(a) and 485 Deg. C., while taking in the feed water at 130 Deg.C from the deaerator. The entire waste gas from the remelting kiln will be utilized in the waste heat boiler for the steam generation.

5 TPH of steam generated in the boiler would be fed to the main steam line. About 0.25 TPH of steam would be used for the ejector and turbine gland sealing after pressure and temperature reduction to 25 KSC(a) and 235 Deg.C. Around 0.096 TPH of feed water would be used as spray. 29.75 TPH of steam would be fed to the extraction cum condensing turbine. The uncontrolled extraction from the turbine at 4.0 Ksc(a) would give 4.02 TPH of steam approximately at a temperature of 210 Deg.C. This steam would be used in the dearator, for heating up the feed water to temperature of 130 Deg. C.

A quantity of 25.73 TPH of steam, being the difference between the input and the extracted steam quantity, would be exhausted at 0.18 ksc(a) to the air-cooled condenser of the power turbine. The condensate from the condenser storage tank of the condenser would then be pumped to the feed water system by the condensate extraction pumps. In addition to the above quantity, the condensate from the gland steam condenser and the ejector condensers amounting to a total approximate quantity of 0.445 TPH would be added to the feed system through the condensate storage tank. With the CPP from waste heat operating at the rated capacity, the gross power generation will be 6 MW.

In addition to this company also proposes to set up a 1.2 MW fluidized bed combustion boiler.

Atmospheric Fluidised bed Combustion Boiler

Fluidised bed combustion is a “Clean Technology for a better tomorrow” where technology and economy have been interwoven harmoniously in quest of a better environment. The environmentally friendly perspectives of this technology are as follows:

• At the low combustion temperature of 850oC / 900oC, no Nitrogen Oxides result from the

Nitrogen in the combustion air, with the end result of extremely low NOx emissions even with fuels rich in Nitrogen.

• Formation of SOx is essentially prevented by the addition of limestone. This is both mixed into the fuel and blown into the combustion chamber. Due to the favorable conditions in the fluidized bed, about 90% of the resulting Sulphur Oxides can be removed.

• A broad selection of fuels thereby enabling use of Char produced in the DRI Plant replacing about 30% of coal. • Better plant flexibility at partial loads of about 25% and quick load changes. • Low Auxiliary Power consumption compared to other coal fired Boiler versions.

The Steam Generator would be semi-outdoor type, natural circulation, balanced draft, Bi-drum, designed for firing different grades of coal. The Boiler is of bubbling fluidized bed type to handle even high ash coal.

Capacity of AFBC coupled with adjacent WHRB has been selected to ensure adequate margin over the requirement of turbine at 100% MCR. AFBC would be designed to operate with “The HP heaters out of

service “ condition (resulting in lower feed water temperature at Economiser inlet) and deliver Steam to meet the Turbo-Generator requirement at 100% MCR. Economiser section of the Boiler would be non-Steaming type. Super heater sections would be convection type and designed so as to maintain rated Steam temperature of 460oC (:i: 5oC) at super heater outlet over the control range of 60% to 100%, MCR. Attemperator is provided at the outlet of convection super heater for the temperature control at Steam Generator outlet.

The Boiler furnace and flue gas passages would be designed for appropriate low velocities in order to minimize erosion.

Suitable balanced draft System would be provided for the Steam Generator with two(2) forced draft and two(2) induced draftfans. Each of these fans would be capable of meeting the air requiremtn at 60% Boiler MCR load. The forced draft fans would be radial type with inlet vane control for regulation of airflow. The induced draft fans would be radial type with multi louver damper control the regulation. The forced draft fans would control total airflow to Boiler and the induced draft fan would control furnace draft of the boiler through automatic control loops. In addition to the FD fan, two (2) primary air fan of 60% capacity each shall be provided for transportation of fuel with one working and one standby. The boiler would be top supported type and would be provided with all supporting Steel platforms, galleries and stairways for easy approach and Maintenance of the Unit. Adequate weather protection would be provided for instruments and operating personnel. Necessary insulation along with skin casing to limit outside surface temperature to the safe level would be provided. Capacity TPH 18 No. of Steam Generator No. 1 Superheated Steam Pressure Kg/Cm2 (a) 66 Superheated Steam temperature oC 485 +/-5 Feed Water temperature oC 050 Flue Gas outlet temperature at AH outlet oC 150 Fuel used Main Fuel Lignite and Char -- Performance Fuel Lignite and Char -- Startup Fuel Light Diesel Oil --

Steam Turbine Generator and Auxillaries

Steam Turbine

The Steam turbine will be condensing type. The set will be complete with Condenser, Air Evacuation System, 2 * 100% Condensate Extraction Pumps, Generator Cooling system, Gland Sealing with Gland Vent Condenser, Lube Oil System, LP and HP Re-generative Feed Heaters, etc.

Generators

Generator will be rated for 5 MVA (4 MW) with 0.8 lagging Power Factor, delivering Power at 11 KV.

Advantage of the Power Plant

• The waste heat gases emitted out of the sponge iron plant and MBF will be utilized for generating

power, thereby removing the need for installation of pollution control equipments. • The company will be generating power from Non-conventional resources and hence may be eligible for

carbon credits under the Clean Development Mechanism (CDM). This will also result into substantial economic benefits to the company in the long term.

• The WHRB based power plant is comparatively less capital intensive than other conventional methods due to small size of the plant.

• Utilization of waste heat and waste fuel means conserving the limited conventional natural fuel resources. • The technology is time tested and has already been successfully tried by other sponge iron manufacturers • CPP will achieve energy efficiency through recovery of waste heat of Kiln exhaust and also reduces the

thermal pollution to atmosphere to a large extent. • The in house power generation would ensure uninterrupted power supply and elimination of

dependence on the State Electricity Board to a large extent. It would also result in substantial savings to the company making it very competitive in terms of total cost of production of steel.

• With the Electricity Act now being passed, the company has the option to sell its surplus power if any to the Grid.

HUMAN RESOURCES POLICY

In each enterprise or industry employees are key contributors for business success. Accordingly, the Company will focus on recruiting, training and retaining the best people possible. It believes that a combination of its position as one of the cheapest steel manufacturer in the region, its working environment and competitive compensation programs will allow it to attract and retain talented / quality people. It believes that relationship with its employees will be congenial. None of its present employees belong to a union.

The following table sets out the number of the proposed employees:

Departmen

Total Number of

Production & Engineering 25 Finance, Accounting, Audit and Legal 10 Purchasing and Imports 5 Human Resources and Administration 1

Plant Maintenance 15 Quality Assurance and R & D 3 IT & EDP 2

Others 80 Total Number of Employees 160

Hiring

Employees hired will undergo training session conducive to company’s manufacturing process, marketing, plant maintenance and HR policy. The first stage will be an aptitude test with a focus on problem solving and analytical ability. The employees will be provided with orientation course on technology and management by bringing in experts from the industry who are knowledgeable and brought in innovation in the operation of the system

Training

The Company will place special emphasis on the training of its employees to enable them to develop their skills to keep abreast of the changing technology and to provide efficient and effective Operations, Maintenance & customer services. It will focus on an initial learning program for its trainees as well as continuous learning programs for all of its employees. All newly hired employees will be required to attend training programs to equip themselves with knowledge on Company’s business ideas and operations.

Employee Retention and Care

The Company strives to foster a feeling of well being in its employees through care and self-respect. It has several structured processes including employee mentoring and grievance management programs, which are intended to facilitate a friendly and cohesive organizational culture. Off-site activities will be encouraged to improve inter- personal relationships. Company will reward employees who will show exceptional talent, sincerity and dedication.

Compensation and Performance Management

The Company’s compensation policy will be performance based and inline with industry standards in India. Its compensation packages would be adjusted annually based on industry salary correction, compensation surveys. From time to time, employees who will meet or exceeded performance standards would be awarded bonuses.

Employee Post-Retirement Benefits

Employees’ post-retirement benefits will include a provident fund and a gratuity. Both of these are covered under the relevant statutory authorities. All employees earning up to BDT. 9,500 per month are entitled to provident fund benefits as laid down under the law. Each such employee makes monthly contributions to the plan equal to 12% of the employee’s basic monthly salary and Company will contribute a matching amount as per the Law. It will also be covering its employees with gratuity coverage from the LIC as per the norms of the LIC. Employee Insurance The Company will cover its employees with ESIC cover and for employees at managerial & above levels (including their direct dependents) it will provide medical insurance cover, which includes hospitalization benefits

Safety, Health and Environmental Regulation and Initiatives The Company is subject to extensive, evolving and increasingly stringent safety, health and environmental laws and regulations governing its manufacturing processes and facilities. Such laws and regulations address, among other things, air emissions (particularly volatile organic compounds), waste water discharges, the generation, handling, storage, transportation, treatment and disposal of chemicals, materials and waste, workplace conditions and employee exposure to hazardous substances. The Company is installing all environment control equipment’s as per the norms set out by the State Pollution Control Board and environment ministry.

Further, the adoption of new safety, health & environment laws and regulations, new interpretation of existing laws, will be done in order to maintain environment control equipment’s.

To help maintain the health and safety of its employees, Company will provide employees with periodic safety check-ups, safety equipment and continually update and distribute safety manuals.

Human resources are essential to company’s growth plans and the company will devote commensurate resources and attention to ensure that the right talent is hired and motivated to work for mutual benefit. The company will follow a two-pronged strategy to meet its human resource requirements. Key employees will be hired by the company and included in its payroll and others on contractual basis.

Motivation The company believes in motivating the employees for modernizing the operation namely to meet the competitiveness of the market by innovative cost cutting and in different levels of manufacturing by introducing latest methodology adopted in India & abroad. The employees will be provided with exposure in the latest technology and competitive market scenario with a focus to meet the challenges of national & international competitive atmosphere. WATER POLLUTION At present, the effluent undergoes the necessary treatment in the existing Effluent Treatment Plant before getting discharged into the Panchayat Drain. But, after the installation of the proposed project, zero discharge concepts shall be adopted. The water will be re-circulated through cooling and treatment. The entire treated effluent will be recycled for various purposes inside the plant. Domestic effluent from the various buildings/sheds of the plant will be conveyed through separate drains to septic tanks. The effluent from the septic tank will be disposed of through soil percolation by providing dispersion trenches/soak pits. The proposed units will be installed within the existing plot. The raw water will be drawn from the existing bore well, located inside the existing plant premises. Total make-up water requirement is 720 KLD (528 KLD for Induction Furnace, 96 KLD for TMT Rolling Mill. ENVIRONMENTAL IMPACTS OF PROPOSED PROJECTS IMPACTS ON AIR QUALITY

The Stack emissions from the plant are mostly Particulate matters, SO2 & NOx. There will be additional 1 (one) stack after the proposed project, which will be attached to TMT Bars Rolling Mill. There is no provision of any stack with the proposed Induction Furnaces (IF) as the reverse flow bag filter house shall be installed to control the dust emissions, generated from IF. Only cleaned gas with the maximum concentration level of 50 mg/Nm3 shall be discharged into the atmosphere. This system is well tested in local condition with a similar system, proposed installation at Steel Melting Shop at the proposed plant of SSL located at Gazipur Industrial Area near Gazipur in the Capital Dhaka, which is well in operation showing the design efficiency level. In order to evaluate the impact on ambient air quality due to such releases, the ground level concentrations (GLCs) as a result of the plant emissions have been evaluated through mathematical modeling using computer-aided techniques. The computation has been made applying Industrial Source Complex (ISC3) model, developed by United States Environmental Protection Agency (USEPA), which is most widely used and also recommended by CPCB (PROBES/70/1997-98). The model is based on some assumption such as steady state conditions, continuous homogeneous flow, inert passive pollutants, no ground absorption and a Gaussian distribution of the plume in both horizontal and vertical planes. As recommended by CPCB, GLCs at various receptor locations within 10 km radius have been computed for the three months’ period (15th March, 2008 – 16th June, 2008) representing the summer season, based on the hourly meteorological data of this period. It may, therefore, be concluded that due to the proposed project, there will not be any intolerable impact on the ambient air quality. IMPACTS ON WATER QUALITY SSL will follow “the zero wastewater discharge concept” and the entire wastewater will be recycled to the plant for various uses. As no wastewater will be discharged outside the plant premises, there will be no impact on the water quality of any surface water bodies of the area. No thermal pollution is expected as closed cycle cooling system will be adopted. IMPACTS ON SOIL There will be solid waste generation, but will be managed in the proper manner. This will ensure that there will not be any impact on soil quality due to the disposal or deposition of solid waste. IMPACTS ON LAND USE The proposed development will take place only inside the existing plant premises, so there will not be any impact on the land use pattern of the area. IMPACTS ON BIOLOGICAL ENVIRONMENT The surrounding area has substantial vegetation in the form of village orchards, roadside trees and agriculture. If the gaseous emission is controlled properly, there will not be significant impact. There will be intensive plantation of trees in the plant site. All these measures if implemented properly will ensure insignificant impact on the local vegetation from the proposed project and may improve the vegetation scenario of the area. No wastewater will be discharged outside the plant premises. There is, therefore, no impact on the

aquatic ecology of the water bodies. IMPACTS ON SOCIO-ECONOMIC ENVIRONMENT The project will offer substantial employment potential during construction phase and operation phase, which will have a beneficial impact. ENVIRONMENTAL MANAGEMENT PLAN SSL. Will develop various management activities for the Environmental Management Program which will meet all statutory requirements and help to improve environmental quality. . In order to improve the aesthetic look of the area and enhance the land use as well as to compensate for any loss in ecology during construction, adequate plantation programs around the project site have been planned and will be adopted. Development of green belt will include plantation of trees along boundary of the factory, roads, raw material yard and other available spaces. Over 33% of total area of factory will be covered under green cover. A detailed monitoring for different environmental parameters will be carried out as per direction of State Pollution Control Board. An environmental management group will be established to implement the management plan.

MARKETING STRATEGY

There is good potential for the Company, as in the western region there is substantial gap between demand and supply of finished steel and the Company plans to sell their maximum production within the state of Gujarat, Maharashtra and Rajasthan. The demand for TMT bars/ structural is set to increase due to growth in construction and infrastructural activities especially in the region of Gazipur and its unique positioning near to Dhaka city Khlna, Rajsahi, Barisal and Sylhet Division.

Moreover, the promoters are experienced in the steel sector and their existing distribution & marketing network will ensure that the finished goods of the company are sold with minimum efforts.

BUSINESS STRATEGIES

The company proposes to devise following strategies considering the existing competition in the industry and future entrants: SSL proposes to set up a vertically integrated steel plant. The billets, which would further be rolled into TMT bars along with installation of captive power plant utilizing the waste heat from the Billet remelting plant would improve the overall profitability of the project making it financially more viable. The integrated nature of the plant provides cushion against fluctuation in the supply and prices of inputs required for its Billet and Re-rolling division.

The project also envisages a 4 MW captive power plant, which would ensure uninterrupted power supply and would eliminate the dependence on the State Electricity Board to a large extent. Further, on account of the captive power plant, power would be available to the unit at a cheaper cost, which in turn would improve the company’s profitability.

FUTURE PROSPECTS

Bangladesh Steel Sector is expected to witness growth in next few years backed by domestic drivers such as infrastructure and automobiles demand along with close co-relation with the rising global trend. The growth of the Chinese economy has accelerated the global demand for the basic materials, required for building infrastructure and automobiles, resulting in tbe global growtb rates of steel, aluminum and coal which nearly doubled in tbe last two years as compared to tbe 90's Bangladesh is uniquely positioned to play a significant part in servicing Ibis global demand due to its low cost advantage.

3D View of Rolling Mill

3D View of Assembly of Rotary Shear (Head & Tail) & Pinch Roll

3D View of Flying Shear

APPLICATIONS OF HOT STEEL ROLLING MILLS MANUFACTURED BY US:

SMT manufactures Steel Rolling Mill Plants & Machinery for the rolling of TMT (GOLD) Bars &

Wire Rod in Coils, Squares / RCS, Rounds, Flats, Hexagonal, Light- Medium & Heavy Special

Sections: Angle, T – Iron, H-Beam / Joist, Channel, H-Beam, I-Beam, HR Strip up to 410 mm,

Railway Tracks Section, Lift T’s and Non-ferrous metals with a production capacity of up to

800,000 Tons per year.

By Virtue of rich and vast experience of the promoter himself and with his team of technical staff in

this field, we have established our name both in Indian and Overseas markets. The Company also

has a well-organized working structure to facilitate Smooth and Hurdle less flow of material.

CONSULTANCY:

Consultancy & Engineering Division of SMT can handle Customer requirements promptly and

suggest best possible solutions with various alternatives. Once the customer’s needs are identified,

we can provide the most economical Mill Layouts resulting in high productivity and product quality.

We lay special emphasis on Specific Fuel & Power Consumption and ensure environment friendly

pollution free facilities. SMT’s Consultancy Services Division also undertakes technology up-

gradation and modernization of existing Mills for Higher Productivity, Better Quality, Fuel & Power

Efficiency and Reduction in Environment Pollution.

SMT

Has got complete technical know-how to Design, Manufacture and Install Rolling Mill Plants as per Customer’s Specific needs from 30,000 to 3,00,000 M.T. production per annum.

Covers vast product ranges of 125-750 mm {5–30 inch)} complete Rolling Mill Plants with

desired Automation.

Also undertakes manufacturing of Hot Rolling Mills for Rolling of Graded and all types of Stainless Steel, Alloy Steel, Copper, etc. as per specific needs of Customers.

Provides Roll Pass Design for the Rolling of TMT Bars, Rod, various shapes & sections, Special Profiles and Railway Tracks, etc.

Also takes up Engineering job work as per Customer’s Drawing and Specifications to utilize

Spare Machining Capacity.

Prepares feasibility reports (FRs), Detailed Project Reports and Layouts for Rolling Mills

Takes up Modernization, Revamping and Refurbishing of existing Mills

3D View of Automatic Rake Type Cooling Bed

TECHNICAL SUPPORT

Since, Steel Rolling Mills are facing problem of low realization on finished products with higher

manufacturing costs, SMT has come forward to help the Rolling Mills to attain better quality

standards with Higher productivity & Reduce Cost of Production through: -

- Enhanced Production in Existing Plants - Lower Specific Power Consumption - Reduced Specific Fuel Rate - Better Product Quality - Better Industrial Norms - Roll Pass Designing - Development of New Products

To achieve the above goals, modernization, revamping & refurbishing of existing Rolling Mills can

be carried out based on our proposals which will certainly reduce the manufacturing cost and will

enhance the production rate to a great extent. To derive maximum benefit, you may please intimate

us your requirement of up-gradation either in particular aspect namely production, Power

consumption, Fuel, Quality, etc. or the total up-gradation of the Plant.

CLIENTELLE The Executed Turnkey Projects and miscellaneous machinery supplied by us

have earned us name in the Overseas Market as well as at Home. We have exported our

machinery to various Countries like Bangladesh, Kenya, Sri Lanka, Vietnam, Tanzania, Mauritius,

Belgium, Abu Dhabi, Dubai, Uganda, Ghana, Zambia, Sudan, Nepal, Ethiopia, Nigeria, South

Africa, Sharjah, Iran etc. Also, the never ending list of Overseas and Indian customers is

expanding everyday.

FLOW CHART

FOW CHART OF STEEL ROLLING MILL PROJECT

WEIGHING

l

UNLOADING

l

CHEMICAL & PHYSICAL TESTING

l

CUTTING

l

l

FEEDING TO RE-HEATING FURNACE

l

ROLLING

l

INSPECTION AT THE TIME OF ROLLING

l

TMT QUENCHING BOX

CUTTING

l

COOLING BED

l

INSPECTION

l

BUNDLING & TAGGING

l

READY FOR DESPATCH

TECHNICAL & GENERAL CHARACTERISTICS

1. ROLLING MILL LAYOUT:

The layout of the proposed rolling mill has been based on providing an efficient and

effective operating facility with particular attention given to the flow of material

starting at the billet bay, through to the final storage of the bundles into the finishing

storage bay, using automatic process procedures.

The Rolling Mill Plant comprises of the following equipment, namely:

A) Billet Charging System: The cold billets are loaded on a charging bank by crane,

namely called the Charging Grid.

The billet charging will be through mechanical Pusher Type and the billets are

pushed / charged into the furnace by group.

B) Re-heating Furnace: The re-heating furnace is frontal charging and side

discharging type, having a nominal capacity of 15 Metric Tons / Hour, complete

with charging grid / table, Mechanical Pusher and Ejector / Expeller.

C) Rolling Mill: The hot billet after being ejected / discharged from the re-heating

furnace will be moved to 1st Roughing Stand (410mm PCD) – 3 Hi – Fibre Type

Bearing type having 7 passes, with the help of conveyor. There will be a ‘Y’

Table and a Turning Wall on either sides of the 1st Stand and there will be an

operator facilitated with a control desk to control the movement of the material

through various passes on Conveyors etc. The material will further move to

another 2 Set of Roughing Mill Stands One No. of 3 Hi and One No. of Alt. 2

Hi having 1 Pass each with the help of Repeaters. The Roughing Mill will

operate through 1250 HP AC Motor.

The material will move from the Roughing Mill to the Intermediate Mill with the

help of Bar Way, in the process, it will be passed through 2 Pinch Rolls and a set

of Rotary Shears which will Crop the Bad Front and Back ends of the incoming

Bar from the Roughing Stand. The material will be moving continuously towards

the first Intermediate – cum – finishing mill stand.

The Intermediate Mill which consists of a total of 4 Stands of 310mm PCD

(Antifriction Spherical Roller Bearing Type) – 2 Hi Type, alongwith a Set of

Repeaters and Snap Shears. The Intermediate Mill will operate through 800 HP

AC Motor.

The material is further transferred to a Set of Continuous Type Stands of 280

mm PCD (Antifriction Spherical Roller Bearing Type) having 6 Sets of Mill

Stands with DC Motors of 200/235 kW and Single Input Single Output Type

Reduction-cum-Pinion Gear Box.

D) The incoming finished bar is moved into the Manual Type Cooling Bed.

E) The finished bar is evacuated from the Cooling Bed with the help of Run Out

Conveyor and then cut into required lengths of 6-12 Meters with the help of Cold

Shearing Machine and the Bar is finally moved to the Cradle area where it is

bundled and Strapped using the Strip Bundling Machine.

F) The material is finally moved to the Finish Product Storage Area with the help of

Overhead Crane.

The Rolling Mill is provided with various Rotating Shears, Snap Shears, Pinch Rolls

and Bar Ways etc. to avoid any heavy manpower and maintenance procedures.

2. ANNUAL PRODUCTION / YIELD:

The production of Rolling Mill is calculated for 60,000 M.T. approx. of Square Billets

/ Pencil Ingots (3½ x 4½ x 1.5 Meter x 2 Pcs.), 100 x 100 x 1.5 Meter x 2 Pcs., in one

shifts of 10 Hours each per day for 300 working Days of a year.

The procedure of calculation between the weight of billets and weight of the finished

products is as follows: -

Difference Between The Weight Of Charged Billets And Weight Of Re-Bars

Weight of Billets Charged in the Re-heating Furnace 63,000 T/Y

Furnace Scale Loss (About 1.5% of Charged Billet) 945 Tons

Scraps for Heads and Tails (About 1% of Charged Billet) 630 Tons

Scraps for Miss Roll etc. (About 1.5 % of Charged Billet) 945 Tons

Total Weight of Finished Product 60,480 T/Y

Yield of Rolling Mill:

63,000 – 2,520

Yield = ----------------------------------- x 100 = 96% Approx.

63,000

The Yield of the plant will be conditioned on the mix of finished products.

3. RAW MATERIAL:

The details of various sizes of Billets / Pencil Ingots that can be used as Raw Material

in the production process are as follows:

Size Length Section Weight / Meter (in K )

Total Weight (in Kg.) 100 x 100 1.5 Meter 78 117

130 x 130 1.5 Meter 132 198

3½ x 4½ 1.5 Meter 78 117

4 x 5 1.5 Meter 102 153

Quality Common Steel (Carbon Steel) for Reinforced Concrete

Tolerances According to International Standards

4. FINISH PRODUCT / SIZE RANGE:

The finished product will be foreseen for this production line will be as follows: -

ROUND (PLAIN) BAR / DE-FORMED BAR / TMT BAR

Sizes (in mm) 8 10 12 14 16 18 20 25 32

Weight Kg/M 0.39 0.62 0.89 1.20 1.58 2.00 2.46 3.85 6.31

Length From 6 Meters to 12 Meters as Required.

***Important: All products to be rolled shall confirm to relevant standards***

5. WORKING TIME:

The working time schedule to reach the above mentioned production has been

calculated as follows:

WORKING TIME TABLE

No. of Shifts 2+1

Production / Working Shifts 2 - (10 Hours each)

Maintenance Shift 1 (4 Hours)

Working Days Per Year 300

Available Hours per Year 7200

Effective Working Hours /Year 5100

Efficiency of Plant 70.50% Approx.

The above mentioned working hours availability has been calculated following

International Standards.

6. CONSUMPTION:

The average consumption for each 1 Ton of finished product will be as follows:

CONSUMPTIONS FOR 1 TON OF FINISHED PRODUCT

Electric Power (according to the sizes) 80 – 110 KW Approx.

Re-heating Furnace Oil 35-40 Liters

Cooling Water (Rolling Mill Water) 8 m3 – 12 m3

Compressed Air 15Nm3 – 20Nm3

Rolls and Rolling Equipment 5 Kg. Approx.

The above mentioned consumptions are indicative not binding.

7. INDUSTRIAL WATER:

The water quantity required for the plant is as follows. The requirement of water will be

made available through a specifically designed system.

Direct Cooling 200m3

Indirect Cooling 55m3

Temp. of Supply Water Maximum 35oC

Pressure of Supply Water Minimum 3.5 Kg/cm2

Water Req. for 1 Ton of 8mm Bar 45 Liters Approximately

8. ELECTRIC POWER:

The characteristics for the electric equipment will be as follows:

ELECTRIC DATABASE

Incoming Line (to be specified by the customer) 11 / 22 / 33kV

Installed Power 3500 kW approx.

Machines feeding tension 415 Volts

Frequency 50 Hz

Auxiliary AC tension 220 Volts

Auxiliary DC tension 24 Volts

The design voltage variation is + 10 % and design frequency variation is + 3%

10. PRODUCTION PROGRAM / SPEEDS:

The production of the plant is round reinforced bars. The characteristics of

productivity according with the size of re-bars is shown below along with there

production capacity and operating speed.

PRODUCTION CAPACITY PER HOUR WITH BILLET 100X 100 x 1.5 METER

Sizes

in MM

Weight

Kg/M

Max

Speed

M/Sec

% of

Production

No. of

Days

Annual

Tonnage

8.0 0.39 16.0 25 75 15,000

10.0 0.62 13.0 25 75 15,000

12.0 0.89 8.5 15 45 9,000

16.0 1.58 6.0 15 45 9.000

20.0 2.46 6.0 10 30 6,000 25.0 3.85 6.0 5 15 3,000

32.0 6.31 2.4 5 15 3,000

Total 100 300 60,000

Note: It should be emphasized here that the figures indicated above are tentative only

and exact figures shall be furnished / calculated / provided after detailed Design &

Engineering.

BILLET RE-HEATING FURNACE (18-20 MT/HOUR)

BILLET REHEATING FURNACE (CAPACITY 18-20 M.T. / HOUR)

1 Equipment : Double Row, Double Zone, Billet Re-heating F ( ith Sid Fi i )

2

Capacity :

18-20 Tons/hour.

3

Fuel :

Diesel Oil / Furnace Oil / Light Oil

4

Billet/ Ingot Size :

100 x 100 x 1500 mm x 2 rows 130 x 130 x 1500 mm x 2 rows

5

Max. Operating Temp. :

1250° C

6

Normal Operating Temp. :

1200° C

7

Overall Furnace Length :

Approx 24000 mm

8

Overall Furnace Width :

Approx 4740 mm

9

Effective Furnace Length :

Approx 22500 mm

10

Inside Furnace Width :

3400 mm

11

No. of Rows :

2

12

Recuperator :

Convective type Double Pass. Comprising of 50 % Seamless pipe &

Scope of Supply

1 Complete Furnace Shell Fabricated Out Of M.S. Plates 6mm/8mm/ 10 Mm & ISMB 150/ISMB 200/ ISMC 150 Etc. Air & Oil pipe Lines From Blower & H & P Unit To Burners.

2 C. I. Castings like Rails, Furnace Doors & Frames, C. I. Damper Plate & C.I. Clamps Assy.

For Holding Suspended Roof Bricks

3 Combustion Equipments

4 COAL GASIFIER – 01 No. Coal Gasifier having capacity of 20 TPH. Indian or Chinese

Make.

BURNERS

Type of Burners : Low Excess Air – Oil Fired Burner No. of Burners in Soaking Zone : 4 Nos. (Size 5A) 30-120 Ltrs. each No. of Burners in Heating Zone (Side Firing): 9 Nos. (Size 4A) 10-85 Ltrs. Each (All Burners Will Be Supplied Along With Accessories Like Burner Mounting Plate, Micro Valve, and Butterfly Valves. “Y” Stainer & S.S. Breaded Flexible Pipes, & Hoses Etc.)

COMBUSTION AIR BLOWERS :

Type of Blower :

For Oil

SMT Make Centrifugal No. Of Blowers : 01 Motor Rating : Air Cap. : Static Pressure :

100 HP./1440 RPM 9500 Cfm Each 40” W.G.

OIL HEATING & PUMPING UNIT

Model :

Oil Heating Cap. :

SMT Make Duplex –I, Comprising of 2 Gear Oil Pumps with Single Oil Pre-Heaters. 24 K.W.

Motor Rating : Gear Oil Pump Size & Cap. :

1 HP ¾” & 900 Liters. / Hour

4

Recuperator

Model & Type :

SMT Make 50 S & Metallic Heating Surface Area :

No. Of Passes : 50 Sq. Meters 2 (50% Seamless Tube & 50% “C”

Hot Air Temp. :

ERW) 225-275°C

Temp. Of Flue Gas before & After : Recuperator Pressure of Air Before & After Recuperator

650-300°C

1000-900 Mm W.C.

5

Furnace Discharge Doors

Type : No. of Doors : Size : Door Operation : Material

Raise & Fall 2 600 Width X 450 Height Manual C.I. Casting

6

Furnace Charging Door

Type : No. Of Doors :

Raise & Fall 1

Door Operation : Material :

Manual C.I. Casting

7

Furnace Inspection Doors

Type :

Hinge Type No. Of Doors :

Material : 7 - 9 C.I. Casting

8

Furnace Skids

Material : Type & Size : Projection above Hearth Level

Alloy Cast Iron Solid, 150 mm X 1375 (In Small segments) 35 M

9

Refractories & Insulations Details Zone

Insulation IS-6 IS-8 Cr/ Hi/Al. Hyesil Board Total Thickness

Hearth

Mag 50%

Soaking Zone 230 - 230 115 - - 575 Heating Zone 230 75 115 - 115 - 535 Pre-Heating Zone 230 190 115 - - - 535

Mm

Side Walls Soaking Zone

230

-

-

-

230

50

510 Heating Zone 230 - - - 230 50 510 Pre-Heating Zone 230 - 230 - - 50 510 Section

Soaking Zone &

230

Section 1.02 Burner Walls - - - - 50

510

Heating Zone

Furnace Roof (Suspended Type) Soaking Zone 115 - - - 300 - 415

Heating Zone 115 - - 300 - 415 Pre Heating Zone 115 - 300 - - - 415

Mm

Flue Passage Side Walls & Roof 115 115 - - - - 230mm Length of flue passage considered 45’ Long from Furnace Flue Outlet to Chimney.

10. FURNACE SKIDS:

Type : C.I. rails for portion of the firing zone hearth top mild steel

Billet skids for preheating zone hearth top.

No. of Skid rows : 4 (Four)

Projection above

Hearth level : 25 mm

Skid supports : Rests on furnace hearth refractory.

11 Chimney

Type : Self Supported

Size : 750 Mm Ø X 30 Meters Height

Plate Thickness : Conical Portion 8 Mm Thick Cylindrical

Portion 5-6 Mm Thick

Flange Thickness : 14 Mm / 16 Mm Thick

12. CHARGING PUSHER: - EXTRA HEAVY DUTY

Type - Electro-mechanical power screw type with guide rods.

Total weight of billets

to be pushed - 100 MT (based upon 1500 mm X 130 mm sq Billets)

Thrust Load - 60 MT (max.)

Stroke of the cylinder - 1000 mm

Stroke Speed - 2.5 Meters / Minute (approx.)

Gear box type & size - Multi Stage type Reduction Gear Box

Power Pack Motor HP - Not Included

13. DISCHARGE EJECTOR:

Quantity - One (1) No.

Type - Electro-mechanical & Mill Housing Type

complete with forward and side travel. (Double

Support)

Mill Stand Housing - Cast Iron, Open Top, Roller Bearing Type

Bearing - Antifriction Spherical Roller Bearings (ZKL/TIMKEN)

Roll Material - Forged EN-9

Stroke - 3500 mm [adjustable]

Drive roll - Steel wheels with bearing arrangement & guide

Flange spring loading for pinching arrangement.

Forward / reverse - By Gearbox & motor (Motor HP: 10)

Side travel - By Gearbox & motor (Motor HP: 3)

Side travel - 750 mm

Ejector bar - 4 ½ Meter Length M.S. Billet (Not Included)

Motor / Electrical - Not Included

14 Electrical Control Panel &Temp. Measuring Instruments

The furnace will be equipped with 1 no. Floor mounted type centralized electrical control

panel with following items.

1 Suitable contactors & overload relays for motors.

2 Suitable voltmeter and ampere meter.

3 Suitable fuses (All EE Make)

4 Indication lamps & push button BCH/ Vaishno

5 2-Nos. temperature indicator, 2 Nos. thermocouples along with compensating lead.

410 MM PCD ROUGHING MILL

1. Gear Coupling

410 MM PCD ROUGHING MILL

Quantity - Three (3) Sets – Heavy Duty

Material - EN-9 will suit the speed and duty as required.

Mounting - To be mounted between Motor to Flywheel, Flywheel to

Reduction Gear Box & Reduction Gear Box to Pinion Stand.

Type - Double Engagement type, geared teeth type

Flange Hole - Reamed

Lubrication - Allen Bolt, Forced greased Type

2. Fly-Wheel

Quantity - One (1) Set

Type - Antifriction Spherical Roller Bearings

Bearing - SKF / FAG Make

Material - Cast Iron Casting duly Machined, Bored & Balanced

Weight - 5 / 6 M.T. Approx. ( Suitable for 750 RPM (Max.)

- One (1) No. Forged Class-IV Steel Shaft.

- Shaft end to suit mounting of Geared Coupling

- One (1) Set of Steel Fabricated Base Plates

- One (1) Set Spherical Roller Bearings

- One (1) Set Bearing Blocks (Extra Heavy Duty)

- One (1) Set Bolts with Nuts for Base Plate to Bearing Block

3. Reduction Gear Box




Casting - Welded Steel Structure, Stress Relieved.

Gear - Double Helical, Heat Treated upto 240 / 260 BHN

Material - EN-24 Steel for Pinion & EN-19 Steel for Big Gear

Shaft - Forged Class-IV

Lubrication - Complete with Internal Pipeline for lubrication of Gears &

Double Oil Seal will be provided to avoid leakage of oil.

- One (1) Set C.I. Foundation Rails

- One (1) Set Tee Bolts with Nuts & Spacers

Loads - Normal - 1250 H.P., Maximum - 2500 H.P., Peak - 5000 H.P

Reduction Ratio- Input RPM - 740, Output RPM – As Required

4. Pinion Stand (410 mm PCD) 3 HI




Casing - Welded Steel Structure, Stress Relieved

Housing - Horizontal Split, Oil Leak Proof Type

Gear - Double Helical, Heat-treated upto 240 / 260 BHN before cutting

Material - EN-19

Lubrication - Complete with Internal Pipeline for lubrication of gears &


- One (1) Set Wobblers manufactured out of Forged Steel.



Loads - Normal - 1250 H.P., Maximum - 2500 H.P., Peak - 5000 H.P.

RPM - Input = Output of Red. Gear Box, Output = Input

5. Mill Stands (410 mm PCD)

Quantity - Three (3) Sets

Type - 2 No. - 3Hi Horizontal, Open top, Middle Roll fixed

1 No. – 2Hi Horizontal, Open top,

Material of Housing - Steel Casting duly machined

Size - 410 mm PCD

Bearing Type - 1 Set Fibre Type, 02 Sets – Spherical Roller Bearing Type

Roll Barrel Length - 1200mm – 1000mm – 800mm

Each mill stand will include a One (1) Set of the following: -

- EN-9 Pressure / Thrust Screw with Crown Wheel Arrangement

- Top Roll to be balanced by Springs through suspension rods

- Steel Fabricated Rest Bars & Side Bars (Swedish Type)

- Steel Fabricated Side Flaps

- Adjustment Screws and L-Keys

- Set of C.I. Breakers

- Phosphor Bronze Nut/bush

- S.S. Rod for bottom roll adjustment

- Cap fixing will be with levers & double wedges

- Top roll screw down system will be with Crown and Crown wheel

- Wearing Plate on the inside of Mill Stands for Long Life.

- Effectively designed EN-9 Steel Fibre Bearing Chocks alongwith

Fibre Bearings & Bearing Chocks with 24048 Bearings (SKF/FAG)

- CI Couplings

- Star type Spindles manufactured out of Forged Steel

- Tie Rods with Nuts & Spacers

- C.I. Foundation Rails

- Tee Bolts with Nuts & Spacers

Including - Rolls, Foundation Bolts & Bearings

6. Motor C.I. Foundation Rails (For X-Y-Z axis movement)

(a) C.I. Foundation Rail for 1500 H.P. Motor - Four (4) Nos.

(b) Foundation Bolts with Nuts & Spacers - As Required

(b) Tee Bolts with Nuts & Spacers - Twelve (12) Nos.

7. Oil Lubrication System:

To lubricate gears & bearings of Pinion & Reduction Box of Roughing Mill

Quantity - One (1) No.

Type - Pit hole type

Pumping Capacity - 150 LPM

Reservoir Capacity - 1500 liters

Material - Steel Plate Body

Accessories - Heat Exchanger

- Oil Strainer

- Contact Thermometer / Manometer

- Duplex Filter

- Pressure Gauge

- Pressure / Flow Switch

- Inlet & Outlet nozzles

- Complete Pipeline to & from the Gear Boxes

- Complete with the Control Panel

Electrical - Not Included

310 MM PCD INTERMEDIATE-CUM-FINISHING MILL

310 MM PCD INTERMEDIATE-CUM-FINISHING MILL

1. Gear Coupling

Quantity - Three (3) Sets


Mounting - To be mounted between Motor to Flywheel, Flywheel to

Reduction Gear Box & Reduction Gear Box to Pinion Stand.

Type - Double Engagement type, geared teeth type

Flange Hole - Reamed

Lubrication - Allen Bolt, Forced greased Type

2. Fly-Wheel


Type - Antifriction Spherical Roller Bearing

Bearing Make - SKF / FAG make

Material - Cast Iron Casting duly Machined, Bored & Balanced

Weight - 3/4 M.T. approx. (Suitable for 750 RPM (Max.))

- One (1) No. Forged Class-IV Steel Shaft.

- Shaft end to suit mounting of Geared Coupling

- One (1) Set of Steel Fabricated Base Plates

- One (1) Set of Spherical Roller Bearings

- One (1) Set Bearing Blocks (Extra Heavy Duty)

- One (1) Set Bolts with Nuts for Base Plate to Bearing Block

3. Reduction Gear Box




Casting - Welded Steel Structure, Stress Relieved.


Material - EN-24 Steel for Pinion & EN-19 Steel for Big Gear


Lubrication - Complete with Internal Pipeline for lubrication of Gears &




Loads - Normal - 800 H.P., Maximum - 1600 H.P., Peak - 3200 H.P

Reduction Ratio- Input RPM – 740, Output RPM – As Required

4. Pinion Stand (310 mm PCD) 3 HI





Housing - Horizontal Split, Oil Leak Proof Type


Material - EN-19

Lubrication - Complete with Internal Pipeline for lubrication of gears &


- One (1) Set Wobblers manufactured out of Forged Steel.



Loads - Normal - 800 H.P., Maximum - 1600 H.P., Peak - 3200 H.P.


Quantity - Four (04) Sets

Type - Alternate 2 HI, Horizontal, Open top

Material of Housing - Steel casting, duly machined

Size - 310 mm PCD

Bearing - Antifriction Spherical Roller Bearing Type – 24032 Ckw

Min/Max Roll OD - 310 mm/ 360 mm

Roll Barrel Length - 510 mm

Roll Neck Dia - 160 mm


- EN-9 Pressure / Thrust Screw with Crown Wheel Arrangement

- Top Roll to be balanced by Springs through suspension rods

- Steel Fabricated Rest Bars (Degree Type) & Side Bars (Swedish Type)

- Steel Fabricated Side Flaps

- Adjustment Screws and L-Keys


- Phosphor Bronze Nut/bush

- Cap fixing will be with levers & double wedges

- Top roll screw down system will be with Crown and Crown wheel

- Wearing Plate on the inside of Mill Stands for Long Life.

- Effectively designed Cast Steel Bearing Chocks without

Spherical Roller Bearings of No. 24032 C3CK30 W33 (SKF/FAG)

- Effectively designed Universal Couplings

- Universal Spindles manufactured out of Forged Steel

- C.I. Foundation Rails

- Tee Bolts with Nuts & Spacers

Including: a) Rolls c) Bearings. b) Foundation Nuts and Bolts.

6. Motor C.I. Foundation Rails

(a) Straight Type & ‘L’ Type for 800 HP Motor- Four (04) Nos. each

(b) Foundation Bolts with Nuts & Spacers - As Required

(b) Tee Bolts with Nuts & Spacers - Twelve (12) Nos.


To lubricate gears & bearings of Pinion & Reduction Box of Intermediate Mill Quantity - One (1) No. Type - Pit hole type Pumping Capacity - 150 LPM Reservoir Capacity - 1500 liters Material - Steel Plate Body Accessories - Heat Exchanger - Oil Strainer

- Contact Thermometer / Manometer - Duplex Filter - Pressure Gauge

- Pressure / Flow Switch - Inlet & Outlet nozzles - Complete Pipeline to & from the Gear Boxes - Complete with the Control Panel Electrical - Not Included 8. Speed Increaser-cum-Pinion Stand (305 mm PCD) Quantity - One (1) Set Type - Spherical Roller Bearing Type (SKF / FAG) Casting - Welded Steel Structure, Stress Relieved. Gear - Double Helical, Heat Treated upto 240 / 260 BHN before cutting Material - EN-19 Steel for Big Gears, EN-24 Steel for Input Side Pinions and EN-19 Steel for Output Side Pinions Shaft - Forged Class-IV Lubrication - Complete with pipeline for lubrication of Gears & Double Oil Seal will be provided to avoid leakage of oil. - One (1) Set Universal Couplings & Spindles of Forged Steel - C.I. Foundation Rails - One (1) Set Tee Bolts with Nuts & Spacers

Loads - Normal - 500 H.P., Maximum - 1000 H.P., Peak - 2000 H.P Speeds - Input and Output - As Required

280 MM PCD CONTINUOUS FINISHING MILL

280 MM PCD CONTINUOUS FINISHING MILL

1. Gear Coupling

Quantity - Six (06) Sets, Flexo Type


Mounting - To be mounted between Motor to Reduction Gear Box cum

Pinion Stand.

Type - Double Engagement type, Nylon Round Pad

Flange Hole - Reamed 2. Reduction cum Pinion Gear Box – 2 Hi

Quantity - Six (06) Sets Single Input Single Output with inbuilt Pinion

Type - Antifriction Spherical Roller Bearing Type (ZKL / TIMKEN)


Gear - Double Helical, Heat Treated upto 240 / 260 BHN before cutting Material - EN-19 Steel for Big Gears, EN-24 Steel for Input Side

Pinion and EN-19 Steel for Output Side Pinions


Lubrication - Complete with internal pipeline for lubrication of Gears &


- One (1) Set Universal Cross Couplings & Universal Spindles.

- One (1) Set Steel Casting Foundation Rails

- One (1) Set Hexagonal Bolts with Nuts & Spacers

Loads for S.I.S.O. Normal - 300 H.P., Maximum - 600 H.P., Peak - 1200 H.P. Speeds

- Input – As Required, Output – As Required


Quantity - Six (06) Sets

Type - 2 HI, Horizontal, Open top

Material of Housing - Steel Casting/ Steel Fabricated, Duly Machined

and MIG Welded

Size - 280 mm PCD (SKF / FAG)

Bearing - Spherical Roller Bearing No. 24030 ckW

Min/Max Roll OD - 260 mm / 300 mm

Roll Barrel Length - 500-510 mm


- Pressure Bolts with Worm Wheel arrangement and Handle

- Steel Fabricated Rest Bars & Side Bars (Swedish Type)

- Adjustment Screws


- Steel Chocks without Spherical Roller Bearing No. 24030 ckW

- Universal Cross Couplings

- Universal Cross

- One (1) Set of C.I. Foundation Rails- Patra Type

- One (1) Set of Tee Bolts with Nuts & Spacers.

Rolls - For all 4 Stands Roll Quantity – 08 Nos.

BL – 510 mm

Roller Bearing – 24030cKW

Material – Definite Chill with Class–IV Shaft

Shore Hardness – 65 - 70

Excluding: a) Rolls c) Foundation Nuts and Bolts. b) Bearings

4. Motor C.I. Foundation Rails

(a) Cast Steel Straight Type & ‘PATRA TYPE’ 235 KW Motor - Six (06) Sets

(b)

(b)

Foundation Bolts with Nuts & Spacers

Tee Bolts with Nuts & Spacers

- As Req

- Six (06) Sets


To lubricate gears & bearings of Gear box cum Pinion Stand of Continuous Mill Quantity - Two (02) No.

Type - Pit hole type

Pumping Capacity - 100 LPM

Reservoir Capacity - 1000 liters

Material - Steel Plate Body

Accessories - Heat Exchanger

- Oil Strainer

- Contact Thermometer / Manometer

- Duplex Filter

- Pressure Gauge

- Pressure / Flow Switch

- Inlet & Outlet nozzles

- Foundation Bolts

- Complete Pipeline to & from the Gear Boxes

- Complete with the Control Panel

Electrical - Not Included

MISCELLANEOUS ITEMS

MISCELLANEOUS ITEMS

1. Material Handling Equipment: One (1) Set Material Handling Equipment complete for

the transfer of material from Reheating Furnace to Roughing Mill, and finally upto Continuous

Finishing Mill & Cooling Bed, such as run out table etc. comprising of: a) Furnace Charging: Charging Grid for preparing the set of Raw Material, complete

with Charging Roller Table, driven by Chain Sprocket arrangement through AC Electric

Motors (motors not included) complete with Counters, V-Belt Pulleys & V-Belts or as required,

for taking the cold billets upto the Pusher or the feeding side of the Re- heating Furnace.

b) Discharging Roller Table: For taking the Hot Billets from Reheating Furnace to

Roughing Mill, driven by Chain Sprocket arrangement through AC Electric Motors (motors

not included) complete with Counters, V-Belt Pulleys & V-Belts or as required.

c) Guide Roll Assembly: Two (2) Nos. to be installed, One (1) No. at Furnace Exit & and

One (1) No. at 1st Roughing Stand Entry, with AC Electric Motors (motors & starters not

included) & starters.

d) ‘Y’ Table & Turning Wall: To be installed as per requirement for Entry / Delivery of

the Material to 1st Roughing Stand, with AC Electric Motors (motors not included), Counters, V-Belt Pulleys & V-Belts or as required.

e) Bar Way / Nozzles / Rollers: For transferring the material from Various Finishing

stands upto the Cooling Bed.

f) Cooling Bed & Run-Out Table: Cooling Bed conveyors of 78 meters and cold shear

conveyor of 12 meters for moving the Bar from the Cooling Bed upto the Cold Shearing Machine

and upto the Bundling Section, driven by V-Belt arrangement through AC Electric Motors

(motors not included) complete with Counters, V-Belt Pulleys & V-Belts or as required. 2. Repeaters: One (1) Set of Two (2) Nos. Repeaters for transfer of material in Roughing

Mill and One (1) Set of Four (04) Nos. Repeaters for Intermediate Mill, complete with Pedestal,

Jack, Pipe Nozzles, and Foundation Rails & Foundation Bolts.

3. Snap Shears: Two (02) Nos. Pneumatic Snap Shears for cutting the material while

transfer or miss roll in Intermediate Mill, complete with FESTO make cylinders and solenoid

valves. 4. Pinch Roll:

Quantity - Four (04) Nos.

Type - Mill Housing Type complete with frame SMT - 305

Capacity - Suitable to push 32mm hot square or equivalent round

Mill Stand Housing - Cast Iron, Open Top, Roller Bearing Type

Pinion Housing - Steel Casting Housing

Gear Material - EN–19

Roll Material - Forged EN-9

Bearing - Antifriction Spherical Roller Bearings (ZKL/TIMKEN)

- Two Nos. suitable capacity Universal Joints

- Complete with internal lubrication pipeline &

V-Belt Pulley

Excluding - Motors, V-Belts and Foundation Bolts. 5. Rotary Shearing Machine:

Quantity - Two (02) Nos.

Type - Fix Type - SMT - 450

Capacity - Suitable to cut 32mm hot square

Housing - Steel Casting Housing

Gear Material - EN–19

Bearing Type - Antifriction Spherical Roller Bearings

Bearing Make - ZKL / TIMKEN (TWB) Make

Blades - One Set of Shears made from Army Tank Plates

- Complete with internal lubrication pipeline

- V-Belt Pulleys,

Excluding - Motor, V-Belts and Foundation Bolts.

6. Guiding System: One (1) Set complete for Roughing Mill, Intermediate Mill and

Continuous Mill comprising of Twist Pipes, Roller Guide Boxes, plate etc. 7. Cold Cutting Machine: Quantity - One (01) No. Type - Mechanical Clutch Type Capacity - Suitable to cut 8-32 mm cold Bars Working Pressure - 120 – 150 MT Body - Fabricated Steel Body Gear Material - EN–9 Bearing Type - Taper Roller Bearings Bearing Make - ZKL / TIMKEN (TWB) Make Blades - One Set of Shears made from old Army Tank Plates Along with - V-Belt Pulley Excluding - Motor, V-Belts, Motor Side V-Belt Pulley & Foundation Bolts, Grease & Oil Circulation Pump

1 8 mm Rod 50 Pcs at a time 2 10 mm Rod 35 Pcs at a time 3 12 mm Rod 25 Pcs at a time 4 16 mm Rod 15 Pcs at a time 5 20 mm Rod 10 Pcs at a time 6 25 mm Rod 07 Pcs at a time 7 28 mm Rod 06 Pcs at a time 7 32 mm Rod 03 Pcs at a time

TECHNICAL DETAILS 1) Motor Pulley - 4” x 3 Groove, C Section. 2) Main Pulley - 16” x 3 Groove, C Section 3) Flywheel - 360 RPM - Cast Iron ( Dia – 1000 mm & Face – 250 mm) 4) Flywheel Weight - 800 Kg 5) Stroke Length - 64 mm 6) Stroke - 25-30 per minute 7) Shafts Material - EN - 8 8) Crank Shaft - EN-9 9) Crank - Crank Off Set - 45 mm

Crank Dia - 255 mm 10)

Slide & Link

Crank Length – 555 mm - 125 mm x 890 mm x 460 mm

11) Gears - Helical Gear Double Stage 12) Bearings - 04 Nos. - 32220 & - 01 No. - 22216 13) Body of MS Plate - 40 mm 14) Bush - Gun Metal 15) Blade - 30 x 125 x 460 mm 16) Motor - 25 H.P. / 1440 RPM

WORKSHOP MACHINERY / TOOL ROOM 1. Lathe Machines: Complete with all standard accessories.

Length Bed Centre Dog Chuck Qty. Alongwith

16 24" 22" 30" 01 7.5 H.P. Motor 12' 20" 18" 24" 03 5.0 H.P. Motor 8' 15" 13" 16" 01 3.0 H.P. Motor

2. Shaping Machine: One (1) No. of 30” / 32” Stroke with 3 H.P. Motor & Oil

Pump. 3. Radial Drilling Machine: One (01) Nos. Capacity 40 mm complete with Electricals. 4. Tool Grinder: Two (2) No. Motorized with 2 H.P. Electric Motor & 10" Stone. 5. Electrical Hand Grinder: Three (03) Nos. 6. Hand Vice: Two (02) Nos. with Stand. 7. Welding Set: Two (02) Nos. Heavy Duty, Duplex type, 5 kW, Air cooled

Complete.

8.

Water Pumps:

Four (04) Nos. of capacity 40 H.P. complete with all standard accessories.

9. Gas Cutting Set: Two (02) Nos. alongwith Gas Cutting Torch, Pipe,

Oxygen Gauge, LPG Gauge, etc.

10.

Air Compressors:

Three (03) Nos. of 10 H.P. complete with Air Storage Tanks & Electricals.

ELECTRICALS

1. Main Motor for Roughing Mill: One (1) No. 1250 H.P, 740 RPM, 3 Phase, 50

Cycles, 440 Volts, AC Slipring SPDP, Rolling Mill duty, Marathon (Ex Alstom) /

Crompton Greaves Make.

2. Main Motor for Intermediate Mills: One (1) No. 800 H.P, 740 RPM, 3 Phase, 50

Cycles, 440 Volts, AC Slipring SPDP, Rolling Mill duty, Marathon (Ex Alstom) /

Crompton Greaves Make. 3. Main Motor for Continuous Finishing Mills: Six (06) Nos. 200/235 kW, 0-1000-

1500 RPM, 3 Phase, 50 Cycles, 440 Volts, DC Motor, Rolling Mill duty, Crompton

Greaves Make. 4. Mill Auxiliary Motors: Motors required for shearing machines, pinch rolls, oil

lubrication system etc. 5. Water Starters: Two (02) No. liquid type Water Starters for A.C. Motors. 6. D.C. Drive & Panel: For conversion of A.C. to D.C. Digital PLC Control Panel

complete with Thermocouples and Synchronized Systems, etc.

7. Main Panel Board: Main Panel Board as per requirement of Electric Motors Input

type fitted with Bus Bars, Capacitors, LT. OCB / ACB Non Draw-Out type, AMP Meter,

Voltage Meter, Copper Wire, Voltage Selector Switch, Push Button Indicators, CT Control

Center, Micro Switch, Earth Release, Overload Release Switch etc., maximum components to

be SIEMENS / ABB make

8. Small Panel Boards: Small Panel Boards for Electric Motors of Smaller Powers as

per requirement (For Reheating Furnace, Tool Room, Cooling Bed, E.O.T. Cranes etc)

fitted with Bus Bars, Capacitors, L.T. OCB / ACB Non Draw-out type, Amp Meter,

Voltage Meter, Copper Wire, Voltage Selector Small, Push Button Indicators, C.T., Control

Center Micro Switch, Earth Release, and Overload Release Switch etc., maximum components

to be SIEMENS / ABB make

9. Control Desk / Boards: Complete with Start – Stop Push Buttons, Forward –

Reverse Toggle switches, Signal Lamps, Analog / Digital Counters, Tachometric indicators

with scale calibrated in RPM, Manual Control, Alarm Control, Set of Connections etc., for AC

and DC Motors, as and where required shall be provided on various places such as Pusher,

Ejector, Roughing, Intermediate, Continuous Finishing Mill, Flying Shear, Cooling & Oil

Lubrication System etc. 10. One (1) Nos. Main Transformers 3000 kVA each complete with Main Electric

Supply to all the Control Panels and Desks, High Voltage / Low Voltage Distribution Boards,

Protective Devices, Instruments etc.

AUXILIARY EQUIPMENTS

CHEMICAL & PHYSICAL LAB 100 M.T. Universal Testing Machine complete with Chemical / Physical testing facilities LIST OF CHEMICAL AND PHYSICAL LABORATORY

1 CARBON APPRATOUS

Complete with transformer, tube-furnace, W.frame, glass part, etc.

Or same as above but with digital temp. Indicator

2

MUFFLE - FURNACE

Complete with thermocouple & pyrometer or

same as above but with digital controller 3 BALANCE Chainomatic / Air Dumping (Balman) 4 HOT PLATE Single Disc 5 BAROMETER Without Mercury 6 WATER STILL Aluminum Casted body

Computerized Universal Testing Machine (Cap. 100 Ton) complete with all accessories to carry out Tension, Compression, Bending tests, etc. The System consists of: 1. Load censor 2. Displacement transducer (Encoder) 3. Least Count Standard Features 1. Pre Load 2. Load display on Monitor 3. Elongation display on Monitor 4. Cross – Sectional Area 5. Ultimate Tensile Strength 6. Print our of graph and test data 7. Online display of Load Vs. Elongation 8. Percentage elongation at the time of breaking 9. Data storage The System will be complete, with fully functional Computer comprising 17” Color Monitor, 2.4 G Hz. Intel Processor, 80 G.B. Hard Disk, 256 MM Ram, DVD Combo Drive & HP LaserJet 1020 / 1030 A4 size printer. The Machine will be supplied with Rockwell Hardness Testers Model STI-RA

2. CNC RIB CUTTING MACHINE

Sr. No Description of Goods Quantity

1 Special Purpose ROLL BRANDING MACHINE (22/25)

Max Roll Dia – 500 mm, Max Roll Length – 2000 mm

1 No

2 Copper Electrodes (8 mm) 6 Nos.



5 Copper Electrodes (12 mm 6 Nos.

6 Copper Electrodes (ISI LOGO)

For Dia – 8-16 mm

4 Nos.

Total 3. WEIGH BRIDGE Fully Electronic Weigh Bridge, Platform Size 12500 X 2500 Mm, Capacity 60000 Kg, Mounted on Six (6) Nos. Shear Beam Type Load Cells of 10000 Kg Capacity each. Steel Structure made of 3 Nos. fabricated Transoms of 400 X 140 mm and 05 Nos. of R.S. Joists of 500 X 180 mm Deck made out of 16 mm thick M S Plate with Anti Skid Strip Welding.

4. E.O.T. Crane Capacity 10 Ton Capacity : 10 Ton (SWL) Standard : Confirm to IS: 807 & IS: 3177 Span : 24 Mtrs (approx.) Height of lift : 08 Mtrs. (approx.) Type : Double Girder Class of Duty : IV, M-8, (Extra Heavy Duty) Speeds Hoist : 08-09 Mtrs./min. Approx. L.T. : 45-50 Mtrs./min. “ C.T. : 25-30 Mtrs./min. “ Motors Hoist : 30.0 H.P........960 RPM (1 No.) L.T. : 09.0 H.P........960 RPM (2 Nos.) C.T. : 03.5 H.P........960 RPM (1 No.) (All the motors of Hoist & L.T. will be slipring make- CROMPTON GREAVES /ALSTOM (MARATHON)/KIRLOSKAR). Gear Boxes Gears made out of EN 9 Pinions made out of EN 24 (All the gearboxes will be multi stages helical types with arrangements for splash lubrication). Brakes Hoist : 300 mm Dia...............(1 No.) L.T. : 200 mm Dia...............(2 Nos.) C.T. : 200 mm Dia...............(1 No.) (All the brakes will be Electro Hydraulic Thrustor Operated/ Electro Magnetic FAIL SAFE TYPE. Make - CRANE-N-CONTROL). Couplings : All the Couplings will be Gear type & made out of EN-9 forging and heat treated. Rope : 6x36 Const.

Make-"Ushá Martin” Hoist Rope 19 mm.(4 Falls) Safety Factor : 8 (Eight)

Bridge/Beam : The bridge will be box girder type fabricated out of tested MS Plates as per IS:2062. It will have platform for easy maintenance in full length on one side & two small maintenance platforms on other side. End Carriage : Also Box type Wheels Assembly : “L” Type bearing arrangements for easy maintenance with heavy duty double spherical roller bearings. Wheels : Made out of EN-9 forging & Heat treated Control : All the accessories of Control panel & switch gear will be of L & T / SIEMENS / BCH / ABB make etc. & control with 110 volts through cabin with master controller. Cross Conductors : The Cross Conductors supply will be festoon type trailing cable Arrangements with ISI marked and tested at 1100 Volts cables. Limit Switches : Crane Duty Limit Switches will be provided. (Make SPEED-N-SYSTEM/ CRANE-N- CONTROL). Resistance Boxes : S.S. Punch/ Wire Grid Type (10 min. rating) (Make SPEED -N- SYSTEM/ CRANE -N-CONTROL). Emergency Stop : Switch will be provided for extra safety. Hook : C-type plain shank hook, 360 degree swiveling type Make Hercules PAINTS Under Coat : Double Coat Zinc Chromate Golden yellow : Double Coat (Make –NEROLAC/BERGER/ASIAN/ICI or any ISI/ISO)

PRICE & BRIEF LOOK UP OF THE COMPLETE PLANT

PRICE & SCOPE OF SUPPLY FOR THE COMPLETE PLANT Scope of Supply: Our scope of supply strictly covers only those items as are included in our above mentioned

detailed and following brief price Schedule. The scope of work of shall be as given below: - Complete Design, manufacture, and supply of equipments covered in this specification - All the Foundations Drawings and relevant documents listed below shall be supplied in

English language - Civil drawings for the foundations will have to be arranged by the buyer at his own cost. - Supply of Layout, Schematic and dimensional General Arrangement drawing

PRICE & BRIEF LOOK UP OF THE COMPLETE PLANT

S. No. Description of Goods Covered Quantity Price in USD A. Billet/Ingot Reheating Furnace – 18-20 MT / HOUR a) Burners 06 Nos.

390,000.00

b) Combustion Air Blower 01 No. c) Chimney 30 Meters d) Recuperator 01 No. e) Blower 01 No. f) Refractory Complete g) Discharging Ejector for 5” Billet Eject 01 No. h) Mechanical Pusher – Extra Heavy Duty 01 No. B. 410 mm PCD Roughing Mill a) Gear Couplings - EN-9 Forged 03 Sets

345,000.00

b) Flywheel Assembly - Steel Casting 01 Set

c) Reduction Gear Box - EN-19/24 Gears Includes - C.I. Foundation Rails, Foundation Bolts , T Bolts etc.

01 Set

d)

Pinion Stand - EN-19 Gears Includes - C.I. Foundation Rails Foundation Bolts , T Bolts etc.

01 Set

e)

Mill Stands (Fibre Type & Bearing Type) Also Includes - Rolls - Bearing & Bearing Chocks - 24048 - Rest Bars & Side Bars - Fiber Bearings & Chocks - Spindles - C.I, Couplings - Foundation Rails, F.Bolts & T Bolts

03 Sets

f) Motor Foundation Rails With Foundation Nuts & Bolts, T Bolts

01 Set

g) Oil Lubrication System – 150 LPM With Panel

01 No.

C. 310 mm PCD Intermediate Mill a) Gear Couplings - EN-9 Forged 03 Sets 260,000.00 b) Flywheel Assembly - Steel Casting 01 Set

c)

Reduction Gear Box - EN-19/24 Gears Includes - C.I. Foundation Rails with Nuts & Bolts etc.

01 Set

d)

Pinion Stand - EN-19 Gears Includes - C.I. Foundation Rails with Nuts & Bolts etc.

01 Set

e)

Mill Stands (Antifriction Spherical Roller Bearing Type) Also Includes - Steel Casting - Rolls - Bearing & Bearing Chocks - Rest Bars & Side Bars - Universal Spindles - Universal Couplings - Foundation Rails, F.Bolts & T Bolts etc.

04 Sets

f) Motor Foundation Rails With Foundation Nuts & Bolts, T Bolts

01 Set

g) Oil Lubrications System with Panel – 150 LPM 01 No.

h) Speed Increaser-cum-Pinion Stand (305mm PCD) With Foundation Rails with Foundation Bolts

01 No.

D. 280 mm PCD Continuous Finishing Mills a) Gear Couplings - EN-9 Forged 06 Sets

300,000.00

b)

Reduction Gear Box cum Pinion Stand (SISO) Includes - Cast Steel Patra Type F. Rail, F.Bolts & T Bolts

06 Sets

c)

Mill Stands (Antifriction Spherical Roller Bearing Continuous Type) Also Includes - Rolls - Bearing & Bearing Chocks - Rest Bars & Side Bars - Universal Cross - Universal Cross Couplings - Foundation Rails, F.Bolts & T Bolts etc.

06 Sets

d) Motor Foundation Rails with F.Bolts & T Bolts 06 Sets e) Oil Lubrication System with Panel – 100 LPM 02 Nos. F. Material Handling Equipment

a)

All Conveyors- Furnace Charging Table Furnace Discharging Table Mill working Roller Table Y Table 8 meter x 1200 BL Extension Roller Table 6 meter x 1200 BL Extension Roller Table 6 meters x 8 B.L. C I Nozzles Cooling Bed Conveyors - 78 Meters Cold Shearing Conveyor - 12 Meters

01 lot

265,000.00

b) Repeaters 02+04 Nos. 32,250.00 b) Snap Shears - with FRL Unit 02 Nos. 5,000.00 c) Pinch Roll - 305 Centre 04 Nos. 125,500.00 d) Rotary Shearing Machine - SMT 450 – fix type 02 Nos. 19,800.00 e) Guiding System - Guide Box & Twist Pipe 01 No. 21,000.00 f) Cold Cutting Machine - Heavy Duty 01 No. 24,500.00 G. ELECTRICALS a) Main Motor for Roughing Mill (1250 HP) 01 No. 56,000.00 b) Main Motor for Intermediate Mill (800 HP) 01 No. 43,000.00 c) Main Motor for Cont. Finishing Mill (D.C. –200/235kW) 06 Nos. 92,500.00

d) Mill Auxiliary Motors for lubrication system, pinch rolls, shearing machine, furnace etc.

1 Lot

45,000.00

e) Water Starters 02 Nos. 22,000.00 f) D.C. Drive & Panels 06 Nos. 92,500.00 g) Main Panel Board

Complete

155,000.00 h) Small Panel Board

I) Control Desk j) Transformer – 3000 kVA 01 No. 70,000.00

H. WORKSHOP / TOOL ROOM MACHINES a) Lathe Machines with Dog Chucks – 16’-01, 12’-03, 8’-01 05 Nos.

95,000.00

b) Shaping Machine – 30/32” 01 Nos. c) Radial Drilling Machine – 1 ½” 01 No. d) Tool Grinder – 10” Stone 02 Nos. e) Electrical Hand Grinder - 5”-01, 7”-01, 9”-01 03 Nos. f) Hand Vice 02 Nos. g) Welding Set – 450 Amp, Air Cooled 02 Nos. h) Gas Cutting Set 02 Nos. i) Water Pumps – 40 HP 04 Nos. j) Air Compressor – 10 HP 03 Nos. I. AUXILIARY EQUIPMENTS a) UTM Machine – 100 UTM – Computerized 01 No. 44,450.00 b) CNC Branding Machine 01 No. 36,500.00 c) Weigh Bridge – 60 MT 01 No. 30,000.00 d) EOT Crane – 10 MT with platform and trolley 01 No. 65,000.00

TOTAL PRICE - USD 2.633,050.00

PACKING AND FOB CHARGES - USD 140,000.00 -- -------------------- GRAND TOTAL - USD 2, 773,050.00 --------------------

(US DOLLARS TWO MILLION SEVEN HUNDRED SEVENTY THREE THOUSAND FIFTY ONLY)

MANAGEMENT ORGANISATION STRUCTURE

BOARD OF DIRECTORS

DIRECTOR

COMPANY SECRETARY & MANAGER (F&A)

MANAGER (COMMERCIAL & STORES)

MANAGER WORKS MANAGER WORKS (SMS)

FOREMAN (ROLLING

MANAGER WORKS (POWER PLANT)

ACCOUNTAN T

ACCOUN

OFFICE ASSISTA

ASSISTANT MANAGER

CHEMIS T

SUPERVIS FITTE

R

SUPERVIS FITTE R

TRAINEE

SUPERVIS FITTE

R

T TECHNICIAN S S

SUPERVIS FITTE R

CASHIE TECHNICIAN

S TRAINEE S

TECHNICIAN S

STORE INCHAR GE

RECEIP T

DESPATC H

SKILLED WORKER

UNSKILLED WORKERS

SKILLED WORKER

UNSKILLE D WORKERS

TRAINEE S

SKILLED WORKER

TECHNICIAN S

UNSKILLE D WORKERS

TRAINEE S

SKILLED WORKER

UNSKILLE D WORKERS

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